Study On The Design And Manufacture Technique Of A Large Discharge Emulsification Pump’s Crankshaft

With the improvement of exploiting coal and acceleration of working surface propulsion speed, large discharge and long life has become a trend in development of emulsion pump. Crankshaft is the key energy conversion part in emulsion pump and the best complex component in the processing techniques. To the large discharge emulsion pump, crankshaft works under the low speed and heavy-duty condition. so that the design and manufacture of crankshaft is reliable and proper or not relates the development of emulsion pump successful or fail directly. Therefore, the study of crankshaft’s design and development is a very significant subject. According to the subject. some main job has been done in the thesis as follows.Firstly, after analyzing the working condition and main failure forms of a large discharge emulsion pump crankshaft, the basic design principle of crankshaft was generalized. The assemblage program of the parts in crankshaft and their location mode were drafted. It was given that the method and theory basis of determining shafts’ diameters and lengths in the preliminary design. What’s more, the design and calculation method of the crankshaft dimension chain was put forward. And the reasonable designed dimension chain was determined finally. At the same time, the material selection, heat treatment process and means of crankshaft were investigated.Secondly, the calculation method of the support forces of the three supporting five crankshafts crankshaft was given by MATLAB software. The decision method of three supporting five crankshafts crankshaft’s dangerous position and phase angle was proposed. The intensity and rigidity were checked taking the crankshaft in cross-project for example.Thirdly, the three-dimensional model of the crankshaft was built by Pro/E, which was used to get the ANSYS model by leading-in ANSYS. By ANSYS analyzing the whole crankshaft model in multi-angle, the dangerous spot and phase angle was found, which verified the former theory calculation and prepared for the subsequent optimization. To improve the crankshaft material usage and economy, the crankshaft volume minimization became the target of optimizing crankshaft.Finally. the mechanical graph about optimized crankshaft was drawn, by which the crankshaft process scheme was fixed and process card was worked out. The special tooling, which was used on universal machine tools, was designed according to the small batch quantity producing characteristics, design features and process difficulties of the crankshaft in the development stage. The special template measuring and controlling the key dimensions directly was designed too. and the template was applicable to the mass production. The test method about cranks’ eccentricity and phase angle by the general measuring tools was given. The basic principles of the error analysis and calculation were represented. The feasibility of the method was verified with the example.