【作者】 王刚；

【导师】 王黎明； 贾秀杰；

【作者基本信息】 山东大学 ， 机械工程（专业学位）， 2023， 硕士

【摘要】 零部件再制造是实现“碳达峰、碳中和”目标的重要举措之一。曲轴作为柴油机最为关键的核心部件,其工作于温度高、压力高的环境中,尤其是其高速旋转的工作特性,常导致曲轴出现损坏,本文介绍了柴油机曲轴特点,对曲轴常见失效形式进行了分析,并对曲轴修复常见修复技术进行了介绍,结合淄柴公司EL6160ZLC型大缸径柴油机曲轴修复在市场上的实际需求的,研究并制定了电刷镀技术在以42CrMoA为材料的大缸径柴油机曲轴的再制造修复技术工艺,提高了废旧大缸径船用曲轴的再利用率。本文阐述了电刷镀技术特点及设备组成,通过组织性能、力学性能、耐磨性和硬度分析,完成EL6160ZLC型船用柴油机曲轴的电刷镀工艺设计和实施方案,对修复后曲轴进行了性能检测、台架试验和实船验证,表明了电刷镀技术在42CrMoA大缸径船用柴油机曲轴再制造过程中的有效性。本文主要研究内容如下:(1)分析了曲轴的常见失效形式和修复技术,结合淄柴公司对EL6160ZLC型大缸径柴油机曲轴再制造的实际需求,以及现阶段电刷镀技术在车用曲轴和机床主轴上应用的现状,提出了研究内容。(2)结合淄柴公司生产和售后反馈,分析了曲轴最为常见的磨损失效形式,以市场保有量较大的EL6160ZLC型大缸径柴油机作为样机,针对其42CrMoA曲轴材料,对电刷镀电源、镀笔、溶液进行了选型,通过正交试验确定了电刷镀修复工艺参数。(3)通过对镀层的组织性能分析、力学性能分析、耐磨和硬度分析,确定了EL6160ZLC型柴油机曲轴可修复的磨损极限尺寸,并制定了电刷镀修复工艺路线。(4)根据制定的电刷镀修复工艺路线对一条EL6160ZLC型柴油机曲轴进行了修复,对修复后的曲轴按照新机标准进行检查、装配和台架试验,并进行了实船运行,证明了电刷镀技术修复工艺在42CrMoA为材料的大缸径船用柴油机曲轴再制造上应用的有效性。更多还原

【Abstract】 Remanufacturing of parts and components is one of the important measures to achieve the goal of carbon peak and carbon neutralization.Crankshaft,as the most critical core component of diesel engine,works in the environment of high temperature and high pressure,especially its high-speed rotation,which often leads to crankshaft damage.This paper introduces the characteristics of diesel engine crankshaft,analyzes the common failure forms of crankshaft,and introduces the common repair technology of crankshaft.According to the actual market demand of EL6160ZLC large-bore diesel engine crankshaft repair,the remanufacturing repair technology of 42CrMoA large-bore diesel engine crankshaft with brush plating technology is studied and formulated,which improves the reuse rate of waste large-bore marine crankshaft.In this paper,the characteristics of brush plating technology and the composition of the equipment are described,the design and implementation scheme of brush plating process for EL6160ZLC marine diesel crankshaft are completed through the analysis of organizational properties,mechanical properties,wear resistance and hardness,and the performance testing,bench test and ship verification of the repaired crankshaft are carried out.The results show that the brush plating technology is effective in the remanufacturing process of 42CrMoa large-bore marine diesel engine crankshaft.The main contents of this paper are as follows:(1)The common failure forms and repair technologies of crankshaft are analyzed,and the research contents are put forward according to the actual requirements of remanufacturing EL6160ZLC large-bore diesel engine crankshaft in ZiBo Diesel Engine Company and the application status of brush plating technology in vehicle crankshaft and machine tool spindle..(2)Combined with the production and after-sale feedback of ZiBo Diesel Engine Company,the most common wear failure forms of crankshaft were analyzed.EL6160ZLC large cylinder diesel engine with large quantity in the market was taken as the prototype.According to its 42CrMoA crankshaft material,the brush plating power supply,plating pen and solution were selected,and the brush plating repair process parameters were determined by orthogonal test.(3)The repairable wear limit size of EL6160ZLC diesel engine crankshaft was determined by analyzing the microstructure,mechanical properties,wear resistance and hardness of the coating,and the repair process route of brush plating was formulated.(4)The crankshaft of EL6160ZLC diesel engine was repaired according to the established brush plating repair process route.The repaired crankshaft was inspected,assembled and tested on the bench according to the new engine standard,and the actual ship operation was carried out.The effectiveness of the application of brush plating technology repair process in the remanufacturing of marine diesel crankshaft with large cylinder diameter made of 42CrMoA was proved.更多还原