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The article is devoted to the achievement of the maximum wear resistance of the cylinder mirror of a diesel engine by technological provision of a given dimensional accuracy and geometric shape of the cylinder mirror, as well as roughness parameters in accordance with a given Abbott diagram. The solution of the problem is complicated by the inhomogeneity of the structure of the metal of the casting and the geometry of the outer surface of the cast cooling fins of the cylinder, which leads to variable stiffness and inconstancy of elastic deformations when cutting the cylinder. The problem was solved by optimizing the structure of the technological process and replacing the equipment with a new, more rigid and accurate one.

An example of the rationalization of the current technology for manufacturing a cylinder of a small-sized diesel engine at PA “TULAMASHZAVOD” from a cast iron is given. It is shown that lowpower obsolete equipment leads to an increase in the number of technological operations and equipment used. However, even if all the generally accepted technological recommendations are followed, only 80% of the parts meet the requirements for the required parameters of accuracy and quality of the cylinder bore surface. Studies have found that the main reasons for insufficient quality are the presence of residual stresses in the casting, which cannot be removed during artificial aging, as well as insufficient accuracy and rigidity of metal cutting equipment at turning and boring operations. The use of more powerful and accurate modern equipment is theoretically and experimentally justified, which, due to increased refinement, allows reducing the number of machining operations. Replacement of artificial thermal aging by natural, combined with the replacement of shaft furnaces for heat treatment of workpieces with chamber furnaces of lower power and higher capacity, reduce energy consumption for the manufacturing by almost 4 times.

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