Zabar dama sashi na simintin gyare-gyare ba game da zabar mafi arha ba. Yana da game da daidaita halayen ƙarfe, kwanciyar hankali mai girma, da sarrafa tsari zuwa matsi na ainihi-matsi mai ƙarfi, hawan keke na zafi, lalacewa. Mun ga gidaje da yawa na famfun ruwa suna fashe a psi 3,000 saboda ba a tabbatar da jurewar simintin yashi a kan kiran GD&T ba. Wasu sun kasa gwajin aiki bayan maganin zafi-ba daga zaɓi mara kyau ba, amma ƙimar sanyaya mara daidaituwa a cikin kogon mold. Madaidaici da ingantaccen farashi ba sa gasa. Suna haɗuwa lokacin da ake yin simintin gyare-gyare, zaɓin kayan aiki, da injinan simintin simintin gyare-gyare suna aiki azaman tsari ɗaya.
Fara da Hanyar Load-Ba Zane ba
Kowane high-mutunci sashi na simintin gyare-gyare ya fara da yadda karfi ke bi ta cikinsa. Gidajen silinda na piston ba wai kawai yana riƙe da ruwa ba - yana canza juzu'i, yana ƙunshe da lodin radial daga majalisai masu jujjuyawa, kuma yana tsayayya da tursasawa axial yayin hawan matsin lamba. Wannan yana canza komai: rarraba kauri na bango, wuri mai tashi, gating geometry. Mun taɓa sake fasalin jikin bawul ɗin cobalt-alloy don famfo mai laka ta hanyar canza babbar kofa daga sama zuwa gefe. Sakamako? An kawar da microporosity a cikin yanki mai mahimmanci na rufe kafada-da yanke guntun kayan aikin bayan-machining daga 18% zuwa 2.3%. Me yasa? Domin karfe yana gudana daidai da hanyar lodi, ba akansa ba.
Wannan ba ka'idar ba ce. Yana nufin ƙayyadadden mafi ƙarancin kauri na sashe * kowane yanki mai aiki*, ba kowane sashi ba. Yana nufin bitar daftarin kusurwoyi ba don sakin ƙira kaɗai ba-amma don yadda suke shafar maida hankali a ƙarƙashin hawan keke. Kuma yana nufin zalunta izinin raguwa ba a matsayin ƙayyadaddun kaso ba, amma a matsayin ma'auni mai alaƙa da lokacin ƙarfafawar gida da ƙaramar ƙarami.
Zaɓin Abu ne Tsari Tsari-Ba Takaddun Takaddun Takaddar Ba
AMS 5387 cobalt alloy bai "mafi kyau" fiye da ductile iron ba. Amsar da ta dace ce kawai lokacin da ku sashi na simintin gyare-gyare dole ne ya riƙe ƙarfin amfanin ƙasa sama da 650°C *kuma* tsayayya da fashewar damuwa na sulfide a cikin mahalli mai tsami. Amma irin wannan gami yana buƙatar kulawar damshin kyallen takarda a cikin simintin yashi-kuma yana gabatar da mummunan lalacewa idan aka yi amfani da shi ba tare da ingantaccen isar da sanyaya ba da zaɓin ƙimar carbide.
Muna bin abubuwan da ba za a iya sasantawa ba don kowane yanke shawara na abu:
- Batch ganowa komawa zuwa lambar zafi da ingantattun rahotannin gwajin niƙa-ba kawai “ya bi ASTM A487 ba”
- Tabbatar da ƙananan tsarin ta hanyar samfurori masu sassa daban-daban don yankuna masu mahimmanci (misali, girman hatsi a cikin filaye masu ɗaukar hoto na winch center shaft rollers)
- Tabbatar da magani bayan zafi ta yin amfani da taswirar taurin kai a cikin hadaddun kwandon shara, ba kawai gwaje-gwajen Rockwell-maki ɗaya ba
Lokacin da abokin ciniki na Turai yana buƙatar simintin ƙarfe na bakin karfe don tushen famfo ruwan teku, mun gudanar da gwaje-gwajen juzu'i akan batches biyar daban-daban - duk da cewa duk sun hadu da ASTM A743 Grade CF8M. Bashi ɗaya ya nuna ƙarancin haɓakar 12% a lokacin hutu saboda ƙaramar gangariyar rabon Mn/Si. Wannan rukunin bai taɓa barin filin ginin mu ba.
Haɗin kai yana Buga Hannu-Kowane Lokaci
Rarrabe simintin gyare-gyare daga injina yana haifar da ɓoyayyiyar kuɗi: sake yin aiki daga walƙiya mara amfani, ɓoyayyiyar sassa saboda ƙarancin ƙasa da ba a gano ba, jinkirta isar da saƙo daga ƙa'idodin dubawa mara kyau. A QINGDAO QIANGSENYUAN TECHNOLOGY CO., LTD., CNC machining kayan aiki an tsara su *lokacin * ci gaban tsari-ba bayan an gama simintin gyaran kafa ba. Masu shirye-shiryen mu na CMM suna karɓar bayanan sikanin 3D daga ƙera kore-yashi * kafin* fara zubowa. Me yasa? Don hango ko hasashen inda ainihin motsi zai ture girma daga juriya - da daidaita aikin injina a hankali.
Wannan haɗin kai tsaye yana ba da sakamako masu aunawa:
- Matsayin kwanciyar hankali ya inganta ta 40% akan jikin bawul ɗin matsa lamba yana buƙatar jurewar matsayi na ± 0.025 mm
- Matsakaicin ƙarewar saman da aka ɗaga daga Ra 3.2 µm zuwa Ra 1.6 µm akan bututun ƙarfe na cobalt-alloy - ba tare da niƙa na biyu ba.
- Rage lokacin jagora na kwanaki 11-17 akan umarni matsakaici, wanda aka tabbatar a cikin ayyuka 42 a cikin 2023
Hakanan yana nufin ƙin zanen "mai kyau". Lokacin da wani abokin ciniki na Arewacin Amurka ya aiko mana da taswirar GD&T tare da madaidaitan bayanan datum don gidan famfo na T800 alloy, mun dawo da sigar alama wacce ke nuna daidai waɗanne fasalulluka za su shuɗe ƙarƙashin haɓakar thermal — kuma mun ba da shawarar wasu madaidaicin tsarin datum guda biyu waɗanda ke goyan bayan sakamakon kwaikwayo na FEA.
Ƙimar Kuɗi yana Rayuwa a cikin Bayanan da kuke Sarrafa
Ƙimar farashi na gaskiya yana farawa kafin a zubar da ladle na farko. Yana zabar saka hannun jari a kan yashi don ƙaramin cobalt-alloy toshe-ba don yana da “kyau ba,” amma saboda yana kawar da sa’o’i 3.5 na ɗaurin hannu a kowane ɓangare kuma yana rage lokacin dubawa na ƙarshe da kashi 60%. Yana ƙayyadaddun abubuwan haɗin harsashi na tushen ZrO₂ don simintin simintin AMS 5387 don guje wa ɓarnawar saman da ke haifar da sodium yayin lalata. Yana sarrafa tsarin ƙididdiga akan zafin jiki * da * zafi na yanayi-ba kawai narke zafin jiki ba.
Muna auna farashi ba dala a kowace kilogiram ba, amma a cikin jimlar farashin kowane ɓangaren da ya cancanta da aka kawo. Wannan ya hada da:
- Ƙimar ƙira mai alaƙa da lahani masu alaƙa da simintin gyare-gyare (porosity, rufewar sanyi, haɗawa)
- Ƙaddara lokacin aiki na biyu saboda rashin daidaito kamar simintin lissafi
- Sa'o'in aikin injiniya sun yi amfani da su don magance rashin daidaituwa tsakanin matakan simintin gyaran kafa da injiniyoyi
- Kudin dabaru na kayan maye gurbin jigilar kaya bayan gazawar filin
Ga ɗaya daga cikin injiniyoyin abin hawa winch shaft na abokin ciniki na kudu maso gabashin Asiya, sauyawa daga daidaitaccen ƙarfe mai launin toka zuwa EN-GJS-600-3 ductile iron wanda aka gyara - haɗe tare da sanyaya mai sarrafawa da rage damuwa - yanke farashin kiyaye rayuwa da kashi 37% duk da 22% mafi girman farashin simintin farko.
Babban aiki sashi na simintin gyare-gyare masana'anta suna buƙatar fiye da kayan aikin tushe ko injinan CNC. Yana buƙatar injiniyoyi waɗanda suka riƙe bawul ɗin ruwa mai fashe a hannunsu da ƙarfe 2 na safe kuma suka gano gazawar zuwa ƙirar hawan. Yana buƙatar masanan ƙarfe waɗanda suka san yadda vanadium carbides ke nuna halayen T800 a yayin canjin jiha mai ƙarfi. Yana buƙatar tsarin inganci waɗanda ke ɗaukar kowane wurin dubawa azaman madaidaicin amsa-ba mai tsaron ƙofa ba. Makomar ta abokan hulɗa ce waɗanda ke ganin yin simintin ba a matsayin mataki na tsaye ba, amma a matsayin ginshiƙi na madaidaicin tsarin rayuwar gaba ɗaya—daga narkakken ƙarfe zuwa aikin manufa mai mahimmanci.
