WO2018176827A1 - 连杆超声辅助裂解加工方法及其加工装置 - Google Patents

连杆超声辅助裂解加工方法及其加工装置 Download PDF

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Publication number
WO2018176827A1
WO2018176827A1 PCT/CN2017/108237 CN2017108237W WO2018176827A1 WO 2018176827 A1 WO2018176827 A1 WO 2018176827A1 CN 2017108237 W CN2017108237 W CN 2017108237W WO 2018176827 A1 WO2018176827 A1 WO 2018176827A1
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Prior art keywords
cracking
connecting rod
ultrasonic
vibration
wedge
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PCT/CN2017/108237
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English (en)
French (fr)
Inventor
姜银方
沙德利
康志强
王科委
姜文帆
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江苏大学
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Application filed by 江苏大学 filed Critical 江苏大学
Priority to US16/499,032 priority Critical patent/US10899037B2/en
Publication of WO2018176827A1 publication Critical patent/WO2018176827A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
    • B26F3/00—Severing by means other than cutting; Apparatus therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • B21D53/84—Making other particular articles other parts for engines, e.g. connecting-rods

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  • the invention relates to the field of connecting rod processing, in particular to a ultrasonic assisted cracking processing method for a connecting rod and a processing device thereof.
  • the main process of the traditional connecting rod processing method is to rough-mill the forging blank first, grind the two sides of the connecting rod, and mill the connecting rod cover and the rod, respectively machine the connecting rod cover and the bolt hole on the rod, and then grind separately.
  • the joint surface of the connecting rod cover and the rod portion is cut, and finally, the assembled connecting rods are subjected to fine grinding of the two sides, the fine-sized head hole and the like.
  • the cutting process of the rod and the cover in the conventional processing process and the grinding process of the joint surface of the rod and the cover are relatively low in productivity, and the processing precision is relatively high, and the scrap rate after processing is high and the cost is large. At present, there are very few factories in the world that use traditional processing methods.
  • the cracking of the connecting rod is based on the theory of material fracture. Firstly, the cracking groove is opened on the forged hole of the forged connecting rod blank to form stress concentration. Then, a radial force is applied to the inner side of the big hole of the connecting rod on the cracking processing device, so that the crack continuously expands from the inside to the outside until the connecting rod is completely cracked. Finally, with the fracture surface fully engaged, thread the bolt and tighten to the required torque.
  • the cracking processing method is a whole processing, which requires only 6 processes, and has the advantages of simple processing method, saving of finishing equipment, energy saving of materials, and low production cost.
  • the connecting rod cracking process has been selected by most of the world's connecting rod processing manufacturers because of its great superiority, but it is difficult to control the deformation of the fracture surface and ensure the quality of the fracture surface during the cracking process of the connecting rod, which will lead to the cracking of the connecting rod. Can not be fully engaged, so far no good solution has been found, so the material of the cracking link is limited, and it is impossible to crack the conventional connecting rod material such as 40Cr steel.
  • the connecting rod directional cracking machine adopts a pull-down wedge-shaped cracking mechanism, which moves linearly along the axial direction through a wedge-shaped pull rod driven by a hydraulic cylinder.
  • the action of the wedge-shaped pull rod forces the specially designed expansion and movement sleeve to move horizontally, and exerts a horizontal effect on the big hole of the connecting rod. Force, the rapid cracking process of the big end of the connecting rod is completed under the action of instantaneous load, but the same problem also exists.
  • the patent publication number is CN202701336U, and the patent publication date is January 30, 2013.
  • the patented method is to use a brittle metal at a cracking surface of a conventional connecting rod material such as 40Cr steel to form a composite bimetal cracking link, such as 40Cr.
  • the steel connecting rod material can be cracked.
  • the bimetallic cracking link increases the manufacturing process of the composite bimetal, which is difficult to apply to large-scale production, and the composite bimetallic connecting rod fails to solve the deformation, slag, meshing quality and assembly in the cracking process of other cracking methods. Problems such as accuracy.
  • Ultrasonic vibration is used for auxiliary machining during the cracking process of the connecting rod, which can effectively reduce the cracking force required for cracking of the connecting rod, reduce the deformation of the fracture surface, reduce the number of slag on the fracture surface during the cracking process, and reduce the deviation of the fracture line.
  • the movement, the large hole of the connecting rod are out of round, the cracking of one side, the cracking of the crack, etc., so that the processing cost can be reduced, the positioning accuracy of the connecting rod and the cover and the assembly quality can be improved, thereby improving the production efficiency and the pass rate of the connecting rod cracking. .
  • the ultrasonic vibration is used for auxiliary processing in the cracking process of the connecting rod of the present invention, which can effectively reduce the cracking force required for cracking of the connecting rod, reduce the deformation of the fracture surface, and reduce the number of slag on the fracture surface during the cracking process.
  • the occurrence of the break line offset, the large hole of the connecting rod, the unilateral cracking, the crack splitting, etc. can reduce the processing cost, improve the positioning accuracy of the connecting rod and the cover, and the assembly quality, thereby improving the cracking of the connecting rod. Production efficiency and pass rate.
  • Ultrasonic vibration is added to the cracking process of the connecting rod, and a stress wave is generated on the connecting rod, the frequency of which is the frequency of the ultrasonic vibration; when the ultrasonic stress wave propagates on the connecting rod, the connecting rod is under the action of the alternating load; the ultrasonic vibration is added On the connecting rod, microscopically, the microcracks gradually grow under the action of the alternating load, that is, the stress wave; at the same time, because the ultrasonic vibration wave is refracted and reflected on the crack surface, the closer to the crack tip The more likely it is to impact or rub against each other, the more easily the crack tip breaks; the ultrasonic vibration wave is transmitted inside the connecting rod, but when the ultrasonic stress wave passes through the crack, The vibration of the metal materials on both sides of the crack is inconsistent.
  • the two sides of the crack frequently contact and separate.
  • the crack tip When the ultrasonic wave passes through the crack tip, the cracks collide and slide into heat, and the crack tip temperature is the highest, which helps to reduce the crack.
  • the ultrasonic vibration wave acts on the crack.
  • the crack expands under the alternating load, because there is always an alternating force. In the crack region, each alternating crack of the force will grow once; since the cracking of the crack and the reflection of the dislocation always proceed along the direction of the lattice slip, in the case of ultrasonic vibration cracking, the cracking is easier.
  • the cracking force is lower; the increase of ultrasonic vibration frequency and amplitude has a great influence on the crack propagation of the connecting rod; the increase of ultrasonic vibration frequency and amplitude will cause the vibration frequency and vibration amplitude of the material microparticle to increase microscopically.
  • the kinetic energy of the particles of the connecting rod material increases, resulting in an increase in the thermal energy and fatigue load of the crack tip. Fatigue fracture and thermal deformation of the crack tip; at the same time, the inertial force of the crack tip is increased, thereby promoting crack tip cracking and lattice dislocation development, and the crack stops only when the kinetic energy of the crack tip is consumed. Therefore, the increase in vibration amplitude and vibration frequency accelerates the crack propagation.
  • Ultrasonic vibration is set on the conventional cracking processing device.
  • the material of the cracking region of the connecting rod is in the ultrasonic vibration, and the stress concentration phenomenon is rapidly formed in the cracking groove region of the connecting rod, and the acceleration is accelerated.
  • the breakage of the connecting rod weakens the influence of the plastic zone and residual stress at the crack tip on the crack propagation.
  • the amplitude, frequency and vibration mode of the ultrasonic vibration the crack propagation and the formation of the fracture are controlled, and the crack separation is completed under the action of the wedge rod force and the ultrasonic vibration.
  • the cracking surface formed after the cracking and separation is closed, the amplitude, frequency and vibration mode of the ultrasonic vibration are re-adjusted, and the cracking sections are mutually agitated at a low amplitude and a high frequency under the action of ultrasonic vibration, thereby reducing Due to the influence of the barbs, sharp edges and corners on the cracking section of the connecting rod and the quality of the meshing, the cracking surface achieves the required degree of matching, improves the meshing precision of the joint surface of the rod and the joint, and improves the assembly quality of the connecting rod.
  • the ultrasonic assisted cracking processing method of the connecting rod is provided with ultrasonic vibration on a conventional cracking processing device.
  • the material of the cracking region of the connecting rod is in the ultrasonic vibration, and the plastic region of the crack tip is And the residual stress is controlled to improve the cracking quality;
  • the cracking surface formed after the cracking separation is closed, the amplitude, frequency and vibration mode of the ultrasonic vibration are re-adjusted, and the cracking sections are mutually synchronized with low amplitude and high frequency under the action of ultrasonic vibration.
  • Step S1 installing the rack on the test bench, opening a cracking groove in the large hole of the connecting rod to be cracked, installing the small end of the connecting rod to be cracked on the small head positioning block, and installing the big end of the connecting rod On the cleavage set and the cleavage sleeve;
  • Step S2 Debug the screw nut mechanism to drive the small head positioning block so that the small end of the connecting rod has a certain pressing force, and adjust the horizontal pressing cylinder to drive the pressing block so that the large end of the connecting rod has a pressing force.
  • the vertical locking cylinder is debugged to stabilize the compression of the pressing block, and the pressing force on both sides of the connecting rod is about the cracking force.
  • Step S3 adjusting the amplitude, frequency and vibration mode of the ultrasonic vibration in the horn, the transducer and the ultrasonic power supply system, and starting the ultrasonic power supply, so that the wedge rod vibrates at a certain amplitude, frequency and vibration mode;
  • Step S4 starting the cracking hydraulic cylinder, thereby driving the wedge rod to move down at a certain rate, so that the large end of the separated connecting rod forms a cracking crack surface and then the ultrasonic power source is turned off;
  • Step S5 re-adjust the frequency, amplitude and vibration mode of the ultrasonic vibration, or use the original ultrasonic vibration parameter to start the ultrasonic power supply, restart the cracking hydraulic cylinder, and move the wedge-shaped pull rod upward, so that the wedge-shaped pull rod is again lysed and cracked.
  • the movable sleeve is tightly combined under the ultrasonic vibration environment; thus the large end of the separated connecting rod is reclosed, and at this time, the cracking hydraulic cylinder is closed to stop working;
  • Step S6 According to the scale mark on the big end of the connecting rod, the laser distance measuring device is used to detect the degree of coincidence of the cracking surface, so that the meshing precision reaches the use requirement, the ultrasonic power source is turned off, and the bolt is assembled to complete the cracking work.
  • ultrasonic vibration assisted processing can be replaced by other vibration modes.
  • the ultrasonic generator frequency adjustment range is 15KHz-60KHz when the connecting rod is cracked; the ultrasonic amplitude range is 100 ⁇ m-200 ⁇ m; the vibration mode adopted by the ultrasonic wave during the cracking process is axial vibration or radial vibration, vibration direction and movement of the wedge rod The same direction.
  • the frequency adjustment range is 20KHz-60KHz
  • the ultrasonic amplitude range is 20 ⁇ m-150 ⁇ m
  • the vibration mode adopted by the ultrasonic wave in the cracking process is axial vibration or radial vibration
  • the processing device based on the ultrasonic assisted cracking processing method of the connecting rod comprises a connecting rod small head hole pressing mechanism, a connecting rod big head hole cracking mechanism, a connecting rod cover pressing mechanism, a slider mechanism, a laser ranging system and an ultrasonic vibration system,
  • the utility model is characterized in that ultrasonic vibration is set on a conventional cracking processing device, and the amplitude, frequency and vibration mode of the ultrasonic vibration are controlled, so that the material of the cracking region of the connecting rod is in the ultrasonic vibration, the micro-cracking morphology of the material is controlled, and the cracking is reduced.
  • the cracking separation is completed under the combined force of the wedge rod force and the ultrasonic vibration, and then the frequency and amplitude of the ultrasonic vibration are re-adjusted, or the original ultrasonic vibration parameter is used, so that the cracking surface formed after the crack separation is performed under the ultrasonic vibration condition. Combined, the cracking surface is brought to the required degree of conformity under the action of ultrasonic vibration;
  • the connecting rod small head hole pressing mechanism comprises a screw nut mechanism pushing the adjusting block to the right, positioning the small head positioning block mounted on the adjusting block body, pressing the connecting rod, and the detecting system comprises a laser distance measuring device and cracking
  • the scale on the sleeve and the split sleeve can detect the degree of coincidence of the cracking surface.
  • the ultrasonic vibration mechanism includes a horn, a transducer and an ultrasonic power supply, the horn and the wedge rod are connected by a stud, and the horn passes through the fixed table. It is mounted on the rail frame and moves on the rail frame as the wedge lever moves up and down, causing vibration in the vertical direction during operation.
  • the screw nut mechanism pushes the adjustment block to the right, so that the small head positioning block presses the link.
  • the ultrasonic vibration can be loaded on the back pressure device.
  • the horn of the ultrasonic vibration device and the wedge rod are tightly connected by the stud, so that the wedge rod generates vibration in a vertical direction during the working process, and the ultrasonic vibration device passes through the fixed table along the wedge rod to move up and down with the wedge rod. Move on the shelf.
  • connection between the pull-down wedge rod in the expansion sleeve and the cracking hydraulic cylinder has a vibration isolator.
  • the processing method expands the range of materials used for the cracking connecting rod, reduces the cracking force required for the cracking of the connecting rod, the deformation of the fracture surface, the slag generated during the cracking process, and the rounding of the big end of the connecting rod. Produce, improve the meshing precision of the joint surface of the connecting rod and the cover, and improve the assembly quality and assembly precision of the connecting rod.
  • Ultrasonic vibration is set on the conventional cracking processing device.
  • the material of the cracking region of the connecting rod is in the ultrasonic vibration, and the plastic zone and residual stress of the crack tip are weakened to crack propagation.
  • the effect of controlling the amplitude, frequency and vibration mode of the ultrasonic vibration to control the crack propagation and the formation of the fracture reduce the cracking force required for the cracking of the connecting rod, the deformation of the fracture surface, and the slag generated during the cracking process.
  • the rod hole is out of round and the like is generated, and the crack separation is completed under the action of the wedge rod force and the ultrasonic vibration.
  • the cracking surface formed after the cracking and separation is closed, and the amplitude, frequency and vibration mode of the ultrasonic vibration are re-adjusted, and the cracking surfaces are mutually agitated under the action of ultrasonic vibration, so that the cracking surface meets the requirements.
  • the degree of coincidence improves the meshing accuracy of the joint surface of the connecting rod and the cover, and improves the assembly quality of the connecting rod.
  • the cracking surfaces are mutually agitated, so that the cracking surface can reach the required degree of matching, the meshing precision of the joint surface of the rod and the lid is improved, and the assembly quality of the connecting rod is improved.
  • a vibration isolator is arranged between the wedge-shaped pull rod and the cracking hydraulic cylinder, which can slow the vibration of the cracking hydraulic cylinder with the wedge-shaped pull rod and improve the stability of the cracking hydraulic cylinder.
  • Figure 1 is a front view of the ultrasonic assisted cracking processing device of the connecting rod
  • Figure 2 is a schematic view of cracking of the large end of the connecting rod after processing
  • Figure 3 is a schematic diagram of the combined force of the cracking force and the ultrasonic vibration.
  • the connecting rod ultrasonic assisted cracking processing device comprises a frame 4, a fixed block 5, a slider 22 and a slider seat 30; the frame 4 is fixedly mounted on the experimental bench, and the frame 4 is provided with a hole; The block 5 and the slider block 30 are both mounted on the frame 4; the slider seat 30 is mounted with a slider 22; the slider 22 and the slider block 30 are correspondingly formed with a vertical stepped hole B, and a vertical ladder is formed.
  • a vertical locking cylinder 29 is installed in the hole B; a fixed step 5 is combined with the slider seat 30 and the slider 22 to form a vertical stepped hole A, and a vertical wedge hole 12 is mounted in the vertical stepped hole A; the wedge rod a rectangular connecting block 2 is mounted on the lower end of the 12; the rectangular connecting block 2 is connected to the cracking hydraulic cylinder 1; the upper end of the vertical stepped hole A is provided with a cracking sleeve 11 and a cracking sleeve 16; the cracking sleeve 11 and The splitting sleeve 16 constitutes an inverted T-shaped hole; the wedge-shaped pull rod 12 passes through the inverted T-shaped hole; the upper end surface of the fixed block 5 is provided with a pit, and the adjusting block 8 is disposed in the recess; the adjusting block 8 a screw nut mechanism 7 is disposed on the side; the screw nut mechanism 7 includes a screw nut 7-1 and a screw nut holder 7-2; the screw nut holder 7-2
  • the wedge-shaped pull rod 12 and the cracking sleeve 11 are cylindrical, and the splitting sleeve 16 is tapered.
  • a guide sleeve 6 is mounted on the wedge rod 12; the guide sleeve 6 is fixed to the lower end of the fixed block 5 and the slider holder 30.
  • the lower end of the frame 4 is provided with a connecting bracket 3; the connecting bracket 3 is provided with a hole, and the hole is matched with the rectangular connecting block 2.
  • the lead screw nut holder 7-2 is L-shaped.
  • a threaded connection is made between the wedge rod 12 and the rectangular connecting block 2, in order to prevent the rotation of the piston rod and the wedge rod 12 in the cracking hydraulic cylinder 1, the nut is tightly packed between the piston rod and the rectangular connecting block 2 in the cracking hydraulic cylinder 1 And a rectangular window is opened on the top panel of the connecting bracket 3, and the left and right sides thereof are maintained in a tolerance relationship with the rectangular connecting block 2. While the wedge rod 12 is moving downward, it is guided by the guide sleeve 6.
  • a “back pressure type” cracking method is adopted.
  • the screw nut mechanism 7 pushes the adjusting block body 8 to the right, so that the small head positioning block 9 mounted on the adjusting block body 8 is positioned and pressed.
  • Tightening the connecting rod 10 while a horizontal pressing cylinder 20 is pressed against the large end of the connecting rod 10 by a pressing block 18 connected to the end of its piston rod, and is locked by a vertical locking cylinder 29, so that the connecting rod 10 is large.
  • the end center fracture surface is in a pre-compacted state.
  • the screw nut mechanism 7 pushes the adjusting block 8 to the right to make the adjustment in the adjustment.
  • the small head positioning block 9 on the block 8 positions and presses the connecting rod 10, while a horizontal pressing cylinder 20 presses the large end cap end of the connecting rod 10 through the pressing block 18 connected to the end of the horizontal cylinder piston 21.
  • the vertical locking cylinder 29 immediately acts to raise the locking piston rod 28 having the inclined surface and press the horizontal piston rod 21.
  • the slider 22 carrying the cap end horizontal compression cylinder 20 and the vertical lock cylinder 29 has been driven by the back pressure cylinder 26 and is pressed against the block 5 of the rod end of the link 10.
  • Debug the amplitude, frequency, vibration mode and direction of the ultrasonic vibration turn on the ultrasonic vibration device, actuate the hydraulic cylinder 1 to drive the wedge rod 12 to move downward, and the horn 13 moves downward with the wedge rod 12 during the movement.
  • the vibration in the vertical direction is generated, and the wedge rod 12 and the horn 13 are connected by a stud, and the horn 13 is mounted on the guide rail 36 by the fixing table 35, and moves on the guide rail 36 as the wedge rod 12 moves up and down.
  • the wedge tie rod 12 then changes the downward force into a horizontal force, thereby pushing the split sleeve 16. Under the horizontal force of the splitting sleeve 16, the crack will rapidly expand along the pre-processed cracking groove at the center of the large end of the connecting rod 10, thereby separating the large end of the connecting rod 10.
  • the slider 22 will also be rightward Moving, the rearward movement of the slider 22 will cause the back pressure piston 34 of the back pressure cylinder 26 to compress the rear chamber hydraulic oil, while the reversing valve of the back pressure cylinder 26 does not reverse direction, so that a small amount of higher pressure hydraulic oil flows. Accumulator 27. This ensures that the connecting rod cover is also under back pressure during the cracking process, so that a good fracture surface can be obtained.
  • the amplitude, frequency and vibration mode of the ultrasonic vibration are debugged, and the ultrasonic vibration device is turned on.
  • the cracking portion of the connecting rod is rapidly broken. Since the cover end will be separated from the body when the connecting rod is broken, the cover end will have a certain amount of displacement.
  • a back pressure cylinder 26 is used, and the back pressure cylinder rear chamber communicates with the hydraulic accumulator 27.
  • the hydraulic oil of the back pressure cylinder 26 is discharged into the accumulator 27, which ensures that the back end of the connecting rod always has a back pressure during the cracking process.
  • the "back pressure" fracture mode the fracture surface with better meshing property can be obtained, the tearing phenomenon of the fracture can be reduced, and the amount of slag can be reduced, thereby achieving the purpose of improving the cracking quality of the connecting rod.
  • the ultrasonic power source 15 is turned off, the amplitude, frequency and vibration mode of the ultrasonic vibration are readjusted, or the ultrasonic vibration device is turned on using the original vibration parameter, and then the cracking hydraulic cylinder 1 drives the wedge rod 12 to start the reset, the slider 22
  • the forward movement is driven by the back pressure cylinder 26 to close the cracking sleeve 16 and the cracking sleeve 11.
  • the separated link cover 17 is engaged with the link body 10.
  • the laser detection system, the cracking sleeve 16 and the scale on the cracking sleeve 11 are used to detect the degree of coincidence of the cracking surface, so that the meshing accuracy reaches the use requirement, and the ultrasonic vibration device is turned off.
  • the processing method of the ultrasonic assisted cracking processing device of the connecting rod comprises the following steps:
  • Step S1 mounting the frame 4 on the test bench, opening a cracking groove in the large hole of the connecting rod 10 to be cracked, and installing the small end of the connecting rod 10 to be cracked on the small head positioning block 9 to connect the connecting rod
  • the large end of the 10 is installed on the cracking sleeve 11 and the cracking sleeve 16;
  • Step S2 Debug the screw nut mechanism 7 to drive the small head positioning block 9 so that the small end of the connecting rod 10 has a certain pressing force, and adjust the horizontal pressing cylinder 20 to drive the pressing block 18 so that the big end of the connecting rod 10 Some pressing force, at the same time, the vertical locking cylinder 20 is adjusted to stabilize the pressing of the pressing block 18, and the pressing force on both sides of the connecting rod is about the cracking force.
  • Step S3 adjusting the amplitude of the ultrasonic vibration in the system of the horn 13, the transducer 14 and the ultrasonic power source 15 by 100 ⁇ m-200 ⁇ m, the frequency of 15 KHz-60 KHz, and the vibration mode axial vibration or radial vibration, thereby starting the ultrasonic power source 15, thereby
  • the wedge rod 12 is caused to vibrate at a certain amplitude, frequency and vibration mode;
  • Step S4 start the cracking hydraulic cylinder 1 so that the wedge rod 12 is moved down at a certain rate, so that the large end of the separated connecting rod 10 forms a cracking crack surface, and then the ultrasonic power source 15 is turned off, and the pulling force Q of the cracking hydraulic cylinder against the wedge rod 12 is
  • the relationship between the cracking forces N acting horizontally on the connecting rod is:
  • ⁇ is the wedge wedge angle
  • Step S5 After the connecting rod is cracked and meshed, the frequency and amplitude of the ultrasonic vibration are re-adjusted, or the original ultrasonic vibration parameter is used, the frequency adjustment range is 20KHz-60KHz, the ultrasonic amplitude range is 20 ⁇ m-150 ⁇ m, and the vibration mode adopted by the ultrasonic wave during the cracking process is Axial vibration or radial vibration; starting the ultrasonic power source 15, restarting the cracking hydraulic cylinder 1 so that the wedge rod 12 is moved upward, so that the wedge rod 12 is again tightly coupled with the cracking sleeve 11 and the cracking sleeve 16 in an ultrasonic vibration environment. Thereby the large end of the separated connecting rod 10 is reclosed, at which time the cracking hydraulic cylinder 1 is closed to stop working;
  • Step S6 According to the scale mark 31 on the large end of the connecting rod 10, the laser distance measuring device 32 is used to detect the degree of coincidence of the cracking surface, so that the meshing precision reaches the use requirement, the ultrasonic power source 15 is turned off, and the bolt is assembled to complete the cracking work.

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Abstract

一种连杆超声辅助裂解加工方法及其加工装置，涉及连杆(10)加工领域，包括机架(4)、定块(5)、滑块(22)和滑块座(30)、垂直锁紧油缸(29)、楔形拉杆(12)、调整块体(8)等，该方法及其装置扩大了裂解连杆(10)使用材料的范围；减小了连杆(10)裂解时所需的裂解力、断裂面的变形、裂解过程中产生的掉渣、连杆大头孔失圆等情况的产生；提高了连杆(10)与连杆盖(17)接合面的啮合精度和连杆(10)装配质量。

Description

连杆超声辅助裂解加工方法及其加工装置 技术领域
本发明涉及连杆加工领域，尤其涉及到连杆超声辅助裂解加工方法及其加工装置。
背景技术
传统的连杆加工方法的主要工序是对锻件毛坯首先粗铣，磨连杆的两个侧面，并将连杆盖与杆铣开，分别加工连杆盖与杆上的螺栓孔，再分别磨削连杆盖与杆部的结合面，最后对装配在一起的连杆进行精磨两侧面、精镗大小头孔等工序。传统的加工工艺中的杆与盖的切断以及杆与盖结合面磨削这两道工序的生产效率较低，并且对加工精度的要求比较高，加工之后的废品率较高，花费成本较大，目前世界上使用传统加工方法的工厂已经很少了。
连杆裂解是利用材料断裂理论，首先在锻造的连杆毛坯大头孔上开裂解槽，形成应力集中。然后在裂解加工设备上对连杆大头孔内侧面施加径向力，使裂纹由内向外不断扩展直至连杆完全裂解。最后在断裂面完全啮合的条件下，穿入螺栓并拧紧至所要求的扭矩。裂解加工方法为整体加工，仅需6道工序，具有加工方法简单、节省精加工设备、节材节能、生产成本低等优势。连杆裂解工艺凭借其巨大的优越性已被世界上大部分连杆加工产商所选择，但是连杆裂解过程中很难控制断裂面的变形和保证断裂面的质量，会导致连杆裂解后不能完全啮合，到目前为止还没有找到较好的解决办法，因而裂解连杆的材料受到一定的限制，无法对常规的连杆材料如40Cr钢进行裂解。
自从连杆裂解加工技术产生以来，美国福特公司、MTS公司、德国ALFLING公司以及日本的多家公司先后研究开发了裂解加工设备。例如美国通用公司采用“气动下拉式”方法对连杆进行裂解加工，并申请了专利，其专利公开号为US4768694，专利公开日期Sep.6,1988；美国福特公司采用“水平式”工装对连杆大头孔进行裂解加工，其专利公开号为US5105538A，专利公开日期Apr.21，1992；美国MTS公司采用“装有液压活塞的裂解块”进行裂解加工，其专利公开号为US4754906A，专利公开日期Jul.5,1988；德国ALFLING公司采用“水平力作用”的工装进行裂解加工，其专利公开号为US5169046，专利公开日期Dec.8,1992；日本实用新型者采用“偏心转轴作用方式”进行裂解加工，其专利公开号为特开平11-245122，专利公开日期平成11年1999月14日……，上述生产技术或专利技术中主要存在的主要问题是在裂解完成后，连杆大头孔变形较大，杆与盖接合面变形较大，影响杆与盖的啮合质量和装配精度，并无法对常规的连杆材料 如40Cr钢进行裂解。
吉林大学自行研究开发了具有“背压”裂解功能的连杆定向裂解机床，并申请了专利，其专利公开号为CN2511428Y，专利公开日期为2002年9月18日。连杆定向裂解机床采用下拉式楔形裂解机构，通过由液压缸驱动的楔形拉杆沿轴向直线运动，靠楔形拉杆的作用迫使专门设计的胀断移动套水平运动，对连杆大头孔施加水平作用力，在瞬时载荷的作用下完成连杆大头的快速裂解过程，但同样也存在以上问题。
专利公开号为CN202701336U，专利公开日期为2013年1月30日，该专利方法是在传统的连杆材料如40Cr钢上需裂解面处使用脆性金属，形成复合双金属裂解连杆，使如40Cr钢连杆材料可以进行裂解加工。但是双金属裂解连杆增加了复合双金属制造工艺，很难应用到大规模生产，而且复合双金属连杆未能很好解决其他裂解方法的裂解过程中的变形、掉渣、啮合质量和装配精度等问题。
有文献资料对振动载荷下合金的裂纹扩展进行了研究，发现高频振动下，带有缺口的物体会在缺口处迅速形成应力集中现象，加快物体在缺口处的断裂；同时可以削弱裂纹尖端的塑性区和残余应力对裂纹扩展的影响，但是并未对高频振动产生裂纹、振动对裂纹的控制以及提高断裂面的啮合质量有所描述，也未有把振动用于连杆裂解。
在连杆裂解过程中使用超声振动进行辅助加工，可以有效地减小连杆裂解时所需的裂解力、减少断裂面的变形、减少裂解过程中断裂面的掉渣数，减少了断裂线偏移、连杆大头孔失圆、单边裂解、裂纹分叉等情况的产生，从而可以降低加工成本，提高连杆与盖的定位精度以及装配质量，进而提高连杆裂解的生产效率和合格率。
发明内容
根据上述问题，本发明连杆裂解过程中使用超声振动进行辅助加工，可以有效地减小连杆裂解时所需的裂解力、减少断裂面的变形、减少裂解过程中断裂面的掉渣数，减少了断裂线偏移、连杆大头孔失圆、单边裂解、裂纹分叉等情况的产生，从而可以降低加工成本，提高连杆与盖的定位精度以及装配质量，进而提高连杆裂解的生产效率和合格率。
在连杆裂解工艺中加入超声振动，连杆上产生应力波，其频率为超声振动的频率；超声应力波在连杆上传播时，连杆处在交变载荷的作用下；将超声振动加到连杆上，从微观上看，微小裂纹在交变载荷的作用即应力波的作用下逐渐长大；同时又因为超声振动波在裂纹面上进行折射和反射，越是离裂纹尖部近的越容易发生相互冲击或者相互摩擦，裂纹尖部越容易断裂；超声振动波就在连杆内部传递，但超声应力波经过裂纹时， 裂纹两边的金属材料的振动并不一致，裂纹的两侧频繁的进行接触和分离，超声波通过裂纹尖部时裂纹相互撞击和滑动转化为热，裂纹尖部温度最高，这些都有助于减小裂纹扩展过程中的阻力；同时从微观动力学角度看，超声振动波作用于裂纹实际上是存在一个惯性力对裂纹尖部进行作用，裂纹在交变载荷作用下扩展，由于一直有交变力作用于裂纹区域，力的每一次交变裂纹就会长大一次；由于裂纹的开裂和位错的反射一直沿着晶格滑移的方向进行，因此在超声振动裂解的情况下，裂解更容易，裂解力更低；超声振动频率和振幅的增大对连杆裂纹扩展有很大的影响；超声振动频率和幅值的增大在微观上会导致材料微粒子的振动频率和振动幅值的增大；超声振动的频率和振幅增大后，连杆材料粒子的动能增大，导致裂纹尖部热能和疲劳载荷增大，引起裂纹尖部的疲劳断裂和热变形；同时引起裂纹尖部的惯性力增大，从而促进裂纹尖部开裂和晶格位错的发展，裂纹只有在裂纹尖部的动能消耗完毕才会停下来，因此振动幅值和振动频率的增大加快了裂纹的扩展。
在常规的裂解加工装置上设置超声振动，通过控制超声振动的振幅、频率和振动模态，使连杆裂解区域材料处于超声振动之中，并且在连杆裂解槽区域迅速形成应力集中现象，加速连杆的断裂，削弱裂纹尖端的塑性区和残余应力对裂纹扩展的影响。通过控制超声振动的振幅、频率和振动模态，来控制裂纹的扩展和断口的形成，并在楔形拉杆力和超声振动的共同作用下完成裂解分离。
完成连杆的裂解分离后，把裂解分离后形成的裂解面合上，重新调整超声振动的振幅、频率和振动模态，在超声振动的作用下使裂解断面以低振幅高频率相互磨合，减少因连杆裂解断面上倒勾、尖锐棱角以及杂质对啮合质量的影响，使裂解面达到要求的吻合度，提高杆与盖接合面的啮合精度，提高连杆装配质量。
连杆超声辅助裂解加工方法，在常规的裂解加工装置上设置超声振动，通过控制超声振动的振幅、频率和振动模态，使连杆裂解区域材料处于超声振动之中，对裂纹尖端的塑性区和残余应力实施控制，改善裂解质量；把裂解分离后形成的裂解面合上，重新调整超声振动的振幅、频率和振动模态，在超声振动的作用下使裂解断面以低振幅高频率相互磨合，减少连杆裂解断面上倒勾、尖锐棱角，使裂解面达到要求的吻合度，提高裂解连杆的装配质量；包括如下步骤：
步骤S1：将机架安装在实验台上，在待裂解的连杆的大头孔开设裂解槽，将待裂解的连杆的小头端安装在小头定位块上，将连杆的大头端安装在裂解定套与裂解动套上；
步骤S2：调试丝杠螺母机构从而带动小头定位块使得连杆的小头端有一定的压紧力， 调整水平压紧油缸从而带动压紧块使得连杆的大头端有的压紧力，同时调试垂直锁紧油缸从而使得压紧块的压紧稳定，连杆两侧压紧力约为裂解力的
Figure PCTCN2017108237-appb-000001
步骤S3：调整变幅杆、换能器和超声电源系统中的超声振动的振幅、频率和振动模式，启动超声电源，从而使得楔形拉杆在一定的振幅、频率和振动模态上振动；
步骤S4：启动裂解液压缸，从而带动楔形拉杆以一定的速率下移，使得分离的连杆的大头端形成裂解裂纹面后关闭超声电源；
步骤S5：重新调整超声振动的频率、振幅和振动模态，或使用原超声振动参数，启动超声电源，重新启动裂解液压缸，使得楔形拉杆上移，从而使得楔形拉杆再次与裂解定套和裂解动套在超声振动环境下紧密结合；从而分离的连杆的大头端重新合上，此时，关闭裂解液压缸使其停止工作；
步骤S6：根据连杆大头端上的刻度标记，利用激光测距装置检测裂解面吻合度，使啮合精度达到使用要求，关闭超声电源；装配螺栓，完成裂解工作。
进一步的，超声振动辅助加工可以用其它的振动方式代替。
进一步的，连杆裂解时超声波发生器频率的调节范围15KHz-60KHz；超声波振幅范围为100μm-200μm；超声波在裂解过程采用的振动模式为轴向振动或径向振动，振动方向与楔形拉杆的运动方向相同。
进一步的，调节裂解液压缸对楔形拉杆(12)的拉力Q与水平作用在连杆上的裂解力N之间的关系为：
Figure PCTCN2017108237-appb-000002
其中：α为楔形块楔角，
Figure PCTCN2017108237-appb-000003
为楔形块与定套之间的摩擦角，
Figure PCTCN2017108237-appb-000004
为楔形块与动套之间的摩擦角。
进一步的，连杆裂解后啮合过程，频率调节范围为20KHz-60KHz，超声波振幅范围为20μm-150μm，超声波在裂解过程采用的振动模式为轴向振动或径向振动；
基于连杆超声辅助裂解加工方法的加工装置，包括连杆小头孔压紧机构、连杆大头孔裂解机构、连杆盖压紧机构、滑块机构、激光测距系统以及超声振动系统组成，其特征在于在常规的裂解加工装置上设置超声振动，通过控制超声振动的振幅、频率和振动模式，使连杆裂解区域材料处于超声振动之中，控制材料的微观裂解形貌，减少裂解时的塑性变形，在楔形拉杆力与超声振动的合力作用下完成裂解分离，然后重新调整超声振动的频率和振幅，或使用原超声振动参数，使裂解分离后形成的裂解面在此超声振动条件下进行合装，在超声振动的作用下使裂解面达到要求的吻合度；
所述连杆小头孔压紧机构包括丝杠螺母机构向右推动调整块体，使安装在调整块体上的小头定位块定位、压紧连杆，检测系统包括激光测距装置、裂解定套和裂解动套上的刻度，可以检测裂解面的吻合度，超声振动机构包括变幅杆、换能器以及超声电源，变幅杆与楔形拉杆通过螺柱连接，变幅杆通过固定台安装在导轨架上，随着楔形拉杆的上下移动而在导轨架上移动，在工作过程中产生竖直方向上的振动。
进一步的，丝杠螺母机构向右推动调整块体，使小头定位块压紧连杆。
进一步的，超声振动可加载在背压装置上。
进一步的，超声振动装置的变幅杆与楔形拉杆通过螺柱紧密连接，使楔形拉杆在工作过程中产生竖直方向上的振动，并且超声振动装置通过固定台随着楔形拉杆上下移动而在导轨架上移动。
进一步的，胀套内的下拉式楔形拉杆与裂解液压缸间的连接有震动隔离器。
有益效果：
1.该加工方法扩大了裂解连杆使用材料的范围，减小连杆裂解时所需的裂解力、断裂面的变形、裂解过程中产生的掉渣、连杆大头孔端失圆等情况的产生，提高连杆与盖接合面的啮合精度，提高连杆装配质量和装配精度。
2.在常规的裂解加工装置上设置超声振动，通过控制超声振动的振幅、频率和振动模态，使连杆裂解区域材料处于超声振动之中，削弱裂纹尖端的塑性区和残余应力对裂纹扩展的影响，通过控制超声振动的振幅、频率和振动模态，来控制裂纹的扩展和断口的形成，减小连杆裂解时所需的裂解力、断裂面的变形、裂解过程中产生的掉渣、连杆大头孔失圆等情况的产生，并在楔形拉杆力和超声振动的共同作用下完成裂解分离。
3.完成连杆的裂解分离后，把裂解分离后形成的裂解面合上，重新调整超声振动的振幅、频率和振动模态，在超声振动的作用下裂解面相互磨合，使裂解面达到要求的吻合度，提高连杆与盖接合面的啮合精度，提高连杆装配质量。
4.采用一种连杆超声辅助裂解加工方法与装置，扩大裂解连杆使用材料的范围，对常规的连杆材料如40Cr钢可以进行裂解。
5.减小连杆裂解时所需的裂解力、断裂面的变形、裂解过程中产生的掉渣、连杆大头孔失圆等情况的产生，使原来常规的裂解工艺更加完善。
6.在超声振动的作用下裂解面相互磨合，使裂解面达到要求的吻合度，提高杆与盖接合面的啮合精度，提高连杆装配质量。
7.调整超声振动的振幅、频率和振动模态，可以适应不同材料、不同尺寸的连杆的 裂解要求；可有效减少加工成本，降低废品率。
8.楔形拉杆与裂解液压缸之间设置有震动隔离器，可以起到减缓裂解液压缸随着楔形拉杆振动，提高裂解液压缸工作的稳定性。
附图说明
图1为连杆超声辅助裂解加工装置的主视图；
图2为加工后的连杆大头裂解示意图；
图3为裂解力和超声振动的合力示意图。
附图标记如下：
1.裂解液压缸；2.矩形连接块；3.连接支架；4.机架；5.定块；6.导向套；7.丝杠螺母机构；8.调整块体；9.小头定位块；10.连杆；11.裂解定套；12.楔形拉杆；13.变幅杆；14.换能器；15.超声电源；16.裂解动套；17.连杆盖；18.压紧块；19.定位销；20.水平压紧油缸；21.水平油缸活塞杆；22.滑块；23.连接块；24.定位螺杆；25.连接板；26.背压油缸；27.液压蓄势器；28.活塞杆；29.垂直锁紧油缸；30.滑块座；31.刻度标记；32.激光测距装置；33.垂直锁紧液压缸；34.背压活塞；35.固定台；36.导轨。
具体实施方式
为对本发明做进一步的了解，现结合附图做进一步的描述：
结合附图1，连杆超声辅助裂解加工装置，包括机架4、定块5、滑块22和滑块座30；机架4固定安装在实验台上，机架4上开设有孔；所述定块5和滑块座30均安装在机架4上；滑块座30上安装有滑块22；滑块22和滑块座30对应位置形成竖直阶梯孔B，且形成竖直阶梯孔B内安装有垂直锁紧油缸29；定块5与滑块座30和滑块22相结合处组成竖直阶梯孔A，且竖直阶梯孔A内安装有楔形拉杆12；所述楔形拉杆12下端安装有矩形连接块2；所述矩形连接块2与裂解液压缸1相连接；所述竖直阶梯孔A上端安装有裂解定套11和裂解动套16；所述裂解定套11和裂解动套16组成倒T形孔；所述楔形拉杆12穿过倒T形孔；定块5上端面一侧设置有凹坑，凹坑内设置有调整块体8；所述调整块体8一侧设置有丝杠螺母机构7；所述丝杠螺母机构7包括丝杠螺母7-1和丝杠螺母座7-2；所述丝杠螺母座7-2固定安装在定块5侧壁上；所述丝杠螺母7-1一端安装在丝杠螺母座7-2上，另一端与调整块体8配合；所述调整块体8上端面上安装有小头定位块9；所述楔形拉杆12上端设置有变幅杆13；所述变幅杆13上端与换能器14相连接；所述变幅杆通过固定台35安装在导轨36上；所述换能器14与超声电源15相连接；裂解动套16右侧设置有压紧块18；所述压紧块18通过定位销19与水平油缸活塞 杆21一端相连接；所述水平油缸活塞杆21安装在水平压紧油缸20内；所述水平油缸活塞杆21另一端与竖直的活塞杆28垂直接触；所述活塞杆28安装在垂直锁紧油缸29内；所述活塞杆28与垂直锁紧液压缸33相连接；滑块22远离定块5端的竖直面上设置有连接块23和定位螺杆24；所述连接块23和定位螺杆24另一端均设置在连接板25上，所述连接板25置于机架4上，且连接块23通过背压活塞34与背压油缸26相连接，所述背压油缸26与液压蓄势器27相连接。其中，所述楔形拉杆12与裂解定套11配合处为圆柱形，与裂解动套16配合处为锥形。楔形拉杆12上安装有导向套6；所述导向套6固定在定块5和滑块座30下端。机架4下端设置有连接支架3；所述连接支架3上开设有孔，且孔与矩形连接块2相配合。丝杠螺母座7-2为L形。楔形拉杆12与矩形连接块2之间采用螺纹连接，为防止裂解液压缸1中的活塞杆及楔形拉杆12的转动，在裂解液压缸1中的活塞杆与矩形连接块2间采用螺母备紧，并在连接支架3的顶面板上开一个矩形窗口，其左右两侧面与矩形连接块2保持公差配合关系。而楔形拉杆12向下运动过程中，用导向套6导向。
在连杆裂解加工中采用了“背压式”的裂解方式，在裂解前丝杠螺母机构7向右推动调整块体8，使安装在调整块体8上的小头定位块9定位、压紧连杆10，同时一个水平压紧油缸20通过连接在其活塞杆端部的压紧块18来压紧连杆10的大头端，由一个垂直锁紧油缸29锁紧，使得连杆10大头端中心断裂面处于预压紧状态。
当连杆10小头端放入小头定位块9，连杆10大头端置于裂解定套11、裂解动套16后，丝杠螺母机构7向右推动调整块体8，使安装在调整块体8上的小头定位块9定位、压紧连杆10，同时一个水平压紧油缸20通过连接在水平油缸活塞21端部的压紧块18来压紧连杆10大头端盖端，在水平油缸20驱动压紧块18压紧连杆10后，垂直锁紧油缸29立刻动作，使具有斜面的锁紧活塞杆28上升并压紧水平活塞杆21。
此时，载有盖端水平压紧油缸20与垂直锁紧油缸29的滑块22已由背压油缸26驱动，压紧在连杆10杆端的定块5上。调试超声振动的振幅、频率、振动模态和方向，开启超声振动装置，裂解液压缸1动作，驱动楔形拉杆12向下运动，变幅杆13随着楔形拉杆12向下运动，在运动过程中产生竖直方向上的振动，楔形拉杆12与变幅杆13通过螺柱连接，变幅杆13通过固定台35安装在导轨36上，随着楔形拉杆12的上下移动而在导轨36上移动。楔形拉杆12再将向下作用力变成水平作用力，从而推动裂解动套16。在裂解动套16水平作用力下，裂纹将沿连杆10大头端中心处预先加工好的裂解槽快速扩展，从而使连杆10大头端分离。在楔形拉杆12向下运动的过程中，滑块22也将向右 移动，滑块22向后移动将使背压油缸26的背压活塞34压缩后腔液压油，而此时背压油缸26的换向阀并不换向，使少量较高压力的液压油流向蓄势器27。这样可保证在裂解过程中连杆盖也处于背压状态下，从而可获得较好的断裂面。
调试超声振动的振幅、频率和振动模态，开启超声振动装置，在楔形拉杆12的向下作用下，连杆裂解部位快速断裂。由于连杆断裂时盖端将与本体分离，盖端将有一定量的位移，为保持裂解时所需的背压力，采用背压油缸26，背压油缸后腔与液压蓄势器27相通。当盖端产生位移时，背压油缸26的液压油排入蓄势器27中，可保证在裂解过程中连杆盖端始终有背压力的作用。在“背压”断裂方式下，可获得啮合性较好的断裂面，减少断裂的撕裂现象，减少掉渣的数量，从而达到提高连杆裂解质量的目的。
结合图2和3，关闭超声电源15，重新调整超声振动的振幅、频率和振动模态，或使用原振动参数，开启超声振动装置，然后裂解液压缸1驱动楔形拉杆12开始复位，滑块22在背压油缸26驱动下向前运动，使裂解动套16与裂解定套11合拢。使分离后的连杆盖17与连杆体10啮合。使用激光检测系统、裂解动套16和裂解定套11上的刻度检测裂解面吻合度，使啮合精度达到使用要求，关闭超声振动装置。
连杆超声辅助裂解加工装置的加工方法，包括如下步骤：
步骤S1：将机架4安装在实验台上，在待裂解的连杆10的大头孔开设裂解槽，将待裂解的连杆10的小头端安装在小头定位块9上，将连杆10的大头端安装在裂解定套11与裂解动套16上；
步骤S2：调试丝杠螺母机构7从而带动小头定位块9使得连杆10的小头端有一定的压紧力，调整水平压紧油缸20从而带动压紧块18使得连杆10的大头端有的压紧力，同时调试垂直锁紧油缸20从而使得压紧块18的压紧稳定，连杆两侧压紧力约为裂解力的
Figure PCTCN2017108237-appb-000005
步骤S3：调整变幅杆13、换能器14和超声电源15系统中的超声振动的振幅100μm-200μm、频率15KHz-60KHz和振动模态轴向振动或径向振动，启动超声电源15，从而使得楔形拉杆12在一定的振幅、频率和振动模态上振动；
步骤S4：启动裂解液压缸1，使楔形拉杆12以一定的速率下移，使得分离的连杆10的大头端形成裂解裂纹面后关闭超声电源15，裂解液压缸对楔形拉杆12的拉力Q与水平作用在连杆上的裂解力N之间的关系为：
Figure PCTCN2017108237-appb-000006
其中：α为楔形块楔角，
Figure PCTCN2017108237-appb-000007
为楔形块与定套之间的摩擦角，
Figure PCTCN2017108237-appb-000008
为楔形块与动套之间的摩擦角；
步骤S5：连杆裂解后啮合，重新调整超声振动的频率、振幅，或使用原超声振动参数，频率调节范围为20KHz-60KHz，超声波振幅范围为20μm-150μm，超声波在裂解过程采用的振动模式为轴向振动或径向振动；启动超声电源15，重新启动裂解液压缸1，使得楔形拉杆12上移，从而使得楔形拉杆12再次与裂解定套11和裂解动套16在超声振动环境下紧密结合；从而分离的连杆10的大头端重新合上，此时，关闭裂解液压缸1使其停止工作；
步骤S6：根据连杆10大头端上的刻度标记31，利用激光测距装置32检测裂解面吻合度，使啮合精度达到使用要求，关闭超声电源15；装配螺栓，完成裂解工作。
所述实施例为本发明的优选的实施方式，但本发明并不限于上述实施方式，在不背离本发明的实质内容的情况下，本领域技术人员能够做出的任何显而易见的改进、替换或变型均属于本发明的保护范围。

Claims (10)

  1. 连杆超声辅助裂解加工方法，其特征在于，在常规的裂解加工装置上设置超声振动，通过控制超声振动的振幅、频率和振动模态，使连杆裂解区域材料处于超声振动之中，对裂纹尖端的塑性区和残余应力实施控制，改善裂解质量；把裂解分离后形成的裂解面合上，重新调整超声振动的振幅、频率和振动模态，在超声振动的作用下使裂解断面以低振幅高频率相互磨合，减少连杆裂解断面上倒勾、尖锐棱角，使裂解面达到要求的吻合度，提高裂解连杆的装配质量；包括如下步骤：
    步骤S1：将机架(4)安装在实验台上，在待裂解的连杆(10)的大头孔开设裂解槽，将待裂解的连杆(10)的小头端安装在小头定位块(9)上，将连杆(10)的大头端安装在裂解定套(11)与裂解动套(16)上；
    步骤S2：调试丝杠螺母机构(7)从而带动小头定位块(9)使得连杆(10)的小头端有一定的压紧力，调整水平压紧油缸(20)从而带动压紧块(18)使得连杆(10)的大头端有的压紧力，同时调试垂直锁紧油缸(20)从而使得压紧块(18)的压紧稳定，连杆两侧压紧力约为裂解力的
    Figure PCTCN2017108237-appb-100001
    步骤S3：调整变幅杆(13)、换能器(14)和超声电源(15)系统中的超声振动的振幅、频率和振动模式，启动超声电源(15)，从而使得楔形拉杆(12)在一定的振幅、频率和振动模态上振动；
    步骤S4：启动裂解液压缸(1)，从而带动楔形拉杆(12)以一定的速率下移，使得分离的连杆(10)的大头端形成裂解裂纹面后关闭超声电源(15)；
    步骤S5：重新调整超声振动的频率、振幅和振动模态，或使用原超声振动参数，启动超声电源(15)，重新启动裂解液压缸(1)，使得楔形拉杆(12)上移，从而使得楔形拉杆(12)再次与裂解定套(11)和裂解动套(16)在超声振动环境下紧密结合；从而分离的连杆(10)的大头端重新合上，此时，关闭裂解液压缸(1)使其停止工作；
    步骤S6：根据连杆(10)大头端上的刻度标记(31)，利用激光测距装置(32)检测裂解面吻合度，使啮合精度达到使用要求，关闭超声电源(15)；装配螺栓，完成裂解工作。
  2. 根据权利要求1所述的连杆超声辅助裂解加工方法，其特征在于，超声振动辅助加工可以用其它的振动方式代替。
  3. 根据权利要求1所述的连杆超声辅助裂解加工方法，其特征在于，连杆裂解时超 声波发生器(15)频率的调节范围15KHz-60KHz；超声波振幅范围为100μm-200μm；超声波在裂解过程采用的振动模式为轴向振动或径向振动，振动方向与楔形拉杆(12)的运动方向相同。
  4. 根据权利要求1所述的连杆超声辅助裂解加工方法，其特征在调节裂解液压缸对楔形拉杆(12)的拉力Q与水平作用在连杆上的裂解力N之间的关系为：
    Figure PCTCN2017108237-appb-100002
    其中：α为楔形块楔角，
    Figure PCTCN2017108237-appb-100003
    为楔形块与定套之间的摩擦角，
    Figure PCTCN2017108237-appb-100004
    为楔形块与动套之间的摩擦角。
  5. 根据权利要求1所述的连杆超声辅助裂解加工方法，其特征在于，连杆裂解后啮合过程，频率调节范围为20KHz-60KHz，超声波振幅范围为20μm-150μm，超声波在裂解过程采用的振动模式为轴向振动或径向振动；
  6. 根据权利要求1所述的基于连杆超声辅助裂解加工方法的加工装置，其特征在于，包括连杆小头孔压紧机构、连杆大头孔裂解机构、连杆盖压紧机构、滑块机构、激光测距系统以及超声振动系统组成，其特征在于在常规的裂解加工装置上设置超声振动，通过控制超声振动的振幅、频率和振动模式，使连杆裂解区域材料处于超声振动之中，控制材料的微观裂解形貌，减少裂解时的塑性变形，在楔形拉杆力与超声振动的合力作用下完成裂解分离，然后重新调整超声振动的频率和振幅，或使用原超声振动参数，使裂解分离后形成的裂解面在此超声振动条件下进行合装，在超声振动的作用下使裂解面达到要求的吻合度；
    所述连杆小头孔压紧机构包括丝杠螺母机构(7)向右推动调整块体(8)，使安装在调整块体(8)上的小头定位块(9)定位、压紧连杆(10)，检测系统包括激光测距装置(32)、裂解定套(11)和裂解动套(16)上的刻度，可以检测裂解面的吻合度，超声振动机构包括变幅杆(13)、换能器(14)以及超声电源(15)，变幅杆(13)与楔形拉杆(12)通过螺柱连接，变幅杆(13)通过固定台(35)安装在导轨架(36)上，随着楔形拉杆(12)的上下移动而在导轨架(36)上移动，在工作过程中产生竖直方向上的振动。
  7. 根据权利要求6所述的连杆超声辅助裂解加工装置，其特征在于，丝杠螺母机构(7)向右推动调整块体(8)，使小头定位块(9)压紧连杆(10)。
  8. 根据权利要求6所述的连杆超声辅助裂解加工装置，其特征在于，超声振动可加载在背压装置上。
  9. 根据权利要求6所述的连杆超声辅助裂解加工装置，其特征在于，超声振动装置 的变幅杆(13)与楔形拉杆(12)通过螺柱紧密连接，使楔形拉杆(12)在工作过程中产生竖直方向上的振动，并且超声振动装置通过固定台(35)随着楔形拉杆(12)上下移动而在导轨架(36)上移动。
  10. 根据权利要求6所述的连杆超声辅助裂解加工装置，其特征在于，胀套内的下拉式楔形拉杆(12)与裂解液压缸(1)间的连接有震动隔离器。
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