APPLICATIONS TO PROGRAMS INFORMATICS ANSYS-CATIA FOR THE PISTON GROUPS AND THE PROCESSING BY ELECTRICAL EROSION. Part 2.

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APPLICATIONS TO PROGRAMS INFORMATICS ANSYS-CATIA FOR

THE PISTON GROUPS AND THE PROCESSING BY ELECTRICAL

EROSION. Part 2.

IOAN BADIU

1

, MARCEL S. POPA

2

1

Technical University of Cluj-Napoca, ROMANIA, e-mail:

[email protected]

2

Technical University of Cluj-Napoca, ROMANIA, e-mail: [email protected]

Abstract: A piston machine body, which has a reciprocating motion in a cylinder and which is

designed to close a space of variable volume of the cylinder, filled with air or a fuel mixture under pressure fluid. The piston is used for converting internal energy into mechanical work on cars engines, or vice versa, generating machines. In the first case the piston is driven by the internal energy, and in the second he acts on air or fluid (compressor, hydraulic motor).

Several producers of oil engines use injectors for each the piston in part to facilitate their cooling. The injectors are mounted on the engine block and the oil injected into an opening located in the piston head.

Keywords: pistons , engine oil injectors, cooling, heat accumulated, circular holes ,EDM.

1.INTRODUCTION

Usually the piston is coupled to a crank mechanism, which converts the rectilinear motion in a circular motion (the engine) and vice versa (on pump). The piston is used as a constructive element in the implementation of piston pumps, which is similar in principle of operation with the compressor. The pistons are made mostly of cast iron or metal alloy lightweight, heat-stable properties.On machines that heat distribution is through the windows, the piston has the function to open or close them.Several producers of oil engines use injectors for each the piston in part to facilitate their cooling. The injectors are mounted on the engine block and the oil injected into an opening located in the piston head.

Figure 1: The oil Injector the piston

Oil injected into the piston head is discharged through circular holes thus eliminating heat in the piston.

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2. THE MACHINES

PROCESSING ELECTRICAL

EROSION

Figure 2: Electrical erosion processing machine ZNC – 50.

2.1.EXPERT SYSTEMS USED TO PROCESS THE PISTONS

Figure 3: The machine processed interface electrical erosion.

Figure 4: The use of expert systems. 2.2.FEATURES

1.Build in Expert System.

2.The EDM parameter can be changed according to the Auto program setting. 3.Automatic 14-step fine machining in single pass.

4.Equipped with high precision Heidenhain 1μmălinearăencoder.

5.Chinese/ English; Metric/ Inch unit can be displayed on screen.

6.60 sets working coordinate setting. 7.Automatic Z axis calibration and positioning.

8.Be able to machining large area with stable and slow retracting of residue.

9.High precision ball screw for delicate transmission.

10.Be able to machining deep hole with retracting of residue efficiently.

11.Unify operation screen interface is easy to be understood.

12.Be able to indicate electrode wearing, surface toughness, sparking gap of electrode.

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100 13.0.5A circuit system for finest finish.

14.Multiple fire-proof detection system. 15.Double erect type filtration system separates carbon residue more efficiently.

2.3.SPECIFICATIONS. SPECIFICATIONS ZNC - 50 Work Tank Dimensions 940 x 530 x 350 mm Work Table Dimensions 630 x 360 mm

XYZ Axis Travel 350 x 250 x 200 mm Distance from Main

Axis to Table 520 mm Auxiliary Travel of Z Axis 200 mm Max. Workpiece Weight 500 kg Max. Electrode Weight 50 kg Max. Capacity of Dielectric 300 liters Max. Machining Speed 420 mm 3 / min Min. Wear Rate < 0.1 % Best Surface Finish <ăRaă0.18ăμmă Max. Output Current 50 A

Input Power 3.3 kVA

Machine Dimensions L x W x H 140 x 138 x 220 cm Total Weight of Machine 1,375 kg 2.4.MACHINE LAYOUT.

Figure 5: Electrical erosion machine dimensions.

Figure 6: Electrical erosion machine dimensions.

3. THE GROUP THE

PISTON

For a better understanding of the distribution of temperatures on the body of a the piston in an engine design phase, graphic stations is done using finite element analysis. Piston,

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101 three-dimensional model is undergoing a heat source, resulting the temperatures distribution:

Figure 7: The temperatures distribution in the body of the piston.

1. 267 °C 2. 235 °C 3. 226 °C 4. 218 °C 5. 191 °C

In conclusion to limit the thermal load of a the piston engine should operate at low engine speeds and loads more.

3.1. ADVANCED

TECHNOLOGIES FOR APPLIED

TO THE PISTONS.

3.1.1. THERMAL PROTECTION OF THE PISTON OF THE HEAD (

Federal Mogul – Thermoshield).

Since 2006 Federal Mogul pistons started marketing Thermoshield, for high power motors. The innovation consists in coating the piston of the head with a ceramic coating to withstand temperatures up to 1093°C with durability compared with conventional pistons

Figure 8: The piston Thermoshield.

The method consists of a special electroless plating to the surface of the piston converted into a complex ceramic high thermal and mechanical resistance. This technology can be applied and fire channel segment, thus avoiding microsudurile between the piston and segment.

3.1.2. OF STEEL THE PISTONS (Federal Mogul -Monosteel).

In 2006, during a ceremony held on April 3rd in Detroit, Federal Mogul company receives PACE Award for innovation, technological advancement and business performance. This award is given to suppliers in the industry that produce, process or offering automobile manufacturers.

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4. APPLICATIONS PROGRAMS

OF INFORMATICS FOR

PROCESSING EROSION

ELECTRICAL TO PISTON.

4.1. APPLICATIONS PROGRAMS OF INFORMATICS ANSYS FOR

PROCESSING EROSION ELECTRICAL TO PISTON.

Figure 10: The graphics of the piston with programs informatics ANSYS.

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4.2.APPLICATIONS PROGRAMS OF INFORMATICS CATIA FOR

PROCESSING EROSION ELECTRICAL TO PISTON.

Figure 20: The programs informatics for the model piston CATIA.

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5.THE EXPERIMENTAL

RESULTS PROCESSING

ELECTRICAL EROSION

Figure 27: The table electrical erosion parameter values.

Figure 28: The shape 3D graphics parameters electrical erosion.

Figure 29: The values of parameters electric erosion in a graphic form 3D.

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Figure 40: Points that determines the parameters The electrical erosion.

Figure 41: Straight lines The electrical parameters and equations erosion 2D

shapes.

Figure 42: The straight lines and The electrical erosion parameters such

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6.CONCLUSIONS

The product category piston Monosteel has won. Innovative technologies underlying the piston Monosteel contribute to improved performance of heat resistance, mechanical, abrasive and corrosive, this the piston is used in road transport diesel applications. Federal Mogul engineers developed a friction welding technology, which gave birth to a light steel piston called Monosteel. In addition to increased mechanical strength piston also benefits from oil cooler massive galleries that allow higher thermal regimes.

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