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1、英文文献及翻译Investigation of Remanufacturing Technology and evaluation system of Heavy Duty Caterpillar Engine1 IntroductionWith the resource increasingly drying up and the environment contaminative pricking up, the significance of continual development was understood gradually by people. The remanufactu
2、ring engineering is came into being and became one new engineering subject as the resource requirement was increasingly went up by human being. And it is regarded importantly by all the countries and become one important technology support to carry out the strategic of continual development1,2.Owing
3、 to the mal-conditions of operating and the high reinforcement, heavy duty caterpillar engines have a very short service life comparing with the civil vehicle. It is the unequal-life of the engines parts and working surfaces that results in the failure of some parts and working surfaces and the engi
4、nes goes to out-of-service. Short service life of engine and unconformity with the life cycle of vehicle had become a bottleneck to the maintenance in the armored cavalry3.It is urgent for the ensuring and maintaining of armored equipment to start the remanufacturing of armored vehicle engine based
5、on high technology for prolonging its service life. Notable benefit in economy and military fairs will be gained by the same service life with the vehicle after remanufacturing of the engine. 2 feasibility analysisThe manufacturing technology used in the heavy duty caterpillar engine is following th
6、e old technology of the soviet times, which have 50 years up to now. And a great many new technique and material have occurred in these 50 years.The suface engineering technology, which adopting many surface intensify technology to consolidating the surface of material and getting the high wearabili
7、ty, was developed from the 1980s. It provides a technology base to remanufacturing the equipment engine4. Now, the employ life-span of civilian engine have reached at 800010000h as using the new technology, new material and new surface treatment technology. According to the “cannikin theory” of prod
8、uct life, it will prolong the life-span of engine as long as increasing the length of those shortest board, which can influence the performance of engine, Namely, prolonging the life-span of key friction mate for engine such as cylinder/piston, bending axis/tile, camshaft/valve adjusting set5. All t
9、hese provides the sustain of theory and practice.Therefore, it is feasibility both in theory and technology to remanufacturing the equipment engine from the above analysis.3 Remanufacturing of heavy duty caterpillar engine3.1 Conception of remanufacturing for heavy duty caterpillar engineNot all the
10、 products are suitable for remanufacturing. Heavy duty caterpillar engine has an obviously difference in designing, fabrication process , working condition and service life with civil vehicle engine. For example, the friction surface has a same life to the main body of engine (equal-life designing a
11、s DEUTZ engine)and most parts have wear out after an overhaul life of a civil vehicle engine, while for heavy duty caterpillar engine, it is another case that many parts have an ability to service more long, some are even in the better state. So the remanufacturing of heavy duty caterpillar engine i
12、s different from the civil in the goal, technique project and method6.Generally speaking, the fixed parts such as case, housing and bearing block have a long life while the service life of moving parts is shorter and the friction surfaces have shorter life than the parts which deliver the torque. It
13、 is the unequal-life of parts and their working surfaces which result in the failure of some parts/working-surface and out-of-service of equipment as a whole. In other words, the unequal-life of parts and their working surfaces provides a material base for remanufacturing7.Because of the long terms
14、of design and service, remanufacturing is an upgrade procedure for heavy duty caterpillar engines. Based on the prototype version, many advanced technology and new parts are adopted to promoting some key performances of the old products greatly, i.e. the remanufacturing of engines is coincident with
15、 the society of resource-saving and green environmental protection. The goals of heavy duty caterpillar engine remanufacturing are as follows: based on the systematic analyzing to engine, improve the wearing and friction state of engines fricative pairs by the surface strengthening of key parts appl
16、ying the multi-surface engineering technology, find a more suitable material with matching surface modified nature to reduce the attrition of working surfaces, and finally double the service life of the engine. 3.2 Key remanufacturing techniqueA lot of key techniques applied in remanufacturing come
17、from the up-to-date achievement of science and technology such as advanced surface technique, micro and nano-coating and wear-resistance self-recovery material and technique, renovation heat treatment technique, molding technique of remanufacturing blank and up-date of outdated products. The main cl
18、assification of key technology for remanufacturing was summarized as Fig.18.Advanced surface technique and composite surface techniqueRepairing heat treatmenttechniqueRemanufacturing celerity figuration techniqueEmergence celerity maintain techniqueRemanufacturing special machining techniqueRemanufa
19、cturing mechanism machining techniqueEquipment alteration and capability upgrade techniqueNano coatings and nano material restore techniqueKeyremanufacturingtechnologyFig.1 Classification of key technology for remanufacturingThe key technique of remanufacture engineering includes many types, in whic
20、h the advanced and compound surface techniques play an important role in repairing and strengthening the failure surfaces of waste and old parts. Various surface coating techniques are widely used because the attrition wear and corrosion of waste and old parts appear mainly on the surface. Based on
21、micro and nano-materials, for micro and nano-coating and wear-resistance self-recovery technique, a special coating technology can be used for reinforcing surface with promotion of performance, or self-recovery technology forming film at affected position of friction surface guided by tribochemistry
22、 to solve the problems in remanufacturing. The holistic performances of parts can be recovered from initialization of inner construction by renovation heat treatment technique. Besides the technique mentioned above, normal and some special machinery are also used in remanufacturing engineering.3.3 G
23、eneral planningUnlike traditional overhaul, remanufacturing completes a progress of upgrading for promotion of performance and service life against the engine out-of-service.Measured and analyzed systematically, the main parts of engine were sorted into four classes by their status: used without any
24、 treating, remanufactured, new and upgrade. The degree of wear was analyzed for the parts used continuously and remanufactured, and the service life of the parts was evaluated by life predicted method. The remanufacturing process was according to the new parts productive standard and the key parts w
25、ere reinforced by means of multi-surface engineering technologies such as laser-quenching, ion-implant, ion-sulfurizing at normal temperature, magnetron sputtering, supersonic plasma spray, nanometer brush plating, nitriding, boriding, nanometer oil additive, intellectual oil infiltrating for lubric
26、ation ,and plasma submerge injection.The procedure of remanufacturing to engine is stepped as follows: first, find out the main parts which have a strong effects to engine service life such as cylinder/rings, crankshaft journal/bearings bush on referencing the experience of repair factory; then by a
27、nalyzing of work condition, materials, fabrication process and the normal failure form of these parts, basic test researching would be carried out in laboratory using some new material and craft especially the advanced surface engineering; the third thing to do is the bench test to compared various
28、combinations of different methods. To some extant, the remanufacturing of these key parts determines success or not of remanufacturing to whole engine. Some other problems as scale deposit, carbon deposit, failure of sealing should be taken into consideration owing to the prolonged engine service li
29、fe. As for the remanufacturing times (cycles) of main structural parts, it needs to be studied specially in fatigue life.3.4 Treatment of main friction pairsBecause of particularity in use of heavy duty caterpillar engine, the remanufacturing program has its uniqueness and different technical measur
30、es would be used for different pasts. As the first time to remanufacture to the tank engine, we make our focus on the main key friction pairs which have s strong affection on the service life of engine while untreated new products were used for accessories section like turbocharger, oil pump and wat
31、er pump.3.4.1 Crankshaft and connecting rod mechanismRecovering the size of journals by nano-electronic brush plating;Anti-carbon deposit and TBS coat were used synchronously at piston crown to reduce heat transfer from piston and improve the working condition of first ring groove while the piston s
32、kirt was plasma sprayed with Al alloy to recover size and strengthen.At the friction surface of gas ring Mo layers were sprayed to reduce the coefficient of friction and abrasion of cylinder with rings.A self-lubricating film was gained at inner surface of cylinder by medium-frequency quenching and
33、ion sulfurizing at normal temperature. Supersonic plasma spray was applied at outside surface of cylinder for reducing cavitation wear.3.4.2 Air distributing mechanismSulfurizing at journal of camshaft to reduce the friction and wear.The coefficient between valve and guide was reduced by ion sulfuri
34、zing at normal temperature and nano-addition agent in the oil.3.4.3 Engine bodyUsing supersonic plasma spray, the surfaces were strengthened and recovered in size for engine case, bearing saddle bore.4 Design of evaluation criterion systemIt is necessary that the stability of engine performance, rel
35、iability and anti-resistance abradability be verified by bench test to evaluate the processing set-up and technical measure used in tank engine remanufacturing. The standards aim at the change of engine performance and the state of main parts, i.e. the engines performance become bad or not, the abra
36、sion of the main parts is overproof or not after running at test bed for 1000 hours guided by warrant test program.The tests should be completed are as follows: full load characteristic test, constant speed characteristic test at rated speed, lub-oil consumption measure, lub-oil sample optical spect
37、rum analysis, reliability test, engine vibration measure. Besides the items specified in the Chinese standard and military standard, the circulate flow measurements of oil and cool water were done for judging the states of oil pump and water pump indirectly, the vibration of the crankcase was measur
38、ed to monitor the fit clearances of piston/cylinder and main journal/bearing. The performance index measured must be converted first to number at the standard atmospheric condition by Chinese standard and then the change rates of performance reflecting engine technical statues be analyzed such as ra
39、ted power, brake specific fuel consumption(BSFC), smoke, and specific lub-oil consumption. Based on the research to test specifications of civil vehicle engine and combining the working condition of tank engine, we take the criterion as follows: the test will be considered as meeting the demands of
40、engine performance if the rated power reduces not more than 4%, lub-oil specific consumption increases not more than 25% and the BSU(Bosch smoke unit) increases not more than 10% after the reliable test.As to the abrasion of engine parts, metallographic analysis and size measuring should be done for
41、 the parts remanufactured such as piston, cylinder, crankshaft, valve, camshaft. If the sizes of main parts are not overrun and there are not breaking-off on the working surface of bearings, we can say that the remanufacturing technique is successful.5 ConclusionIntroducing the significance of reman
42、ufacture to tank engine, the author analyzed the service of tank engine and the failure of main parts first, then pointed out that the remanufacture for heavy duty caterpillar engine has its special content and style to normal civil vehicle engine. The applying of remanufacture technique is to promo
43、te the service life of tank engine by using modern surface engineering. After introducing the remanufacture technique program and measure in detail, a preliminary criterion was offered to judge if the remanufacture is success or not for the tank engine and it is beneficial to the building of engine
44、remanufacture criterion system.references1Xu Binshi, Li Renghan, Liang Xiubing. The development of green remanufacturing engineering. China Surface Engineering. 2001, 14(2): 1-4.2Xu Binshi, Ma Shining, Liu Shican. The remanufacturing engineering of 21 centuriesJ. Chinese mechanism engineering. 2000,
45、11 (1):36-38.3 Liang Zhijie , Xu Binshi,et al.Discussion and Feasibility Analysis of Remanufacturing technology for Armored Equipment Engines, J China Surface Engineering. 2006 (19)5: 89 -91.4 Liu Qian,Dai Qingrong .Present Condition of Again Manufacture of the Automobile Engine and its Crucial Tech
46、niqueJ. Plant Maintenance Engineering Beijing.2003 No.2 :9-105Zhang Ping, Liang Zhijie, Wang Haijun. Study on Remanufacturing technology of Cylinder Liner/Piston Ring for Armored Equipment Engine. China Surface Engineering. 2006 (19)5: 92 -95.6 Zhang Guoqing , Jing Xuedong , et al. Assessment on Rem
47、anufacturability of the Automobile Engines J. China Mechanical Engineering. Beijing. 2005,(16)8:739-7427Xu Binshi, Ma Shining, Liu Shican. Application od surface engineering and remanufacturing engineeringJ. Material protection. 2000,33 (1):1-5.8Zhu shaohua, Liu Shican, Zhusheng. Discussiong of conn
48、otation and subject structure for remanufacturing engineering. China Surface Engineering. 2001, 14(2): 5-7.重载履带车辆发动机再制造技术分析与评估体系探讨1 前言随着资源的日益枯竭和环境污染的加剧，人们逐渐认识到可持续发展的重要意义，并不断探索实现可持续发展的手段。再制造工程就是在人类对资源要求的日益增长和对环境保护的迫切需要的情况下形成的一门新的工程学科，且因其巨大的资源、环境、社会效益而受到世界各国的重视，成为落实可持续发展战略的重要技术支撑1，2。再制造工程是以装备全寿命周期设计和管
49、理为指导,以装备实现性能跨越式提升为目标,以优质、高效、节能、节材、环保为准则,以先进技术和产业化生产为手段,对装备进行修复和改造的一系列技术措施或工程活动的总称。再制造是零件水平上的制造,零件的附加值得以保留,具有相当的经济效益,有利于环保和可持续发展。汽车零部件的再制造是研究最早的领域,已经形成了相当规模的产业。对汽车再制造而言,发动机的再制造占主要的份额,国内许多厂家如济南复强动力公司和上海大众等针对发动机的再制造做了大量的研发工作,可以预言再制造发动机在未来的汽车发动机市场上所占的比例一定会越来越高3。目前世界范围军用重载履带车辆绝大多数以柴油机为动力,其可靠性直接影响重载履带车辆的机动性能和战斗力。由于强化程度较高和工作条件恶劣, 重载履带车辆发动机的使用寿命普遍较短,远低于一般民用车辆。重载履带发动机的寿命短以及与车体寿命周期不一致已经成为制约装备保障维修的瓶颈