Lokacin da yawancin mutane a cikin masana'antar kera motoci suka ji 'simintin saka hannun jari na kera', suna tunanin manyan ƙafafun turbocharger ko rikitattun abubuwan watsawa. Wannan gaskiya ne, amma kuma shine inda kuskuren gama gari ya fara - cewa tsari ne kawai 'Premium' don sassa masu kyau. Gaskiyar da ke ƙasa ta fi damuwa kuma mafi ban sha'awa. Ba wai kawai game da sarƙaƙƙiya ba ne don sarƙaƙƙiya; yana da game da warware takamaiman, matsalolin samar da gnarly waɗanda wasu hanyoyin ba za su iya taɓawa ba tare da tsadar tuki ko jagorar lokaci ta cikin rufin ba. Na ga zane-zane da yawa sun shigo inda injiniyan ya ƙayyadad da simintin saka hannun jari saboda yana jin babban fasaha, kawai don mu dole mu dawo da su zuwa taron da aka hatimi wanda ya kasance 40% mai rahusa kuma 95% yana da kyau. Ƙimar gaske ba ta cikin lakabin; yana cikin sanin daidai lokacin da za a yi amfani da shi.
Tushen Tsarin: Inda Ka'idar ta Haɗu da Grime Foundry
Littafin karatun ya ce simintin saka hannun jari, ko simintin kakin zuma da aka rasa, yana ba da kyakkyawan ƙarewar ƙasa da daidaiton girma. Abin da littafin yakan yi haske a kai shi ne yawan adadin masu canji da za su iya rushe waccan alkawari. Yana farawa da tsarin kakin zuma. Samun zafin allura ko matsa lamba ba daidai ba ta ɗan ƙaramin gefe, kuma kuna gabatar da damuwa waɗanda kawai ke bayyana a matsayin murdiya bayan an harba harsashin yumbu kuma an zubar da ƙarfe. Na tuna wani aiki don mahalli na firikwensin inda muke da batch-to-batch mai girman 0.3mm. Ya ɗauke mu mako guda na bi - mold temp? lokacin sanyaya?—kafin mu iske canjin yanayi ne a cikin yanayin zafi yana shafar crystallization na kakin zuma. Wannan shine nau'in hannu-da-hannun-hannun-hannun-hannun-hannun-hannu-da-hannu-da-kusa-sani-ku-sani-ku-san-da-kai-a-kai-a-kai-a-kai-a-kai-a-kai-a-kai-a-kai-a-kai-a-kai-a-kai-a-kai-a-kai-a-kai-a-kai.
Sannan akwai ginin harsashi. Zagayowar tsoma-da-stucco alama madaidaiciya. Amma slurry danko, da bushewa yanayi (zazzabi da zafi, sake), da kuma sa refractory yashi ga kowane gashi-shi ne girke-girke da cewa kowane tushe gadi a hankali. Harsashi wanda ba shi da rauni sosai yana fashe a lokacin dewaxing ko zuba; wanda yayi kauri sosai baya zubewa da kyau kuma yana kaiwa ga hadawa. Mun taɓa yin aiki tare da sabon slurry na tushen zirconia don babban ɓangaren gami da nickel. Bayanan dakin gwaje-gwaje sun kasance cikakke. A kan tseren matukin jirgi na farko, rabin harsashi sun fashe. Batun? Matsakaicin haɓakar haɓakar thermal ya kasance ɗan kashi na kashi ɗaya daga cikin rigunan ajiyar ajiya, yana haifar da damuwa mai ƙarfi yayin babban zafin jiki na autoclave dewax. Komawa allon zane.
Zuba kanta wani lokaci ne mai mahimmanci. Tare da kayan kamar bakin karfe ko na tushen nickel, zafin zafi mai zafi da saurin zubowa suna da mahimmanci. Yi hankali sosai, kuma kuna samun hazo gudu ko sanyi rufe. Yayi sauri sosai, kuma kuna lalata cikin harsashi mai laushi, yana gabatar da abubuwan haɗa yumbu a cikin ɓangaren. Don abubuwan kera motoci kamar manifolds na shaye-shaye ko gidajen turbo, waɗanda ke ganin hawan keken zafi, haɗawa shine tabbacin gazawa. Ba wai kawai batun narkewar karfe ba ne; game da sarrafa yanayin yanayin zafi na gabaɗayan tsarin - mai ƙarfi, harsashi, iska na yanayi - a cikin taga na daƙiƙa 90.
Zaɓuɓɓukan Kayayyaki: Ba Ƙarfi kawai ba ne
Da yake magana game da kayan, yunƙurin da masana'antar kera motoci ke yi zuwa mafi sauƙi, mafi zafi, da ingantaccen tsarin ya haifar da haɓakar haɓakar haɓaka kai tsaye. simintin gyare-gyaren mota. Duk da yake ductile baƙin ƙarfe da carbon steels ne workhorses for brackets da tsarin guda, aikin yana cikin musamman gami. Ɗauki kayan aikin turbocharger. Suna wucewa fiye da maki na Inconel gama gari zuwa abubuwan da aka keɓancewa waɗanda ke daidaita juriya mai raɗaɗi tare da rayuwar gajiyar zafi. Amma ga abin da ya faru: waɗannan ci-gaba na alloys sau da yawa mafarki ne don jefawa. Suna da kunkuntar matakan ƙarfafawa, yana sa su zama masu saurin tsagewa. Babban abubuwan narkewa suna buƙatar ƙarin tsarin harsashi. Kamfanin da ya kewaya wannan tsawon shekaru, kamar Qingdao Qiangsenyuan Technology Co., Ltd. (QSY), yana yin amfani da dogon tarihinsa wajen yin simintin gyare-gyare da gyare-gyare don gina wannan ilimin. Abu daya ne a zuba maballin gwaji na cobalt gami; wani abu ne da a kai a kai samar da sirara mai katanga, hadadden mahalli na injin turbin tare da hanyoyin zubewar sifili.
Aluminum zuba jarin simintin gyaran mota shine nasa dabba. An tura shi da ƙarfi don rage nauyi-tunanin ruɗaɗɗen jikin magudanar ruwa ko shingen tsari. Amfanin shine 'yancin zane. Kuna iya haɗa tashoshi masu sanyaya, shugabannin hawa, da ƙarfafa haƙarƙari a cikin yanki ɗaya. Kalubalen shine porosity. Aluminum yana riƙe da iskar gas, kuma saurin ƙarfafa sassan bakin ciki na iya kama shi. Mun shafe watanni muna kan sitiyarin ƙwanƙwasa, muna tweaking tsarin gating, ƙara huɗa mai sanyi, har ma da yin gwaji da hanyoyin kawar da iskar gas daban-daban don narkewa kafin mu sami tsaftataccen simintin X-ray. Mai da hankali ne marar karewa akan daki-daki wanda ke raba kantin samfuri daga mai shirye-shiryen samarwa.
Sannan akwai post-casting. Mutane da yawa suna tunanin an yi aikin da zarar an girgiza sashin daga harsashi. Nisa daga gare ta. Maganin zafi sau da yawa ba za a iya sasantawa ba. Don mahimmin abu mai mahimmanci kamar dutsen caliper birki, takamaiman zafin jiki (kamar T6 don aluminium) dole ne a buga shi daidai a duk faɗin ɓangaren, wanda zai iya zama mai wahala tare da bambance-bambancen kauri. Wannan shine inda haɗin kai tsaye na mai kaya, kamar haɗin QSY na zuba jari kuma a cikin gida CNC machining, biya kashe. Za su iya haifar da ƙaramar murdiya amma da za a iya tsinkaya daga maganin zafi a cikin kayan aikinsu, suna ceton babban ciwon kai a ƙasa. Yin aikin simintin simintin gyare-gyare tare da hannun jari mai ma'ana shine girke-girke don karyewar kayan aiki da tarkace.
Matsakaicin Kuɗi: Tabbatar da Premium
Wannan yana haifar da babbar matsala a cikin mota: farashi. Kayan aikin simintin saka hannun jari (ƙarfe ya mutu don ƙirar kakin zuma) yana da tsada. Tsarin yana aiki ne da ƙarfin kuzari. Don haka, kuna buƙatar hujja mai ƙarfi. Nasarar al'ada ita ce haɗin gwiwa. Na yi aiki a kan bakin injin wanda asalinsa ƙirƙira ne na guntuwar ƙarfe guda shida masu hatimi da welded. Mun sake tsara shi azaman simintin saka hannun jari na aluminum guda ɗaya. Mun kawar da duk walda, rage lokacin taro, yanke nauyi da 15%, da ingantaccen tauri. Kudin simintin kashi ɗaya ya fi girma, amma jimlar farashin ƙasa, ƙididdigewa a cikin taro da dabaru, ya yi ƙasa. Wannan shine wuri mai dadi.
Wani dalili shine aikin da sauran hanyoyin ba zasu iya bayarwa ba. Wuraren sanyaya na ciki a cikin babban aikin birki caliper babban misali ne. Kuna iya gwada injin su, amma yana da tsada ta fuskar taurari. Kuna iya gwada simintin yashi, amma ƙarshen saman da daidaiton hanyar ba zai yi kyau ba, yana shafar ingancin sanyaya. Zuba jari ita ce hanya guda daya tilo. Yana da game da jimlar farashin tsarin da aiki, ba kawai farashin yanki akan ƙididdiga ba.
Tarkon ya wuce gona da iri. Na ga abubuwan haɗin gwiwa tare da juriya na +/- 0.5mm ƙayyadaddun azaman simintin saka hannun jari lokacin da simintin yashi mai kyau zai iya riƙe +/- 0.8mm daidai da ɗan ƙaramin farashi. Dole ne tattaunawar ta fara da aikin: Menene ainihin ma'auni mai mahimmanci? Menene lokuttan kaya? Menene yanayin lalata ko yanayin zafi? Sau da yawa, hanyar haɗaɗɗiyar hanya tana aiki mafi kyau-amfani da simintin saka hannun jari don mahimmanci, hadaddun ginshiƙan ɓangaren, da walda ko kulle akan sassa ƙirƙira mai sauƙi, mai rahusa. Rigidity a cikin zaɓin tsari shine injiniyoyin motoci na alatu ba za su iya ba.
Kasawar Duniya ta Gaskiya da Darussa
Kuna koyon ƙarin daga gazawa fiye da nasara. A farkon lokacin da nake ma'amala da wannan, muna da oda don bacin bakin karfe EGR bawul bawul. Buga ya yi kyau. Mun gudanar da samarwa. An wuce binciken labarin farko. Amma yayin gwajin matsin lamba na abokin ciniki, muna da ƙimar gazawar 30% daga ƙananan leaks. Bala'i. Tushen dalili? Ƙirar tana da ƙayyadaddun yanayin zafi mai kaifi daga flange mai kauri zuwa ɓangaren bututu na bakin ciki. Madaidaicin gating ɗinmu ya haifar da ɗan raguwar porosity a cikin yankin miƙa mulki. Gyaran ba wani tsari ba ne; tweak ne mai sauƙi na ƙira-ƙara ƙaramin radiyon fillet don haɓaka ƙarfafawar jagora. Mun kwashe kuɗin wannan rukunin. Darasin ya kasance mara gogewa: haɗin gwiwa na gaskiya tsakanin mai tsarawa da injiniyan injiniya a cikin DFM (Design for Manufacture) lokaci ba abu ne mai kyau ba; ita ce kadai hanyar yin simintin gyare-gyaren mota abin dogara da tattalin arziki.
Wani darasi ya fito daga samfurin isarwa na lokaci-lokaci. Mota yana gudana akan madaidaitan jadawali. Muna da cikakkiyar tsari don madaidaicin hannun hannu. Sa'an nan, mabuɗin mai samar da albarkatun kasa don tace yumbu (wanda aka yi amfani da shi a cikin tsarin gating) yana da ƙarancin lalacewa. Sabbin masu tacewa sun ɗan bambanta da yanayin kwarara. Ya isa ya canza tsarin cikawa, haifar da tashin hankali wanda ya haifar da fina-finai na oxide a cikin wuraren da ba su da mahimmanci amma na gani. Sassan sun kasance masu sauti na aiki, amma an ƙi su da gani. Ya dakatar da layin. Yanzu muna samar da mahimman abubuwan amfani guda biyu kuma muna da ka'idojin bincike masu shigowa don abubuwan da bamu taɓa tunanin bincikawa ba. Sarkar samar da kayayyaki wani bangare ne na tsari.
Waɗannan abubuwan sun nuna dalilin da yasa tsayin daka a cikin wannan fage ke da mahimmanci. Kamfanin da ke aiki sama da shekaru 30, kamar QSY, babu makawa ya ga waɗannan zagayowar - ƙarancin kayan aiki, hauhawar farashin makamashi, haɓaka ƙayyadaddun gami. Wannan ƙwaƙwalwar ajiyar cibiyoyi abu ne mai ma'ana. Wataƙila sun gina ingantattun tsare-tsare da tsare-tsare na ajiya don yanayin gazawar gama gari, wanda ke fassara kai tsaye zuwa dogaro ga abokan cinikinsu na kera. Ba wai kawai game da samun kayan aiki ba ne; game da samun zurfin ilimin abin da za a yi lokacin da, babu makawa, wani abu ya ɓace daga rubutun.
Kallon Kasa Hanya
Ina yake simintin gyare-gyaren mota ya nufi? Electrification shine babban direba, amma ba kamar yadda wasu suke tunani ba. Ee, yawan adadin sassan simintin na iya raguwa a cikin motar baturi da injin konewa na ciki. Babu ƙarin hadaddun kayan abinci da yawa ko abubuwan shaye-shaye. Koyaya, sauran sassan galibi suna da wahala. Yin nauyi ya fi mahimmanci don daidaita nauyin baturi, turawa don ƙarin aluminum da simintin gyare-gyaren magnesium tare da bangon sirara. Tsarin kula da yanayin zafi don batura da injina sun haɗa da hadaddun, hadedde hanyoyin ruwa waɗanda suka dace don simintin saka hannun jari.
Bugu da ƙari, tura fakitin baturi ko babba, haɗaɗɗen ƙananan firam ɗin abin hawa (megacastings) galibi yanki ne na babban simintin simintin gyare-gyare ko simintin yashi saboda girman. Amma a cikin waɗancan manyan majalisu, za a sami ƙarami, matsananciyar matsananciyar damuwa, da ƙwanƙolin ƙima ko masu haɗawa inda saka hannun jari zai iya zama mafita mafi kyau. Gaba ba shi da ƙaranci game da ƙara kuma ƙari game da ƙima-warware ƙayyadaddun, matsalolin matsananciyar wahala waɗanda sauran matakai masu girma ba za su iya ba.
Har ila yau, fasahar da ke cikin ginin ma'adanin tana ci gaba. Buga 3D na ƙirar kakin zuma ko ma harsashi na yumbu yana cire wasu ƙa'idodin gargajiya na kayan aiki, yana ba da damar haɓaka ƙirar ƙira da sauri. Amma yana gabatar da sababbin masu canji - mannewar Layer, halayen ƙona guduro. Wani kayan aiki ne, ba mai sihiri ba. Babban ƙa'idodin ƙarfe na ƙarfe, sarrafa zafi, da ƙirar gating har yanzu suna aiki. Ƙwarewar tushe daga shekarun da suka gabata na al'ada zuba jari shi ne abin da ke ba da kafaffen damar samun nasarar yin amfani da waɗannan sabbin fasahohin ba tare da faɗowa cikin sababbin ramuka masu tsada ba. Sana'a ce mai jujjuyawa, gwargwadon ilimin kimiyya.
