Leveler shaft rollers da rollformer kayayyakin gyara da kyar suke kasawa saboda dalili guda, tabbataccen dalili. A cikin ci gaba da layukan galvanizing, abin nadi wanda ya yi kama da aikin da za a iya amfani da shi a kan zane zai iya ƙarewa a cikin makonni-ko kuma ya haifar da tsayawar layi lokacin da ɗaukar hoto ya kama kuma nadi ya sauko daga gidansa. Bambanci tsakanin abin nadi wanda ke dawwama da wanda ya zama ciwon kai na kulawa yawanci yakan sauko zuwa yanke shawara guda biyu da aka yanke tun kafin sashin ya kai ga layin: yadda aka gano yanayin gazawar, da kuma ko kayan da jiyya a zahiri sun dace da yanayin aiki.
Wannan jagorar yana bincika manyan hanyoyin gazawa a cikin rollformer da rollformer, zaɓin kayan da taurin da ke magance su, da buƙatun geometric waɗanda ke ƙayyadaddun ko sabon ɓangaren kayan aikin yana yin yadda aka yi niyya ko ya zama gazawar maimaitawa ta gaba.
Me yasa Leveler Shaft Rollers ya gaza a Layin Galvanizing
Mataki na farko na tantance abin nadi shine fahimtar abin da a zahiri ya gaza. A cikin matakan tashin hankali na galvanizing, hanyoyin gazawar biyu sun mamaye, kuma suna buƙatar mafita daban-daban.
Roll surface lalacewa da spalling. Rubutun aikin yana tuntuɓar tsiri ƙarƙashin ƙarfi da lanƙwasawa. Lokacin da siffar tsiri ba ta da kyau - taguwar ruwa ta gefe, buckles na tsakiya, ko ƙwanƙwasa walda - saman nadi yana ɗaukar tasiri mai tasiri da abrasive lamba. Bincike kan jujjuyawar aikin matakan tashin hankali yana gano ɓarna a matsayin tsarin sawa na farko, tare da lahanin siffar tsiri mai zafi da aka ambata a matsayin babban abin da ke haifar da lalacewa mara kyau. Sikeli da al'amuran waje da aka kama tsakanin jujjuyawar aiki da nadi na baya suna haifar da matsala, suna haifar da rashin ƙarfi da lalacewar saman da ke jujjuyawa zuwa tsiri. A cikin lokuta masu tsanani, alamun jujjuyawa ko lahani na ƙasa na iya yaduwa zuwa abubuwan da suka faru, ko da a ƙarƙashin ƙaramin juzu'i na mirgina masu daidaitawa.
Rashin gazawar juzu'i da jujjuyawa. Yanayin gazawa na musamman ga ƙungiyoyin lanƙwasa matakan tashin hankali ya cancanci kulawa daban. Bincike a cikin ci gaba da layukan galvanizing ya nuna cewa sojojin axial da ke aiki a kan ƙarshen aikin nadi yana haifar da ci gaba. Da zarar igiyar gefe ɗaya ta yi kyau sosai, kishiyar juzu'i na iya tserewa daga hannun goyan bayan sa - wanda ya haifar da faɗuwar juzu'i daga gidan, da zazzage tsiri, kuma yana iya haifar da karya layi. Wannan ba matsalar jiki ba ce. Al'amari ne na matakin tsarin da ya ƙunshi zaɓin ɗaukar hoto, ingancin taro, da sarrafa nauyin axial. Maye gurbin abin nadi ba tare da magance yanayin ɗawainiya da daidaitawa ba ba zai hana sake dawowa ba.
Ma'anar aiki mai sauƙi ce: kafin yin odar maye gurbin abin nadi, tabbatar ko ɓangaren da ya gaza ya nuna lalacewa-mamaye ko lalacewar mu'amala. Tsohuwar tana nuni zuwa ga haɓaka kayan abu da taurin; na karshen yana buƙatar sake duba taron da ke kewaye.
Zaɓin Abu don Leveler da Rollformer Rolls
Zaɓin kayan abu don masu daidaitawa da rollformer rollformer shine ma'auni tsakanin juriya na lalacewa da ainihin tauri. Garin da aka taurare tare da babban carbon da abun ciki na chromium yana tsayayya da abrasion amma yana iya zama mai karyewa ƙarƙashin nauyin lanƙwasawa. Ƙarfe-ƙarfe mai ƙaƙƙarfan ƙarfi mai kyau na iya yin sawa da sauri a saman. Zaɓin daidai ya dogara da wane yanayin gazawar ya mamaye.
High-carbon chromium karfe kamar nau'in nau'in GCr15 sun zama ruwan dare a aikace-aikacen nadi inda lalacewa ta jiki shine babban abin damuwa. Suna amsa da kyau don taurare kuma suna iya cimma taurin ƙasa a cikin kewayon HRC 58-62, yana sa su dace da jujjuyawar aiki waɗanda ke tuntuɓar sikeli ko gurɓataccen oxide. A cikin tashoshi masu ƙira, maki iri ɗaya suna bayyana azaman kayan abin nadi, galibi tare da platin chrome mai wuya don ƙarin kariya ta saman.
Alloy kayan aiki karafa irin su 9Cr2Mo da nau'in nau'in 60CrMoV suna ba da ma'auni daban-daban. Suna samar da isasshiyar juriya tare da mafi kyawun tauri fiye da ma'aunin chromium-carbon, yana sa su fi dacewa inda kayan lanƙwasa suna da mahimmanci kuma dole ne jujjuyawar ta yi tsayayya ba tare da fashewa ba. Don aikace-aikacen masu daidaitawa inda aka iyakance diamita na nadi ta hanyar lissafi na mahalli, wannan tauri tabarbare yana da mahimmanci.
Alloys na tushen Cobalt shigar da hoton lokacin da yanayin aiki ko bayyanar sinadarai ya zarce abin da abubuwan haɗin ƙarfe na ƙarfe za su iya jurewa. An lura da daidaitattun 42CrMo4 rollers suna fashe a cikin mahalli masu wadatar sulfide, yayin da AMS 5387 cobalt alloy ke tsayayya da galling a yanayin zafi mai tsayi kuma yana kiyaye kyakkyawan yanayin ƙasa bayan niƙa. Wannan baya nufin cobalt alloys sune tsoffin haɓakawa ga kowane layin nadi na galvanizing. Su ne mafita da aka yi niyya don yanayin da hawan keken zafi ko lalatawar kafofin watsa labarai ke lalata karafa na al'ada da sauri fiye da lalacewa na inji kadai zai iya hasashen.
Rollformer kafa nadi yi aiki a ƙarƙashin fifiko daban-daban. Lankwasawa da kafa lodi sun mamaye, kuma galvanizing-line thermal falling ba ya nan. Ƙayyadaddun kayan aikin masana'antu yawanci suna lissafin GCr15 ko AISI 1045 karfe don ƙirƙirar rolls, tare da tauri a cikin kewayon HRC 58-62 da zaɓin chrome plating. Muhimmin abin da ake buƙata don rollformer rollformer shine daidaiton bayanin martaba da daidaiton girma a cikin saitin nadi, ba yanayin zafi mai girma ba.
Tauraruwar Sama da Zaɓuɓɓukan Jiyya
Da zarar an zaɓi kayan tushe, jiyya na saman yana ƙayyade tsawon lokacin da nadi ya ƙi sawa kafin ya isa iyakar maye gurbinsa.
Ƙunƙarar ƙaddamarwa ya kasance daidaitaccen tsarin kula da madaidaicin aikin rolls. Manufar ita ce shimfidar wuri mai wuya (yawanci HRC 58-63) wanda ke da goyan bayan babban tushe mai ƙarfi. Zurfin taurin yana buƙatar hukunci: mai zurfi sosai kuma shari'ar ta sawa ta hanyar ko spalls a ƙarƙashin kaya; ma zurfi da saura damuwa ko brittleness yana ƙaruwa. A matsayin jagororin aikin injiniya na gabaɗaya, ana adana ingantaccen shari'ar sau da yawa a cikin 5% zuwa 10% na diamita na juzu'i, amma takamaiman shawarwari masu zurfi yakamata su fito daga masana'anta na nadi dangane da bayanan aikace-aikacen, ba daga tebur na gabaɗaya ba.
Hard chrome plating yana yin amfani da dalilai guda biyu a cikin rollformer da rollformer. Yana ba da ƙasa mai ƙarancin jujjuyawa wanda ke rage lalacewa mai ɗaurewa da ɗaukar kayan, kuma yana ba da kariya ta lalata a cikin mahalli inda zuriyar zinc ko danshi yake. Ana samun juzu'in aikin matakan tashin hankali na kasuwanci tare da babban taurin chrome plating a kauri a kusa da μm 65, haɗe tare da ƙayyadaddun ƙayyadaddun yanayi. Don Rollformer Rolls da ke aiki akan galvanized ko fenti da aka riga aka yi, rufin chrome na kusan 0.05 mm ƙayyadaddun abu ne na kowa.
Ikon gamawa saman ba ya rabuwa da taurin kai da sutura. Ƙaƙƙarfan ƙasa amma mai ƙasƙanci zai iya ɗaukar ma'auni kuma yana sawa da wuri. Akasin haka, ƙasa mai santsi fiye da kima na iya rage ƙwanƙwasa tsiri a wasu matakan daidaitawa ko ƙirƙira ta hanyar wucewa. Rashin dacewar da ta dace ya dogara da tsarin: aikin nadi na tuntuɓar tsiri yawanci yana ƙayyadadden ƙayyadaddun ƙayyadaddun ƙayyadaddun ƙayyadaddun ƙayyadaddun bayanai, yayin da jujjuyawar ajiya ko naɗaɗɗen jagora na iya jure wa filaye masu ƙarfi. Ayyukan ma'aunin tashin hankali na kasuwanci yana mirgine lissafin yanayin ƙasa mai kyau kamar Ra 0.2 μm ko ƙasa don wasu aikace-aikace, amma bai kamata a kula da wannan azaman manufa ta duniya ba.
Haƙuri da Abubuwan Bukatun Sama waɗanda ke Shafi Rayuwar Rubutu
Ingantacciyar yanayin juzu'i na abin nadi mai ma'auni ba wai kawai tsiri mai laushi ba yana shafar rayuwa da kuma yanayin lalacewa na nadi.
Roundness da cylindricity kai tsaye yana tasiri yadda kaya ke rarrabawa a duk faɗin abin ɗauka da faɗin tsiri. Rubuce-rubucen tare da ƙarancin zagaye zai sanya nauyin radial na cyclic akan abubuwan da ke cikin sa tare da kowane juyin juya hali, yana haɓaka gajiya. Ana ba da jujjuyawar aikin kasuwanci don masu daidaita tashin hankali tare da juriya mai ƙarfi kamar 0.010 mm ko ƙasa, da juriya na cylindricity a cikin kewayon 0.005-0.01 mm. Waɗannan alkaluman suna wakiltar madaidaicin samfuran ƙasa, ba ƙarfin injin gabaɗaya ba, kuma yakamata a ƙayyade kawai lokacin da aikace-aikacen ya tabbatar da farashin.
Runout madauwari yana rinjayar rawar jiki da bin diddigin tsiri. Nadi wanda ya ƙare gaskiya zai haifar da bambancin kauri na lokaci-lokaci ko alamar ƙasa. Irin ƙayyadaddun kasuwanci iri ɗaya suna lissafin juriyar juriyar runout madauwari ta 0.010-0.018 mm.
Daidaiton diamita a fadin saitin nadi buƙatu ne da ake mantawa akai-akai. A cikin ma'auni ko rollformer, nadi da yawa suna aiki a jere. Idan jujjuyawar maye ta bambanta da diamita daga saitin asali, saitunan rata da alaƙar mirgina suna canzawa, suna shafar duka sakamakon tsari da rarraba kaya tsakanin rolls. Wannan juriya ce ta matakin tsarin, ba juriyar juzu'i ɗaya ba, kuma yakamata a magance shi cikin ƙayyadaddun sayan.
Ƙunƙarar saman yana buƙatar daidaitawa da aikace-aikacen maimakon rage girman. Yayi tauri sosai kuma rubutun yana nuna tsiri; santsi mai santsi kuma ƙwanƙwasa na iya zama rashin isa a wasu fastoci. Domin galvanizing line leveler rolls, da dace kewayon dogara a kan tsiri kauri, tashin hankali, da kuma ko nadi na aikin yi ko madadin yi.
Rollformer Shaft Rollers da Samar da Rolls: Ayyuka daban-daban, Babban fifiko daban-daban
Rollformer shaft rollers da kafa nadi suna raba sunan "nadi" tare da abubuwan da aka gyara, amma yanayin aikinsu da ƙayyadaddun abubuwan fifiko suna bambanta ta hanyoyi masu mahimmanci.
Leveler roller a cikin layukan galvanizing suna gwagwarmaya tare da haɓakar yanayin zafi, gurɓataccen zinc, da buƙatar murkushe sikelin yayin lanƙwasa tsiri. Rollformer yana yin nadi, da bambanci, tsiri mai siffa ta cikin jerin tashoshi a yanayin zafi. Hanyoyin gazawar su mafi rinjaye sune lalacewa daga saman tsiri da gajiya daga maimaita hawan keke, ba lalatawar thermal ko lalata zinc ba.
Wannan bambance-bambance yana canza kayan aiki da mahimmancin magani. Rollformer form Rolls yawanci ana amfani da GCr15 ko AISI 1045 karfe tare da taurin zuwa HRC 58-62 da chrome mai wuya na zaɓi. Shafts a rollforming kayan aiki sau da yawa ana kayyade a matsayin 40Cr ko AISI 1045 karfe tare da tempering jiyya, nuna bukatar torsional ƙarfi da gajiya juriya maimakon surface lalacewa juriya kadai.
Don Rollformer Rolls, daidaiton bayanan martaba da saita daidaito suna ɗaukar nauyi fiye da zaɓin gami da zafin jiki. Rollformer wanda ke samar da bayanin martabar rashin haƙuri saboda an ƙera nadi mai maye zuwa wani kwane-kwane daban-daban zai haifar da tarkace ba tare da la'akari da yadda kayan ke da juriya ba. Ƙayyadaddun ya kamata ya ba da fifiko ga girman bayanan ƙirƙira da alaƙar girma tsakanin nadi a tashar.
Daidaita Magani zuwa Yanayin gazawa: Tsarin Aiki
Abubuwan da zaɓuɓɓukan magani da ke sama suna zama masu amfani kawai lokacin da aka haɗa su da ainihin gazawar da aka lura akan layi. Tsarin da ke gaba yana tsara tsarin yanke shawara.
Idan saman nadi yana nuna lalacewa, zura kwallo, ko gogewa: Bukatar farko ita ce taurin saman sama tare da isasshen ƙarfi. Yi la'akari da chromium mai ƙarfi mai ƙarfi ko ƙarfe kayan aiki na gami, tabbatar da cewa hardening induction ya kai ga ƙayyadadden zurfin yanayin, da kuma sake duba ƙarewar saman. Idan ma'auni ko al'amuran waje shine tushen ɓarna, haɓaka tsabtace tsiri ko yanayin juzu'i na iya zama mahimmanci kamar canza kayan nadi.
Idan saman nadi ya nuna spalling, pitting, ko subsurface fashe: Taurin saman saman ba zai magance wannan ba. Bincika lahani na ƙasa a cikin kayan da ke shigowa, bitar tsarin taurara don zurfin yanayin da ya wuce kima ko rashin isassun zafin jiki, da bincika ko nauyin tasirin da ba na al'ada ba (weld seams, nakasar siffa) yana fara lalacewa. Ana iya buƙatar wani abu mafi ƙarfi ko ƙayyadaddun ƙayyadaddun taurare da aka sake fasalin.
Idan gazawar tana ɗauke da kamawa ko jujjuyawa: Kar a saka sabon abin nadi har sai an sake duba yanayin ɗaukar nauyi, nauyin axial, da jeri na taro. Littattafan madaidaicin tashin hankali yana gano ƙarfin axial akan goyan bayan goyan baya a matsayin tushen sanadin faɗuwar al'amura. Nadi mai maye gurbin da aka shigar a cikin mahalli mara kyau zai gaza daidai da na asali. Ayyukan gyaran gyare-gyare sun haɗa da nau'in bita na nau'in nau'in nau'in nau'in nau'in nau'in nau'in nau'in nau'in nau'in nau'in nau'in nau'in nau'i nau'i nau'i nau'i nau'i nau'i nau'i nau'i nau'i nau'i nau'i nau'i nau'i nau'i nau'i nau'i nau'i nau'i nau'i nau'i nau'i nau'i nau'i nau'i nau'i nau'i nau'i nau'i nau'i nau'i nau'i nau'i nau'i nau'i)), ingantattun hanyoyin haɗuwa, da aiwatar da gyare-gyaren ma'auni don rage nauyin axial.
Idan tsiri flatness ko ingancin saman ya lalace ba tare da bayyananniyar lalacewa ba: Bincika daidaiton diamita na nadi a cikin saitin, zagaye da gudu na juzu'in nadi guda ɗaya, da yanayin jujjuyawar ajiya. Nadi mara kyau amma ba a sawa ba zai iya samar da tsiri da ba za a yarda da shi ba.
Tambayoyin da ake yawan yi
Ta yaya madaidaicin shaft abin nadi ya bambanta da abin nadi mai nadi?
Madaidaicin shaft abin nadi yana aiki ƙarƙashin lanƙwasawa kuma sau da yawa yana ɗaga zafin jiki a cikin layin daidaitawa ko tashin hankali, tare da lalacewa ta hanyar lamba da sikeli. Rollformer shaft abin nadi yana tuƙa yin nadi mai siffar tsiri a yanayin zafin yanayi, tare da lalacewa ta hanyar samar da lodi da lambar bayanin martaba. Abubuwan fifiko na kayan aiki da buƙatun haƙuri sun bambanta daidai da haka.
Shin za a iya haɓaka daidaitaccen abin nadi na 42CrMo4 don sabis na layin galvanizing?
42CrMo4 na iya yin isasshe a wasu aikace-aikacen matakin, amma yana da sauƙin fashewa a cikin mahalli masu wadatar sulfide. Haɓakawa zuwa gariyar tushen cobalt ko ƙarfe mai ƙarfi sosai na iya zama dacewa inda hawan zafin jiki ko bayyanar sinadarai ke da tasiri. Ya kamata yanke shawara ya dogara ne akan yanayin ɓangaren da ya gaza, ba akan darajar kayan kawai ba.
Sau nawa ya kamata a maye gurbin madaidaitan rolls?
Babu tazara ta duniya. Maye gurbin ya dogara da ƙarar tsiri, ingancin tsiri, kayan nadi, da kuma ko nadi nadin aiki ne ko nadi na madadin. Ƙididdiga na tushen yanayi-auna rashin ƙarfi na saman, duba don ƙididdigewa, da sa ido kan ingancin tsiri-ya fi dogaro fiye da maye gurbin kalanda.
Menene ke haifar da jujjuyawar juzu'i daga gidanta?
An gano juzu'in jujjuyawar matakan lankwasa raka'o'in lankwasawa zuwa sanye da goyan bayan ƙarshen aikin nadi a ƙarƙashin ƙarfin axial. Lokacin da ɗaukar hoto ɗaya ya sa, kishiyar juzu'i na iya tserewa daga hannun goyan bayan sa, yana barin nadi ya cire. Zaɓin ɗaukar nauyi, ingancin taro, da sarrafa nauyin axial sune wuraren gyara masu dacewa.
Kammalawa: Gano kasawar Kafin Zabar Kayan
Nadi mai wuya ba koyaushe shine mafi kyawun abin abin nadi ba. A cikin masu daidaita layi na galvanizing, ɓangaren da ya gaza yana iya zama saman nadi, wurin ɗaukar hoto, ko daidaitawar taro-kuma kowanne yana buƙatar amsa daban. Haɓaka kayan abu da taurin saman na iya tsawaita rayuwa sosai lokacin da lalacewa ta zama babbar hanyar. Ba za su gyara mahalli mara kyau ba ko matsalar lodin axial wanda ke lalata bearings.
Don kayan aikin rollformer, abubuwan da suka fi dacewa suna canzawa zuwa daidaiton bayanin martaba, saita daidaito, da juriya na gajiya, tare da ƙarancin fifiko akan juriya na zafi da lalata. Ƙayyadaddun nau'ikan nadi biyu daga dabaru iri ɗaya yana watsi da ayyuka daban-daban da kowannensu ke yi.
Hanyar da ta fi dacewa ita ce bincika ɓangaren da ya gaza, gano ko lalacewa, ɓarna, ɓarna, ko juzu'i na geometric shine batu na farko, da ƙayyadaddun kayan aiki da magani don magance wannan takamaiman hanyar. Masu ba da kayayyaki waɗanda suka fahimci aikace-aikacen za su iya ba da gudummawa ga wannan ganewar asali; odar siyayya kadai ba zai iya ba.
