Lokacin da injiniyoyi suka ƙididdige sassa don famfo na ruwa, bawul na filayen mai, ko tsarin winch mai nauyi, “haƙuri mai ƙarfi” ba kalmar tallace-tallace ba — buƙatu ne da ba za a iya sasantawa ba. Matsakaicin 0.01 mm a cikin kujerar cobalt alloy bututun ƙarfe na iya haifar da yashwar da wuri. Matsakaicin 0.025 mm a cikin gidan famfo na silinda na piston na iya haifar da asarar matsa lamba mai bala'i. Shi ya sa OEMs na duniya da masu samar da Tier-1 ba sa nemo kawai cnc ainihin machining sassa factory. Suna nemo wanda ke kula da kwanciyar hankali na juzu'i, daidaiton ƙarfe, da ingantacciyar aiki azaman fannonin da ba za a iya raba su ba.
Haƙurin gaske na duniya yana buƙatar fallasa gibin tsari-da sauri
Mun gan shi akai-akai: abokin ciniki yana ƙaddamar da zane mai wadatar GD & T don AMS 5387 cobalt alloy toshe, yana tsammanin ± 0.005 mm akan ƙwanƙwasa mai mahimmanci da matsayi na gaskiya a cikin 0.01 mm. Nau'in na farko ya wuce dubawa na gani-amma ya kasa gwajin kwarara a 3,000 psi. Me yasa? Domin mai samar da kayan aiki ya nada sashin *don bugawa*, ba *don aiki* ba. Sun tsallake tantance tarihin zafin rana bayan maganin zafi. Sun yi amfani da daidaitattun abubuwan da ake sakawa na carbide akan kayan tushen cobalt na T800-wanda ke haifar da ƙananan guntuwa a radii. Mun kama shi a lokacin binciken mu na CMM a aiki na biyu. Wannan shine lokacin da nazarin injiniya ya canza daga "Za ku iya yin shi?" "Yaya zamu bada garantin yin aiki?"
Hanyoyi huɗu na sarrafawa-ba ayyuka huɗu kawai ba
Ƙarfin haƙuri na gaskiya na gaskiya ba a sanya shi a saman injina na gaba ɗaya ba. An gina shi a cikin aikin aiki - daga takaddun shaida na kayan aiki zuwa gwajin aiki na ƙarshe. A QINGDAO QIANGSENYUAN TECHNOLOGY CO., LTD., wannan yana nufin:
- An gasa gano kayan abu a ciki: Kowane billet AMS 5387 yana zuwa tare da cikakkun rahotannin gwajin niƙa. Muna bincika sinadarai a kan ASTM A494 kuma muna tabbatar da tsarin hatsi ta hanyar aikin ƙarfe kafin a fara aikin mashin ɗin.
- Machining calibrated zuwa gami hali: Don abubuwan haɗin cobalt-nickel na T800, muna amfani da kayan aikin PCD da aka yi wa cryogenically da ƙimar ciyarwa da aka daidaita ta kowane batch-ba shirye-shiryen CNC na gabaɗaya ba. An tabbatar da ingancin saman saman tare da farar-haske interferometry, ba kawai karatun Ra ba.
- An tsara kayan aikin simintin gyare-gyare, ba a ɗauka ba: Iron da bakin karfe simintin gyare-gyaren annashuwa na kawar da damuwa *kafin* injin na ƙarshe-ba a taɓa yin hakan ba. Me yasa? Saboda ragowar damuwa a cikin simintin ginin famfo zai yi rauni a ƙarƙashin ƙarfi, yana kawar da jeri. Muna auna juzu'i kafin da bayan damuwa ta amfani da sikanin 3D na gani.
- Tabbatarwa na ƙarshe yana da alaƙa da ilimin lissafi na aikace-aikacen: Gidajen bawul ɗin matsa lamba baya samun rahoton CMM kawai. Yana samun gwajin hujja na hydrostatic a matsi mai ƙima na 1.5 ×, sannan duban mai shigar da rini akan duk wuraren rufewa. Babu ware.
Me ya sa "al'ada" bai kamata ya zama ma'anar "daidaitawa" ba
Wasu shagunan suna ɗaukar abubuwan da aka keɓance na al'ada a matsayin masu fita - waɗanda aka keɓe cikin lokacin injina tare da ƙaramin shirye-shirye. Wannan samfurin yana rushewa da sauri lokacin da ɓangaren ku ya kasance babban abin nadi na tsakiya mara daidaituwa don tsarin winch abin hawa: mai taurara zuwa HRC 58-62, tare da yanke yankewa a cikin ɓangarorin taurare 12, da buƙatun ƙarewar ≤0.4 μm Ra akan mujallu masu ɗaukar nauyi.
Mun sanya irin wannan ayyuka zuwa kwazo Kwayoyin — ma'aikatan da aka horar da a kan cobalt gami yarjejeniya, da goyan bayan metrology technicians bokan zuwa ISO 17025, da kuma goyan bayan wani zane tawagar m a ASME Y14.5 da ISO 1101. Lokacin da wani North American famfo OEM ya tambaye mu mu sake tsara su piston famfo Silinda gidaje, mu inganta zuba jari a + hybrids. Multi-axis machined bayani. Mun riƙe tashoshi masu sanyaya na ciki na simintin gyare-gyare (wanda ba zai yuwu don yin simintin simintin gyaran na'ura ba) yayin da muke ƙara haɓakar juriyar juriya ta waje ta hanyar niƙa 5-axis. Lokacin jagora ya ragu da kashi 22%. Nauyi ya tsaya iri ɗaya. Aiki ya karu da kashi 17% a gwaje-gwajen hawan keke na thermal.
Abin da “abokiyar dogaro” ke bayarwa a zahiri-bayan maganar
Amintaccen abokin haɗin gwiwa yana haifar da haɗarin ƙirƙira *kafin* yankan ƙarfe-ba bayan faɗi ba. Muna dawo da zane-zane tare da bayanin yuwuwar GD&T: "Wannan matsayi na gaskiya ya ci karo da daftarin kusurwa-ba da shawarar sake matsugunin datum B zuwa saman na'ura." Ko: "T800 abu a cikin wannan ɓangaren bango na bakin ciki zai buƙaci tallafi yayin kammalawa; bayar da shawarar ƙara haƙarƙari na wucin gadi (magani mai cirewa bayan zafi)."
Wannan ba ɓacin rai ba ne. Yana da guje wa farashi. Ɗaya daga cikin abokin ciniki na Turai ya guje wa $84,000 ta hanyar karɓar shawararmu don canzawa daga simintin yashi zuwa simintin saka hannun jari don jikinsu na cobalt alloy bututun ƙarfe-dangane da bambancin bayanan kauri daga bangon da suka rigaya. Wani ceton makwanni 3 ta hanyar ɗaukar tsarin maganin zafin da aka ba mu shawarar, wanda ya kawar da matakin daidaitawa na biyu.
Wannan tsarin yana da ma'auni. Ko kuna buƙatar samfura guda 3 don tabbatarwa ko raka'a 1,200 / shekara na bawul ɗin matsa lamba, ƙa'idar dubawa ta kasance iri ɗaya. Abubuwan gano kayan suna zama iri ɗaya. Injiniyan da ke nazarin zanen ku ya yi aiki akan sassan AMS 5387 na tsawon shekaru 11-ba watanni 11 ba.
Neman gaba: inda daidaito ya hadu da tsinkaya
Iyaka ta gaba ba ta fi ƙarfin haƙuri kaɗai ba. Yana da ƙaƙƙarfan haɗin kai tsakanin kimiyyar abin duniya, injiniyoyin kimiyyar lissafi, da ingantaccen aiki. Muna faɗaɗa R&D akan ɗimbin aikin simintin gyare-gyare-machining workflows don hadaddun taron famfo-da gina iyawar ciki don tabbatar da hasashen rayuwar gajiyawa game da bayanan sabis na duniya na ainihi daga abokan fage.
Idan aikace-aikacen ku yana buƙatar maimaita juzu'i na 0.01 mm akan superalloys, daidaitaccen tsarin ƙayyadaddun ƙayyadaddun ƙayyadaddun raka'a 500, ko isar da sifili akan mahimmin abubuwan haɗin hydraulic - kuna buƙatar fiye da guda ɗaya. cnc ainihin machining sassa factory. Kuna buƙatar abokin tarayya wanda ma'anar "madaidaicin" ya fara inda zane ya ƙare.
