1 Scope
This document specifies the technical requirements, test methods, inspection rules, marking, packaging, transportation and storage of the plunger coupling of small and medium power diesel injection pumps.
This document applies to the manufacture of small and medium power diesel injection pump plunger coupling.
2 normative reference documents
The content of the following documents through the normative references in the text and constitute the essential provisions of this document. Among them, note the date of the reference document, only the date of the corresponding version applies to this document; do not note the date of the reference document, its latest version (including all the revision of the list) applies to this document.
GB/T 1031 Geometrical Product Specifications (GPS) - Surface texture - Wheel method - Surface roughness parameters and their values
GB/T 1958 Geometrical Product Specifications (GPS) - Geometrical Tolerance Testing and Verification
GB/T 2828.1 Sampling Procedures for Inspection by Attributes Part 1; Sampling Plan for Lot by Lot Inspection Indexed by Ru Acceptance Quality Limit (AQL)
GB/T 3077 Alloy Structural Steel
GB/T 10610 Geometrical Product Specifications (GPS) - Rules and Methods for Evaluating Surface Texture by Profile Method
GB/T 10826.1 Fuel Injection Device Vocabulary Part 1: Fuel Injection Pump
GB/T 18,254 High Carbon Chromium Bearing Steel
GB 19147 Automotive Diesel Fuel
JB/T 9730 Metallographic Inspection for Fuel Injection Nozzle Couples, Plunger Couples and Delivery Valve Couples of Diesel Engines
JB/T 9736 Magnetic Particle Inspection Method for Fuel Injection Nozzle Couple, Plunger Couple, Oil Delivery Valve Couple
JB/T 12033 Reliability Assessment Method of Injection Pump Plunger Coupler Bench Test Method and Failure Judgment
3 Terms and definitions
The terms and definitions defined in GB/T 10826.1 apply to this document.
4 Technical requirements
4.1 Manufacture
Diesel injection pump plunger couplings (hereinafter referred to as plunger couplings) shall be manufactured in accordance with the product drawings and technical documents approved by the prescribed procedures.
4.2 Material
Plunger and split plunger sleeve should be used GB/T 18254 in the provisions of the GCr15 high-carbon chromium bearing steel manufacturing, flanged plunger sleeve should be used GB/T 3077 in the provisions of the 20CrMo alloy structural steel manufacturing. The plunger and plunger sleeve are allowed to use other grades of steel manufactured in accordance with the material requirements.
4.3 Metallographic organization
The plunger and plunger sleeve should be heat-treated so that the dimensions remain stable and the metallographic organization should conform to the provisions of JB/T 9730. If the material used is outside the provisions of JB/T 9730, the metallographic organization shall be in accordance with the provisions of the technical documents of both the supplier and the demander.
4.4 Hardness
The hardness of the plunger and plunger sleeve made of GCr15 high-carbon chromium bearing steel shall be 61HRC~64HRC. The hardness of the plunger sleeve made of 20CrMo alloy structural steel shall be 58HRC~61HRC.
4.5 Flaw detection
The plunger and plunger sleeve should be tested and demagnetized by magnetic particle inspection. 4.6 Geometric tolerances
The main geometric tolerances of the plunger shall be in accordance with the provisions of Figure Ⅰ and Table 1, the main geometric tolerances of the split plunger sleeve shall be in accordance with the provisions of Figure peal and Table 1, and the main geometric tolerances of the flanged plunger sleeve shall be in accordance with the provisions of Figure 3 and Table 1.
4.7 Surface roughness
The surface roughness of the plunger and plunger sleeve shall conform to the provisions of GR1031, and the surface roughness Ra value of the main parts shall meet the following requirements:
a) plunger sleeve and plunger with the inner and outer cylindrical working surface roughness Ra value is not more than 0.04 pum, allow parts guide surface
Individual parts of the surface roughness Ra value of not more than 0.08 pm;
b) The surface roughness Ra of the working surface of the round laurel of the plunger using the matching grinding process is not more than 0.10 um; c) The surface roughness Ra of the inner cylindrical working surface of the plunger sleeve using the honing process is not more than 0.10 um; d The surface roughness Ra of the sealing end face of the split plunger sleeve is not more than 0.16 p.m.
4.8 Diameter sealing values
4.8.1 The inner and outer cylindrical working surfaces of the plunger sleeve and the plunger shall have a certain radial clearance, the radial clearance shall be expressed by the diameter sealing value of the plunger coupling measured by the oil equal pressure method.
4.8.2 When the plunger sleeve inlet and return holes in the same axis, using the oil isometric test, the plunger coupling diameter seal value should be in accordance with the provisions of Table 2.
4.8.3 When the plunger coupling has a drain hole, drain groove or structural parameters not in accordance with 4.8.2, its diameter sealing value shall be in accordance with the provisions of the technical documents approved by certain procedures.
4.8.4 The grouping requirements of the plunger coupling for multi-cylinder engines shall be agreed between the manufacturer and the client.
4.9 Sliding
The plunger should have good sliding properties in the plunger sleeve.
4.10 Reliability
4.10.1 The calculation of the reliability assessment index of the plunger coupling shall conform to the provisions of JB/T 12033.
4.10.2 The reliability evaluation index of the plunger coupling; the mean working time (MTTF) before failure shall not be less than 3 000 h, or according to the agreement between supply and demand, but shall not be lower than the requirements stipulated in this document.
4.11 Appearance
4.11.1 The edge of the plunger coupling surface which plays the role of oil distribution (the working end face of the plunger, beveled groove and the oil distribution hole of the plunger sleeve, etc.) should be maintained with sharp edges, and no projection, depression, chamfering v flaking and burrs are allowed.
4.11.2 Plunger and plunger sleeve with the inner and outer cylindrical working surface should be uniform reflective surface, not allowed to have knife marks, grinding marks and burns.
4.11.3 Plunger coupling trademark should be clear, the appearance is not allowed to have rust spots, value based on the level of sink.
5 test methods
5.1 Metallographic inspection
The metallographic test method of plunger and plunger sleeve shall be carried out according to the provisions of JB/T9730.
5.2 Hardness test
Split plunger sleeve hardness test sampling site for either end face, flange type plunger sleeve hardness test sampling site for the inner cylindrical work surface, plunger hardness test sampling site for the cylindrical work surface,
5.3 Flaw detection
The flaw detection method of plunger and plunger sleeve shall be carried out according to the provisions of JB/T9736, and other non-destructive testing methods specified in the technical documents shall be allowed.
5.4 Geometric tolerance testing
5.4.1 The detection of the geometric tolerances of the plunger and plunger sleeve, except for special provisions, shall be carried out in accordance with the provisions of GB/T 1958.
5.4.2 roundness measurement using the roundness meter accuracy should not be less than 0.1 pum, the probe radius should not be less than 0.25 mm, filter block; fine research plunger selected 1 upr ~ 50 upr block, with grinding plunger selected 1 upr ~ 15 upr block.
5.5 Surface roughness inspection
5.5.1 Plunger and plunger sleeve surface roughness test method according to the provisions of GB / T 10610.
5.5.2 Plunger and plunger sleeve inside and outside the cylindrical surface roughness of the working surface allows the use of standard samples to compare the test.
5.6 Diameter sealing test
5.6.1 The plunger coupling diameter sealing test is carried out using the oil equivalent pressure test method. Test, the plunger sleeve seal end plug, plunger. The pressure in the space of the plunger is 20 MPa ± 0.3 MPa,
5.6.2 plunger relative to the plunger sleeve back to the angular position of the hole (plunger geometric effective stroke), should be consistent with the provisions of Table 2 or according to the provisions of the program! approved technical documents.
5.7 Sliding test
After carefully cleaning and lubricating the parts with well-filtered OO diesel oil in accordance with GB 19147, set the axis of the plunger coupling to a horizontal position of 45", withdraw the plunger cylindrical working surface from the plunger sleeve to a length of about one-third, turn the plunger around its own axis to any position, let go, the plunger can slide down by its own weight, without allowing any blocking phenomenon,
5.8 Reliability test
The reliability of the plunger coupling shall be tested and evaluated according to the provisions of JB/T 12033.
5.9 Appearance inspection
The appearance of the plunger coupling is inspected visually.
6 Inspection rules
6.1 The plunger coupling should be inspected by the quality inspection department of the manufacturer according to this document, and only after passing can the product leave the factory, the product should be accompanied by a certificate of conformity or a conformity mark.
6.2 factory inspection, sampling test, type test inspection items in accordance with the provisions of Table 3.
6.3 piston coupling product quality sampling inspection methods and qualified rules, according to the provisions of Appendix A.
6.4 Distribution units and supporting units acceptance should be in accordance with the provisions of this document, but also according to the agreement between the supply and demand sides.
7 Marking, packaging, transport and storage
7.1 Each pair of plunger coupling should be marked at least the following content in a clear position, the mark should be clear and not easy to wear;
--Manufacturer's factory mark or trademark
--the product type.
7.2 Each pair of plunger couplings shall be corrosion-proofed and packaged.
7.3 The plunger coupling treated and packed with corrosion protection, together with the product certificate of conformity and the relevant factory documents sealed by the inspector, should be packed in a moisture-proof box with a mass of not more than 30 w per box.
On the outer surface of the box is marked;
--the name of the product
--Product type
--the number of this document
--the number of boxes
--Manufacturer's mark or trademark;
--the name of the manufacturer
--Manufacturer's address;
--Date of packing (year, month);
--Transport protection mark.
7.4: During transport, the packaging should be sufficient to ensure that the plunger coupling is not subject to mechanical damage, chemical corrosion and moisture.
7.5: The plunger coupling shall be stored in a dry warehouse and shall not be stored together with acids, alkalis and other chemicals that can cause corrosion. Under normal storage conditions, the manufacturer shall ensure that the product does not rust or corrode within one year from the date of delivery.
1 Scope
2 normative reference documents
3 Terms and definitions
4 Technical requirements
5 test methods
6 Inspection rules
7 Marking, packaging, transport and storage
1 Scope
This document specifies the technical requirements, test methods, inspection rules, marking, packaging, transportation and storage of the plunger coupling of small and medium power diesel injection pumps.
This document applies to the manufacture of small and medium power diesel injection pump plunger coupling.
2 normative reference documents
The content of the following documents through the normative references in the text and constitute the essential provisions of this document. Among them, note the date of the reference document, only the date of the corresponding version applies to this document; do not note the date of the reference document, its latest version (including all the revision of the list) applies to this document.
GB/T 1031 Geometrical Product Specifications (GPS) - Surface texture - Wheel method - Surface roughness parameters and their values
GB/T 1958 Geometrical Product Specifications (GPS) - Geometrical Tolerance Testing and Verification
GB/T 2828.1 Sampling Procedures for Inspection by Attributes Part 1; Sampling Plan for Lot by Lot Inspection Indexed by Ru Acceptance Quality Limit (AQL)
GB/T 3077 Alloy Structural Steel
GB/T 10610 Geometrical Product Specifications (GPS) - Rules and Methods for Evaluating Surface Texture by Profile Method
GB/T 10826.1 Fuel Injection Device Vocabulary Part 1: Fuel Injection Pump
GB/T 18,254 High Carbon Chromium Bearing Steel
GB 19147 Automotive Diesel Fuel
JB/T 9730 Metallographic Inspection for Fuel Injection Nozzle Couples, Plunger Couples and Delivery Valve Couples of Diesel Engines
JB/T 9736 Magnetic Particle Inspection Method for Fuel Injection Nozzle Couple, Plunger Couple, Oil Delivery Valve Couple
JB/T 12033 Reliability Assessment Method of Injection Pump Plunger Coupler Bench Test Method and Failure Judgment
3 Terms and definitions
The terms and definitions defined in GB/T 10826.1 apply to this document.
4 Technical requirements
4.1 Manufacture
Diesel injection pump plunger couplings (hereinafter referred to as plunger couplings) shall be manufactured in accordance with the product drawings and technical documents approved by the prescribed procedures.
4.2 Material
Plunger and split plunger sleeve should be used GB/T 18254 in the provisions of the GCr15 high-carbon chromium bearing steel manufacturing, flanged plunger sleeve should be used GB/T 3077 in the provisions of the 20CrMo alloy structural steel manufacturing. The plunger and plunger sleeve are allowed to use other grades of steel manufactured in accordance with the material requirements.
4.3 Metallographic organization
The plunger and plunger sleeve should be heat-treated so that the dimensions remain stable and the metallographic organization should conform to the provisions of JB/T 9730. If the material used is outside the provisions of JB/T 9730, the metallographic organization shall be in accordance with the provisions of the technical documents of both the supplier and the demander.
4.4 Hardness
The hardness of the plunger and plunger sleeve made of GCr15 high-carbon chromium bearing steel shall be 61HRC~64HRC. The hardness of the plunger sleeve made of 20CrMo alloy structural steel shall be 58HRC~61HRC.
4.5 Flaw detection
The plunger and plunger sleeve should be tested and demagnetized by magnetic particle inspection. 4.6 Geometric tolerances
The main geometric tolerances of the plunger shall be in accordance with the provisions of Figure Ⅰ and Table 1, the main geometric tolerances of the split plunger sleeve shall be in accordance with the provisions of Figure peal and Table 1, and the main geometric tolerances of the flanged plunger sleeve shall be in accordance with the provisions of Figure 3 and Table 1.
4.7 Surface roughness
The surface roughness of the plunger and plunger sleeve shall conform to the provisions of GR1031, and the surface roughness Ra value of the main parts shall meet the following requirements:
a) plunger sleeve and plunger with the inner and outer cylindrical working surface roughness Ra value is not more than 0.04 pum, allow parts guide surface
Individual parts of the surface roughness Ra value of not more than 0.08 pm;
b) The surface roughness Ra of the working surface of the round laurel of the plunger using the matching grinding process is not more than 0.10 um; c) The surface roughness Ra of the inner cylindrical working surface of the plunger sleeve using the honing process is not more than 0.10 um; d The surface roughness Ra of the sealing end face of the split plunger sleeve is not more than 0.16 p.m.
4.8 Diameter sealing values
4.8.1 The inner and outer cylindrical working surfaces of the plunger sleeve and the plunger shall have a certain radial clearance, the radial clearance shall be expressed by the diameter sealing value of the plunger coupling measured by the oil equal pressure method.
4.8.2 When the plunger sleeve inlet and return holes in the same axis, using the oil isometric test, the plunger coupling diameter seal value should be in accordance with the provisions of Table 2.
4.8.3 When the plunger coupling has a drain hole, drain groove or structural parameters not in accordance with 4.8.2, its diameter sealing value shall be in accordance with the provisions of the technical documents approved by certain procedures.
4.8.4 The grouping requirements of the plunger coupling for multi-cylinder engines shall be agreed between the manufacturer and the client.
4.9 Sliding
The plunger should have good sliding properties in the plunger sleeve.
4.10 Reliability
4.10.1 The calculation of the reliability assessment index of the plunger coupling shall conform to the provisions of JB/T 12033.
4.10.2 The reliability evaluation index of the plunger coupling; the mean working time (MTTF) before failure shall not be less than 3 000 h, or according to the agreement between supply and demand, but shall not be lower than the requirements stipulated in this document.
4.11 Appearance
4.11.1 The edge of the plunger coupling surface which plays the role of oil distribution (the working end face of the plunger, beveled groove and the oil distribution hole of the plunger sleeve, etc.) should be maintained with sharp edges, and no projection, depression, chamfering v flaking and burrs are allowed.
4.11.2 Plunger and plunger sleeve with the inner and outer cylindrical working surface should be uniform reflective surface, not allowed to have knife marks, grinding marks and burns.
4.11.3 Plunger coupling trademark should be clear, the appearance is not allowed to have rust spots, value based on the level of sink.
5 test methods
5.1 Metallographic inspection
The metallographic test method of plunger and plunger sleeve shall be carried out according to the provisions of JB/T9730.
5.2 Hardness test
Split plunger sleeve hardness test sampling site for either end face, flange type plunger sleeve hardness test sampling site for the inner cylindrical work surface, plunger hardness test sampling site for the cylindrical work surface,
5.3 Flaw detection
The flaw detection method of plunger and plunger sleeve shall be carried out according to the provisions of JB/T9736, and other non-destructive testing methods specified in the technical documents shall be allowed.
5.4 Geometric tolerance testing
5.4.1 The detection of the geometric tolerances of the plunger and plunger sleeve, except for special provisions, shall be carried out in accordance with the provisions of GB/T 1958.
5.4.2 roundness measurement using the roundness meter accuracy should not be less than 0.1 pum, the probe radius should not be less than 0.25 mm, filter block; fine research plunger selected 1 upr ~ 50 upr block, with grinding plunger selected 1 upr ~ 15 upr block.
5.5 Surface roughness inspection
5.5.1 Plunger and plunger sleeve surface roughness test method according to the provisions of GB / T 10610.
5.5.2 Plunger and plunger sleeve inside and outside the cylindrical surface roughness of the working surface allows the use of standard samples to compare the test.
5.6 Diameter sealing test
5.6.1 The plunger coupling diameter sealing test is carried out using the oil equivalent pressure test method. Test, the plunger sleeve seal end plug, plunger. The pressure in the space of the plunger is 20 MPa ± 0.3 MPa,
5.6.2 plunger relative to the plunger sleeve back to the angular position of the hole (plunger geometric effective stroke), should be consistent with the provisions of Table 2 or according to the provisions of the program! approved technical documents.
5.7 Sliding test
After carefully cleaning and lubricating the parts with well-filtered OO diesel oil in accordance with GB 19147, set the axis of the plunger coupling to a horizontal position of 45", withdraw the plunger cylindrical working surface from the plunger sleeve to a length of about one-third, turn the plunger around its own axis to any position, let go, the plunger can slide down by its own weight, without allowing any blocking phenomenon,
5.8 Reliability test
The reliability of the plunger coupling shall be tested and evaluated according to the provisions of JB/T 12033.
5.9 Appearance inspection
The appearance of the plunger coupling is inspected visually.
6 Inspection rules
6.1 The plunger coupling should be inspected by the quality inspection department of the manufacturer according to this document, and only after passing can the product leave the factory, the product should be accompanied by a certificate of conformity or a conformity mark.
6.2 factory inspection, sampling test, type test inspection items in accordance with the provisions of Table 3.
6.3 piston coupling product quality sampling inspection methods and qualified rules, according to the provisions of Appendix A.
6.4 Distribution units and supporting units acceptance should be in accordance with the provisions of this document, but also according to the agreement between the supply and demand sides.
7 Marking, packaging, transport and storage
7.1 Each pair of plunger coupling should be marked at least the following content in a clear position, the mark should be clear and not easy to wear;
--Manufacturer's factory mark or trademark
--the product type.
7.2 Each pair of plunger couplings shall be corrosion-proofed and packaged.
7.3 The plunger coupling treated and packed with corrosion protection, together with the product certificate of conformity and the relevant factory documents sealed by the inspector, should be packed in a moisture-proof box with a mass of not more than 30 w per box.
On the outer surface of the box is marked;
--the name of the product
--Product type
--the number of this document
--the number of boxes
--Manufacturer's mark or trademark;
--the name of the manufacturer
--Manufacturer's address;
--Date of packing (year, month);
--Transport protection mark.
7.4: During transport, the packaging should be sufficient to ensure that the plunger coupling is not subject to mechanical damage, chemical corrosion and moisture.
7.5: The plunger coupling shall be stored in a dry warehouse and shall not be stored together with acids, alkalis and other chemicals that can cause corrosion. Under normal storage conditions, the manufacturer shall ensure that the product does not rust or corrode within one year from the date of delivery.
Contents of GB/T 5264-2022
1 Scope
2 normative reference documents
3 Terms and definitions
4 Technical requirements
5 test methods
6 Inspection rules
7 Marking, packaging, transport and storage
