CN109098871B - Manufacturing method of ship engine cylinder sleeve - Google Patents
Manufacturing method of ship engine cylinder sleeve Download PDFInfo
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- CN109098871B CN109098871B CN201810909005.4A CN201810909005A CN109098871B CN 109098871 B CN109098871 B CN 109098871B CN 201810909005 A CN201810909005 A CN 201810909005A CN 109098871 B CN109098871 B CN 109098871B
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
- F02F1/00—Cylinders; Cylinder heads
- F02F1/004—Cylinder liners
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- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D3/00—Electroplating: Baths therefor
- C25D3/02—Electroplating: Baths therefor from solutions
- C25D3/04—Electroplating: Baths therefor from solutions of chromium
- C25D3/08—Deposition of black chromium, e.g. hexavalent chromium, CrVI
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- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D3/00—Electroplating: Baths therefor
- C25D3/02—Electroplating: Baths therefor from solutions
- C25D3/56—Electroplating: Baths therefor from solutions of alloys
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- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D3/00—Electroplating: Baths therefor
- C25D3/02—Electroplating: Baths therefor from solutions
- C25D3/56—Electroplating: Baths therefor from solutions of alloys
- C25D3/562—Electroplating: Baths therefor from solutions of alloys containing more than 50% by weight of iron or nickel or cobalt
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- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25F—PROCESSES FOR THE ELECTROLYTIC REMOVAL OF MATERIALS FROM OBJECTS; APPARATUS THEREFOR
- C25F3/00—Electrolytic etching or polishing
- C25F3/02—Etching
- C25F3/06—Etching of iron or steel
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
- F02F2200/00—Manufacturing
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- Organic Chemistry (AREA)
- Combustion & Propulsion (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Cylinder Crankcases Of Internal Combustion Engines (AREA)
- Electroplating Methods And Accessories (AREA)
Abstract
The invention discloses a manufacturing method of a cylinder sleeve of a ship engine, which comprises the following steps: the method comprises the following steps: rough machining, namely performing rough machining on the cylinder sleeve; step two: pretreatment, namely performing oil removal and rust removal treatment on the cylinder sleeve; step three: electroplating, namely placing the cylinder sleeve in electroplating solution for electroplating treatment, plating an abrasion-resistant layer on the inner wall of the cylinder sleeve, and plating an corrosion-resistant layer on the outer wall of the cylinder sleeve; step four: cleaning; step five: anodic etching, namely, carrying out anodic etching treatment on the cylinder sleeve to form micro-reticulate patterns on the inner wall of the cylinder sleeve; step six: cleaning; step seven: and (4) finish machining, namely finish machining the inner wall and the outer wall of the cylinder sleeve respectively. The surface hardness and the wear resistance of the inner wall surface of the cylinder sleeve can be improved, the corrosion resistance of the outer wall surface of the cylinder sleeve can be improved, the long-term use reliability of the engine cylinder sleeve is improved, and the service life is prolonged.
Description
Technical Field
The invention relates to the manufacturing of a ship engine cylinder, in particular to a manufacturing method of a ship engine cylinder sleeve.
Background
Wear and corrosion are the main causes of failure of the cylinder block or cylinder liner of an internal combustion engine under service conditions in marine environments. The cylinder sleeve and the piston of the ship engine do reciprocating motion in a working state, and experience severe high temperature, pressure cycle impact and strong abrasion, so that the cylinder sleeve and the piston are the most key parts for the efficient operation of the engine and are main parts for determining the maintenance cost of the ship.
The proper treatment of the inner surface of the engine cylinder sleeve or the piston to improve the surface wear resistance is a main means for improving the working performance and the service life of the internal combustion engine. Currently, in the manufacturing process of the cylinder and the piston of the internal combustion engine, the surface treatment method mainly comprises two types.
One is that the hardness and the wear resistance of the inner surface of the cylinder are improved through surface modification, coating or plating, and the adopted method mainly comprises surface quenching, hard chromium electroplating, chemical plating metal, laser surface quenching, plasma surface quenching and the like; CN107377890A discloses a method and a device for improving the wear resistance of an inner bore of a cylinder liner of a marine diesel engine, which perform surface quenching on the inner surface of the cylinder liner in an as-cast state to improve the strength and wear resistance of the inner surface of the cylinder liner, and only optimize the wear resistance of the inner surface, which cannot ensure the corrosion resistance of the outer surface.
And secondly, the friction coefficient between friction pairs is reduced through an oil storage structure on the surface, the lubricating condition is improved, and the abrasion is reduced. CN101839341B discloses a piston ring and a surface loose hole chromium plating process thereof, wherein the working surface of the piston ring is plated with loose hole chromium to form a chromium layer mesh groove, thereby reducing the friction coefficient between the piston ring and a cylinder sleeve and prolonging the service life of the piston ring.
In the operation process of a large ship, strong abrasion is generated between the inner wall of a cylinder sleeve and a piston ring at higher temperature and under higher pressure, the service environment is worse, and heavy oil is used as engine oil, so that carbon deposition, corrosive gas and other impurities enter between friction pairs, more serious abrasive wear and corrosive wear are generated, the phenomena of cylinder scuffing and burning are easier to occur, and the replacement period is even shortened to less than one year. More seriously, the consumption of fuel oil and engine oil is very high, the emission can not meet the requirement of environmental protection, and the consumption cost of the engine oil is high. In addition, the outer surface of the engine cylinder sleeve is easy to generate erosion damage, also called cavitation erosion, because cooling liquid can contact corrosive media such as seawater and the like, and the failure of the cylinder sleeve is accelerated.
At present, the prior art improves the material and casting process of the cylinder sleeve, and carries out laser etching or flat-top honing on the inner surface to generate certain wear resistance and oil storage structure on the surface, and the achieved wear resistance and lubrication conditions reach or approach the limit of the traditional manufacturing method. The conventional production process of the cylinder sleeve comprises the following steps: casting blank, rough boring, rough machining, rough turning of excircle and end face, turning of excircle, fine boring, fine turning of excircle, end face and grooving, inner surface honing and inner surface treatment. The existing oil storage structure on the inner surface of the honing cylinder sleeve for the large ship mainly depends on flat-top honing, and a few products adopt loose-hole chromium plating. The processing characteristics of the honing cylinder sleeve are divided into two stages of rough honing and fine honing, the type and the characteristics of the grinding material for honing in the actual production and the randomness in the manufacturing process, and the formed oil storage structure depends on uneven grinding marks, so that the requirements of high-performance ships on the performance of the internal combustion engine cannot be met. Meanwhile, the surface of the steel plate is not reinforced, the service life is greatly reduced, the maintenance period is shortened, and the cost is greatly improved. The laser etching technology belongs to one of the applications of laser processing, obtains an oil storage structure with a certain shape by controlling laser process parameters, laser beams or the movement of a workpiece, and effectively improves the abrasion condition of the inner surface of a cylinder. In the 80 s, laser etching and honing are combined to form a main manufacturing method of friction pair parts of an internal combustion engine cylinder at present, but an oil storage structure formed by laser etching cannot meet requirements on a cylinder body and a cylinder sleeve facing a large-scale ship heavy-load internal combustion engine, so that the requirements of users cannot be met at present, the maintenance cost and the engine oil loss are very high, and the energy requirement and the operation cost are increased. Loose chrome plating has been mentioned in patents and literature to strengthen the inner surface of the liner while forming dense oil-retaining grooves to improve wear resistance and reduce the coefficient of friction with the piston. However, the reported effects of reducing the friction coefficient and saving the engine oil are not obvious, a stable process cannot be formed in China, and the application is relatively less.
For important application occasions including large ships, the requirements on wear performance and oil saving are higher, and the requirements cannot be met by only adopting a single technical means or the conventional mature manufacturing method.
Disclosure of Invention
The invention aims to provide a manufacturing method of a ship engine cylinder sleeve, which can improve the hardness and the wear resistance of the inner wall surface of the cylinder sleeve, can also improve the corrosion resistance of the outer wall surface of the cylinder sleeve, improves the reliability of the engine cylinder sleeve in long-term use and prolongs the service life.
The invention relates to a manufacturing method of a cylinder sleeve of a ship engine, which comprises the following steps:
the method comprises the following steps: rough machining, namely roughly machining the cylinder sleeve, wherein the cylinder sleeve is made of gray cast iron, vermicular cast iron or alloy cast iron;
step two: pretreatment, namely performing oil removal and rust removal treatment on the cylinder sleeve;
step three: electroplating, namely placing the cylinder sleeve in electroplating solution for electroplating treatment,
plating a wear-resistant layer on the inner wall of the cylinder sleeve, wherein the wear-resistant layer is one of hard chromium, chromium nickel, chromium iron and chromium cobalt alloy, the surface hardness is HV 650-HV 1100,
plating an anti-corrosion layer on the outer wall of the cylinder sleeve, wherein the anti-corrosion layer is made of chromium-based metal and contains 70-98% of chromium;
step four: cleaning, namely cleaning, drying and dehydrogenating the cylinder sleeve in sequence;
step five: anodic etching, namely, carrying out anodic etching treatment on the cylinder sleeve to form micro-reticulate patterns on the inner wall of the cylinder sleeve;
step six: cleaning, namely cleaning and drying the cylinder sleeve;
step seven: and (3) finish machining, namely finish machining the inner wall and the outer wall of the cylinder sleeve respectively, wherein the roughness of the inner wall is 0.3-0.8 mu m, the roughness of the outer wall is 3-10 mu m, the ovality of the inner diameter is +/-3-5 mu m, and the verticality of the inner diameter is +/-3-10 mu m.
Further, the size parameters of rough machining in the first step are as follows: the inner diameter of the rough cylinder sleeve is 400-800 mu m larger than the inner diameter of a finished product, the outer diameter of the rough cylinder sleeve is 20-200 mu m smaller than the outer diameter of the finished product, the roughness of the inner wall of the rough cylinder sleeve is 1-10 mu m, and the roughness of the outer wall of the rough cylinder sleeve is 3-20 mu m.
Further, the oil removing treatment in the second step is as follows: placing the cylinder sleeve in a cleaning solution, and removing oil for 5-30 min at the temperature of 50-100 ℃; the rust removal treatment comprises the following steps: and derusting the cylinder sleeve by adopting one of acid washing, mechanical polishing and sand blasting.
Further, the composition of the electroplating solution of the wear-resistant layer and the corrosion-resistant layer in the third step is as follows:
the electroplating solution of the corrosion-resistant layer comprises the following components: the content of chromic anhydride is 180-250 g/L, the content of sulfuric acid is 1-2.5 g/L, and the acid ratio is CrO3 /SO4100/1-200/1;
when the wear-resistant layer is a hard chromium plating layer, the compositions of the electroplating solutions of the wear-resistant layer and the corrosion-resistant layer are the same;
when the wear-resistant layer is one of chrome nickel, ferrochrome and chrome cobalt alloy, the electroplating solution comprises the following components: the content of chromic anhydride is 180-250 g/L, the content of sulfuric acid is 1-2.5 g/L, and the acid ratio is CrO3 /SO4100/1-200/1, 10-35 g/L nickel sulfate, 5-20 g/L ferric chloride/ferric sulfate and 5-25 g/L cobalt sulfate.
Preferably, the composition of the electroplating solution of the wear-resistant layer and the corrosion-resistant layer in the third step is as follows: the content of chromic anhydride is 200g/L, the content of sulfuric acid is 2.0g/L, and the acid ratio is CrO3 /SO4Is 120/1.
Further, the technological parameters of electroplating the wear-resistant layer and the corrosion-resistant layer in the third step are as follows:
when the wear-resistant layer is a hard chromium plating layer, the wear-resistant layer and the corrosion-resistant layer are simultaneously electroplated in the same electroplating solution by adopting independent power supplies;
when the wear-resistant layer is one of chromium nickel, chromium iron and chromium cobalt alloy, the wear-resistant layer and the corrosion-resistant layer are respectively electroplated in corresponding electroplating solutions;
the electroplating temperature is 50-65 ℃, and the current density is 40-75A/dm2The electroplating time is 1-18 h, and the thickness of the plating layer is 20-400 μm.
Preferably, the process parameters of the electroplating wear-resistant layer are as follows: the electroplating temperature is 55 ℃, and the current density is 65A/dm2The electroplating time is 6h, and the thickness of the plating layer is 310 mu m.
Preferably, the process parameters of the electroplating corrosion-resistant layer are as follows: the electroplating temperature is 55 ℃, and the current density is 50A/dm2The plating time is 1h, and the thickness of the plating layer is 40 mu m.
Further, the composition of the anode etching solution in the fifth step is as follows: 20-100 g/L of sodium hydroxide, 30-200 g/L of sodium carbonate, 2-20 g/L of sodium phosphate, 1-5 g/L of disodium hydrogen phosphate and 2-10 g/L of sodium metaphosphate.
Preferably, the composition of the anode etching solution in the fifth step is as follows: 65g/L of sodium hydroxide, 100g/L of sodium carbonate and 2g/L of sodium phosphate.
Further, the process parameters of the anode etching in the fifth step are as follows: a pulse direct current power supply is adopted, the pulse frequency is 1-10 Hz, and the current density is 10-20A/dm2And the etching time is 3-10 min.
Preferably, the process parameters of the anode etching in the fifth step are as follows: adopting a pulse direct current power supply, the pulse frequency is 10Hz, and the current density is 15A/dm2The etching time is 7 min.
Further, the dimension parameters of the micro-texture in the fifth step are as follows: the micro reticulate pattern is cross reticulate pattern and/or independent groove, the length is 0.1-15 μm, the depth is 20-100 μm, and the reticulate pattern density is 15-60% of unit area.
Preferably, the dimension parameters of the micro-texture in the fifth step are as follows: the micro-texture is in the shape of cross-texture and/or independent grooves, the length is 8 mu m, the depth is 78 mu m, and the texture density is 50% of the unit area.
And further, an anticorrosive resin coating is coated on the outer surface of the corrosion-resistant layer of the cylinder sleeve after the seventh fine machining, so that the anticorrosive performance of the outer wall of the cylinder sleeve can be better improved by coating the anticorrosive resin coating, and the anticorrosive effect is ensured.
Further, the anticorrosive resin coating is epoxy resin or phenolic resin.
Compared with the prior art, the invention has the following beneficial effects.
1. According to the invention, the material of the cylinder sleeve is limited to be gray cast iron, vermicular cast iron or alloy cast iron, the inner wall and the outer wall of the cylinder sleeve are respectively plated with the wear-resistant layer and the corrosion-resistant layer by adopting an electroplating process, the hardness of the inner wall of the cylinder sleeve is improved, the wear-resistant property of the inner wall and the corrosion-resistant property of the outer wall of the cylinder sleeve are increased, and the micro-reticulate pattern is formed on the inner wall of the cylinder sleeve by adopting an anodic etching process, so that the lubricating condition and the reliability of a ship engine in long-term service are improved, the engine oil consumption is reduced by 50.
2. The micro-grid structure on the inner wall of the cylinder sleeve is not limited to the working areas of the upper dead center and the lower dead center of the piston, so that the micro-grid structure is convenient to repair and reuse, and can be quickly repaired and continuously used for 1-3 overhaul periods after being repaired.
3. The invention ensures that the performances of the wear-resistant layer and the corrosion-resistant layer can meet the requirements by specially limiting the electroplating solution and the electroplating process parameters. The micro-mesh size is adjusted by adjusting the composition of the anodic etching liquid and the anodic etching process parameters, so that the controllability of the micro-mesh size is realized, and the consumption of engine oil of the cylinder sleeve is reduced because the micro-mesh has an oil storage function.
4. According to the invention, through the integral design of the manufacturing material, structure and manufacturing process of the cylinder sleeve, the comprehensive performance of the cylinder sleeve is improved, the composite cylinder sleeve which is more corrosion-resistant and longer in service life than the traditional honing or laser etching process is obtained, unnecessary process links and material consumption are reduced, and the production cost is reduced.
Drawings
FIG. 1 is a schematic illustration of the construction of a cylinder liner of the present invention;
FIG. 2 is a process flow diagram of the present invention;
FIG. 3 is a schematic view showing the micro-patterns on the inner wall of the cylinder liner according to the first embodiment of the present invention;
FIG. 4 is a schematic cross-sectional view of a micro-texture on the inner wall of the cylinder liner according to an embodiment of the present invention;
FIG. 5 is a graph showing roughness of the inner wall of the cylinder liner according to an embodiment of the present invention;
FIG. 6 is a schematic view showing the micro-patterns on the inner wall of the cylinder liner in accordance with the second embodiment of the present invention;
FIG. 7 is a graph showing roughness of the inner wall of the cylinder liner according to the second embodiment of the present invention;
FIG. 8 is a schematic view showing the micro-patterns on the inner wall of the cylinder liner in the third embodiment of the present invention;
FIG. 9 is a schematic view showing the micro-patterns on the inner wall of the cylinder liner in the fourth embodiment of the present invention;
FIG. 10 is a schematic view of the micro-patterns on the inner wall of the cylinder liner in the fifth embodiment of the present invention.
In the figure, 1 is a cylinder sleeve body, 2 is an abrasion-resistant layer, 3 is an corrosion-resistant layer, and 4 is a micro reticulate pattern.
Detailed Description
First embodiment, referring to fig. 2, a method for manufacturing a cylinder liner of a marine engine, includes the steps of:
the method comprises the following steps: rough machining, wherein the finished size of the cylinder sleeve is as follows: the inner diameter is 400mm, the outer diameter is 600mm, and the length is 900 mm;
the cylinder sleeve is manufactured by adopting a casting method, and then rough machining is carried out on the cylinder sleeve, the material of the cylinder sleeve is gray cast iron, the inner diameter of the rough machined cylinder sleeve is 600 mu m larger than the inner diameter of a finished product, the outer diameter of the rough machined cylinder sleeve is 70 mu m smaller than the outer diameter of the finished product, the roughness of the inner wall of the rough machined cylinder sleeve is 5 mu m, and the roughness of the outer wall of the rough machined cylinder sleeve is 8 mu m.
Step two: and (2) pretreatment, namely firstly, carrying out oil removal treatment on the cylinder sleeve, applying ultrasonic auxiliary cleaning for 25min by adopting a mixed aqueous solution of sodium hydroxide, sodium carbonate, sodium phosphate, a surfactant and an emulsifier at the temperature of 80 ℃, then carrying out rust removal treatment, carrying out acid cleaning for 5min by adopting a 10% sulfuric acid aqueous solution, and then cleaning for 3min by using clear water to ensure that no residue exists.
Step three: electroplating, namely placing the cylinder sleeve in electroplating solution for electroplating treatment, plating an abrasion-resistant layer on the inner wall of the cylinder sleeve, wherein the abrasion-resistant layer is a hard chromium plating layer, and plating an corrosion-resistant layer on the outer wall of the cylinder sleeve, wherein the corrosion-resistant layer is chromium metal; the wear-resistant layer and the corrosion-resistant layer are simultaneously electroplated in the same electroplating solution by adopting an independent power supply, the temperature is 55 ℃, and the electroplating solution comprises the following components: chromic anhydride CrO3Has a content of 200g/L, sulfuric acid H2SO4The content of (A) is 2.0g/L, and the acid ratio is CrO3 /SO4120/1;
the electroplating process parameters of the wear-resistant layer are as follows: current density 65A/dm2The electroplating time is 6h, burrs are punched at intervals of 0.5h, the surface hardness is HV750, and the thickness of a plating layer is 310 mu m;
the parameters of the corrosion-resistant layer electroplating process are as follows: current density 50A/dm2The plating time is 1h, and the thickness of the plating layer is 40 mu m.
Step four: cleaning, namely cleaning, drying and dehydrogenating the cylinder sleeve in sequence, firstly carrying out ultrasonic cleaning at the temperature of 50 ℃ for 10min, then drying, and then dehydrogenating for 3h in an oven at the temperature of 200 ℃.
Step five: anodic etching, namely, carrying out anodic etching treatment on the cylinder sleeve to form micro-reticulate patterns on the inner wall of the cylinder sleeve; the anode etching liquid comprises the following components: 65g/L of sodium hydroxide, 100g/L of sodium carbonate and 2g/L of sodium phosphate; the technological parameters of the anodic etching are as follows: adopting a pulse direct current power supply, the pulse frequency is 10Hz, and the current density is 15A/dm2Etching time is 7 min; referring to fig. 3 and 4, the micro-texture shape shown is a cross-texture having a length of 8 μm and a depth of 78 μm, and a texture density of 50% per unit area.
Step six: cleaning, namely ultrasonically cleaning the inner wall of the cylinder sleeve at 50 ℃ for 5min, and then drying.
Step seven: finish machining, namely finish machining the inner wall and the outer wall of the cylinder sleeve respectively; performing fine grinding treatment on the inner wall of the cylinder sleeve by adopting an internal grinder to remove a micro-convex structure on the surface of a micro-reticulate pattern, and referring to fig. 5, wherein the roughness of the inner wall of the cylinder sleeve is 0.5207 mu m, the ovality of the inner diameter is +/-3 mu m, and the verticality of the inner diameter is +/-7 mu m; and (3) performing finish machining on the outer wall of the cylinder sleeve until the finished product requires assembly precision, wherein the surface roughness of the corrosion-resistant layer is 5 mu m, and then coating an epoxy resin coating on the outer surface of the corrosion-resistant layer.
Referring to fig. 1, the cylinder sleeve of the ship engine comprises a cylinder sleeve body 1, wherein an abrasion-resistant layer 2 is plated on the inner wall of the cylinder sleeve body 1, a corrosion-resistant layer 3 is plated on the outer wall of the cylinder sleeve body 1, and micro-grid lines 3 are etched on an anode of the abrasion-resistant layer 2. The arrangement of the wear-resistant layer 2 and the corrosion-resistant layer 3 improves the hardness of the inner wall of the cylinder sleeve, increases the wear-resistant performance of the inner wall of the cylinder sleeve, and simultaneously adopts an anodic etching process to form micro-reticulate patterns on the wear-resistant layer, so that the lubricating condition and the reliability of the long-term service of the ship engine are improved, and experiments prove that the engine oil consumption is reduced by 55 percent, and the service life is prolonged by 3.5 times.
In a second embodiment, a method for manufacturing a cylinder liner for a marine engine includes the steps of:
the method comprises the following steps: rough machining, wherein the finished size of the cylinder sleeve is as follows: the inner diameter is 320mm, the outer diameter is 500mm, and the length is 780 mm;
the cylinder sleeve is manufactured by adopting a casting method, and then rough machining is carried out on the cylinder sleeve, the material of the cylinder sleeve is alloy cast iron, the inner diameter of the rough machined cylinder sleeve is 500 mu m larger than the inner diameter of a finished product, the outer diameter of the rough machined cylinder sleeve is 80 mu m smaller than the outer diameter of the finished product, the roughness of the inner wall of the rough machined cylinder sleeve is 8 mu m, and the roughness of the outer wall of the rough machined cylinder sleeve is 12 mu m.
Step two: pre-treating, namely firstly removing oil from the cylinder sleeve, performing ultrasonic-assisted cleaning for 30min at the temperature of 70 ℃ by adopting a mixed aqueous solution of sodium hydroxide, sodium carbonate, sodium phosphate, a surfactant and an emulsifier, then performing rust removal treatment, performing acid cleaning for 5min by adopting a 10% sulfuric acid aqueous solution, and cleaning for 3min by using clear water to ensure that no residue exists.
Step three: electroplating, namely placing the cylinder sleeve in electroplating solution for electroplating treatment, and plating a wear-resistant layer on the inner wall of the cylinder sleeve, wherein the wear-resistant layer is a chromium-nickel alloy, and the electroplating solution comprises the following components: chromic anhydride CrO3Has a content of 220g/L, sulfuric acid H2SO4The content of (A) is 2.5g/L, and the acid ratio is CrO3 /SO4110/1, nickel sulfate 10 g/l;
the electroplating process parameters of the wear-resistant layer are as follows: current density 60A/dm2The electroplating time is 8h, burrs are punched at intervals of 0.5h, the surface hardness is HV800, the thickness of a plating layer is 310 mu m, and the temperature is 60 ℃;
the outer wall of the cylinder sleeve is plated with a corrosion-resistant layer, the corrosion-resistant layer is a chromium plating layer, and the electroplating solution comprises the following components: chromic anhydride CrO3Has a content of 250g/L, sulfuric acid H2SO4The content of (A) is 2.5g/L, and the acid ratio is CrO3 /SO4100/1;
the technological parameters of the electroplating corrosion-resistant layer are as follows: the electroplating temperature is 55 ℃, and the current density is 50A/dm2The plating time is 1h, and the thickness of the plating layer is 40 mu m.
Step four: cleaning, namely cleaning, drying and dehydrogenating the cylinder sleeve in sequence, firstly carrying out ultrasonic cleaning at the temperature of 40 ℃ for 15min, then drying, and then dehydrogenating for 1.5h in an oven at the temperature of 250 ℃.
Step five: anodic etching, to cylinder linerCarrying out anodic etching treatment to form micro-reticulate patterns on the inner wall of the cylinder sleeve; the anode etching liquid comprises the following components: 80g/L of sodium hydroxide, 75g/L of sodium carbonate and 2.5g/L of sodium metaphosphate; the technological parameters of the anodic etching are as follows: adopting a pulse direct current power supply, the pulse frequency is 8Hz, and the current density is 10A/dm2Etching time is 6 min; referring to fig. 6, the micro-texture shape shown is a cross-texture with a length of 5 μm and a depth of 90 μm, and a texture density of 45% per unit area.
Step six: cleaning, namely ultrasonically cleaning the inner wall of the cylinder sleeve at 50 ℃ for 5min, and then drying.
Step seven: finish machining, namely finish machining the inner wall and the outer wall of the cylinder sleeve respectively; performing fine grinding treatment on the inner wall of the cylinder sleeve by adopting an internal grinder to remove a micro-convex structure on the surface of a micro-reticulate pattern, and referring to fig. 7, wherein the roughness of the inner wall of the cylinder sleeve is 0.6127 mu m, the ovality of the inner diameter is +/-3.5 mu m, and the verticality of the inner diameter is +/-5.5 mu m; and (3) performing finish machining on the outer wall of the cylinder sleeve until the finished product requires assembly precision, wherein the surface roughness of the corrosion-resistant layer is 8 mu m, and then coating an epoxy resin coating on the outer surface of the corrosion-resistant layer.
In a third embodiment, a method for manufacturing a cylinder liner of a marine engine includes the steps of:
the method comprises the following steps: rough machining, wherein the finished size of the cylinder sleeve is as follows: the inner diameter is 400mm, the outer diameter is 550mm, and the length is 750 mm;
the cylinder sleeve is manufactured by adopting a casting method, and then rough machining is carried out on the cylinder sleeve, the material of the cylinder sleeve is vermicular cast iron, the inner diameter of the rough machined cylinder sleeve is 400 microns larger than the inner diameter of a finished product, the outer diameter of the rough machined cylinder sleeve is 100 microns smaller than the outer diameter of the finished product, the roughness of the inner wall of the rough machined cylinder sleeve is 5 microns, and the roughness of the outer wall of the rough machined cylinder sleeve is 10 microns.
Step two: and (2) pretreatment, namely firstly, carrying out oil removal treatment on the cylinder sleeve, spraying and cleaning the cylinder sleeve for 30min by adopting a mixed aqueous solution of sodium hydroxide, sodium carbonate, sodium phosphate, a surfactant and an emulsifier at the temperature of 60 ℃, then carrying out rust removal treatment, carrying out acid cleaning for 3min by adopting a 10% sulfuric acid aqueous solution, and cleaning for 3min by using clear water to ensure that no residue exists.
Step three: electroplating, namely placing the cylinder sleeve in electroplating solution for electroplating treatment, and plating a wear-resistant layer on the inner wall of the cylinder sleeve, wherein the wear-resistant layer is hardThe corrosion-resistant layer is plated on the outer wall of the cylinder sleeve and is chromium-based metal; the wear-resistant layer and the corrosion-resistant layer are simultaneously electroplated in the same electroplating solution by adopting an independent power supply, the temperature is 60 ℃, and the electroplating solution comprises the following components: chromic anhydride CrO3Has a content of 200g/L, sulfuric acid H2SO4The content of (A) is 1.8g/L, and the acid ratio is CrO3 /SO4110/1;
the electroplating process parameters of the wear-resistant layer are as follows: current density 50A/dm2The electroplating time is 4.5h, burrs are punched at intervals of 0.5h, the surface hardness is HV850, and the thickness of a plating layer is 210 mu m;
the parameters of the corrosion-resistant layer electroplating process are as follows: current density 60A/dm2The electroplating time is 1.5h, and the thickness of the plating layer is 52 mu m.
Step four: cleaning, namely cleaning, drying and dehydrogenating the cylinder sleeve in sequence, firstly carrying out ultrasonic cleaning at the temperature of 60 ℃ for 15min, then drying, and then dehydrogenating for 2.5h in an oven at the temperature of 200 ℃.
Step five: anodic etching, namely, carrying out anodic etching treatment on the cylinder sleeve to form micro-reticulate patterns on the inner wall of the cylinder sleeve; the anode etching liquid comprises the following components: 100g/L of sodium hydroxide, 150g/L of sodium carbonate and 1.5g/L of sodium dihydrogen phosphate; the technological parameters of the anodic etching are as follows: adopting a pulse direct current power supply, the pulse frequency is 10Hz, and the current density is 20A/dm2Etching time is 10 min; referring to fig. 8, the micro-texture is shown as individual grooves 15 μm in length and 95 μm in depth with a texture density of 20% per unit area.
Step six: cleaning, namely ultrasonically cleaning the inner wall of the cylinder sleeve at 40 ℃ for 10min, and then drying.
Step seven: finish machining, namely finish machining the inner wall and the outer wall of the cylinder sleeve respectively; performing fine grinding treatment on the inner wall of the cylinder sleeve by adopting an internal grinder to remove a micro-convex structure on the surface of a micro reticulate pattern, wherein the roughness of the inner wall of the cylinder sleeve is 0.8 mu m, the ovality of the inner diameter is +/-3 mu m, and the verticality of the inner diameter is +/-5 mu m; and (3) performing finish machining on the outer wall of the cylinder sleeve until the finished product requires assembly precision, wherein the surface roughness of the corrosion-resistant layer is 8 mu m, and then coating an epoxy resin coating on the outer surface of the corrosion-resistant layer.
In a fourth embodiment, a method for manufacturing a cylinder liner for a marine engine includes the steps of:
the method comprises the following steps: rough machining, wherein the finished size of the cylinder sleeve is as follows: the inner diameter is 300mm, the outer diameter is 450mm, and the length is 900 mm;
the cylinder sleeve is manufactured by adopting a casting method, and then rough machining is carried out on the cylinder sleeve, the material of the cylinder sleeve is alloy cast iron, the inner diameter of the rough machined cylinder sleeve is 500 micrometers larger than the inner diameter of a finished product, the outer diameter of the rough machined cylinder sleeve is 50 micrometers smaller than the outer diameter of the finished product, the roughness of the inner wall of the rough machined cylinder sleeve is 3 micrometers, and the roughness of the outer wall of the rough machined cylinder sleeve is 15 micrometers.
Step two: pre-treating, namely firstly removing oil from the cylinder sleeve, performing ultrasonic-assisted cleaning for 30min at the temperature of 70 ℃ by adopting a mixed aqueous solution of sodium hydroxide, sodium carbonate, sodium phosphate, a surfactant and an emulsifier, then performing rust removal treatment, performing acid cleaning for 3min by adopting a 10% sulfuric acid aqueous solution, and cleaning for 3min by using clear water to ensure that no residue exists.
Step three: electroplating, the cylinder sleeve is placed in electroplating solution for electroplating treatment, the inner wall of the cylinder sleeve is plated with a wear-resistant layer, the wear-resistant layer is ferrochrome, and the electroplating solution comprises the following components: chromic anhydride CrO3Has a content of 180g/L, sulfuric acid H2SO4The content of (A) is 2.0g/L, and the acid ratio is CrO3 /SO 4200/1, iron sulfate 18 g/l; the electroplating process parameters of the wear-resistant layer are as follows: the electroplating temperature is 55 ℃, and the current density is 55A/dm2The electroplating time is 8h, burrs are punched at intervals of 0.5h, the surface hardness is HV900, and the thickness of a plating layer is 260 mu m;
plating a corrosion-resistant layer on the outer wall of the cylinder sleeve, wherein the corrosion-resistant layer is chromium-based metal, and the electroplating solution comprises the following components: chromic anhydride CrO3Has a content of 190g/L, sulfuric acid H2SO4Has a content of 1.9g/L and an acid ratio of CrO3 /SO4100/1; the parameters of the corrosion-resistant layer electroplating process are as follows: the electroplating temperature is 55 ℃, and the current density is 40A/dm2The electroplating time is 0.8h, and the thickness of the plating layer is 27 mu m.
Step four: cleaning, namely cleaning, drying and dehydrogenating the cylinder sleeve in sequence, firstly carrying out ultrasonic cleaning at the temperature of 50 ℃ for 8min, then drying, and then dehydrogenating for 1.5h in an oven at the temperature of 250 ℃.
Step five: anodic etching, namely, carrying out anodic etching treatment on the cylinder sleeve to form micro-reticulate patterns on the inner wall of the cylinder sleeve; the anode etching liquid comprises the following components: 80g/L of sodium hydroxide, 200g/L of sodium carbonate and 5g/L of sodium phosphate; the technological parameters of the anodic etching are as follows: adopting a pulse direct current power supply, the pulse frequency is 10Hz, and the current density is 18A/dm2Etching time is 5 min; referring to fig. 9, the micro-texture is shown as individual grooves with a length of 13 μm and a depth of 85 μm, with a texture density of 15% per unit area.
Step six: cleaning, namely ultrasonically cleaning the inner wall of the cylinder sleeve at 50 ℃ for 10min, and then drying.
Step seven: finish machining, namely finish machining the inner wall and the outer wall of the cylinder sleeve respectively; performing fine grinding treatment on the inner wall of the cylinder sleeve by adopting an internal grinder to remove a micro-convex structure on the surface of a micro reticulate pattern, wherein the roughness of the inner wall of the cylinder sleeve is 0.8 mu m, the ovality of the inner diameter is +/-4 mu m, and the verticality of the inner diameter is +/-7 mu m; and (3) performing finish machining on the outer wall of the cylinder sleeve until the finished product requires assembly precision, wherein the surface roughness of the corrosion-resistant layer is 10 mu m, and then coating an epoxy resin coating on the outer surface of the corrosion-resistant layer.
In a fifth embodiment, a method for manufacturing a cylinder liner for a marine engine includes the steps of:
the method comprises the following steps: rough machining, wherein the finished size of the cylinder sleeve is as follows: the inner diameter is 450mm, the outer diameter is 650mm, and the length is 780 mm;
the cylinder sleeve is manufactured by adopting a casting method, and then rough machining is carried out on the cylinder sleeve, the material of the cylinder sleeve is gray cast iron, the inner diameter of the rough machined cylinder sleeve is larger than the inner diameter of a finished product by 800 microns, the outer diameter of the rough machined cylinder sleeve is smaller than the outer diameter of the finished product by 95 microns, the roughness of the inner wall of the rough machined cylinder sleeve is 5 microns, and the roughness of the outer wall of the rough machined cylinder sleeve is 10 microns.
Step two: and (2) pretreatment, namely firstly, carrying out oil removal treatment on the cylinder sleeve, applying ultrasonic auxiliary cleaning for 40min by adopting a mixed aqueous solution of sodium hydroxide, sodium carbonate, sodium phosphate, a surfactant and an emulsifier at the temperature of 80 ℃, then carrying out rust removal treatment, carrying out acid cleaning for 5min by adopting a 10% sulfuric acid aqueous solution, and then cleaning for 3min by using clear water to ensure that no residue exists.
Step three: electroplating, namely placing the cylinder sleeve in electroplating solution for electroplatingPlating, namely plating a wear-resistant layer on the inner wall of the cylinder sleeve, wherein the wear-resistant layer is a hard chromium plating layer, plating a corrosion-resistant layer on the outer wall of the cylinder sleeve, the corrosion-resistant layer is chromium-based metal, the wear-resistant layer and the corrosion-resistant layer are simultaneously plated in the same electroplating solution by adopting an independent power supply, the temperature is 60 ℃, and the components of the electroplating solution are as follows: chromic anhydride CrO3Has a content of 250g/L, sulfuric acid H2SO4The content of (A) is 1.8g/L, and the acid ratio is CrO3 /SO4180/1; the electroplating process parameters of the wear-resistant layer are as follows: current density 75A/dm2The electroplating time is 8.5h, burrs are punched at intervals of 0.5h, the surface hardness is HV980, and the thickness of a plating layer is 410 mu m; the parameters of the corrosion-resistant layer electroplating process are as follows: current density 50A/dm2The electroplating time is 1.8h, and the thickness of the plating layer is 49.5 mu m.
Step four: and cleaning, namely cleaning, drying and dehydrogenating the cylinder sleeve in sequence, namely firstly performing water spray cleaning at the temperature of 60 ℃ for 25min, then drying, and then dehydrogenating for 3h in an oven at the temperature of 300 ℃.
Step five: anodic etching, namely, carrying out anodic etching treatment on the cylinder sleeve to form micro-reticulate patterns on the inner wall of the cylinder sleeve; the anode etching liquid comprises the following components: 95g/L of sodium hydroxide, 180g/L of sodium carbonate, 2g/L of sodium phosphate and 1g/L of sodium metaphosphate; the technological parameters of the anodic etching are as follows: adopting a pulse direct current power supply, the pulse frequency is 8Hz, and the current density is 20A/dm2Etching time is 10 min; referring to fig. 10, the micro-texture shapes shown are cross-textures and isolated trenches, 12 μm in length and 65 μm in depth, with a texture density of 40% per unit area.
Step six: cleaning, ultrasonic cleaning the inner wall of the cylinder sleeve at 50 ℃ for 10min, and drying.
Step seven: finish machining, namely finish machining the inner wall and the outer wall of the cylinder sleeve respectively; performing fine grinding treatment on the inner wall of the cylinder sleeve by adopting an internal grinder to remove a micro-convex structure on the surface of a micro reticulate pattern, wherein the roughness of the inner wall of the cylinder sleeve is 0.57 mu m, the ovality of the inner diameter is +/-5 mu m, and the verticality of the inner diameter is +/-10 mu m; and (3) performing finish machining on the outer wall of the cylinder sleeve until the finished product requires assembly precision, wherein the surface roughness of the corrosion-resistant layer is 9 mu m, and then coating an epoxy resin coating on the outer surface of the corrosion-resistant layer.
Claims (7)
1. A manufacturing method of a cylinder sleeve of a ship engine is characterized by comprising the following steps:
the method comprises the following steps: rough machining, namely roughly machining the cylinder sleeve, wherein the cylinder sleeve is made of gray cast iron, vermicular cast iron or alloy cast iron;
step two: pretreatment, namely performing oil removal and rust removal treatment on the cylinder sleeve;
step three: electroplating, namely placing the cylinder sleeve in electroplating solution for electroplating treatment,
plating a wear-resistant layer on the inner wall of the cylinder sleeve, wherein the wear-resistant layer is one of hard chromium, chromium nickel, chromium iron and chromium cobalt alloy, the surface hardness is HV 650-HV 1100,
plating an anti-corrosion layer on the outer wall of the cylinder sleeve, wherein the anti-corrosion layer is made of chromium-based metal and contains 70-98% of chromium;
step four: cleaning, namely cleaning, drying and dehydrogenating the cylinder sleeve in sequence;
step five: anodic etching, carrying out anodic etching treatment on the cylinder sleeve to form micro-reticulate patterns on the inner wall of the cylinder sleeve, wherein the anodic etching solution comprises the following components:
65-100 g/L of sodium hydroxide,
75-200 g/L of sodium carbonate,
one or two of 2-20 g/L sodium phosphate, 1-5 g/L disodium hydrogen phosphate and 2-10 g/L sodium metaphosphate;
the technological parameters of the anodic etching are as follows: a pulse direct current power supply is adopted, the pulse frequency is 1-10 Hz, and the current density is 10-20A/dm2Etching for 3-10 min;
the micro reticulate pattern is cross reticulate pattern and/or independent groove, the length is 0.1-15 μm, the depth is 20-100 μm, and the reticulate pattern density is 15-60% of unit area;
step six: cleaning, namely cleaning and drying the cylinder sleeve;
step seven: and (3) finish machining, namely finish machining the inner wall and the outer wall of the cylinder sleeve respectively, wherein the roughness of the inner wall is 0.3-0.8 mu m, the roughness of the outer wall is 3-10 mu m, the ovality of the inner diameter is +/-3-5 mu m, and the verticality of the inner diameter is +/-3-10 mu m.
2. The method for manufacturing a cylinder liner for a marine engine according to claim 1, wherein: the size parameters of rough machining in the first step are as follows: the inner diameter of the rough cylinder sleeve is 400-800 mu m larger than the inner diameter of a finished product, the outer diameter of the rough cylinder sleeve is 20-200 mu m smaller than the outer diameter of the finished product, the roughness of the inner wall of the rough cylinder sleeve is 1-10 mu m, and the roughness of the outer wall of the rough cylinder sleeve is 3-20 mu m.
3. The manufacturing method of a cylinder liner for a marine engine according to claim 1 or 2, characterized in that: the oil removing treatment in the step two is as follows: placing the cylinder sleeve in a cleaning solution, and removing oil for 5-30 min at the temperature of 50-100 ℃;
the rust removal treatment comprises the following steps: and derusting the cylinder sleeve by adopting one of acid washing, mechanical polishing and sand blasting.
4. The manufacturing method of a cylinder liner for a marine engine according to claim 1 or 2, characterized in that: the electroplating solution of the wear-resistant layer and the corrosion-resistant layer in the third step comprises the following components:
the electroplating solution of the corrosion-resistant layer comprises the following components:
the content of chromic anhydride is 180-250 g/L,
the content of sulfuric acid is 1-2.5 g/L,
acid ratio CrO3 /SO4100/1-200/1;
when the wear-resistant layer is a hard chromium plating layer, the compositions of the electroplating solutions of the wear-resistant layer and the corrosion-resistant layer are the same;
when the wear-resistant layer is one of chrome nickel, ferrochrome and chrome cobalt alloy, the electroplating solution comprises the following components:
the content of chromic anhydride is 180-250 g/L,
the content of sulfuric acid is 1-2.5 g/L,
acid ratio CrO3 /SO4Is 100/1 to 200/1, and has a structure,
10-35 g/L nickel sulfate, 5-20 g/L ferric chloride/ferric sulfate and 5-25 g/L cobalt sulfate.
5. The method for manufacturing a cylinder liner for a marine engine according to claim 4, wherein: the technological parameters of electroplating the wear-resistant layer and the corrosion-resistant layer in the third step are as follows:
when the wear-resistant layer is a hard chromium plating layer, the wear-resistant layer and the corrosion-resistant layer are simultaneously electroplated in the same electroplating solution by adopting independent power supplies;
when the wear-resistant layer is one of chromium nickel, chromium iron and chromium cobalt alloy, the wear-resistant layer and the corrosion-resistant layer are respectively electroplated in corresponding electroplating solutions;
the electroplating temperature is 50-65 ℃, and the current density is 40-75A/dm2The electroplating time is 1-18 h, and the thickness of the plating layer is 20-400 μm.
6. The manufacturing method of a cylinder liner for a marine engine according to claim 1 or 2, characterized in that: and coating an anticorrosive resin coating on the outer surface of the corrosion-resistant layer of the cylinder sleeve after the finish machining in the step seven.
7. The method for manufacturing a cylinder liner for a marine engine according to claim 6, wherein: the anticorrosive resin coating is epoxy resin or phenolic resin.
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