HRP960145A2 - A method of manufacturing a cylinder liner for a piston engine , and a cylinder liner - Google Patents

A method of manufacturing a cylinder liner for a piston engine , and a cylinder liner Download PDF

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Publication number
HRP960145A2
HRP960145A2 HR0343/95A HRP960145A HRP960145A2 HR P960145 A2 HRP960145 A2 HR P960145A2 HR 0343/95 A HR0343/95 A HR 0343/95A HR P960145 A HRP960145 A HR P960145A HR P960145 A2 HRP960145 A2 HR P960145A2
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Croatia
Prior art keywords
liner
waves
rolling
piston
tool
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HR0343/95A
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Croatian (hr)
Inventor
Peter Alen Brandt
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Man B & W Diesel Gmbh
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Publication of HRP960145A2 publication Critical patent/HRP960145A2/en
Publication of HRP960145B1 publication Critical patent/HRP960145B1/en

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Classifications

    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02FCYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
    • F02F1/00Cylinders; Cylinder heads 
    • F02F1/18Other cylinders
    • F02F1/20Other cylinders characterised by constructional features providing for lubrication
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23PMETAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P9/00Treating or finishing surfaces mechanically, with or without calibrating, primarily to resist wear or impact, e.g. smoothing or roughening turbine blades or bearings; Features of such surfaces not otherwise provided for, their treatment being unspecified
    • B23P9/02Treating or finishing by applying pressure, e.g. knurling
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23PMETAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P9/00Treating or finishing surfaces mechanically, with or without calibrating, primarily to resist wear or impact, e.g. smoothing or roughening turbine blades or bearings; Features of such surfaces not otherwise provided for, their treatment being unspecified
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B24GRINDING; POLISHING
    • B24BMACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B39/00Burnishing machines or devices, i.e. requiring pressure members for compacting the surface zone; Accessories therefor
    • B24B39/02Burnishing machines or devices, i.e. requiring pressure members for compacting the surface zone; Accessories therefor designed for working internal surfaces of revolution
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02FCYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
    • F02F1/00Cylinders; Cylinder heads 
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02BINTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL
    • F02B75/00Other engines
    • F02B75/02Engines characterised by their cycles, e.g. six-stroke
    • F02B2075/022Engines characterised by their cycles, e.g. six-stroke having less than six strokes per cycle
    • F02B2075/025Engines characterised by their cycles, e.g. six-stroke having less than six strokes per cycle two
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02BINTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL
    • F02B3/00Engines characterised by air compression and subsequent fuel addition
    • F02B3/06Engines characterised by air compression and subsequent fuel addition with compression ignition
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02FCYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
    • F02F7/00Casings, e.g. crankcases or frames
    • F02F2007/0097Casings, e.g. crankcases or frames for large diesel engines

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • General Engineering & Computer Science (AREA)
  • Pistons, Piston Rings, And Cylinders (AREA)
  • Cylinder Crankcases Of Internal Combustion Engines (AREA)
  • Drilling And Boring (AREA)
  • Finish Polishing, Edge Sharpening, And Grinding By Specific Grinding Devices (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)

Description

Ovaj izum odnosi se na metodu izrade košuljice cilindra za klipni motor, kao što je velik dvotaktni klipni motor, po kojoj je radna površina za klipne prstenove na unutrašnjoj površini košuljice izrađena najprije urezivanjem valovitosti s razlikom između razina vrhova i dolova valova od najmanje 0,005 mm na unutarnjoj površini s najmanje jednim reznim alatom koji ima zakrivljen rezni brid i zatim odstranjivanjem vrhova valova, barem na radnoj površini najbližoj krajnjem središnjem položaju vrha klipa, tako da uzdužni dio unutarnje površine gotove košuljice ima djelomično valovitu površinu na kojoj su dolovi valova odvojeni s uglavnom ravnim površinama. This invention relates to a method of making a cylinder liner for a piston engine, such as a large two-stroke piston engine, in which the working surface for the piston rings on the inner surface of the liner is made by first carving corrugations with a difference between the peak and trough levels of the waves of at least 0.005 mm on inner surface with at least one cutting tool having a curved cutting edge and then removing the crests of the waves, at least on the working surface closest to the end center position of the piston tip, so that the longitudinal portion of the inner surface of the finished liner has a partially corrugated surface where the crests of the waves are separated by a generally flat surfaces.

Njemački patent br. 683262 opisuje košuljicu cilindra izrađenu metodom ove vrste, gdje su vrhovi valova odstranjeni brušenjem unutarnje površine košuljice. Ta metoda zahtjeva odmicanje od uređaja za strojno urezivanje valovitosti na unutarnjoj površini, i stavljale u novi položaj na brusilici. Osim toga, samo brušenje je skupo i dugotrajna strojna obrada, pri čemu glava s nekoliko rotirajućih brusnih kamenova prolazi uzduž kroz košuljicu, dok se ona okreće tako da brusni kamenovi stružeći skidaju materijal s vrhova valova. Osobito u slučaju velikih košuljica cilindra, brusna oprema je skupa investicija. German patent no. 683262 describes a cylinder liner made by a method of this type, where the crests of the waves are removed by grinding the inner surface of the liner. This method requires moving away from the device for machine engraving the corrugation on the inner surface, and placing it in a new position on the grinder. In addition, grinding itself is expensive and time-consuming machining, where a head with several rotating grinding stones passes along the liner, while it rotates so that the grinding stones scrape the material off the crests of the waves. Especially in the case of large cylinder liners, grinding equipment is an expensive investment.

Švicarski patent br. 342409 opisuje košuljicu cilindra u kojoj je radna površina za klipne prstenove izrađena s urezanjem valovitosti u unutarnju površinu košuljice. Takova košuljica zove se valoviti urez, i oblik je obično spiralan, rezni alat se gura u uzdužnom smjeru košuljice određenom brzinom dok se košuljica okreće. Unapređenje spomenuto u švicarskom patentu je da se u utorima skuplja ulje od podmazivanja tako da nastaju džepovi ulja koji potiču podmazivanje između klipnih prstenova i unutarnje površine košuljice. Swiss patent no. 342409 describes a cylinder liner in which the working surface for the piston rings is made by cutting corrugations into the inner surface of the liner. Such a liner is called a wavy cut, and the shape is usually spiral, the cutting tool is pushed in the longitudinal direction of the liner at a certain speed while the liner rotates. An improvement mentioned in the Swiss patent is that lubrication oil collects in the grooves so that pockets of oil are formed which promote lubrication between the piston rings and the inner surface of the liner.

Urezivanje valovitosti u unutarnjoj površini košuljice, koja se slaže s uzdužnim smjerom košuljice, osigurava proizvodnu prednost da se izbjegava brušenje unutarnje površine, zbog strojeva za urezivanje valovitosti košuljice na željenu unutarnju izmjeru promjera. Kad se košuljica stavi u pogon, klipni prstenovi skidaju vrhove valova, tako da između dolova valova nastaju ravne površine, ali se klipni prstenovi istovremeno istroše. Cutting the corrugation in the inner surface of the liner, which coincides with the longitudinal direction of the liner, provides the manufacturing advantage of avoiding grinding the inner surface, due to machines for cutting the corrugation of the liner to the desired inner diameter measurement. When the liner is put into operation, the piston rings remove the crests of the waves, so that flat surfaces are formed between the troughs of the waves, but the piston rings wear out at the same time.

Razvoj velikih dvotaktnih klipnih motora ide prema sve većem učinu cilindra, a time također prema povećanju efektivnog prosječnog pritiska. Većina suvremenih motora može se izraditi s učinom cilindra sve do 5,700 kW s efektivnim prosječnim pritiskom od 18,2 bara. To postavlja vrlo velike zahtjeve prema klipnim prstenovima i košuljicama cilindra, jer pad pritiska preko klipnih prstenova, a time također i sile njihovog dodira s unutarnjom površinom košuljice, postaje velik. Stoga je moguće predvidjeti probleme kod uhodavanja klipova i košuljice ako je u unutarnjoj površini košuljice urezana čista valovitost, preostali, oštri vrhovi valova mogu izazvati nagrizanje klipnih prstenova. The development of large two-stroke piston engines leads to an ever-increasing cylinder power, and thus also to an increase in the effective average pressure. Most modern engines can be built with cylinder power up to 5,700 kW with an effective average pressure of 18.2 bar. This places very high demands on piston rings and cylinder liners, because the pressure drop across the piston rings, and thus also the force of their contact with the inner surface of the liner, becomes large. Therefore, it is possible to foresee problems when running in the pistons and the liner if a clean corrugation is etched into the inner surface of the liner, the remaining, sharp crests of the waves can cause corrosion of the piston rings.

Danski patent br. 139111 opisuje košuljicu cilindra koja u svojoj unutarnjoj površini ima spiralno urezani utor u kojem je uspon spiralnog oblika tako velik da su dna valova odvojena ravnim površinama duljine L od, na primjer, 4 mm u uzdužnom smjeru cilindra. Prije nego se utor ureze, košuljica se mora izbrusiti, što izradu košuljice čini skupom, jer u prvoj fazi treba ju strojno obraditi na njenu približnu krajnju unutarnju dimenziju, a zatim se ona mora podvrgnuti brušenju i izbrusiti, i zatim opet vratiti u prvi položaj za urezivanje utora. Košuljice cilindra za velike motore su teški dijelovi čije premještanje na uređajima za strojnu obradu je dugotrajno. Danish patent no. 139111 describes a cylinder liner having a spirally cut groove in its inner surface in which the rise of the spiral shape is so large that the bottoms of the waves are separated by flat surfaces of length L of, for example, 4 mm in the longitudinal direction of the cylinder. Before the groove is cut, the liner must be ground, which makes the manufacture of the liner expensive, because in the first stage it has to be machined to its approximate innermost dimension, then it has to be ground and ground, and then returned to its original position for grooving. Cylinder liners for large engines are heavy parts that take a long time to move on machining equipment.

JP-A 5-65849 opisuje blok cilindra za klipni motor, u kojem se cilindar nakon bušenja podvrgava postupku brušenja stvarajući tragove brušenja ili utore u obliku brazdi. Ti tragovi brušenja uključuju mala oštra ispupčenja koja mogu uzrokovati oštećenje klipnih prstenova. Da se to spriječi unutarnja strana cilindra je polirana s nekoliko alata za valjanje. Taj postupak odstranjivanja malih ispupčenja brušenjem na cilindričnoj površini dobro je poznat postupak. Blok cilindra opisan u tom japanskom dokumentu također treba stavljati u nekoliko položaja na različitim stojevima. JP-A 5-65849 describes a cylinder block for a reciprocating engine, in which the cylinder, after drilling, is subjected to a grinding process to create grinding marks or grooves in the form of grooves. These grinding marks include small sharp protrusions that can cause damage to the piston rings. To prevent this, the inside of the cylinder is polished with several rolling tools. This process of removing small protrusions by grinding on a cylindrical surface is a well-known process. The cylinder block described in that Japanese document also needs to be placed in several positions on different stands.

Predmet izuma je osigurati metodu izrade košuljica cilindra s unaprijeđenim prekidanjem valovitosti na takav način da se može izbjeći opremu za skupo brušenje i da je olakšano rukovanje s košuljicom, te da je manji utrošak vremena za njenu izradu. The object of the invention is to provide a method of manufacturing cylinder liners with improved undulation interruption in such a way that expensive grinding equipment can be avoided and that the handling of the liner is facilitated, and that the time required for its manufacture is less.

S tog stajališta metoda prema izumu naznačena je time, da košuljica cilindra ima unutarnji promjer u rasponu od 25 cm do 100 cm i duljinu u rasponu od 100 cm do 400 cm, da su vrhovi valova odstranjeni bez primjene brušenja, plastičnom kompresijom najmanje 0,004 mm od njihove visine u rečenu uglavnom ravnu površinu, i da su dna valova, nakon kompresije, u razini za najmanje 0,001 mm nižoj od te površine. From this point of view, the method according to the invention is indicated by the fact that the cylinder liner has an inner diameter in the range from 25 cm to 100 cm and a length in the range from 100 cm to 400 cm, that the crests of the waves are removed without applying grinding, by plastic compression of at least 0.004 mm from their heights into said mostly flat surface, and that the bottoms of the waves, after compression, are at a level at least 0.001 mm lower than that surface.

Plastična kompresija može se provesti tehnici nekompliciranim postupkom s relativno jednostavnom i jeftinom opremom A vrlo velike košuljice mogu se držati u jednom te istom namještenom položaju dok se valovitost urezuje u unutarnju površinu košuljice i vrhovi valova se komprimiraju u uglavnom ravnu površinu. K tome, ušteđena su ulaganja u opremu za brušenje, rečena oprema je vrlo skupa za te velike košuljice. Nadalje, u približno ravnoj površini između dna valova unutarnja površina košuljice poprima svojstvo koje je vrlo poželjno za uhodavanje košuljice i klipnih prstenova. Na valjanoj površini nema oštrih ispupčenja, ali s druge strane ona nije potpuno izglačana ili sjajna kao ogledalo, što bi moglo izazvati teškoće podmazivanja između košuljice i klipnih prstenova. Plastic compression can be carried out by a technically uncomplicated process with relatively simple and inexpensive equipment. And very large liners can be held in one and the same fixed position while corrugation is cut into the inner surface of the liner and the crests of the waves are compressed into a mostly flat surface. In addition, investments in grinding equipment were saved, said equipment is very expensive for those large liners. Furthermore, in the approximately flat surface between the bottoms of the waves, the inner surface of the liner takes on a property that is highly desirable for running in the liner and piston rings. There are no sharp bumps on the rolled surface, but on the other hand, it is not completely polished or shiny like a mirror, which could cause lubrication difficulties between the liner and the piston rings.

Plastična kompresija vrlova valova može se provesti, na primjer, valjanjem s malim priborom za valjanje, kojem se daje prednost, jer 36 oprema za to vrlo jednostavna. Alternativno, valjanje se može provesti pomoću jednog valjka koji se proteže po cijelog dužini košuljice. Spomenuta ograničenja visina valovitosti površine posebno su korisna za valovistost koja prije valjanja ima razliku razina imedu dna i vrhova valova od 0,01 - 0,02 mm. S plastičnom deformacijom vrhova valova unutar gornjeg raspona granica, unutarnja površina košuljice dobiva površinu koja osigurava lagano uhodavanje klipnih prstenova. Ako dubina dna valova postaje manja od 0,001 mm, dobiveni uvjeti podmazivanja neće biti zadovoljavajući. Plastic compression of the corrugations can be carried out, for example, by rolling with a small rolling tool, which is preferred because the equipment for this is very simple. Alternatively, rolling can be carried out using a single roller that extends along the entire length of the liner. The aforementioned limitations of the height of the surface corrugation are especially useful for the corrugation which, before rolling, has a level difference between the bottom and the top of the waves of 0.01 - 0.02 mm. With the plastic deformation of the crests of the waves within the upper range of limits, the inner surface of the liner acquires a surface that ensures easy running-in of the piston rings. If the depth of the bottom of the waves becomes less than 0.001 mm, the obtained lubrication conditions will not be satisfactory.

Valovitost se ponajprije urezuje u unutarnoj površini košuljice pomoću spomenutog najmanje jednog reznog alata koji se pomiče u uzdužnom smjeru košuljica pomoću šipke za bušenje s brzinom uvlačenja, dok se košuljice okreće tako da se oblikuje valovitost kao barem jedan spiralni urez, a plastična kompresija se provodi valjanjem unutarnje površine s alatom za valjanje koji se pomiče prema naprijed pomoću iste šipke za bušenje kao i rezni alat. Time se štedi vrijeme potrebno za premještanje košuljice cilindra s jednog jednog stroja te za namještanje na drugi stroj. Kad se spiralni urez ureze u unutarnjoj površini košuljice, šipka za bušenje može se izvući iz košuljice i montira se alat valjanje, nakon čega se šipka za bušenje opet umeće u košuljicu i provodi se valjanje. Alati za rezanje i valjanje također se mogu montirati u određene poprečne klizače ili u određene držače, tako da se pravilna izmjena alata može se provesti povlačenjem alata natrag ili naprijed u odnosu na površinu košuljice prema potrebi. Šipka za bušenje s reznim alatom prilagođena je za namještanje dubine urezivanja reznog alata radijalnim pomicanjem alata, i. stoqa se pritisak valjanja može prikladno podesiti premještanjem alata za valjanje u radijalnom smjeru košuljice tako da se iskoriste postojeće mogućnosti namještanja šipke za bušenje. The corrugation is preferably incised in the inner surface of the liner by said at least one cutting tool which is moved in the longitudinal direction of the liner by means of a drill rod at a feed rate, while the liner is rotated to form the corrugation as at least one spiral notch, and the plastic compression is carried out by rolling internal surfaces with the rolling tool moved forward by the same drill rod as the cutting tool. This saves the time needed to move the cylinder liner from one machine and to adjust it to another machine. When the spiral notch is cut into the inner surface of the liner, the drill rod can be withdrawn from the liner and the rolling tool mounted, after which the drill rod is reinserted into the liner and rolling is carried out. Cutting and rolling tools can also be mounted in specific cross-slides or in specific holders, so that proper tool change can be accomplished by pulling the tool back or forward relative to the liner surface as needed. The drill rod with cutting tool is adapted to adjust the cutting depth of the cutting tool by radially moving the tool, i. so the rolling pressure can be conveniently adjusted by moving the rolling tool in the radial direction of the liner so as to take advantage of the existing possibilities of adjusting the drilling rod.

Valjanje se također može provesti s alatom za valjanje, koji ima nekoliko valjaka montiranih u glavi alata, koja je poznata za valjanje unutarnje površine cijevi, ali takav alat je najprikladniji za relativno male promjere cijevi, gdje je promjer cijevi konstantan. Plastična kompresija provodi se ponajprije valjanjem s alatom za valjanje koji ima samo jedan valjak, čiji radijalan položaj se može namjestiti u odnosu prema unutarnjoj površini košuljice, i koji se može pomaknuti prema naprijed u uzdužnom smjeru košuljice dok se košuljica okreće. To omogućuje da se za valjanje košuljica različitog promjera upotrebljava isti alat. Upotreba jednostrukog valjka također dopušta da se pritisak valjanja podesi vrlo precizno radijalnim pomicanjem valjka, tako da izbjegava prekomjerno poravnavanje valovitosti. Ako se upotrebljava nekoliko valjaka, simultana kontrola valjaka mora se izvršiti u uskim granicama, što može biti teško, osobito jer promjene sila na jednom valjku mogu se prenijeti na drugi valjak (druge valjke). Rolling can also be carried out with a rolling tool, which has several rollers mounted in the tool head, which is known for rolling the inner surface of the pipe, but such a tool is most suitable for relatively small diameter pipes, where the diameter of the pipe is constant. Plastic compression is primarily carried out by rolling with a rolling tool having only one roller, the radial position of which can be adjusted relative to the inner surface of the liner, and which can be moved forward in the longitudinal direction of the liner as the liner rotates. This allows the same tool to be used for rolling liners of different diameters. The use of a single roller also allows the rolling pressure to be adjusted very precisely by radially moving the roller, thus avoiding excessive corrugation alignment. If several rollers are used, the simultaneous control of the rollers must be carried out within narrow limits, which can be difficult, especially since changes in the forces on one roller can be transmitted to the other roller(s).

Poželjno je da je alat za valjanje povezan s indikatorom trenutnog pritiska valjanja, tako da se pritisak valjanja može promatrati i da se može provesti krajnje namještanje tijekom valjanja unutarnje površine. Košuljice cilindra često se proizvode serijski za jedan motor ili za različite motore iste vrste, i u takovoj serijskoj proizvodnji indikator se također može upotrijebiti za ponovnu primjenu iskustva glede prikladnog pritiska valjanja za specifičnu veličinu košuljice cilindra i za namještanje alata za valjanje na početku valjanja košuljice. Preferably, the rolling tool is connected to a current rolling pressure indicator so that the rolling pressure can be observed and final adjustments can be made while rolling the inner surface. Cylinder liners are often produced in series for a single engine or for different engines of the same type, and in such series production the indicator can also be used to re-apply experience as to the appropriate rolling pressure for a specific cylinder liner size and to set up the rolling tool at the start of liner rolling.

Da se olakša izradu košuljice, urezivanje valovitosti može se provesti s tolerancijom razmaka ureza unutarnjeg promjera košuljice, na primjer od, na primjer, ±0,1 - 0,2 mm kad je promjer košuljice u rasponu od 25 i 100 cm. Unatoč toj toleranciji, visina valovitosti urezuje se s mnogo manjom tolerancijom, na primjer, od ±0,003 mm ili manjom, jer lučni oblik reznog brida reznog alata ima vrlo velik radius od, na primjer, 100 mm do 800 mm, ovisno o unutarnjem promjeru košuljice i željenoj visini valovitosti, i budući da se promjene promjera dešavaju tako polako da se susjedni valovi urezuju uglavnom s jednakim promjerima. Zahvaljujući toleranciji promjera košuljice, alat za valjanje može prikladno održavati željeni pritisak valjanja pomicanjem alata u uzdužnom smjeru košuljice, iako se unutarnji promjer košuljice mijenja po duljini košuljice. To facilitate liner fabrication, corrugation notching can be performed with a liner inner diameter notch spacing tolerance of, for example, ±0.1 - 0.2 mm when the liner diameter is in the range of 25 and 100 cm. Despite this tolerance, the waviness height is cut with a much smaller tolerance, for example ±0.003 mm or less, because the arcuate shape of the cutting edge of the cutting tool has a very large radius of, for example, 100 mm to 800 mm, depending on the inside diameter of the liner and the desired corrugation height, and since diameter changes occur so slowly that adjacent corrugations are cut with mostly equal diameters. Thanks to the liner diameter tolerance, the rolling tool can conveniently maintain the desired rolling pressure by moving the tool in the longitudinal direction of the liner, even though the inner diameter of the liner changes along the length of the liner.

Budući da su promjene promjera malene, pritisak valjanja može se održati s vrlo jednostavnom konstrukcijom alata pomoću alata za valjnje poduprtog ručicom koja je savinuta prema unutra u granicama svoje elastičnosti u radijalnom smjeru košuljice kad se primjenjuje pritisak valjanja, čime ručica kompenzira promjene promjera opružnim vraćanjem u radijalni smjer. Alternativno, alat za valjanje može se montirati na križni kliznik koji se može kontinuirano podešavati u radijalnom smjeru pomoću uređaja za namještanje na osnovi signala iz gornjeg indikatora za trenutni pritisak valjanja. Since diameter changes are small, rolling pressure can be maintained with a very simple tool design using a rolling tool supported by a lever that is bent inwards within its elastic limits in the radial direction of the liner when rolling pressure is applied, whereby the lever compensates for diameter changes by springing back into radial direction. Alternatively, the rolling tool can be mounted on a cross slide which can be continuously adjusted in the radial direction by means of an adjusting device based on the signal from the top indicator for the current rolling pressure.

Kad je klipni motor u pogonu, pritisak u komori iznad klipa opada s kasnijim odmicanjem od gornjeg krajnjeg središnjeg položaja, a smanjenje pritiska dovodi do manjih sila između klipnih prstenova i košuljice. When a reciprocating engine is in operation, the pressure in the chamber above the piston decreases with subsequent movement from the upper end center position, and the reduction in pressure leads to lower forces between the piston rings and the liner.

U određenim slučajevima može biti moguće proizvesti košuljicu na takav način da se samo provede valjanje u gornjem odsječku košuljice koji uključuje površinu po kojoj najviši klipni prsten kliže kad se klip odmiče iz svog gornjeg krajnjeg središta, i dio puta klipa prema doljnjem krajnjem središnjem položaju. Valjanje unutarnje površine odvija se tako brzo da se ograničenjem valjanja samo na gornji odsječak košuljice ne uštedi značajno vrijeme, ali se ustediti opremu za valjanje, osobito u slučaju vrlo velikih košuljica duljine sve do 400 cm, jer šipka za bušenje ne mora biti tako velika. In certain cases it may be possible to manufacture the liner in such a way that only rolling is carried out in the upper section of the liner which includes the surface on which the uppermost piston ring slides as the piston moves from its upper end center, and part of the way of the piston towards the lower end center position. The rolling of the inner surface takes place so quickly that limiting the rolling to only the upper section of the liner does not save significant time, but saves rolling equipment, especially in the case of very large liners up to 400 cm long, because the drill rod does not have to be so large.

Vrhovi valova mogu se deformirati valjanjem tako da područje uglavnom ravnih površina između dna valova tvori od 25% do 75% od ukupne površine košuljice u valjanom području. Ako ravna područja tvore manje od 25%, dodirna površina klipnih prstenova postaje premala, što može uzrokovati oštećenja materijala prstenova zbog prekomjernog zagrijavanja, jer se od košuljice toplina ne odvodi dovoljno. Nedovoljna dodirna površina može također uništiti učinak tlačnog brtvijenja klipnih prstenova. Ako ravna područja tvore više od 75%, kvare se uvjeti podmazivanja (tribološki uvjeti) jer uljnji džepovi postaju premaleni. Vrhovi valova ponajprije se deformiraju val jari j em tako da područje uglavnom ravnih površina između dna valova tvori 40% do 60% od ukupne površine u valjanom područiu. To je kompromis između kontradiktornih razmatranja za uvjete podmazivanja i toplinska opterećenja i tlačnu zabrtvljenost, osiguravajući istovremeno prikladan razmak prema gordim početnim ograničenjima, tako da određene proizvodne nepreciznosti neće biti od vitalne važnosti za radne uvjete košuljice. The tops of the waves can be deformed by rolling so that the area of mostly flat surfaces between the bottoms of the waves forms from 25% to 75% of the total surface of the liner in the rolled area. If the flat areas make up less than 25%, the contact surface of the piston rings becomes too small, which can cause damage to the material of the rings due to excessive heating, because the heat is not dissipated enough from the liner. Insufficient contact surface can also destroy the pressure sealing effect of the piston rings. If the flat areas make up more than 75%, the lubrication conditions (tribological conditions) deteriorate because the oil pockets become too small. The crests of the waves are primarily deformed by the wave so that the area of mostly flat surfaces between the bottoms of the waves forms 40% to 60% of the total surface in the rolled area. It is a compromise between the conflicting considerations of lubrication conditions and thermal loads and pressure sealing, while providing adequate clearance to the proud initial constraints, so that certain manufacturing inaccuracies will not be of vital importance to the operating conditions of the liner.

Sposobnost klipnih prstenova da brtve nasuprot vrlo visokim pritiscima u komori za sagorijevanje može se osigurati deformacijom vrhova valova valjanjem tako da se uglavnom ravna površina između konsekutivnog dna vala produži u uzdužnom smjeru košuljice, unutar intervala od ±1 mm, što odgovara četvrtini visine klipnog prstena najmanje visine. Kad se klip u tako izrađenoj košuljici cilindra pomakne se uzdužno u području s valovitošću, svaki od klipnih prstenova je okružen s najmanje dvije konsekutivne ravne površine, koje sprečavaju puhanje komprimiranog plina iznad klipa kroz spiralne utore ili skroz dolje ispod klipnog prstena. Najprikladnije, vrhovi valova mogu se deformirati tako da se uuglavnom ravnu površinu komprimira najmanje 0,006 mm i najviše 0,018 mm, ponajprije najviše 0,015 mm od visine vrhova valova, i da su dna valova pri kod istoj razini najamnje 0,002 mm ispod tih površina. Ako se te neravne granice mjestimično prekorače, ipak je moguće da unutarnja površina košuljice bude prihvatljiva. The ability of the piston rings to seal against very high pressures in the combustion chamber can be ensured by deforming the tops of the waves by rolling so that the generally flat surface between consecutive bottoms of the wave extends in the longitudinal direction of the liner, within an interval of ±1 mm, corresponding to a quarter of the height of the piston ring at least Heights. When the piston in the cylinder liner thus made is moved longitudinally in the undulation region, each of the piston rings is surrounded by at least two consecutive flat surfaces, which prevent the compressed gas from blowing above the piston through the spiral grooves or all the way down under the piston ring. Most conveniently, the crests of the waves can be deformed so that the generally flat surface is compressed at least 0.006 mm and at most 0.018 mm, preferably at most 0.015 mm from the height of the crests of the waves, and the bottoms of the waves at the same level are at least 0.002 mm below those surfaces. If these uneven boundaries are exceeded in places, it is still possible for the inner surface of the liner to be acceptable.

Metoda odsijecanja valovitosti prema izumu, kojoj se daje prednost, preoblikovana je tako, da prosječna radijalna razlika razina između dobivenih, uglavnom ravnih površina i dna valova predstavlja između 7% i 66% od prosječne razlike razina između vrhova valova i dna valova oblika prije kompresije, a ponajprije između 16% i 36% od toga. The preferred waviness cutting method according to the invention is reshaped so that the average radial level difference between the obtained, generally flat surfaces and the bottom of the waves represents between 7% and 66% of the average level difference between the wave crests and the wave bottoms of the shape before compression, and preferably between 16% and 36% of that.

Izum se također odnosi na košuljicu cilindra za klipni motor, kakav je veliki dvotaktni klipni motor, koja ima radnu površinu za klipne prstenove na unutarnjoj površini košuljice, koja radna površina barem u području najbližem do najvišeg krajnjeg središnjeg položaja klipa ima djelomično valovit oblik u kojem su dna valova odvojena s uglavnom ravnim površinama. Ta košuljice cilindra prema izumu obilježena je time da ima unutarnji promjer u rasponu od 25 cm do 100 cm i duljinu u rasponu od 100 cm do 400 cm, da su uglavnom ravne površine valjane površine bez oštrih ispupčenja, da su dna valova u razini za najmanje 0,001 mm ispod od tih površina, i da se uglavnom ravna površina između konsekutivnih dna valova proteže u uzdužnom smjeru košuljice koja unutar raspona ±1 mm odgovara četvrtini visine klipnog prstena najmanje visine. Košuljica cilindra ima gore spomenuta poboljšana svojstva radne površine. The invention also relates to a cylinder liner for a reciprocating engine, such as a large two-stroke reciprocating engine, having a working surface for the piston rings on the inner surface of the liner, which working surface at least in the region closest to the highest end center position of the piston has a partially wavy shape in which wave bottoms separated by mostly flat surfaces. These cylinder liners according to the invention are characterized by the fact that they have an inner diameter ranging from 25 cm to 100 cm and a length ranging from 100 cm to 400 cm, that they are mostly flat rolled surfaces without sharp protrusions, that the bottoms of the waves are level for at least 0.001 mm below those surfaces, and that a generally flat surface between consecutive wave bottoms extends in the longitudinal direction of the liner corresponding within ±1 mm to a quarter of the height of the smallest piston ring. The cylinder liner has the improved working surface properties mentioned above.

Primjeri izuma bit će sada objašnjeni u nastavku u daljnjim pojedinostima s osvrtom na posve shematske crteže, od kojih Examples of the invention will now be explained below in further detail with reference to the fully schematic drawings, of which

slika 1 prikazuje djelomično bokocrt, posebno uzdužni prosjek košuljice cilindra, figure 1 shows a partial side view, especially the longitudinal average of the cylinder liner,

slika 2 prikazuje pogled u perspektivi na košuljicu cilindra postavljenu u uređaj za strojnu obradu, prikazan djelomično, Fig. 2 shows a perspective view of a cylinder liner placed in a machining apparatus, partially shown,

slika 3 je pogled u perspektivi na alat za valjanje, Figure 3 is a perspective view of the rolling tool,

slika 4 prikazuje bokocrt drugog alata za valjanje, Figure 4 shows a side view of another rolling tool,

slika 5 prikazuje jako povećan uzdužni odsječak unutarnje površine košuljice cilindra, valjane prema izumu, figure 5 shows a greatly enlarged longitudinal section of the inner surface of the cylinder liner, rolled according to the invention,

slika 6 pokazuje pet puta povećanu fotografiju unutarnje površine valovitog ureza i djelomično brušenu košuljicu cilindra, figure 6 shows a five-fold enlarged photograph of the inner surface of the corrugated notch and a partially ground cylinder liner,

slika 7 je slična fotografija cilindra košuljice koja je bila valovito urezana i valjana sukladno izumu, Figure 7 is a similar photograph of a liner cylinder that has been corrugated and rolled in accordance with the invention,

slika 8 je snimka mjerenja hrapavosti učinjenog na unutarnjoj površini košuljice prikazane na slici 6, i Figure 8 is a snapshot of the roughness measurement made on the inner surface of the liner shown in Figure 6, i

slika 9 je snimka mjerenja hrapavosti učinjenog na unutarnjoj površini košuljice prikazane na slici 7. Figure 9 is a snapshot of the roughness measurement made on the inner surface of the liner shown in Figure 7.

Slika 1 pokazuje košuljicu cilindra 1 za velik dvotaktni klipni motor. Ovisno o veličini motora košuljica cilindra može biti izrađena u različitim veličinama s unutarnjim promjerima tipično u rasponu od 25 cm do 100 cm, i odgovarajućim tipičnim duljinama u rasponu od 100 cm do 400 cm, Košuljica se normalno radi od lijevanog željeza, i može biti izlivena integralno ili odvojeno, u dva dijela spojena zajedno, kraj na kraj. Na slici 1, prikazana je polovica košuljice u uzdužnom odsječku. Košuljica se može montirati na dobro poznati način u motor, koji nije prikazan, postavljanjem anularne, prema dolje okrenute površine 3 na gornju ploču okvira kućišta motora ili blok cilindra, nakon čega se klip 4 s klipnim prstenovima 5 montira u cilindar, a pokrov cilindra postavljen je na vrh košuljice na svoju anularnu, prema gore okrenutu površinu 6 i pritegnut je na gornju ploču. Figure 1 shows cylinder liner 1 for a large two-stroke piston engine. Depending on the size of the engine, the cylinder liner can be made in various sizes with internal diameters typically ranging from 25 cm to 100 cm, and corresponding typical lengths ranging from 100 cm to 400 cm. The liner is normally made of cast iron, and can be cast integral or separate, in two parts joined together, end to end. In Figure 1, half of the liner is shown in longitudinal section. The liner can be mounted in a well-known manner in the engine, not shown, by placing the annular, downward facing surface 3 on the upper plate of the engine housing frame or cylinder block, after which the piston 4 with piston rings 5 is mounted in the cylinder, and the cylinder cover is placed is on top of the liner on its annular, upwardly facing surface 6 and is clamped to the top plate.

Klipni prstenovi 5 kližu uzduž unutarnje površine košuljice 7, i zbog toga je važno da unutarnja površina ima strukturu koja osigurava dobro podmazivanje između prstenova i unutarnje površine, -tako da se izbjegne struganje ili nagrizanje između stranica prstenova i unutarnje površine košuljice. Tijekom rada klipa i košuljice u novom motoru struktura površine je naročito velike važnosti. The piston rings 5 slide along the inner surface of the liner 7, and therefore it is important that the inner surface has a structure that ensures good lubrication between the rings and the inner surface, -so as to avoid scraping or etching between the sides of the rings and the inner surface of the liner. During the operation of the piston and liner in a new engine, the surface structure is particularly important.

Kako je gore spomenuto, zbog toga je poželjno izraditi košuljicu cilindra s valovitošću na njenoj unutarnjoj površini, gdje se vrhovi valova odstranjuju. Moguće je izraditi košuljicu dotičnog oblika po cijeloj dužini njene unutarnje površine. Valovitost se također može izraditi strojno samo u gornjem dijelu košuljice, tako da klipni prstenovi 5 zahvaćaju odsječak od prvih 40% puta klipa prema dolje. Odječak također može biti drugačijih relativnih veličina, kao što je 20%, 25%, 30% ili 35% ili neke od srednjih vrijednosti. As mentioned above, it is therefore desirable to make a cylinder liner with corrugations on its inner surface, where the crests of the corrugations are removed. It is possible to make a liner of the respective shape along the entire length of its inner surface. The corrugation can also be machined only in the upper part of the liner, so that the piston rings 5 engage a section from the first 40% of the piston's travel down. The reverberation can also be of different relative magnitudes, such as 20%, 25%, 30%, or 35%, or some intermediate value.

Strojna obrada unutarnje površine 7 košuljice gotova je prije skupljanja zračnog raspora 8 strojnom obradom u dolnjem dijelu košuljice. To se vrši na vrlo velikoj bušilici konstruiranoj kao vrsti tokarilice velikih dimenzija, prikazanoj samo djelomično na slici 2. U nastavku stroj se naziva tokarilica. Pomoću dizalice podigne se košuljicu s vodoravnim uzdužnim osima i centrira se u odnosu prema osi rotacije tokarilice, nakon čega se pomoću četiri pritegača 9 jedan kraj košuljice pritegne na pogonsko vreteno tokarilice, dok je drugi kraj košuljice poduprt u središnjem položaju s držačem 10, koji ima nekoliko podupirućih valjaka 11 koji putuju po vanjskoj površini košuljice. Držač 10 može se pomicati po nosaču 12 tokarilice. The machining of the inner surface 7 of the liner is finished before the air gap 8 is compressed by machining in the lower part of the liner. This is done on a very large drill constructed as a type of large lathe, shown only partially in Figure 2. Hereinafter the machine is referred to as a lathe. Using a crane, a liner with horizontal longitudinal edges is lifted and centered in relation to the axis of rotation of the lathe, after which one end of the liner is tightened onto the drive spindle of the lathe by means of four tensioners 9, while the other end of the liner is supported in the central position with a holder 10, which has several supporting rollers 11 that travel on the outer surface of the liner. The holder 10 can be moved on the support 12 of the lathe.

Na suprotnom kraju vretena, tokarilica ima sedlo, koje nije prikazano, koje podupire vrlo tešku i krutu šipku za bušenje 13, koja se pomiče premještanjem sedla na nosaču tokarilice u ili iz košuljice cilindra koaksijalno s njenom uzdužnom osi.. Na kraju najbližem vretenu, šipka za bušenje ima držač alata 14 u obliku križnog klizača sposobnog za podešavanje alata 15 u radijalnom smjeru košuljice. At the opposite end of the spindle, the lathe has a saddle, not shown, which supports a very heavy and rigid boring bar 13, which is moved by moving the saddle on the lathe carriage into or out of the cylinder liner coaxially with its longitudinal axis. At the end nearest the spindle, the bar for drilling has a tool holder 14 in the form of a cross slide capable of adjusting the tool 15 in the radial direction of the liner.

Kad je košuljica postavljena, vreteno s košuljicom se okreće, i unutarnja površina 7 se okreće u smjeru s točnošću od, na primjer, 5 mm prema promjeru. Tada se vrši fino okretanje s oštricom alata koja ima zakrivljen rezni brid tako da se finim okretanjem zarezivanjem dobije željeni oblik dna valova u valovito zarezanoj unutarnjoj površini košuljice. Razmak S (slika 5) između dva konsekutivna vrha vala podešava se po želji pomicanjem prema naprijed uzdužnim pomicanjem šipke za bušenje, razmak je iste brzine kao i brzina uvlačenja. U košuljici cilindra s unutarnjim promjerom od 98 cm, brzina uvlačenja od 8 mm po okretaju košuljice cilindra može biti prikladna, dok je brzina uvlačenja od 4 mm bila odabrana za košuljicu cilindra unutarnjeg promjera od 50 cm ili manjeg. Razmak se može odabrati tako da odgovara polovici visine klipnog prstena najmanje visine. When the liner is installed, the spindle with the liner rotates, and the inner surface 7 rotates in a direction with an accuracy of, for example, 5 mm according to the diameter. Fine turning is then performed with a tool blade that has a curved cutting edge so that the desired shape of the bottom of the waves in the corrugated inner surface of the liner is obtained by fine turning and scoring. The distance S (Figure 5) between two consecutive crests of the wave is adjusted as desired by moving the drill rod forward longitudinally, the distance is the same speed as the feed speed. In a cylinder liner with an inner diameter of 98 cm, a feed rate of 8 mm per cylinder liner revolution may be suitable, while a feed rate of 4 mm was chosen for a cylinder liner with an inner diameter of 50 cm or less. The gap can be chosen to match half the height of the smallest piston ring.

Radijalna razlika u razinama h (slika 5) između vrhova valova i dna određena je zakrivljenošću brida oštrice alata, tako da jača zakrivljenost osigurava veću razliku razina. Razlika u razinama može biti najviše 0,06 mm, ali normalno se preporuča od 0,01 do 0,02 mm. The radial difference in levels h (Figure 5) between the crests and bottoms of the waves is determined by the curvature of the edge of the tool blade, so that a stronger curvature ensures a greater difference in levels. The difference in levels can be a maximum of 0.06 mm, but normally 0.01 to 0.02 mm is recommended.

Nakon urezivanja valovitosti šipka za bušenja se izvlači iz košuljice, i stavlja se alat za valjanje radijalno u odnosu prema unutarnjoj površini 7, nakon čega se valja unutarnja površina tako da se materijal u vrhovima valova plastično deformira, tj . preša se radijalno prema van, tako da završena unutarnja površina dobije oblik prikazan na slici 5 sa spiralnim utorom ili valom kroz 17. Uzdužni odsječak u unutarnjoj površini košuljice, prikazan na slici 5, uništen je zbog razmaka, tako da su dimenzije u radijalnom smjeru produžene više puta. U uzdužnom smjeru dna valova su odvojena ravnim područjima 18, tvoreći zajedno 25-75%, a tipično 40-60% od daljine košuljice s valovitog oblika. After cutting the corrugations, the drill rod is pulled out of the liner, and the rolling tool is placed radially in relation to the inner surface 7, after which the inner surface is rolled so that the material in the crests of the waves is plastically deformed, i.e. is pressed radially outward, so that the finished inner surface takes the shape shown in Figure 5 with a spiral groove or wave through 17. The longitudinal section in the inner surface of the liner, shown in Figure 5, is destroyed due to clearance, so that the dimensions in the radial direction are extended Multiple times. In the longitudinal direction, the bottoms of the waves are separated by flat areas 18, forming together 25-75%, and typically 40-60% of the distance of the liner from the corrugated form.

U jednostavnoj konstrukciji prikazanoj na slici 3 alat za valjanje može uključiti valjak 19, koji je montiran tako da se može okretati u račvastoj glavi 20 na kraju križne ručice 21 učvršćene u udubljenju u držaču alata 22, koji je poduprt sa šipkom za bušenje 13. Držač alata ili sam alat može imati određenu ograničenu savitljivost u radijalnom smjeru košuljice, tako da se s elastičnim savijanjem držača apsorbiraju promjene od nekoliko desetina milimetara u promjeru košuljice. Križna ručica se može podešavati u svom uzdužnom smjeru tj. u radijalnom smjeru košuljice. Drugi primjer konstrukcije alata za valjanje vidi se na slici 4, gdje je valjak 23 jednom stranom uronjen u glavu 24, a na svojoj stražnjoj strani valjak dodiruje podložni valjak 25. In the simple construction shown in Figure 3, the rolling tool may include a roll 19, which is rotatably mounted in a forked head 20 at the end of a cross arm 21 fixed in a recess in the tool holder 22, which is supported with a drill rod 13. Holder of the tool or the tool itself may have a certain limited flexibility in the radial direction of the liner, so that with the elastic bending of the holder, changes of several tens of millimeters in the diameter of the liner are absorbed. The cross handle can be adjusted in its longitudinal direction, i.e. in the radial direction of the liner. Another example of the construction of the rolling tool can be seen in Figure 4, where the roller 23 is immersed in the head 24 on one side, and on its back side the roller touches the supporting roller 25.

Glava je montirana na proizvoljno šireći kruti dio podijeljen na dva dijela, 26a i 26b, koji su međusobno opružni, ali održavaju postavljen pritisak valjanja. Indikator 27 pokazuje magnitudu trenutnog pritiska valjanja. Umjesto vizuelnog indikatora, alat može biti opremljen s induktivnim sistemom za mjerenje pritiska valjanja i za tvorbu električnog signala koji se može upotrijebiti u cilju namještanja ili za dislocirano očitanje. Preko intermedijarnog dijela 28 kruti dio se montira u držač alata 14 šipke za bušenje, tako da se pritisak valjanja može namjestiti radijalnim pomicanjem tog držača alata. Alat tog tipa komercijalno proizvodi njemačka tvrtka W. Hegenscheidt GmbH, Gelle, pod tipskom oznakom EG 14. The head is mounted on an arbitrarily expanding rigid part divided into two parts, 26a and 26b, which are mutually spring-loaded but maintain the set rolling pressure. Indicator 27 shows the magnitude of the current rolling pressure. Instead of a visual indicator, the tool can be equipped with an inductive system for measuring the rolling pressure and for generating an electrical signal that can be used for setting purposes or for dislocation reading. Via the intermediate part 28, the rigid part is mounted in the tool holder 14 of the drill rod, so that the rolling pressure can be adjusted by radially moving the tool holder. A tool of this type is commercially produced by the German company W. Hegenscheidt GmbH, Gelle, under the type designation EG 14.

Indikator pritiska valjanja može biti ugrađen u križni kliznik šipke za bušenje, križni kliznik djeluje uglavnom jednakim radijalnim pritiskom kao alat za valjanje. Posljednji može također imati displej s, na primjer, digitalnim prikazom pomaka križnog kliznika u radijalnom, odnosno aksijalnom smjeru. Takav displej se može resetirati kad se alat za valjanje postavlja na dodir manje sile s unutarnjom površinom košuljice, nakon čega će vanjsko premještanje križnog kliznika predstavljati pritisak valjanja. Uzdužna os valjka može oblikovati slobodni kut α s unutarnjom površinom košuljice, gdje je vrh kuta okrenut u smjeru uvlačenja prikazan strelicom A. A rolling pressure indicator can be incorporated into the cross slide of the drill rod, the cross slide acts with substantially the same radial pressure as the rolling tool. The latter can also have a display with, for example, a digital display of the displacement of the cross slider in the radial or axial direction. Such a display can be reset when the rolling tool is placed in contact with the inner surface of the liner with less force, after which the outward movement of the cross slide will represent the rolling pressure. The longitudinal axis of the roller can form a free angle α with the inner surface of the liner, where the top of the angle is turned in the direction of indentation shown by arrow A.

Sada slijedi opis primjera provedenih s košuljicom cilindra koja je imala unutarnji promjer od 35 cm. Now follows a description of examples carried out with a cylinder liner that had an inner diameter of 35 cm.

Primjer 1 Example 1

Košuljica je bila izrađena od materijala košuljice uobičajenog za velike motore, lijevanog željeza, i nakon grubog tokarenja, unutarnja površina košuljice konačno je iztokarena na svoju punu duljinu sa spiralnim, valovitim oblikom ureza s razmakom S = 4 mm između vrhova valova i visinom vala od približno h = 0,015 mm. Zatim je rezni alat sipke za bušenje je bio zamijenjen s alatom za valjanje prikazanim na slici 3. Pritisak valjanja bio je namješten najprije stavljanjem valjka u dodir s unutarnjom površinom košuljice s manjom silom, nakon čega je križni kliznik šipke za bušenje bio namješten na pomak prema van za F = 0,03 mm mjereno na promjeru, tj. na radijalan pomak od 0,015 mm. Treba spomenuti da namještanje križnog kliznika ne povlači odgovarajući radijalni pomak alata za valjanje, kao bitni dio pomaka za tlačno opterećenje križnog kliznika, tj. da se stvori pritisak valjanja, uzet je držač alata i alat. To je bitna razlika od postavljanja reznog alata normalno upotrijebijenog u tokarilici. Košuljica se je okretala s 90 min-1, što je dalo relativnu brzinu između alata za valjanje i unutarnje površine košuljice od V = 100 m/min, a šipka za bušenje pomicala se je u košuljici brzinom uvlačenja od s = 0,5 mm/okretaju. The liner was made from a liner material common to large engines, cast iron, and after rough turning, the inner surface of the liner was finally turned to its full length with a spiral, wavy kerf shape with a gap of S = 4 mm between wave crests and a wave height of approx. h = 0.015 mm. Then, the drill rod cutting tool was replaced with the rolling tool shown in Figure 3. The rolling pressure was adjusted by first bringing the roller into contact with the inner surface of the liner with less force, after which the cross slide of the drill rod was adjusted to move toward out by F = 0.03 mm measured on the diameter, i.e. at a radial displacement of 0.015 mm. It should be mentioned that adjusting the cross slide does not entail the corresponding radial displacement of the rolling tool, as an essential part of the displacement for the compressive load of the cross slide, i.e. to create the rolling pressure, the tool holder and the tool are taken. This is a significant difference from the setting of a cutting tool normally used in a lathe. The liner was rotated at 90 min-1, giving a relative velocity between the rolling tool and the inner surface of the liner of V = 100 m/min, and the drill rod was moved in the liner at a feed rate of s = 0.5 mm/ they spin.

Vizuelna kontrola pokazala je da bi bio poželjan veći pritisak valjanja i da brzina uvlačenja može biti bitno veća. Visual inspection showed that a higher rolling pressure would be desirable and that the feed speed could be significantly higher.

Primjer 2 Example 2

Neovisno o parametrima valjanja, košuljica cilindra bila je izrađena na isti način kao u primjeru 1. Valjanje je bilo izvršeno s parametrima V = 100 m/min, F= 0,10 mm na promjeru i s = 4,0 mm/okretaju. Regardless of the rolling parameters, the cylinder liner was made in the same way as in example 1. Rolling was performed with the parameters V = 100 m/min, F = 0.10 mm on the diameter and s = 4.0 mm/rev.

Vizuelna kontrola i mjerenje hrapavosti pokazalo je da je brzina uvlačenja bila prikladna, i da su područja između dna valova imala dobro definiranu širinu i bila su uglavnom ravna. Visual inspection and roughness measurement showed that the feed rate was adequate, and that the areas between the bottoms of the waves had a well-defined width and were generally flat.

Primjer 3 Example 3

Neovisno o parametrima valjanja, košuljica cilindra bila je izrađena na isti način kao u primjeru 1. Valjanje je bilo izvršeno s parametrima V = 100 m/min, F = 0,15 mm na promjeru i s - 4,0 mm/okretaju. Regardless of the rolling parameters, the cylinder liner was made in the same way as in example 1. The rolling was performed with the parameters V = 100 m/min, F = 0.15 mm on the diameter and s - 4.0 mm/revolution.

Vizuelna kontrola i mjerenje hrapavosti pokazalo je da je brzina uvlačenja bila prikladna, i da su područja između dna valova su šira i tvorila su otprilike 30% unutarnje površine košuljice. Visual inspection and roughness measurement showed that the feed rate was adequate, and that the areas between the bottoms of the waves were wider and formed approximately 30% of the inner surface of the liner.

Primjer 4 Example 4

Neovisno o parametrima valjanja, košuljica cilindra bila je izrađena na isti način kao u primjeru 1. Valjanje je bilo izvršeno s parametrima V = 100 m/min, F = 0,20 mm na promjeru i s =4,0 mm/okretaju. Regardless of the rolling parameters, the cylinder liner was made in the same way as in example 1. Rolling was performed with the parameters V = 100 m/min, F = 0.20 mm on the diameter and s = 4.0 mm/rev.

Vizuelna kontrola i mjerenje hrapavosti pokazalo je da je brzina uvlačenja bila prikladna, i da su područja između dna valova bila šira i tvorila su otprilike 40% unutarnje površine košuljice. Visual inspection and roughness measurement showed that the feed rate was adequate, and that the areas between the bottoms of the corrugations were wider and formed approximately 40% of the inner surface of the liner.

Bila su provedena usporedbena ispitivanja u kojima je košuljica cilindra bila izrađena na isti način kao u primjeru 1, ali valjanje je bilo zamijenjeno s djelomičnim brušenjem kojim su odstranjeni vrhovi valova. Comparative tests were carried out in which the cylinder liner was made in the same way as in Example 1, but the rolling was replaced by partial grinding to remove the crests of the waves.

Površine košuljica izrađene u primjeru 4 djelomičnim brušenjem bile su fotografirane s povećanjem pet puta, vidi slike 6 i 7, a hrapavost površine bila je izmjerena s Perthenovim uređajem za mjerenje hrapavosti, vidi slike 8 i 9, gdje su bila namještena vrlo velika povećanoj a u radijalnom smjeru. Zapisi na trakama, 10 mm u smjeru osi y pokazuju razmak oči 0,025 mm, dok 10 mm u smjeru osi x Dokazuju razmak od l mm. The surfaces of the liners produced in example 4 by partial grinding were photographed at a magnification of five times, see figures 6 and 7, and the surface roughness was measured with a Perthen roughness measuring device, see figures 8 and 9, where they were set to a very large magnified a in the radial direction. Records on the tapes, 10 mm in the direction of the y axis show a distance of 0.025 mm, while 10 mm in the direction of the x axis prove a distance of l mm.

Slika 6 prikazuje oznake kružnog struganja ili utore od brušenja, a ispitivanje hrapavosti na slici 8 pokazuje velik broj malih točaka u približno ravnom području gdje su vrhovi valova odstranjeni. Figure 6 shows the circular scraping marks or grinding grooves, and the roughness test in Figure 8 shows a large number of small points in an approximately flat area where the crests of the waves have been removed.

Valjana površina prikazana na slici 7 ima značajno bolji izgled, a ispitivanje hrapavosti na slici 9 pokazuje ravna područja između dna valova s daleko neznatnijim oštrim ispupčenim točkama, ali površina ipak ima brojne male zaobljene razlika u razini u ravnim površinama, koja doprinose postizanju dobre adhezije ulja na površinu. The rolled surface shown in Figure 7 has a significantly better appearance, and the roughness test in Figure 9 shows flat areas between the bottoms of the waves with far less sharp raised points, but the surface still has numerous small rounded level differences in the flat surfaces, which contribute to achieving good oil adhesion on the surface.

U gornjim dimenzijskim prikazima pod odsiječenom valovitošću i valovitošću model treba podrazumjeti da su spomenute vrijednosti prosječne vrijednosti. Kako pokazuju ispisi na trakama ispitivanja hrapavosti, površina mjestimice ima velika uleknuća koje nisu uključene u dimenzije, jer to su tipični grafitni taloži u površini ili slične varijacije određene legurom. Uleknuća su također prisutna uglavnom u ravnim područjima koja se također mogu nazvati i područja platoa. In the dimensional views above, under cut waviness and waviness, the model should understand that the mentioned values are average values. As the printouts on the roughness test strips show, the surface has large indentations in places that are not included in the dimensions, as these are typical graphite deposits in the surface or similar variations determined by the alloy. Indentations are also present mainly in flat areas which can also be called plateau areas.

Claims (11)

1. Metoda izrade košuljice cilindra (1) za klipni motor, kao što je veliki dvotaktni klipni motor, u kojoj je radna površina za klipne prstenove na unutarnjoj površini (7) košuljice je izrađena najprije urezivanjem valovitosti, koja ima razliku razina (h) između vrhova i dna valova od najmanje 0,005 mm, u unutarnjoj površini s najmanje jednim reznim alatom, koji ima zakrivljen rezni brid, i zatim odstranivanjem vrhova valova barem u radnoj površini najbližoj krajnjem središnjem položaju vrha klipa, tako da u uzdužnom dijelu unutarnje površine (7) gotova košuljica (1) ima djelomično valovitu površinu, u kojoj su dna valova (17) odvojena uglavnom ravnim područjima (18), naznačena time, da košuljica cilindra ima unutarnji promjer u rasponu od 25 cm do 100 cm i duljinu u rasponu od 100 cm do 400 cm, da su vrhovi valova odstranjeni bez primjene brušenja, već plastičnom kompresijom za najmanje 0,004 mm od njihove visine u rečena uglavnom ravna područja (18), i da je dno vala (17) nakon kompresije u razini za najmanje 0,001 mm nižoj od te površine.1. A method of making a cylinder liner (1) for a piston engine, such as a large two-stroke piston engine, in which the working surface for the piston rings on the inner surface (7) of the liner is made by first notching a corrugation, which has a level difference (h) between peaks and bottoms of waves of at least 0.005 mm, in the inner surface with at least one cutting tool, which has a curved cutting edge, and then removing the peaks of the waves at least in the working surface closest to the extreme central position of the piston tip, so that in the longitudinal part of the inner surface (7) the finished liner (1) has a partially corrugated surface, in which the bottoms of the waves (17) are separated by mostly flat areas (18), characterized in that the cylinder liner has an inner diameter in the range of 25 cm to 100 cm and a length in the range of 100 cm up to 400 cm, that the crests of the waves were removed without applying sanding, but by plastic compression for at least 0.004 mm of their height in said mostly flat areas (18), and that the bottom of the wave (17) after compr ession at a level at least 0.001 mm lower than that surface. 2. Metoda prema zahtjevu 1, naznačena time da je valovitost urezana u unutarnjoj površini košuljice pomoću rečenog najmanje jednog reznog alata, koji je istaknut u uzdužnom smjeru košuljice pomoću šipke za bušenje s brzinom uvlačenja (s) dok se košuljica okreće tako da se valovitost oblikuje kao najmanje jedan spiralni urez, i da se plastična kompresija provodi valjanjem unutarnje površine s alatom za valjanje, koji se kreće prema naprijed pomoću iste šipke za bušenje kao i rezni alat.2. The method according to claim 1, characterized in that the corrugation is incised in the inner surface of the liner by said at least one cutting tool, which is protruded in the longitudinal direction of the liner by means of a drill rod with a feed speed (s) while the liner is rotated so that the corrugation is formed as at least one helical notch, and that the plastic compression is carried out by rolling the inner surface with the rolling tool, which is moved forward by the same boring bar as the cutting tool. 3. Metoda prema zahtjevima l ili 2, naznačena time da se plastična kompresija vrši s alatom za valjanje koji ima jedan valjak (19; 23), čiji se radijalan položaj može. namještati u odnosu prema unutarnjoj površini košuljice, i može se pomaknuti prema naprijed u uzdužnom smjeru košul3ice dok se košuljica (1) okreće.3. The method according to claims 1 or 2, characterized in that the plastic compression is performed with a rolling tool having one roller (19; 23), the radial position of which can be adjusted. adjust in relation to the inner surface of the liner, and can move forward in the longitudinal direction of the liner while the liner (1) rotates. 4. Metoda prema zahtjevu 3, naznačena time da je alatu za valjanje pridružen indikator (27) trenutnog pritiska valjanja.4. The method according to claim 3, characterized in that the rolling tool is associated with an indicator (27) of the current rolling pressure. 5. Metoda prema zahtjevima 3 ili 4, naznačena time da alat za valjanje održava željeni pritisak valjanja kod pomicanja alata u uzdužnom smjeru košuljice, iako se unutarnji promjer košuljice (1) mijenja po duljini košuljice.5. Method according to claims 3 or 4, characterized in that the rolling tool maintains the desired rolling pressure when moving the tool in the longitudinal direction of the liner, although the inner diameter of the liner (1) changes along the length of the liner. 6. Metoda prema bilo kojem od zahtjeva 2 do 5, naznačena time da se valjanje provodi samo u gornjem dijelu košuljice uključivši područje po kojem krajni klipni prsten kliže kad se klip (4) makne iz svog gornjeg krajnjeg središnjeg položaja i dio takta puta klipa dolje prema dolnjem krajnjem središnjem položaju.6. A method according to any one of claims 2 to 5, characterized in that the rolling is carried out only in the upper part of the liner including the area over which the end piston ring slides when the piston (4) is removed from its upper end center position and part of the stroke of the piston travel down towards the lower end central position. 7. Metoda prema bilo kojem od zahtjeva 2 do 6, naznačena time da su vrhovi valova deformirani valjanjem tako da područje uglavnom ravne površine (18) između dna valova (17) predstavlja 25% do 75%, ponajprije od 40% do 60% od ukupne površine košuljice (1) u valjanom području.7. The method according to any one of claims 2 to 6, characterized in that the crests of the waves are deformed by rolling so that the area of the mostly flat surface (18) between the bottoms of the waves (17) represents 25% to 75%, preferably from 40% to 60% of the total surface of the liner (1) in the rolled area. 8. Metoda prema zahtjevu 7, naznačena time da su vrhovi valova deformirani valjanjem tako da se površina uglavnom ravnih područja (18) između konsekutivnih dna valova (17) proteže u uzdužnom smjeru košuljice, koja u rasponu od ±1 mm, odgovara četvrtini visine klipnog prstena najmanje visine.8. Method according to claim 7, indicated by the fact that the tops of the waves are deformed by rolling so that the surface of the mostly flat areas (18) between the consecutive bottoms of the waves (17) extends in the longitudinal direction of the liner, which, within a range of ±1 mm, corresponds to a quarter of the height of the piston ring of the smallest height. 9. Metoda prema bilo kojem od prethodnih zahtjeva, naznačena time da su vrhovi valova deformirani tako da je najmanje 0,006 mm i najviše 0,018 mm, ponajprije najviše 0,015 mm od visine vala komprimirano u uglavnom ravna područja (18), i da su valova (17) u razini za najmanje 0,002 mm ispod tih površina.9. The method according to any of the preceding claims, characterized in that the crests of the waves are deformed so that at least 0.006 mm and at most 0.018 mm, preferably at most 0.015 mm of the height of the wave is compressed into generally flat areas (18), and that the waves (17) ) at a level of at least 0.002 mm below these surfaces. 10. Metoda prema bilo kojem od prethodnih zahtjeva, naznačena time da se urezana valovitost deforimira tako da pros3ečna radijalna razlika u razinama između dobivenih uglavnom ravnih površina (18) i dna valova (17) predstavlja između 7% i 66% od prosječne razlike u razinama (h) između vrhova valova i dna valova u valovitosti prije kompresije, a ponajprije između 16% i 36% od toga.10. The method according to any of the preceding claims, characterized in that the incised corrugation is deformed so that the average radial difference in levels between the obtained substantially flat surfaces (18) and the bottom of the waves (17) represents between 7% and 66% of the average difference in levels (h) between wave crests and wave troughs in undulation before compression, preferably between 16% and 36% thereof. 11. Košuljica cilindra (1) za klipni motor, kao što je veliki dvotaktni klipni motor, koja ima radnu površinu za klipne prstenove na unutarnjoj površini (7) košuljice, koja radna površina barem u području najbližem do vrha klipa u krajnjem središnjem položaju, ima djelomično valovit oblik, u kojem su dna valova (17) odvojena od uglavnom ravnih površina (18), naznačena time, da košuljica cilindra ima unutarnji promjer u rasponu od 25 cm do 100 cm i duljinu u rasponu od 100 cm do 400 cm, da su uglavnom ravna područja (18) valjanje površine bez oštrih ispupčerija, da su dna valova (17) u razini za najmanje 0,001 mm nižoj od tih površina i da uglavnom ravno područje (18) između konsekutivnih dna valova (17), koje proteže u uzdužnom smjeru košuljice u rasponu od ±1 mm, odgovara četvrtini visine klipnog prstena najmanje visine. 11. A cylinder liner (1) for a piston engine, such as a large two-stroke piston engine, having a working surface for piston rings on the inner surface (7) of the liner, which working surface, at least in the region closest to the top of the piston in the end center position, has a partially corrugated shape, in which the bottoms of the waves (17) are separated from the generally flat surfaces (18), characterized in that the cylinder liner has an inner diameter in the range of 25 cm to 100 cm and a length in the range of 100 cm to 400 cm, that are generally flat areas (18) rolling surface without sharp bulges, that the bottoms of the waves (17) are at a level at least 0.001 mm lower than these surfaces and that the generally flat area (18) between consecutive bottoms of the waves (17), which extends in the longitudinal in the direction of the liner in the range of ±1 mm, corresponds to a quarter of the height of the smallest piston ring.
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