Applied science and manufacturing: NAMI and VTZ

Starting from the 1960s, a number of acute problems appeared in the engine building during the transition to diesel engines of a new generation, the engines with direct fuel injection into the chamber in the piston. The short time allotted in the cycle for mixture formation and combustion, especially for high-speed diesel engines, makes it extremely scrupulous to approach this in order to obtain high and stable technical and economic indicators. One of the many problems is the organization of efficient and uniform gas exchange across the samples to reduce the spread of final indicators during mass production. The article deals with this very problem, specifically - in the case of chill casting of individual heads at the Vladimir Tractor Plant (VTZ) using composite rods of inlet and outlet channels. The method of static blowing of inlet channels developed at Central research and development automobile and engine institute NAMI with a quantitative assessment of the resistance and vortex formation in the cylinder was applied. The gas-dynamic parameters (GP) were checked for the heads that received individual numbers in a statistically significant sample of billets on one test bench several times, sequentially according to the stages of the processing. It is shown schematically how these parameters changed during processing and assembly of the heads. It is important that a high “hereditary” correlation is obtained between the GP of the billets and fully machined and assembled cylinder heads. The manufacturing cost of the latter is incommensurably higher than the castings cost. Therefore, according to the results of the work, in order to reduce the cost of products and increase the level and stability of quality, an important decision was made on the early flaw detection of the GP (after casting) with the subsequent remelting of those blanks that are most likely “genetically, hereditarily” will not provide the declared technical and economic indicators in assembled product. Similar approaches can be used in the organization of production and other goods with high added value of technological operations required after procurement to ensure the quality of final products.

engine building, diesel engines, quality of mixture formation, gas-dynamic indicators, early flaw detection of cylinder heads