Lokacin da injiniyoyi suka bayyana a hadaddun karfe simintin factory, ba sa neman wani wuri ne kawai. Suna neman abokin tarayya wanda ya fahimci cewa juriya na 0.02 mm akan gidan AMS 5387 cobalt alloy famfo gidaje ba buƙatu ba ne - yanayin da ba zai yiwu ba don tsarin rayuwa a ƙarƙashin matsin lamba na 400 bar.
A QINGDAO QIANGSENYUAN TECHNOLOGY CO., LTD., Mun jefa da machined fiye da 12,000 musamman geometries don na'ura mai aiki da karfin ruwa bawul, piston famfo Silinda gidaje, da winch cibiyar shaft rollers-sassa inda microstructural rabuwa ko saura danniya na iya haifar da a-filin gazawar a cikin 300 aiki sa'o'i. Mun ga abokan ciniki sun canza masu kaya bayan batches guda uku a jere sun gaza tabbatar da CMM a cikin keɓantawar flange. Mun kuma ga sun tsawaita kwangiloli da shekaru biyu bayan bututun ƙarfe na farko na T800 na cobalt sun wuce gwajin zaizawar zagaye na 15,000 ba tare da juzu'i ba.
Me yasa "Hadadden" Ba kawai Game da Geometry ba-Yana Game da Sarrafa Ƙarfe
Gaskiyar rikitarwa tana farawa kafin a zubar da mold. Tushen famfo mai yashi na baƙin ƙarfe na iya zama mai sauƙi-amma idan ya ɗora famfon mai na 2,000 na HP, ƙididdige nodule ɗin sa na graphite dole ne ya tsaya tsakanin 120-160/mm², abun cikin sa na lu'u-lu'u ≥92%, da bambancin taurin sa a saman 1.2m baseplate da ke riƙe zuwa ± 3 HBW. Wannan matakin na daidaito yana buƙatar sa ido kan yanayin zafi na ainihin lokacin ƙarfafawa-ba kawai binciken bayan aiwatarwa ba.
Mun cusa ma'aunin zafi da sanyio kai tsaye cikin ƙoƙon ƙura don yin simintin gyare-gyare. Injiniyoyin tsarin mu suna daidaita yanayin zafi, ƙirar gating, da ƙimar sanyaya dangane da bayanan yanayin zafi mai rai-ba sigogin tsaye ba. Domin cobalt-nickel alloys kamar AMS 5387, muna preheat molds zuwa 850 ° C da kuma rike su na 90 minutes. Tsallake wannan matakin yana haifar da ƙananan porosity a iyakokin hatsi, wanda daga baya ya zama wuraren farawa a ƙarƙashin hawan keke.
Wannan horo yana bayyana dalilin da yasa simintin ƙarfe ɗinmu ya cimma maimaitawa na ± 0.015 mm akan m bores-ba kawai daidaito ba-kuma me yasa simintin bakin karfe ɗinmu ke kula da Ra ≤0.8 µm kamar yadda simintin simintin gyare-gyare akan saman rufewa, yana kawar da niƙa na biyu a cikin 68% na umarni.
Haɗin Kai Tsaye Wanda A Haƙiƙa Yana Bada Natsuwa Mai Girma
Yawancin shagunan "tsaya ɗaya" suna ba da magani ko ƙarewar zafi. Wannan yana haifar da gibin hannu: simintin gyare-gyare yana yin sanyi ba daidai ba bayan kashewa, sa'an nan kuma ya rikice yayin daidaitawar CNC. Muna sarrafa kowane mataki-daga ɗimbin albarkatun ƙasa zuwa gwajin aikin ƙarshe-a cikin wurin da aka tabbatar da ISO guda ɗaya.
- Yin wasan kwaikwayo: Simintin saka hannun jari don nozzles na bakin ciki mai bango; Yashi mai ɗorewa na simintin gyare-gyare na babban ginin famfo na ƙarfe har zuwa 1,800 kg
- Machining: 5-axis CNC tare da in-aiki bincike don Multi-surface jeri (misali, matching gunkin axis zuwa hawa fuska a cikin 0.008 mm jimlar karatun nuna alama)
- Maganin zafi: Vacuum annealing don T800 gami; tauraruwar yanayi mai sarrafawa don simintin bakin karfe na martensitic
- Ƙarshe: Electropolishing don juriya na lalata; harbi peening ga gajiya tsawon rayuwa a winch shafts
Lokacin da abokin ciniki na Turai ya buƙaci mahalli mara kyau na piston famfo Silinda tare da tashoshi masu sanyaya ciki da hakora na waje, mun fara yin simintin simintin gyare-gyare, sannan tabbatar da rarraba kauri na bango ta hanyar CT scanning-ba kawai gwajin ultrasonic ba. Kawai sai muka damke bangaren aikin injina. Sakamakon? Karɓar labarin farko a Tier-1 OEM audit. Babu sake yin aiki. Babu jinkiri.
Ingancin da Aka Gina A ciki-Ba a Duba shi ba
Ba mu jira binciken ƙarshe don kama al'amura. Kowane tsari yana ɗauke da cikakken abin ganowa: lambar zafi, rahoton bincike narke, ID na jefa kuri'a, sigar shirin CNC, ID na ma'aikaci, da rajistan ayyukan binciken CMM-duk an haɗa su ta lambobi. Idan bawul ɗin matsa lamba ya gaza gwajin hydrostatic, za mu ja ainihin zafin kayan da aka yi amfani da su a cikin simintin, sake yin gwaje-gwajen tensile, kuma mu kwatanta hotunan microstructure gefe da gefe tare da kuri'a da aka karɓa kafin.
Binciken mu mai shigowa ba akwatin-check ba ne. Don allunan cobalt, muna tabbatar da yardawar AMS 5387 ta amfani da sikirin sikirin OES-ba kawai certs na niƙa ba. Muna duba girman hatsi a kowane ASTM E112 akan kowane simintin kashi na uku. Muna yin gwajin shigar da rini akan duk wuraren da aka sanya hatimi-ko da ba a kayyade ba-saboda gwaninta yana nuna kashi 22% na kurakuran da suke fitowa kawai bayan samun sauƙi na machining na ƙarshe.
Wannan tsauri yana ba da sakamako masu aunawa: 99.4% na farko-farko yawan amfanin ƙasa akan abubuwan haɗin gwal na cobalt; filin sifili ya dawo don rashin daidaituwa mai girma a cikin 2023; da matsakaicin lokacin jagora na kwanaki 18 don yin simintin simintin samfur— ƙasa daga kwanaki 32 a faɗin masana'antu.
Haƙiƙa Haɗin Kai Ya Fara Kafin Zane Ya Kammala
"Za ku iya yin wannan?" shine tambayar farko kuskure. Abinda ya dace shine: "Me zai faru idan muka rage kaurin hakarkarin da 1.2 mm?" Muna gudanar da bita-da-kulli-ba a matsayin masu tsaron ƙofa ba, amma a matsayin masu haɗin gwiwa. Muna ba da alamar rikice-rikice na GD&T da wuri: haƙurin matsayi yana kiran ± 0.01 mm akan saman diamita na 200 mm, yayin da juriyar simintin tushe shine ± 0.3 mm. Muna ba da shawarar madadin ƙididdiga ko kusurwoyi da aka bita waɗanda ke adana aiki amma rage farashin da kashi 27%.
Muna tallafa wa abokan cinikin Arewacin Amurka, Turai, da Kudu maso Gabashin Asiya ta hanyar tattaunawa ta injiniya kai tsaye-ba ta matakan fassarar ba. Lokacin da mai yin famfo na Jamus ya sake fasalin jikin bawul ɗin su don rage nauyi, mun ba da shawarar canzawa daga 316 bakin karfe zuwa duplex 2205-ƙididdigar lalata iri ɗaya, ƙarfin 22% mafi girma na yawan amfanin ƙasa, kuma babu buƙatar maganin zafi bayan walda. Sun karbe shi. Umarninsu na gaba ya ninka.
Idan aikace-aikacenku ya buƙaci hadaddun karfe simintin factory iyawa ba kawai iyawa ba - kuna buƙatar horo na ƙarfe, sarrafa tsarin aiki, da rashin haƙuri don zato. Kuna buƙatar abokan haɗin gwiwa waɗanda ke kula da kowane simintin kamar yana riƙe da sanduna 400 na makamashin ruwa-ko adana ruwan haƙon teku a cikin zurfin mita 3,000. Wannan shine ma'aunin da muke ginawa. Kowace rana.
