Repair of automotive bodies. Preparation for painting and painting the car with your own hands. Full set of instructions. Body form restoration methods

Abstract on the topic:

"Repair of the Body and Cab"

Is done by a student

3 courses 33-AK groups

Specialty:

That and repair cars. and Tr-a

1. Defects of the Bodges and Cabin…………………………………………3

2. The technological process of repairing the bodies and cabins ................4

3. Repair of equipment and body mechanisms and cabins ............ ..6

4. Repair of non-metallic parts of the bodies .........................6

5. Assembly and control of bodyworks and cabins ....................................... ..7

Repair of bodies and cabins.

Defects of body and cabins.

Characteristic defects of parts of the body, cab and plumage (Fig. 1.) are corrosion damage, mechanical damage (dents, bugs, breaks, rejected, etc.), disruption of geometric sizes, cracks, destruction of welded joints, etc.

Corrosion destruction is the main type of wear of the metal body and cabins. Here there is an electrochemical type of corrosion at which the metal interaction with the electrolyte solution adsorbed from the air occurs. Corrosion is particularly developing in hard-to-reach places, where the moisture that periodically falls into them is maintained for a long time, and, due to the increase in the ambient temperature, the oxidation reaction is intensified. Corrosion destruction is also found as a result of contacting steel parts with details made of duralumin, plastics, wet wood and other materials.

Cracks arise as a result of metal fatigue, disorders of metal processing technology, the use of low quality valves, defects assembling assemblies and parts, insufficient assembly strength of the node, as well as in prone vibration places.

The destruction of welded compounds occur as a result of poor-quality welding, the effects of corrosion, vibration and loads at normal operation of the car or as a result of emergency damage.

Mechanical damage (dents, skews, gaps, etc.) are a consequence of metal overvoltage as a result of shocks and bends, as well as due to a fragile connection of parts.

but

Fig.1. Characteristic damage :

but -all-metal body car :

1 - front and rear openings of windshields;

2 - doorways;

3 - Racks under the roof;

4 - front and rear spars;

5 - left and right thresholds of the foundation;

6 - bottom;

7-left and right rear mudguards

8 - violation of geometric sizes;

9 - top and bottom of respectively left and right rear mudguards;

10 - left and right front mudguards;

b. - cabin truck :

1 - destruction of welding seams; 2 - breaks; 3 - dents and rejected; 4 - deflection and struts of struts; 5 - platforms; 6 - corrosion; 7 cracks

Technological process of repairing bodies and cabins.

The technological process of repairing the bodies and cabins assembled includes disassembly, full or partial removal of old paint, defecting, repair component parts Or their replacement, assembly, coloring and quality control.

Disassembly of the bodies and cabins are performed in two stages. This is a dismantling of all parts and assembly units installed from the inner and outdoor sides of the bodies and cabins, followed by the disassembly of the body for repair after removing the old paint coating and detect all its defects. Since in most cases, all-metal body bodies and cabins are inepent (connected by welding), then the full disassembly of the housing on the panel and the parts are not produced. It is performed only to such an extent that it is possible to deteriorate and replace or repair the elements of the housing forming the framework.

Depending on the economic feasibility of repairing bodies and cabins apply various methods elimination of defects available on their surfaces.

The greatest labor intensity and cost of repairing bodies and cabins make up work to eliminate defects on their all-metal welded housings. The repair of the body body having various defects provides for the editing of panels, removing damaged parts of the enclosures, eliminate cracks and breaks, fastening the DRD to the places of remote panels, the piping and stripping of old seams, the final editing and stripping of surfaces.

Reliability in the panels are aligned with powder plastics or epoxy compositions. To equalize dents in hard-to-reach places apply tool various shapes (Fig.2). The bent end of the mandrel and the hammer blows are inserted into the hole of the inner panel and the hammer blows align the surface. To eliminate the shallow gentle dents in it, the hole is drilled with a diameter of 6 mm, into which the rod is inserted with the curved end and pull the concave part of the panel to its normal position. Then the hole is close to the solder or epoxy composition.

Fig. 2. Set of tools for removing dents:

1...6 - hammers; 7 I. 8 - Cyans; 9 - mandrels (spoons)

Edit panels with emergency damageprovides work on pulling, alignment, extrusion and disulterators of the deformed body parts or cabins to give them an initial shape and sizes. When performing these operations, it is necessary that the tensile force is applied under the same angle under which the force was applied, which caused damage. For stretching to be adjustable, opposing force should be applied in front of the point of application of the tensile force. When performing these works, control over the process of stretching, as well as for possible associated deformations caused by stretching efforts.

The editing of the emergency bodies and cabins are performed on the stands (Fig. 3) using the set of devices (Fig. 4). Stretching and compression efforts create work cylinders 1, 3 (Fig. 3), in which the liquid comes from the pump. For editing body 4 install on the stand 6, which are fixed on the foundation frame 2. Power transverse pipes are based on the stand, which are plugging the clips behind the ribs of the body thresholds. Fastening the latter to the frame is performed by braces 5. Preliminary edits eliminate deep dents (Fig. 4, b)bends (Fig. 4, in)and the battery (Fig. 4, d).Since cracks or gaps can be formed during editing, which in the future need to be eliminated, the edit is carried out before welding work.

Removing damaged bodies and cabinsperform a gas sharp, an electrified milling tool or a pneumatic cutter. The advantages of the pneumatic cutter are high productivity (0.08 ... 0.1 m / s) compared with gas cutting (0.02m / s) and the best edge quality in the fields of cutting. Defective areas are placed using templates and chalk, and then removed. When removing defective parts of the body or cabin, it is necessary to protect the housing from the geometry distortion due to the weakening of its rigidity and under the action of its own mass.

Cracks and ruptures The body of the body and cabins eliminate semi-automatic arc welding in the carbon dioxide or gas welding medium. When repaired, preference is preferred in carbon dioxide medium, as the performance of this process and the quality of the weld higher. The welding is carried out by semi-automatic agents feeding on sources of direct current of reverse polarity by force 40 A and voltage 30 V using the electrode wire of SV-08GS or SV-08G2C with a diameter of 0.7 mm. To limit the propagation of the crack in the process of welding, its ends must be sewed with a drill with a diameter of 8 mm.

Gas welding eliminate cracks and gaps in panels made of leaf steel with a thickness of 0.5 ... 2.5 mm, burners of UCM-53 or GS-53 with tips No. 1 (for sheets thick in, 5 ... 1.5 MM) and No. 2 (for sheets 1.0 ... 2.5 mm), using a wire of SV-08 or CV-15 with a diameter (0.5l + 1) mm, where H is the thickness of the welded metal. In order for the part to do with heating, it does not lose the form, first produce welding at individual points with a range of 10 mm, and then, as necessary, individual sections boil with a solid seam from the ends of the crack to the middle.

Fig.3. Stand to edit the body of a passenger car:

1,3 - working cylinders;

2 - frame;

4 - body;

5 - stone facility;

6 - stand

Production of an additional repair part Start from editing of the steel sheet, its cutting and cutting blanks on the markup. After its item bends or forming on special equipment, finished parts are cut off, drilled, they rule and cleaned. The material for the manufacture of the repair part is the thin-walled cold-rolled small carbon steel with a thickness of 0.7 ... 1.5 mm.

Fig. four. Fixtures to execute editing deformed body plot:

but- a set of fixture to eliminate overcasts and inflection;

b., in and g.- the use of fixtures when editing;

1 - mandrel for pulling concave parts;

2 and 3 -Son-repaid hydraulic clamps;

4 - mandrel with teeth to capture a straightened panel;

5 - pump;

6 - double grip;

7 – stretching cylinder with a pulling device;

8 – tension cylinder with grippers;

9 - Proper device

Forwarding and stripping weldsit is necessary to harden the place of welding and giving it the required profile. It is performed by a pneumatic hammer using a set of support and brisk. After the search for the place of welding, we clean the abrasive circle installed in pneumatic or electrical portable machines.

Final Editing and Richtovkabody and cabbage panels are designed to ensure the accuracy of assembly and removing small dents and the released remaining on the surfaces. Richtovka is performed by a pneumatic rhytoval device or manually. Eliminate damage to welding.

Repair of equipment and mechanisms of body and cabins.

The bodies and cabins include windows, locks, door limiters, door loops, hood, etc.

Power windowsthere may be the following defects: cracks and detail bugs; Skotes and deformation by robes, frameworks and guides; Weakening of rivet compounds; damage to rubber seals; corrosion details. Power windows and mechanisms for fastening glasses are disassembered, washing, defecting, repair and assembly. When defecting, it is selected: details with broomaches; springs that lost elasticity; Obiama with worn glasses that are not compromised; rivets that are not suspended; Damaged rubber seals and other details with wear on surfaces affecting the normal operation of the mechanism. Cracks on the details are eliminated with welding with the subsequent stripping of welding seams, the recklessness of the details - edited in a cold condition.

Castles doorsthere may be the following defects: cracks and bugs, damage to the threaded holes, corrosion on the surfaces of the part, weakening the springs and rivets fastening parts, the wear of the surfaces of the parts. Repair of locks lies in their disassembly, washing in kerosene, defecting, restoration of damaged parts, assembly and adjustment. Details that are subject to deep corrosion traces, worn surfaces and bugs, springs that have fallen elasticity are subject to sejection. Cracks in the castle housing brew. Bloomred screws in threaded holes are removed. The damaged thread in the hole is brewed, the welding space is cleaned with the base metal, drill the hole and cut the thread according to the size of the working drawing. Minor corrosion raids on the surfaces of parts are cleaned with a timber or grinding paper and washed with kerosene.

Loop doorsthere may be defects: cracks and bugs, wear holes and axes, recklessness. Worn axles of the doors loops are replaced with new ones. Cracks and wear holes are eliminated with welding with subsequent machining. Worn openings under the hinge axis are deployed under the repair size, and the loop intimidation is eliminated by editing.

Repair of non-metallic body parts.

In the manufacture of cars, non-metallic materials are widely used: wood, plastics, synthetic leather glass, rubber, etc. Most parts from these materials are not subject to restoration, but are replaced with new, manufactured at the repair company or the factory.

Wooden platform and body partsmade from lumber of coniferous rocks (pine, spruce), having humidity not higher than 18%. The main defects are breakdowns, cracks, salts, wear holes. Details having destroyed spikes or spike nests are replaced by new ones. Wooden body platform parts are repaired by increasing them in length or replacement of unsuitable boards. The boards or bars are cut on the blanks of certain sizes, they are plane from all sides, the ends are trimmed, the eyes are cut, the grooves, the holes are drilled, etc. The phenol formaldehyde adhesives of the VIIMB-3 type and casein type are used to glue the wooden parts. The sequence of execution of work: the surface intended for gluing is treated so that the parts are tightly lightened to each other and ensure that the adhesive film is uniform over the thickness; The glue is applied to the brush on the bonded surfaces (the time of exposure to air for the adhesive of VIAMB-3 is 4min); assembly Exposure of parts under pressure 0.2 ... 0.3 MPa at a temperature of 16 ... 20 ° C for 5 hours; Holes from underwaying bitch, bolts, screws close up with wooden cylindrical inserts from the same tree of wood, which is repaired by the piece on the glue, and the cracks are filled with mastic, putting on a tree, resin glue, or putting on glue of wooden inserts, tightly fitted at the place broken cracked.

Sewtextile materials or leatherette during the repair of passenger cars are replaced by a new one, since the material is aging in the process of operation, it loses elasticity and other physical and mechanical properties.

Glass cabins and bodiesthey may have risks, scratches, clouding, yellowness, rainbowness, cutting from brushes and other defects. Lobova I. side glass With yellow, irresistible and produce from brushes are selected. Risks and scratches are eliminated with grinding with subsequent polishing. The glass to be restored is purified from dirt, dust and fatty contamination. The glass sections marked with chalk slift the felt upholstery of the circle to which a layer of pasta is applied, which is a water solution of pembol, with a circle rotation frequency of 300 ... 400 min- "until it is completely removed in the rice, scratches and marks. The glass with an aqueous crocus or polyrite solution with a circle rotation frequency of 700 ... 800 min- "to obtain the necessary transparency. After processing the glass is degreased.

Build and control of bodyworks and cabins.

FROMborge of the Bodges and Cabinwhen repairing cars, they are performed in such a sequence:

all details and assembly unitsto be painted together with the body (doors, hood, plumage, trunk lid, etc.), withsting the required gaps between the mating details;

after applying paintwork coatings, the ceiling, sidewalls and panels are installed interior decoration Doors, glasses, seats, noise and heat-insulating gaskets, door seals, electrical equipment, instrument panels, parts of the ventilation and heating of the cabin, etc.

Control are subject to:geometric deviations of the size of the arrangement of holes of holes, interconnected functionally, using for this control and measuring equipment; Operactions of the bodies and cabins and places of conjugations are controlled by templates in the form of a conjugated part; The tightness and dustiness of the body and the cabin. A testing of the tightness of the assembled body is produced in the rain plates at a water pressure of 2 kgf / cm2 for 6 minutes, while the water penetration and the formation of condensate in the lighting and alarm devices are fixed. The door fit density to its impeachment is determined by rubbing seals with chalk. When slapping the door on the body or cabin, a uniform marce imprint should remain. Adjusting the density of adjustment of the door seals is achieved by moving the lock latch.

Article on the main types of car bodywork - tools, work order, tips and recommendations. At the end of the article - video about the important secret of body repair.

The rapid detection of the problem affects both the speed of its implementation and to the substantial savings of money. The slightest scratch or harmless bulb make metal defenseless metal before corrosion, which is capable of disrupting the integrity of the surface during the year.

Varieties and causes of car damage

• mechanical;
• corrosion;
• the destruction of the anti-corrosion surface.

As a result of the car accident, there is a violation of the geometric parameters of the car, the return of which is carried out to the original factory state, service centers and auto repair shops. Moreover, damaged elements can be replaced if they cannot be restored.

Classification of car bodywork

The reconstruction of the body can not always be performed with their own hands, since with extensive damage, diagnostics and specialized tools are required.

Types of body repair:

1. Restoration of geometry. Return of the geometric parameters of the body to the factory. If necessary, it is replaced by parts using cutting and welding metal.
2. Paintwork. Painting body is made after its repair and processing.
3. Selective (local) painting. There are damaged or replaced parts. At the same time, careful attention is paid to the shades of paint, in order not to have a color imbalance.
4. Abrasive polishing. It is used if the LCA has damage in the form of shallow scratches and non-critical defects. Abrasive pastes are used for various grainability. Read the article - do it yourself.
5. Local anti-corrosion works. The affected parts are cleaned to the surface of the metal. For these purposes, rust converters are used.
6. Restoration of the front and rear bumper.
7. Restoration of thresholds. Works imply restoring places for the jack.
8. Tin work.
9. Welding work.
10. Work on the Shelon. A device designed to restore the body shape after accidents.
11. Richtovka.

Before starting work, you should be used by the necessary materials:

• primer and paint;
• emery paper;
• solvent;
• splitel.

If corrosion traces appeared, elaborate paper or sandblasting will be required. The stripping of the affected area should be carried out with the "capture" of the LCP. The nude metal is processed by a solvent, and a spatlet is used to align the working surface.

Repair of the bottom of the car

Riding on roads is not better quality (seeker, forest, with potholes on asphalt coatings, etc.) leads to damage to the bottoms of the vehicle. In this case, it is necessary to protect the scratched metal in a timely manner, since additional (unwanted) sources of ventilation will appear on the influence of corrosion in the floor of the car.

The restoration of the protective bed of the bottom of the car is quite possible to make it yourself. This is a simple process, but uncomfortable. Be sure to have the means to protect the eyes - mask or glasses.

Materials for holding repair work are:

• sandpaper;
• solvent;
• primer;
• bituminous mastic.

First, it is necessary to align the damaged surface. Using a suitable tool (screwdriver, mount, handle hammer) from the inside body detail Apply dosage strength. Rubber tips are used to avoid scratches.

Stripping, putty, primer and coloring are performed after the working surface is maximally aligned.

• niche doors and trunk lids;
• thresholds;
• spars.

Anticorrosive processing is made without a body parts pars. To accurately perform it, you need to refer to the guide for the car, in which there is usually a scheme for conducting anticorrosive works of hidden cavities and ways to access them.

Overhaul

At the same time, the independent alignment of the geometry of the body and further repairs are impossible without specialized tools and suitable conditions. It is in such cases that the access to specialists is relevant.

Equipment required for the reconstruction of the body in service centers:

• lift;
• stipel (used in the restoration of the geometric parameters of the automotive body using electronic high-tech measuring systems);
• welding machine;
• jack;
• sPOTTER (for the execution of richtovka);
• pneumatic tool;
• locksmith tool;
• inventory for hard work.

Consumer Alignment Significantly saves the time of motorists. Financial savings are also evident, as it disappears the need to buy various "cosmetic" means.

Soviet car industry for such a repair is not suitable due to the soft body cover. Do it yourself like this restoration is better not to produce, because without due skill and availability required tools It is almost impossible to get rid of dents without disturbing LCP.

Proceedings:

• irregularities are removed by heating;
• scratches with chips put off and grind;
• when faults are used by heat seater;
• the product is painted with standard methods.

Ricking works are to adjust damaged bodies. These include both the restoration of the geometry of the car and the correction of dents and damage. The ultimate goal of Richtovka is to bring the body parts to the state in which they were after stamping.

Conclusion

Body repair TS can be performed with your own hands if:

• damage not critical level;
• there are necessary inventories and recovery tools;
• the owner has due skills.

Corrosion is the main enemy of the car and its owner. Rust is able to destroy the car of any manufacturer. First anticorrosion processing It must be carried out in service centers. And B. russian conditions This is necessarily even in cases where the car only comes out from the factory conveyor.

With a proper approach and attentive terms, the car is able to serve its owner not one ten years.

Video about the secreet of body repair:

• cleaning
• washing
• slush or wicked body parts
• periodic

In addition, check and tighten the fastenings of the car body, check the condition of doors, door locks, loops, windows, wipers and other equipment and lubricate hurry and other connections.

Dust and dirt removal

In order to avoid scratches, it is impossible to remove dust and dirt with dry vershorized material. The car is better to wash to dry the dirt of the jet of the water of a small pressure using a soft sponge and auto-pump. In the summer, the car is desirable to wash in the shade. If this is not possible, then the washed surfaces should be able to immediately wipe dry, since when drying droplets of water in the sun on the painted surface, spots are formed. In winter, after washing the car in a warm room, a dry body, door seals and a hood should be wiped before departure, as well as blow the locks with compressed air to prevent them from freezing.

When washing the car, it is necessary to ensure that the water does not hit the electrical equipment motor compartmentespecially on the ignition coil and distributor.

To preserve the brilliance of painted surfaces (first of all, auto-polyarols should be regularly applied to the car stored in the outdoor). They close the microcracks and pores that appeared in the paint coating, which prevents the occurrence of corrosion under the layer of paint. Polishing can be performed by VAZ-1 or VAZ-2 paste, and then VAZ-3 or manually similar to it either by an electric drill.

In order for the surface of the body to retain the brilliance, you should not leave the car for a long time in the sun, to allow the surface of the body of acids, solutions of soda, brake fluid and gasoline and apply soda and alkaline solutions for washing. Details from plastics must be wiped with a wet rag or a special tacifer. So that plastic parts do not lose glitter, gasoline or solvents should not be used.

The glasses are cleaned with soft linen rags or suede. Very dirty glasses must be predetermined with water with the addition of niiss-4 liquid or the refiner of glass. To remove ice from glasses and defrosting door locks, it is recommended to use the removal in the aerosol packaging, the brake fluid can be administered inside the locks.

Dust from the upholstery of pillows and the back of the seats should be removed by a vacuum cleaner. To eliminate fatty spots on the upholstery, the "Upholstery Chimney" is used.

In the plates of glass washers in winter time An aqueous solution of a special low-surge liquid NIISS-4 or other similar compositions should be poured in accordance with the recommendations for their use.

Elimination of small body scratches

A small scratch, damaged only to the body color, is rubbed by a degreasing liquid to remove the peeling paint and clean the adjacent areas from the protective polyter, then rinsed with clean water. Painted scratch using a thin brush. Thin layers of paint are applied until the thickness of the painting of the damaged area is equal to the surrounding layer. The paint is dried to its complete drying for several days, then polish the scratch area and apply a wax coating on it.

If the scratch damaged the metal metal, causing rust, use another repair method. Remove rust from the bottom of the scratching solid metal, then apply a primer to prevent the formation of rust in the future. Fill scratch with a special filler based on cellulose. Before the filler in the scratch hardens, it is easy to spend a tampon of cotton fabric, moistened with cellulose composition, on the surface of the filler so that its level is slightly lower than the surrounding layer of paint. After a complete rejection of the filler, it is painted, according to the technology described above.

Care of car windows and checking their lights

Periodically, it is necessary to check the light transmission of the car. The essence of the method of checking light-ups is to determine the normal light of safe glass on the intensity of the light flux, which is skipped by the test glass. Normal light transformation is the ratio of the light flux of the Ft, transmitted by glass, to the total falling light flow Fi.

The schematic diagram of the device to determine the transformation coefficient is shown by the drawing, and its total is on the second.

Fig. Scheme of the EC-1 device (Russia):
1 - light source; 2 - optical system; 3 - diaphragm; 4 - checked glass; 5 - radiation receiver; 6 - measuring instrument

Fig. General view of the EC-1 instrument:
1 - light source; 2 - measuring instrument; 3 - Radiation receiver

The device consists of a measuring unit with a liquid crystal or directional indicator, a light source, a radiation receiver (photodetector). The instrument can be powered by the on-board network of the car or from the battery. The housing of the light source and the photodetector is equipped with powerful ring magnets, which allow you to fix the source of light and the photodetector opposite each other when measuring light source.

When checking the radiation source is installed on one side, and the receiver is on the other hand. In the case of the use of the EC-1 instrument, the glass thickness calibration is not required.

According to the rules of the Road in the Republic of Belarus, participation in the road traffic of vehicles, the degree of light transmission is less than 75% for the front side glasses and less than 70% for the remaining glasses, unless otherwise determined by the President of the Republic of Belarus.

The vehicle must be equipped with the design of windshield wiper and windshield carriers.

The frequency of movement of brushes on wet glass in the mode of maximum wind speed operation must be at least 35 double strokes per minute, with the angle of the scope of the brushes should be no less provided by the design of the vehicle.

The wiper brushes must wipe the cleaning zone for no more than 10 double strokes for buses and no more than 5 double strokes for other vehicles so that the overall width of the blurred strips along the edges of the cleaning zone does not exceed 10% of the brush length. At the same time, the windows maker must ensure the supply of fluid into the glass cleaning zone in an amount sufficient to wet glass.

Check the technical condition of elements that provide visibility is carried out in the specified manner.

1. Inspecting the vehicle glass for compliance with the design, the presence of appropriate marking, the lack of unacceptable damage and applying tinting. In the case of applied on windshields attached or applied transparent band, measure its width or estimate its compliance with the established requirements.
2. Measure the coefficient of light transmission of wind and front side glasses of the vehicle. For windshield, the measurement should be made at three points in the wiper cleaning area at the level, approximately corresponding to the level of the driver's eye during movement, when it is driving a vehicle. For the front side windows, the measurement should be made at three points located on the line passing on the diagonal connecting the lower front (taking into account the direction of movement of the mechanical vehicle) the angle of glass and the top rear. At the same time, the specified points must be approximately equidistant from each other and visible edges of the glass.

For the remaining glasses, the measurement is carried out at one point located on the horizontal line passing in the middle of the glass.

At each point, you must perform at least two dimensions.

Determine the reflective coefficient of wind and front side glasses by the formula:

where xi is the result of measuring light transmission in i-th point on glass,%.

For the value of the transformation coefficient of the remaining glasses, the measurement result is taken at one point. It should be rounded up to an integer. To the obtained values \u200b\u200badd 3%. The result should not exceed the normative value set for the type of glass specifically.

Page \\ * MergeFormat 32

I. . Introduction ..................................................................... 1

II. . Main part ............................................................... 3

2.1. Basic damage to the body .......................................... 3.

2.2. Preparation of the body to repair .......................................... .. 3

2.2.1. Body in repair in repair ................................................... 3

2.2.2. The breaking of the body ............................................................... 7

2.2.3. Reassessing paintwork and cleaning of body bodies

Corrosion ........................................................................ 9.

2.2.4.defectoscopy body ...................................................... ... 10

2.3. Emergency damage to the body ....................................... ... 11

2.4. Damage formed during the operation of the bodies ......... .. 16

2.5.1. Body repair methods ..................................................... 18

2.5.2. Converting method for repair and assembly of the bodies ........................... 18

2.6. Methods for repairing the bodies ................................................... 21

2.6.1. Repair of damaged parts .................................. 21.

2.6.2. Relief of deformed panels and opening mechanical

Exposure .................................................................. 22.

2.6.3. Relief with the use of heating ................................................ 27.

2.7. Restoration of non-metallic parts ............................... 28.

2.8. Repair of the main mechanisms and equipment equipment ............... .. 29

2.9. Build the body .................................................................... 31.

III . Safety and labor protection ......... .. ........................ .. 33

3.1. The main safety safety provisions .............................. 33

3.2. Requirements for technological processes .............................. .. 34

3.3. Requirements for work premises .......................................... 35

IV. . Conclusion ..................................................................... ... 36

V. . List of references used .......................................... .. 37

I. Entering.

One of the reserves of an increase in the country's automotive park is the organization at the proper level of car repair. The need and feasibility of repairs are primarily due to the fact that during long-term operation, cars achieve such a state when the costs of funds and labor associated with maintaining them in a working condition, exceed the income coming from their further operation. Such technical condition of cars is considered limit and due to the inequalization of their details and aggregates. It is known that creating an equal machine, all the details of which would be even uniformly and had the same service life, almost impossible. Consequently, the repair of the car, even only a replacement for some details having a small resource, is always advisable from an economic point of view.

The main source of economic efficiency of car repair is to use the residual resource of their details. About seventy percent of the parts of the car, the service life before the repair, have a residual resource and can be used re-either without repair, or after a small repair impact.

One of the main aggregates of the car is the body. The bodies of passenger cars and buses are also the most difficult in the manufacture of aggregates. The complexity of the body manufacturing, such as passenger cars, is 60% of the total complexity of the car manufacture. The body is also attributed to the plumage: lining of the radiator, hood, wings, trunk lid. The rigidity and strength of the body increase the service life of the car. The failure of the body practically means the failure of the car.

For the rolling stock of the automotive transport of the public sector, the task of maintaining it in good condition, as well as the repair of nodes and aggregates, is successfully implemented a clearly regulated system for controlling and periodic technical impacts at road transport enterprises (ATP) and at car repair factories (ARZ). Currently held a course on the concentration of car repair in production associations The automotive industry will allow to consolidate and specialize enterprises. The major specialized enterprises for car repair are created conditions for the widespread use of the most advanced technological processes, modern high-performance equipment. This general direction in the development of auto repair production will lead to a sharp increase in the quality of car repair and the most complete realization of its economic advantages.

Currently, the parking park owned by citizens sharply increased. Maintaining this fleet in a working condition is possible mainly on the widespread development of the car service system. The whole network of maintenance stations (service station) on which is carried out throughout the country maintenance And repairing personal cars.

II. . Main part.

2.1 Basic Body Damage

During operation, elements and assemblies (assembly units) of the body are experiencing dynamic loads with tension from bending in a vertical plane and twisting, load from their own mass, weight of cargo and passengers. The body and its nodes also affect significant voltages resulting from oscillations of it when driving on irregularities, impetus and blows at the road, as well as due to errors in the balancing of rotating nodes, the shift of the center of gravity in the longitudinal and transverse directions. These stresses cause fatigue accumulation and lead to the destruction of body elements.

In the bodies of cars entering the repair, there are damages, which appeared as a result of increasing changes in the body; These include natural wear, arising in the process of normal technical operation of the vehicle, due to the constant impact on the body of such factors as corrosion, friction, elastic and plastic deformation, and others; Damage, the appearance of which is associated with human actions, constructive flaws, violation of the maintenance rate of the body and maintenance rules, and also caused by transport incidents (accidents).

2.2 Preparation of bodies for repair

2.2.1 Accepting body for repair

The bodies entering the repair must meet the requirements of technical conditions for the delivery and repair of cars with the corresponding body design. In technical conditions there is permissible damage to the body and its particular completeness. Necrossplex bodies or body requiring repair, the volume that exceeds the maximum allowable technical conditions, as a rule, is not taken to repair. Usually check the presence of doors, internal seat upholstery, glasses with ripples and frames, wind, rotary and rear windows, plafoons, internal and outer handles, decorative lining, mechanisms: lock, lifting and lowering glass, heating, ventilation equipment, wipers. The outer sink of the body is produced in a specially equipped room for this purpose, usually before disassembling the car to the aggregates. After the outer washing of the body is subjected to preliminary control, in which they produce a thorough external inspection of nodes and parts subject to mandatory removal from the body during its overhaul (internal body upheat, glass, fittings, decorative lining, etc.), to find out their condition and feasibility of repair. . The main purpose of preliminary control is not to clutter the production premises with unsuitable (duck) details. Then removed from the body all the nodes and parts covering the housing from the inner and outdoor sides, as well as all the aggregates of the chassis of cars from the body of the supporting structure. For a thorough (final) cleaning of the bottom of the body from dirt, it is rinsed again.

The nodes and parts removed from the bodies depending on their state are sent to the appropriate storage, repair, repair or warehouse, and the chassis units in the aggregate repair department. An old paintwork is removed from the body. Disassembled in this way and purified from the old coating of the body undergoes detailed control, in which the nature of the damage is revealed, the order of repair is planned and the complexity of repair work is determined. The results of the preliminary and final control are included in the inspection statement, which is the main document determining the condition of the body to repair. In the control and sorting statement, there are three part groups: suitable, requiring repairs requiring replacement (unfit). A copy of the statement enters the master of the relevant repair area, and the original is in the accounting department of the repair enterprise to determine the cost of repairing the body.

Then the body enters the repair site, where damage is eliminated.

Schemes of technological processes for repair of car bodies, buses and cabins trucks They differ from each other with different equipment and mechanisms on them, as well as damage characteristic of each body design and the methods of eliminating them.

Figure 5 General scheme of the technological process of repairing body

2.2.2 Disassembly of the body

Body disassembly is partial and complete depending on the repair and condition of the body. Partial disassembly is produced when the body is generally in good condition and repair only its individual parts damaged as a result of wear, loosening fasteners or accidents. Complete disassembly produce, as a rule, with overhaul of the car and when most body nodes need to be repaired.

Body nodes can be correctly disassembled only with strict compliance with certain technological sequences.velidity, eliminating the possibility of breakdown and damage to parts. Therefore, the procedure for disassembly is established by the technological process, which is developed for each type of body.

When disassembling the bodies and plumage, labor-intensive work is to reject rusty bolts, nuts and screws, removing rivets, separation of panels cooked with point welding. To remove fastening parts that are not rejected, one of the following methods can be applied: heat the gas flame nut; This method is very effective and operates quickly; After heating, the nut is usually easily rejected; bite off bolt with nutpit or trimmed with knife; cut off the nut chisel; Drill in a bolt head with a diameter of a diameter of the bolt rod; After drilling the head disappears, and the rod of the bolt with the nut is knocked out with a beard. This method is successfully used for checked bolts with a semicircular head connecting wooden parts; Cut the head of the bolt or screw with a gas flame and knock the rod with a nut from the socket.

Currently, special chemical compositions are widely used to alleviate the rejection of rusted bolts and nuts, which, when applied to bolted compounds, partially remove corrosion products on the thread, and due to good penetrating ability, the threads are lubricated between the bolt and the nut and thereby facilitate the dismantling of the threaded connection. Typically, such formulations are issued in aerosol packaging and spray.

In screws that are not rejected as a result of a selection or wear of the head of the head, you should drill the head, and then, removing the item, turn it out, or pull the screw from the tree. The rusted screws of the doors are heated by a gas flame, after which they are easily turned. The declaration of riveted seams is produced so as not to damage the disassembled panels if they are not replaced. Details, strengthened point welding, cut off with a sharp thin chisel or drill welding places through the top sheet of the panel with a non-personal side of the body. Special caution is necessary when disassembling fragile and easily damaged parts. The details to be debited in the pit can be removed by any way accelerating the disassembly up to damage them if they are not withdrawable, but provided that it will not be damaged by the affiliated parts.

With full disassembly of the bodies, the volume of work and the procedure for their implementation largely depend on the structure of the body and on the number and nature of damage. The sequence of body disassembly boils down mainly to removal of the pillows and the backs of the seats, internal equipment, handles, handrails, holders, chrome-plated fittings and decorative linings, finishing frames, armrests, plafoons, internal partitions, internal upholstery, different mechanisms, body glasses, electrical wiring, pipes The heater and other parts and nodes installed inside the body. For the convenience of disassembly, the body is installed on a special stand.

2.2.3 Removing paintwork and cleaning of bodies from corrosion products

Old paint coating can be removed by mechanical manner using sandblast (shot blasting) devices or mechanized hand tools, chemical treatment with special washes and alkaline solutions.

With a shot blasting and cleaning with a mechanized hand tool simultaneously with a paint coating, rust and scale are removed. The most common abrasive material for the shot blasting processing of metal surfaces is a metal fraction manufactured by industry with a grain size of 0.2 - 0.3 mm. To clean the bodies and plumage panels made of sheet steel with a thickness of 0.8-1 mm, from the old coating and obtaining the necessary roughness, the optimal angle of inclination of the flobs to the treated surface should be 45 °, and air pressure - 0.2 - 0.3 MPa. The roughness of the treated surface should not be greater than 20 - 30 μm, which ensures the high quality of the newly applied protective coating.

For the implementation of shot blasting processing, a mobile shot blasting machine with a manual gun is used. This apparatus provides automatic regeneration of abrasive fraction and feeding it into a shot blasting gun.

To remove corrosion products, various installations apply a manual mechanical way. From these plants is the greatest interest is the needlefish. It is made of needle-free segments of high-strength wire with a certain packing density. Such a tool can cut the rust layer, scale, metal with a thickness of 0.01-1 mm. From the hand-held mechanized tool for cleaning the surface and removal of paints, also grinding machines MSH-1, I-144, SHR-2 grinding machines, SHR-6 are used. This cleaning method is used to carry out small amounts of work, as it does not provide the necessary quality and performance of work.

To remove coatings, various washes are used in a chemical method. The washes are applied to the surface with spraying or brush. After a few hours, the coating is exhausted and removed by mechanically, and then the surface is washed with water.

2.2.4 Detectoscopy Body

After removal of the old paint coating, the body is subjected to careful control in order to rejection of unsuitable parts, the selection of suitable, determination of the type and volume of repair work. From the adopted method of flaw detection and thoroughness of its implementation largely depends on the quality of repair. To detect defects in the body housing, as well as to control the newly manufactured parts, welds are used non-destructive testing methods.

The technical condition of the body is usually tested by an outer inspection of the surface of the parts with the naked eye or using the simplest LUC multiple increase. This method allows you to detect surface cracks, corrosion corrosion, deformation, etc. The measurement of special fixtures, templates make it possible to detect the deviations of the geometric dimensions of parts from the initial (silent, deflection, etc.).

However, the external inspection can only be installed large, damage to the eye. In some places of carrier body elements, hair cracks appear, which can be detected by special ways. Methods based on molecular fluid properties obtained the name of capillary methods (penetrating fluid methods). The most common is small and luminescent methods. Kerosene, possessing good wettability and low surface tension, easily penetrates into loosening. The essence of this method is that the surveyed place is wetted by kerosene and wipe dry or dried by a jet of air. Then this place is covered with an aqueous solution of chalk. Due to the absorption chalk of kerosene on the chalk surface, a fat trail appears, repeating the geometry of the detected crack. For this method of flaw detection, you can use the penetrating and exhibiting compositions on the basis of dyes and enamels. The method of paints can be revealed cracks with a width of 0.005 mm and a depth of 0.4 mm. For the correct choice of the method and volume of repair of the body of a car made of thin-sheet steel, with a body flaw detection, it is necessary to determine the depth of corrosion destruction. For this purpose, gamma-thickness gamma based on measuring the intensity of gamma radiation is used. The device allows you to measure the sheets with a thickness of 0 to 16 mm, while the measurement time does not exceed 30 s.

2.3 emergency damage to the bodies

The strongest damage is applied at front collisions of the front part of the body at an angle of 40-45 ° or on the side between two vehiclesmoving towards meeting. With such collisions of the car, the front part of the body is particularly destroyed, while the active heavy loads in the longitudinal, transverse and vertical directions are transmitted to all adjacent framework parts and especially its power elements.

With a frontal collision of the car (Figure 1) the front part of the body in the area of \u200b\u200bthe left front wing, the side member and the left headlights are deformed the front panel, wings, hood, mudguards, front spars, the windows frame and roof. In the picture, it can be seen along the lines specified by the dotted line. At the same time, the invisible deformation is transmitted to the front, central and rear racks on both sides, front and rear left doors, left back wing and even on the rear trunk panel.

Figure 1 Front collision front part of the body

Directions of the distribution of loads and possiblewhen you hit the car to the front of the body at an angle of 40 - 45 ° (Figure 2), the front wings are damaged, the hood, the front panel, the mudguard, the front side member.

Figure 2 Collision of the front left part of the body at an angle of 40-45 °

When hitting the front part of the body (Figure 3) in the front panel area of \u200b\u200bthe front panel with the front of the spar and the left wing, both front wings are deformed, the front panel, the springer sprinkle, the hood. In addition, under the action of tensile efforts, the opening of the left front door is broken, and under the influence of compressive efforts, the opening of the right door and the sidewall of the left front door are deformed. In this case, significant power overloads are transmitted to the front and central racks, causing their deviations from the original position.

Figure 3 Collision on the side of the front in the area of \u200b\u200bthe front panel connection with Langeron and the left wing

When hitting on the side (Figure 4) of the front pillar of the body on the left side, the left front stand, the windows frame, the roof, the floor and the front floors, the front panel, the hood, wings, mudguards, front spars are significantly deformed. At the same time, the front part of the body will be leaving left; The threshold and the upper part of the right sidewall perceive stretching, and the central and rear racks are compressive loads.

Figure 4 Collision on the side of the left front rack

The presence of invisible deformations in the power elements of the body can be set to perform measurements: according to the presence of distortions in the front parts, protrusions of one part relative to the other, unacceptable gaps in the pairing of openings with doors, hood, trunk lid.

From the above examples, it can be seen that as a result of the accidents, the deformation applies to the conjugate elements of the body, causing a violation of the geometry of its openings and base points of the floor. Eliminate such damage requiring replacement of most parts and complex repairs can only with special equipmentUsing repair operations, hydraulic and manual directions, followed by the control of the body geometry.

2.4 Damage formed during the operation of the Body

There are also less significant damage in metal bodies, worsening their appearance.

Dents appear as a result of residual deformation when impact, improper repair, as well as due to Nekcelebrate body parts assembly. Cemen can be simple, easy to repair, and complex - with sharp bends and folds, can be located in the places it is difficult to repair.

Cracks belong to frequently occurring damage. They may appear in any body part as a result of metal overvoltage (blows, bends), as well as due to the fragile connection of nodes and parts and insufficient structural strength.

Rales and holes can be divided into simple, taking the type of normal cracks, and complex, requiring the damaged position of the postposition during the repair.

Cliffs in the parts of the body are characterized by the size of the part of the panel or the plumage. Large breaks often eliminate the formulation of new inserts of a complex profile, and sometimes produce full replacement Details.

The stretched metal surfaces are distinguished by the location of their location: on the surface of the panel in the form of a bulb and in the flange details (stretchedboard and edges).

Corrosion in its external manifestation may occur in the form of uniform when the metal is destroyed evenly over the entire surface, and local when the metal is collapsed in separate areas; This corrosion form is detected on dark spots or deep black points on the metal and is more dangerous, since the metal may in a short time collapsed to form through holes.

The violation of welded compounds is found in the nodes of parts that are connected by point welding, and in solid body welds.

Disruption of riveted seams is the result of loosening or cutting rivets, as well as wear holes for bolts and rivets.

Defgits, dusting and twisting usually appear as a result of emergency load. Socials are inter-slicer and in the plane of one node or part (skew in the door body opening, skew in the door itself, the deflection in the floor thresholds).

Wear of holes and rods occur as a result of rolling friction (axis and holes in door loops) or weakening the attachment of the node with rivets or bolts; Wear surfaces due to a systematic load attached to the surface, for example, when transporting bulk abrasive cargo in car dump trucks.

Constructive flaws of the body nodes often lead not only to the appearance of damage, but complicate their repair, and sometimes performing repair operations up to the need to replace the damaged node new. Constructive flaws in the body, complicating its repair, take place mainly because automotive plants It is not fully taken into account the requirements of motor vehicles and auto repair enterprises to the body structure.

2.5.1 Body repair methods

Repair and assembly of the body are performed by two methods - stationary and trample. In the stationary method of repairing the body is installed on the stand at the repair time. Working, finishing work on the body on one booth, goes to another. With a streaming method, the body during the repair process is consistently moved by specialized work posts, which perform a certain amount of work in a limited time. Practice has shown that this method is the most effective, speeds up and improves the repair of the body and has several advantages compared to stationary.

2.5.2 Power Repair and Build Building Method

The main advantages of the flow method are to be able to place tools and devices in the immediate vicinity of the repaired bodies in the sequence of their application, and the working - with minimal movements and labor costs to quickly perform operations provided by the process; In an increase in the repetition of operations and specialization of workers in certain types of work, it makes it possible to achieve accuracy and perfection of their implementation, improve labor productivity.

A variety of repair and assembly operations performed on the body does not allow them to stretch them into one line geographically and alternate in time consistently one after another. Consequently, a slow-to-level low-level rhythm is needed and the maximum combination of repair and assembly operations in one workplace so that the length of the flow line does not exceed the length of the production premises. When choosing the number of work posts on the stream line, except for the length of the paths of the assembly office, also take into account the staffing, the working, strength, the power of the subsidiary departments and the plots, as well as the need for the arrangement of bodyworks at certain intervals, allowing to perform the necessary work at each post.

Work on the repair and assembly of the bodies can be carried out on a stream with moving or fixed bodies. A stream line with fixed bodies is served by repair brigades, rhythmicly moving on the front of work from the stand to the stand, on each of which they perform the required operations. On the stream line with the movable body body, moves along the work front, consistently exposed to all operations that are performed on a specific operating post. At each post, the body is until the end of the execution of all works scheduled for this post, and then moves to the next post (stand). This type of flow is the most productive.

Repair is most efficient, in which the maximum possible number of parts and components of the body (cab), requiring repair or replacement, is repaired in advance in the appropriate branches of the body workshop or replaced by ready spare parts. This reduces to a minimum number of repair operations on the stream line and, therefore, the duration of the production cycle.

Repair and assembly of the body are made on two parallel lines. On the first line - the body washing, removal of old paintwork, preliminary and final control, disassembly, repair and assembly of the body to staining; On the second - the formulation of aggregates, nodes and parts on the body and the final finish of it after staining. Such a construction of the process justified itself in practice, since it allows the most efficient to use production area. The number of disassembly posts, as well as posts for all other types of work (repair, assembly), depends on the plant program.

To install and move the bodies and car cars in the painting department, various ways are used: the body (cabin) can remain on trolleys before the entire complex of painting works; Upon admission to the painting branch of the body (cab) is installed on stationary stands (rolling conveyors), the size of which does not exceed overall dimensions body (cabin); The cabins hang to the carriages of the suspended conveyor or monorail, mounted above all the preparatory posts and passing through painting and drying chambers.

Sections of disassembly, repair and assembly of the bodies are equipped with equipment required for operation and auxiliary devices designed to create amenities when using manual electrical and pneumatic tools, storage of nodes and parts taken from the body or subject to it, etc.

2.6 Body Repair Methods

2.6.1 Repair of the replacement of damaged parts

Consider the processes for replacing the rear wing of the car after a general disassembly of the body, since this type of repair is most often found in the practice of repair enterprises.

Figure 6 Replacing the rear wing of a passenger car: A - Marking of the cutting line of the wing, b - cutouts on the flanges

Replace the rear wing welded to the car body is as follows. We are planned with a pencil or chalk line of a slice throughout the perimeter of the old wing in such a way as to leave the strips of 20-30 mm wide on the front of the wing, along the arch of the wheel and the top of the wing to its flange (Figure 6a). The old wing is gently cut on the markup by the enrollled machine with a cut-off abrasive circle or chisel and scissors for cutting sheet metal so as not to damage the inner parts of the housing, strengthened to the body under the wing in the seal places. If, after removal of the old wing, the flanges of the upper part remaining on the body do not allow you to carefully fit a new wing at the place of its attachment, these flanges are removed. Remove the points of contact welding from the welded flange to the depth of its thickness and disconnect the flange from the body with the help of pliers or a thin sharp chisel. To drive the welded points, use the drill with a diameter of 6 mm, sharpened at an angle of 150 - 160 °. After trimming the wing, it is thoroughly poured and cleaned up to the metal glitter the surface of the flanges, to which a new wing should be welded. On the latter make cutouts with a radius of 5 -7 mm in a step of 40 - 50 mm throughout the perimeter to be welded (Figure 6B). Install and customized on the place of attachment a new wing and tightly pressed it with a clamp. The welding is made only on the edges of the rational in such a sequence: welded in three to four places the upper front part, then the bottom back is from above in the area of \u200b\u200bthe lantern, and then the arc of the wheel opening, etc. Before the final wing welding. In the process of welding and after its completion of the welded seam, the hammer is picked up using support, and then carefully deteriorate to the metal shine.

2.6.2 Edit of deformed panels and opening mechanical exposure

As a rule, dents in the panels of the body and plumage, where the metal is not stretched after impact, are aligned with the extrusion or stretching the concave portion until it gives it the correct radius of curvature.

With a large tension, metal is formed, which cannot be corrected with a rattling. Reference can be replaced in a cold or heated state. The elimination of the cold state is based on the tensile metal along the concentric circles or by radius from the replenish to the intact part of the metal (Figure 7). This forms a smooth transition from the highest part of the panel surrounding it.

Figure 7 Method of Edit (b) In the Body Panels (A) without heating:

1 - Release, 2 - Panel, 3 - sections of the panel to be stretched by a hammer blow, 4 - the radius of the curvature of the panel after editing are rejected, 5 is the direction of the direction of the hammer blows (indicated by arrows)

A significant stretching of the metal that occurs when eliminating is replenished with a richt in cold condition, increases the true surface of the metal at the repaired area. As a result, the corrosion resistance of the metal worsens. Therefore, the editing of uneven (wavy, small concave surfaces) of metal body panels and the plumage is recommended to be performed by smoothing with special devices, extruding or pulling using the following devices, and are rejected to edit with the use of heating.

For editing of hard-to-reach places use curved support-blades (Figure 8A), the end of which can be introduced between the internal and outer panels of the body through the gaps or mounting hatches (Figure 8B).

Figure 8 Support(but) For editing areas closed by internal panels and a record scheme with their help of the trunk lid (b): 1 - support,2 - Inner panel, 3 - dent, 4 - Ricking hammer, 5 - outer panel

Figure 9 Richting of minor dents on the panels (roofs, doors, hood, etc.)

For editing of hard-to-reach places, curved support-blades are used (Fig. 8a), the end of which can be administered between the internal and outer bodies of the body through the gaps or mounting hatches (Fig. 8b).

Richtovka of minor dents on the roof panels, doors, hood, trunk, wings and other front panels and performing it are shown in Figure 9.

Correction of dents on the bodies having a rounded (oval) facial surface (Figure 10), always begin with the periphery of dents and move to its center.

Figure 10 Sequence (1-9) Correction of dents on body parts having a rounded (oval) facial surface

The elimination of small deformations in the panels in some cases can be performed using a clamping lever. Taking work with this tool, as well as with a hammer and lever, clamps are shown in Figures 10, 11.

Figure 10 Correction of the deformed area using a climbing lever

Figure 11 Correction of dents with hammer and lever-clamp

When used to rather small deformation sections of a special straight hammer (has a notch) and anvil supportthe metal "does not swim", its length is restored to the initial shapes and sizes.

For editing overvaling of windshield opening, the doorway is used hydraulic and screw streamers. Edit the root in the roof using stretching shown in Figure 12a,a skewer in the doorway - in Figure 12.

Figure 12 Edit of the deflection in the roof (a) of the body and eliminate the skew in the doorway (b)

2.6.3 Edit with heating

The essence of the thermal way of editing lies in the fact that the heated area of \u200b\u200bthe panel in the process of thermal expansion meets the opposition from the surrounding cold metal. In the processthe cooling occurs, the decrease is released due to the fact that the areas heated around it, cooling, produce a tightening effect. As a rule, the heating zone should be placed as close as possible to the top of the replenish. Heating is carried out by stains or strips with acetylene-oxygen burner to a temperature of 600 - 650 ° C. Spots with a diameter of up to 30 mm oriented along the long sides of the released. Heating starts on a more hard area and go to less hard. The distance between the centers of spots 70 - 80 mm.

If the form is released approaching the ball, then the heating is carried out by intersecting strips or a strip located on the slopes of the replenish. The heating of each subsequent strip is performed after the complete cooling of the previous one. If there is free access to the released with the outer and inner sides of the panel, then to accelerate edits, you can combine heating with mechanical effects. At the same time, the most stretched part is heated by small stains and blows of a wooden hammer around the heated stain "ride" the speech of metal into this spot (Figure 13).

Figure 13 Scheme of editing rejected in heated state: 1 - approximate direction of hammer blows,2 - Heated spot, 3 - support,

4 - Panel

2.7 Restoration of non-metallic parts

The non-metallic materials used in the bodies include various plastics for the decorative trim of body salons, as well as upholstery.

Damaged body parts and cabinets, for the manufacture of which plastic masses are used, replace with new ones in the repair process, since the technology of their manufacturing is simple and economical. Details, the repair of which is appropriate and economically acquitted, is usually restored by gluing. The selection of glue for the compound of plastic materials depends on the chemical nature of the material, the working conditions of the adhesive compound and the technology of its application. For the manufacture of parts from plastic masses, ertrol, polyamide, organic glass, kapron, etc. are used.

The gluing technology is made up of conventional surface preparation operations, applying glue and exposure of the adhesive composition under pressure. The parts made from ETROL are glued with acetic acid, which is missing surfaces, and then combine them under low pressure and are kept for 0.75-1 hours.

For gluing polyamides, polyamide solutions in formic acid or formic acid are used. The parts made of plastic based on thermosetting resins glue neither temperature, nor moisture and no chemical solvents. The upholstery breaks made from the leatherette or from a polyvinyl chloride film, a reinforced or not reinforced with a mesh of synthetic fibers, are eliminated by the PEF-2/10 polyamide glue inserts. Bonding is carried out at room temperature with subsequent shutter speed under the press for 1-1.5 hours. 88NP glue is used to fit the new upholstery to the cardboard. Material for sewing new upholstery details are cutting on marking or templates with electron-like. Connected upholstery parts are stitching with a certain pitch step at a predetermined distance from the edges of a single or double seam with a non-personal side of the upholstery. To increase the strength of the connection of the upper upholstery of the seat cushion, stocking seams with edging are used. Stitched upholstery should not have weak tightening, distortion, wrinkles, folds and damage on the front side. For assembling pillow and seat backs, a pneumatic stand is used to compress the spring springs to ensure the tension of the material.

2.8 Repair of the main mechanisms and equipment of the body

The main mechanisms and equipment of the bodies and cabins include locks, windows and mechanisms of fastening of glass, the cozovy seats, hinges of doors and hulls, the heating caloric system, etc. All parts of the body mechanisms are relatively simple for its design and repair them comes down to performing uncomplicated fitter welding. operations.

Existing cracks in the enclosures are brewed, the worn outwork surfaces are repaired by surfacing or processing under the repair size. Cabinet parts with brooms are selected. The broken springs and springs that have lost their elasticity are replaced by new ones. Bloomred screws B. threaded connections Remove with twisted if it is possible to capture them for the protruding part, or by drilling the hole with a drill of a smaller diameter than the screw. The square rod is inserted into this hole, with which the proportion of the screw is retracted. After removing the screw, the threads in the hole are driven by the tag. If the thread is damaged in the hole, the hole is brewed, clean the alternates of the metal from welding flush with the base metal of the body, drill the hole under the threads of the desired size and cut a new thread. Weakened rivets are pulled up, and the underlying pull-ups are cut down and replaced with new ones. Destroyed cuffs, glazes, sealing rings and gaskets are replaced with new ones. Minor corrosion raids on the surface of the parts are cleaned with sandpaper or scraper and lubricate kerosene. With deep corrosion traces, damaged parts are replaced with new ones.

With the overhaul of the bodies and cabins, the locks are completely disassembled. All parts are thoroughly rinsed in a bath with kerosene and wipe dry. After repairing parts or their replacement, the lock is collected and adjust.

The technology of repairing windows consists of their full disassembly, washing, control, replacing unsuitable parts with new, assembly and subsequent adjustment. Damaged door glasses are replaced by new.

The most characteristic defects of the seats are scratches, chromium detection and corrosion on the surface of the upper part of the island, deformation of the upper part of the island, cracks and breaks in the bends and places of the soldering, the bent or cliffs of the bends of the scene to the floor and the breakdown of the brackets of the backs of the backs. To restore the decorative coating, chromed parts are removed and a new coating is applied. Violated platforms cleaned from the old solder and other contaminants and disappear. Details having cracks, cliffs and other damage are separated by heating gas burner and replaced with new ones. New parts of the frame are made from a seamless pipe, the outer diameter of which is 25 mm, and the wall thickness is 1.5 mm.

Repair of the hinges of the doors and hoods consists in eliminating the revenue by editing hammer on the plate, cracks and wear, welding with subsequent machining, in restoring holes for repair dimensions. Details of loops that have bugs are replaced by new ones.

2.9 Body assembly

The technological process of building body assembly usually consists of assembly before staining and the overall assembly after staining. A fundamentally common assembly process after staining the body during its repair does not differ from the assembly of the new body, only organizational forms of assembly and the ratio of the complexity of certain types of work are changed. Build the body after overhaul It should be done in the same sequence and with the same thoroughness as the assembly of the new body.

Characteristic feature The assembly is that all the main disadvantages of previous technological operations are found here. If they are made with a retreat from technical conditions, they produce additional processing, fitting and different kinds of finishes affecting the complexity and quality of the assembly.

When assembling the bodies, serious attention is paid to the choice of tools and devices. In addition to universal tools and devices that can be used on any operation corresponding to their purpose (wrenches, screwdrivers, etc.), and special tools intended to perform one completely specific operation are widely used. The use of special devices or tools simplifies and facilitates the assembly process.

The assembly of any body cannot be carried out in an arbitrary sequence. The assembly sequence is determined primarily by the design of the assembled node, as well as the required separation of assembly work. Assembly schemes are taken for clarity to portray so that the corresponding nodes and parts are delivered in the order of their introduction to the technological process of assembly.

Depending on the quality of the repair, the accuracy of the manufacture of individual components and parts of the body and the number of fittings, three main types of assembly distinguish: on the principle of complete interchangeability, according to the principle of individual fit and on the principle of limited interchangeability. The assembly on the principle of complete interchangeability is used mainly in mass and large-scale production. In small-scale production and, especially in a single production, the principle of complete interchangeability is not economically justified and therefore it is used only in some cases. Assembly on the principle of individual fit, the purpose of which to give the details exact dimensions or one or another geometric shape is carried out by fit connected to each other. This operation is usually very complex and time-consuming, therefore, on advanced car repair factories, the assembly on the principle of individual fit is gradually displaced by a more advanced assembly on the principle of limited interchangeability.

The most common types of fit work when assembling the body are works related to the formulation of parts and components taken from the body and repaired or repaired; Quality; drilling and deployment of holes at the place; cutting threads; stripping; Bending. The mechanization of fittings for assembly is mainly carried out by the use of universal and specialized tools with electrical and pneumatic drives.

The build of the bodies before staining is usually associated with a significant amount of fit and produced on the body repair site. Pre-primed doors, front and rear wings, hood, radiator clamp, mudguards, trunk lid and other parts to be stained with the body are installed on the bubble of passenger cars before staining.

The body assembly after staining is produced in a sequence, reverse disassembly of the bodies.

III. Safety and labor protection

3.1 Basic Labor Safety Provisions

Under labor protection, they understand the system of legislation and the corresponding activities aimed at preserving the health and working capacity of workers.

The system of organizational and technical measures and funds preventing production injuries are called safety equipment.

The system of organizational, hygienic and sanitary and technical measures and funds that prevent the incidence of working, called production sanitation.

The main labor protection provisions are set out in the Code of Labor Law (Labor).

One of the main activities to ensure the safety of labor is a mandatory briefing of newly employed and periodic briefing of all employees of the enterprise. Instructing conducts chief Engineer. Recommended to work to work with the main provisions on labor protection, the rules of the internal regulations, fireproof rules and features of the enterprise, the responsibilities of employees to comply with the safety regulations and production sanitation, the order of movement at the enterprise, the means of protecting working and the ways to provide trial assistance to victims.

3.2 Requirements for technological processes

With maintenance and repair of cars, it is necessary to take measures against their independent movement. It is prohibited to maintain and repair vehicles with a working engine (except engine adjustment).

The lifting equipment must be in good condition and used only in their direct intended purpose. Persons who have passed the appropriate training and instructions are allowed to work with this equipment.

During disassembly and assembly of nodes and aggregates, special films and keys must be applied.

It is forbidden to clutter the passages and nodes of the passages between jobs, as well as to scap a large number of parts on the disassembly places.

Increased danger represents the operations of removal and installation of springs, since significant energy has accumulated. These operations must be performed on the stands or using fixtures that ensure safe operation.

Hydraulic and pneumatic devices must be equipped with safety and bypass valves. The working tool must be in good condition.

3.3 Requirements for work premises

The premises in which the worker should be under the car must be equipped with inspection ditch, overpass with guide safety flavors or lifts.

The supply and exhaust ventilation should ensure the removal of the selected vapors and gases and the influx of fresh air.

Workplaces must be provided with natural and artificial lighting sufficient for the safety of work.

On the territory of the enterprise, sanitary and household premises must be equipped: dressing rooms, showers, washbasins (with the mandatory availability of hot water when working with eaten gasoline).

IV. Conclusion

In this term paper The technological process of repair of car bodies is considered. The body malfunctions are considered in detail, as well as the process of defecting parts and methods of eliminating defects, activities for labor protection and safety operations are considered during repair work.

V. Bibliography

1. "Car repair" S.I. Rumyantsev M. Transport 1990-327 p.

2. Egg technology of the machine builder Volume 2 M. Mechanical engineering 1988-240С.

3. Basics of automotive technology and car repair. Mechanical engineering 1991-315 p.

4. E.S. Kuznetsov. Technical operation of cars. Moscow. Transport, 1991.

5. Occuprics at the enterprises of vehicles of Salov F.M. M.: 1991.

6. F.N. Avdonkin "Current car repair" M.: Transportation 1988 with. 271.

7. Device, maintenance and repair of passenger cars. : Tutorial for start. Professional profs.: S.K. Shestopalov. - M.: "Academy" 2006-566С.

8. "Maintenance and repair of cars" L.I. Epifanov. 2004

9. "Locksmith for repair of cars" A.S. Kuznetsov 2006.

10. "Maintenance and repair of cars" V.M. Vlasov 2004.

The road puts in the same conditions of adherents of aggressive manner of driving and neat drivers. Nobody is insured against the accident. In any accident, the car body is most damaging. It can suffer as a result wrong parking, hitting stone. Paint and varnish coating is subject to natural wear. The reasons for the appearance of body fault faults are set, but the result is the same - the need for repair of chips, scratches, and correcting other damage.

In general understanding, body repair is a restoration external view, integrity, machine geometry, basics and paint coating layer. For high-quality listed repairs, special premises, tools, materials, specialists with due level and qualifications are required. Many auto repair shops consider it possible to declare body repair services without preparing the appropriate material and technical base, attracting masters of dubious qualifications.

The result of the appeal to such services is additional costs, aggravation of existing problems, corrosion development.

Customers of auto service "Childreningof" are delivered from the problems of this kind. All who appeal once recommended service to friends and save our contacts. Reviews of work marked the scrupulous compliance with the technology of various types of body repair, accurate diagnosis of damage, the use of high-quality consumables and consistently excellent results.

Types of body repair

Depending on the degree of damage distinguish:

• cosmetic repair of the body, eliminating scratches, chips, dents;
• repair of medium difficulty in which individual elements are replaced;
• complicated. The work suggests the elimination of damage after serious accidents, are carried out on the stapel. During the repair process, a full cycle of recovery activities is carried out: analysis, replacement of elements, priming, putty, staining, polishing.

A specific list of works for each type of repair is determined after inspection of cars, evaluating the degree of damage. The most common list includes:

• local repair and painting of the body;
• removal of dents, scratches;
• repair;
• replacement of glass or repair of chips on them;
• polishing headlights, body.

Features of body repair

Two identical accidents do not happen, therefore, the repair in each case is characterized by stages, technology, materials. The main difficulty in carrying out body repair works is in the competent miscalculation of the sequence of actions. To accurately determine, it is necessary to take into account the type of car body, the characteristics of the model and the brand, the nature of damage.

The specifics of the work is determined by other factors:

• the need to repair indoors, where the temperature regime is similar to the factory parameters of the manufacturers;
• the presence on the service station of the stapel, devices spot welding, hydraulic, computers with specialized software for accurate selection of paintwork coatings;
• ability to estimate the cost of repair and take a decision on the client about its expediency;
• the presence of materials intended for specific cars;
• the need to adjust the gaps in accordance with the factory parameters.

For body repair of any complexity, experienced masters with a narrow specialization are needed: autoswens, colorists, straws, welders, car steamers. Only with the combination of the factors described, high-quality body repair and further safe operation of the car are guaranteed.

Signs of high-quality body repair:

• local damage is visually invisible, in the future they will not become corrosion foci;
• the normal thickness of the non-metallic layer, indicating that instead of a metal, a putty was not used;
• accurate getting into the original color;
• sustainability on the road, without problems Closed doors and trunk, the ability to set the correct values \u200b\u200bof the angles of the wheel installation, which indicates flawlessly reduced geometry.

Sensible people who appreciate their time, finance and security, do not resort to the services of handicraft workshops or helping home-grown craftsmen from the local garage cooperative. Body repair is a complex and responsible work that professionals must be performed.