Lokacin da mafi yawan mutane suka ji 'ƙarfan ƙarfe na foda mai ci gaba', nan da nan suna tunanin manyan fasahohin sararin samaniya ko wataƙila waɗancan ƙwararrun ƙwararrun likitoci. Wannan ba laifi ba ne, amma ɗan ƙaramin ƙasida ce mai kyalli. Gaskiyar, niƙa ta yau da kullun, ya fi game da magance matsaloli masu ma'ana: ta yaya za ku sami wannan hadadden kayan aiki don riƙe sifar sa ta hanyar yin ɓarna ba tare da yaƙe-yaƙe ba, ko ta yaya kuke ci gaba da bugu da ƙima na 7.4 g/cm3 akan aikin samarwa na guda 50,000? Bangaren 'ci gaba' ba kawai foda na kayan abu bane; shi ne dukan jerin tunani, daga foda handling zuwa karshe size aiki. Yawancin shaguna suna da'awar iyawa a nan, amma shaidan yana cikin cikakkun bayanai mafi yawan takaddun takaddun ma ba a ambata ba.
Gidauniyar: Yana farawa kuma yana tsayawa tare da foda
Kowa ya damu da latsawa da ɓacin rai, amma idan abincin foda ɗinku bai dace ba, kuna yin gini akan yashi. Na ga ayyukan kasa saboda gas atomized bakin karfe foda yana da dan kadan kashe barbashi size rarraba. Gudun zuwa cikin mutuwar bai dace ba, wanda ke haifar da ɗimbin ɗimbin yawa waɗanda kawai ke nunawa azaman fashe bayan maganin zafi. Ba za ku iya gyara hakan daga baya ba. Zaɓin tsakanin ruwa da aka lalatar da iskar gas ba kawai game da farashi ba ne; akan rayuwar gajiyar kashi ne. Don sandan haɗin mota mai tsananin damuwa da muka yi aiki a kai, gas-atomized foda's spherical particles da ƙananan abun ciki na iskar oxygen ba za a iya sasantawa ba, har ma da ƙimar 30%. Nan ke nan ci-gaba foda karafa da gaske farawa-a matakin albarkatun kasa, tare da zurfin fahimtar yadda foda ilimin halittar jiki ke bayyana komai a ƙasa.
Sai a gauraya. Yana da sauƙi: haɗa foda na ƙarfe na tushe tare da graphite, mai mai, kuma watakila wasu jan ƙarfe. Amma samun haɗin kai mai kama da juna wanda ba ya rabuwa yayin jigilar kaya zuwa manema labarai ƙaramin sigar fasaha ce. Mun taɓa samun rukuni na sassa inda taurin saman ya kasance cikakke, amma ainihin yana da taushi. Ya ɗauki mako guda don gano shi zuwa ga hada-hadar mai a lokacin ɗan gajeren lokacin canja wuri. An bar tsarin 'ci gaba' ta hanyar wani matsala na sarrafa kayan aiki. Tunatarwa ce mai ƙasƙantar da kai cewa wannan fasaha tana zaune a mahadar sinadarai, kimiyyar lissafi, da injiniyan injiniya mai amfani sosai.
Wannan babban mayar da hankali kan kayan abinci shine dalilin da ya sa haɗin gwiwa tare da amintattun masu kaya ke da mahimmanci. Ba wai kawai game da siyan foda ba; game da samun tattaunawa ta fasaha akan daidaito-zuwa-yawa. Kamfani kamar Qingdao Qiangsenyuan Technology Co., Ltd. (QSY), tare da shekarun da suka gabata a cikin madaidaicin simintin gyare-gyare da machining, ya fahimci wannan sosai. Duk da yake ainihin su a https://www.tsingtaocnc.com yana ba da haske game da simintin gyare-gyaren harsashi da mashin ɗin CNC, wannan haɗin gwiwa na dogon lokaci tare da kimiyyar kayan aiki-musamman gami na musamman kamar waɗanda ke tushen nickel-yana fassara zuwa tushen mutunta kaddarorin kayan da ke fa'ida kai tsaye ga kowane fa'ida cikin samar da kayan ƙarfe ko ƙarewa.
Matsalolin Matsalolin Kayan aiki da Ƙarfin Koren
Tsarin kayan aiki don PM duniya ce ta kanta. Ba rami ba ne kawai; tsari ne na rarraba foda, damtse, da fitar da shi. Kuskuren daftarin aiki kadan ne, bambance-bambancen kauri na bango suna da wahala, kuma raguwa yawanci ba za a tafi ba sai dai idan kuna yin gyare-gyaren ƙarfe na ƙarfe (dan uwan PM). Mun tsara kayan aiki don sprocket tare da ɗan ƙaramin haƙori mai helical. A kan takarda, yana da kyau. A aikace, rashin daidaituwar rashin daidaituwa yayin fitarwa ya haifar da lamination na ɗan lokaci a cikin ɓangaren kore. Ba a iya ganin su har sai sun yi nisa, lokacin da suka buɗe kamar ƙananan laifuffuka. Dole ne mu koma baya, daidaita ƙarshen aikin kayan aiki da jerin fitar da kaya-kananan tweaks waɗanda suka ɗauki makonni biyu a cikin gwajin gwaji.
Ƙarfin kore-ƙarfin ɓangarorin da aka haɗa foda kafin ɓata-wani abu ne mai mahimmanci amma galibi ana mantawa da shi. Yana ƙayyade ko ɓangaren ku zai iya tsira ana sarrafa shi, cire foda, da kuma sanya shi a kan tire mai ƙima. Ya yi ƙasa da ƙasa, kuma yana crumbles; yayi girma sosai, kuma kuna iya yin taurin kai, wanda ke kawo nasa matsalolin. Na tuna da wani abokin ciniki daga masana'antar kayan aikin wutar lantarki wanda ke son ƙayyadaddun mahalli mai katanga. Mun sami ma'aunin lissafi, amma ɓangaren kore yana da rauni sosai don haka yana buƙatar tsarin sarrafa mutum-mutumi na al'ada. Sashin ya kasance nasara ta fasaha, amma tattalin arzikin samarwa ya zama kalubale. Wannan shine ci gaban da aka samu akai-akai ci-gaba foda karafa: tura iyakoki na geometrical yayin kiyaye ƙarfin samarwa.
Wannan shine inda haɗin gwiwa tare da mashin ɗin bayan-sinter ya zama mahimmanci. Sau da yawa, tsarin PM yana samun 95% a can, amma haƙuri mai mahimmanci ko fasali kamar ramukan zaren suna buƙatar injina. Samun ƙwararren machining a cikin gida, kamar ƙarfin CNC na QSY, babbar fa'ida ce. Ba kawai kuna yin ɓangaren PM ba; kana injiniyan hanyar masana'antu. Mashin ɗin yana buƙatar fahimtar tsarin kayan da aka ƙera-yana da ƙura, wanda ke shafar lalata kayan aiki da yanke ƙarfi daban-daban fiye da kayan da aka yi. Wannan ilimin rufaffiyar madauki daga karkatar zuwa mashin ɗin ƙarshe yana hana yawancin nunin yatsa da ɓarna.
Sintering: Inda sihiri da kurakurai suka faru
Sintering shine zuciyar tsari. Rawar zafi ce tare da lokaci, zazzabi, da yanayi. Madaidaicin murhun bel ɗin raga yana da kyau ga sassa da yawa, amma lokacin da kuka shiga ci-gaba foda karafa tare da manyan allunan aiki, galibi kuna kallon vacuum sintering ko yanayi mai tsananin matsi. Manufar ita ce ƙirƙirar haɗin ƙarfe tsakanin ƙwayoyin foda ba tare da narkar da komai ba. Ma'auni ne mai laushi.
Kulawar yanayi shine komai. Wani ɗan ƙaramin yatsa a cikin tanderun yanayi na hydrogen-nitrogen na iya shigar da iskar oxygen, wanda ke haifar da iskar oxygen da ke lalata sashin. Mun taɓa ɓata ɓangarorin abubuwan gami na tushen nickel don aikace-aikacen yanayi mai lalata. Gwajin yawa da taurin sun kasance cikakke bayan sinter. Amma a lokacin gwajin gishiri-gishiri na abokin ciniki, sun gaza da wuri. Mai laifi? Ƙaƙƙarwar da ba a iya ganowa a saman ƙasa, ƙananan ƙananan microns, wanda ya haifar da rashin daidaituwar yanayi yayin riƙe da zafin jiki. Gilashin tanderun sun nuna ɗan tsomawa cikin matsa lamba gas wanda za mu kore shi a matsayin hayaniya. Ya kasance darasi mai tsada a cikin taka tsantsan.
Yawan sanyaya wani lefa ne. Don wasu maki na karfe, zaku iya daidaita sashin sanyaya na tanderun don cimma takamaiman microstructure, yadda ya kamata yin maganin zafi a cikin layi. Wannan haɗin kai alama ce ta ci gaban matakai. Yana kawar da aiki na biyu amma yana buƙatar kulawa mai kyau. Yana tunatar da ni game da madaidaicin da ake buƙata a cikin ayyukan simintin saka hannun jari don ruwan injin turbine, inda sarrafa zafin jiki ke bayyana tsarin hatsi. Kamfanoni waɗanda suka ƙware ƙarfafa ƙarfin sarrafawa, kamar waɗanda suka ƙware a cikin simintin saka hannun jari (sabis mai mahimmanci don QSY), suna da ilhamar tsarin zafi wanda ke iya canjawa kai tsaye don ƙware madaidaicin lanƙwasa.
Bayan-Processing: Ƙarshen Yin-ko-Karshe
Mutane da yawa suna tunanin ana yin sashin ne bayan an gama. Nisa daga gare ta. Sassan ɓangarorin sau da yawa suna buƙatar ƙima (sake dannawa na ƙarshe), maganin tururi, zubar da mai, ko sutura iri-iri. Maganin tururi, alal misali, yana ƙirƙirar shingen magnetite (Fe3O4) wanda ke inganta taurin da juriya ga sassa na tushen ƙarfe. Amma idan zafin tururi ko lokaci ya ƙare, za ku sami oxide mara kyau, kuma sashin ya yi tsatsa maimakon a kare shi. Mataki ne na ƙarshe wanda ke buƙatar girmamawa kamar babban taron.
Ciwon mai ya zama ruwan dare don ɗaukar mai mai da kai. Manufar ita ce a cika haɗin haɗin gwiwa tare da mai. Yana jin kai tsaye, amma samun cikakkiya, rashin ciki iri ɗaya a cikin babban tsari yana da wahala. Mun yi amfani da tsarin da ba a iya cirewa ba, amma duk da haka, juzu'in juzu'i a cikin kwandon. Bangaren da ke da rami makaho na iya kama iska, yana haifar da busasshiyar wuri wanda ke haifar da lalacewa da wuri a cikin sabis. Magance wannan ba game da fasaha ba ne; yana game da ƙira mai ƙima da ingantaccen tsari.
Wannan hankali ga gamawa shine ke raba sashin da ke aiki da sashin da ke dawwama. Irin wannan falsafar da kuke gani a cikin manyan ayyukan simintin gyare-gyare da injina. Ƙimar ƙarshe ba kawai a cikin siffar kusa-net ba; yana cikin ingantaccen aiki. Lokacin da masana'anta kamar QSY suka jera aikinsu tare da cobalt da kayan haɗin nickel don aikace-aikacen buƙatu, yana nuna cikakken ikon ba kawai don ƙirƙirar ba amma gama wani sashi don tsira daga yanayin duniya na ainihi-ko ya fito ne daga simintin simintin gyare-gyare ko kuma ƙarancin PM ya mutu.
Gaskiyar-Duniya Fit da Gaskiyar Tattalin Arziki
Don haka yaushe ne ci-gaba foda karafa yi hankali? Ba shine kawai zaɓi ba. Kullum kuna yin la'akari da mashin ɗin daga hannun jari, simintin saka hannun jari, ko ƙirƙira. Wurin zaki yana da sarkakiya, manyan abubuwa masu girma inda amfani da kayan ke da mahimmanci. Yi la'akari da kayan aikin helical don watsawa: sarrafa shi daga sandar karfe yana lalata sama da 60% na kayan a matsayin kwakwalwan kwamfuta. PM na iya samun rabon kayan 95%. Lokacin da kuke yin dubunnan ɗaruruwan, wannan tanadin kayan yana biyan kayan aikin da sauri.
Amma ba don komai ba. Ƙananan juzu'i? Kudin kayan aiki yana kashe shi. Matsakaicin manyan sassa? Latsa ton kuma girman tanderun ya zama iyaka. Sassan da ke buƙatar matsananci, ductility isotropic? Abubuwan da aka yi har yanzu suna nasara. Makullin shine kima na gaskiya. Na yi magana da abokan ciniki daga yin amfani da PM lokacin da samfurin samfurin su na guda 500 bai tabbatar da kayan aikin $ 80k ba, yana jagorantar su a maimakon yin amfani da mashin ɗin ko ma daurin jetting don samfur. Manufar ita ce a yi amfani da kayan aikin da ya dace don aikin.
Sa ido, haɗin kai na fasaha shine inda aka samu na gaba. Haɗuwa PM preforms tare da ɗan dabaru na CNC machining, ko amfani da PM don ƙirƙirar musamman kayan hade (kamar jan karfe-infiltrated karfe don high conductivity da ƙarfi) da ba zai yiwu a yi ta wasu hanyoyi. A cikin waɗannan hanyoyin haɗin gwiwar ne zurfafan ƙwarewar masana'antu na kamfani ke zama mai kima. Ikon kallon wani ɓangaren zane kuma ba kawai ganin ɓangaren PM ba, amma duba hanya mai yuwuwa wanda zai iya haɗawa da PM don jiki, fasalin injina don zaren mai mahimmanci, da kuma na musamman shafi don juriya - wannan shine cikakke, ingantaccen wasan ƙarshe na ƙarancin ƙarfe na foda. Yana daina zama tsari na tsaye kuma ya zama kati mai ƙarfi a cikin faffadan ginshiƙan mafita na masana'anta.
