Tsarin Simintin Kumfa da Ya ɓace: Abũbuwan amfãni, Iyakoki da Abubuwan da suka dace da Ƙarfe 

Simintin kumfa da aka ɓace (simintin ƙira) fasaha ce ta kusa-net-ƙirar ƙirar ƙarfe wacce ke amfani da ƙirar kumfa EPS mai kashewa maimakon kakin zuma ko ƙirar itace. Ƙarfe na narkakkar yana vaporizes ɗin kumfa kuma ya cika ramin ƙura, yana samar da simintin gyare-gyaren da aka gama ba tare da layukan rabuwa ba kuma babu buƙatar yashi. Gudanar da tsarin da ba daidai ba yana haifar da haɗakarwar carbon, ƙarancin iskar gas da bambancin girma, wanda ke ƙara ƙimar ƙima don ɓarnar ɓarna kumfa. Wannan jagorar yana tafiya cikin cikakkiyar kwararar tsari, ƙayyadaddun fasaha, ribobi da fursunoni, lahani na yau da kullun, kuma yana ba da kwatancen kai tsaye tare da simintin saka hannun jari, yana taimakawa injiniyoyin injiniyoyi da masu siye su zaɓi hanyar masana'anta da ta dace don abubuwan ƙarfe na al'ada.

1. Menene Rasa Kumfa?

Simintin kumfa da aka rasa hanya ce ta simintin simintin ɓata wacce ke kawar da iyakokin simintin yashi na gargajiya. Maimakon rarrabuwa da mold tare da rabuwa Lines da kuma hada da yashi cores, masana'antun samar da cikakken size fadada polystyrene (EPS) kumfa kwafi na kashi na karshe. An lulluɓe tsarin kumfa tare da siraran siraran refractory, an binne shi cikin sako-sako, busasshiyar yashi mara ɗaure, kuma an haɗa shi ƙarƙashin matsa lamba. Lokacin da aka zuba narkakken ƙarfe a cikin tsarin gating, yawan zafin jiki yana haifar da ƙirar kumfa zuwa gas da ragowar carbon. Gas ɗin yana tserewa ta cikin rufi da busassun yashi, kuma ƙarfen ruwa ya maye gurbin cikakken siffar kumfa don samar da ƙaƙƙarfan simintin ƙarfe bayan sanyaya.

Bambanci mafi girma daga simintin gyare-gyare na al'ada: babu layukan rabuwa, babu daftarin kusurwoyi, kuma babu keɓaɓɓen yashi. Wannan siffa ta musamman ta sa tsarin ya zama manufa don hadaddun sassa tare da lankwasa na ciki kwarara wurare.

2. Mataki-by-Mataki Bataccen Tsarin Simintin Kumfa

Cikakken tsarin samarwa yana biye da matakai 7 bayyananne ba tare da hadadden hadadden tsari ba:

1. Ƙirƙirar Tsarin Kumfa EPS: Yanke ko allura-mold m EPS kumfa cikin ainihin siffar simintin da aka gama; manne ware sassan kumfa tare don samar da hadaddun majalisai.
2. Tsarin Bishiyar Taro: Rukunin nau'ikan kumfa da yawa akan tsarin kumfa da tsarin gudu don samar da gungu na simintin gyare-gyare, inganta ingantaccen samarwa.
3. Rufaffen Rufewa & bushewa: Tsoma dukan tarin kumfa a cikin slurry na tushen ruwa akai-akai don gina maɗauri mai yawa, mai da iskar gas; cikakke iska-bushe kowane Layer don hana fashewar shafi yayin zubarwa.
4. Cika Yashi & Matsala: Sanya gunkin kumfa mai rufi a cikin filin simintin gyare-gyare; cika flask ɗin da busasshiyar yashi silica kuma girgiza flask ɗin don cika yashi a kusa da kowane saman. Aiwatar da injin ci gaba da riƙe yashi mai ƙarfi ba tare da masu ɗaure sinadarai ba.
5. Zuba Ƙarfe: Zuba gami da ruwa a cikin sprue; Ƙarfe mai zafi yana vaporizes tsarin EPS kuma yana ci gaba da cika rami. Matsin lambatu yana kiyaye yashi tsayayye yayin da iskar bazuwar kumfa ke fita daga gadon yashi.
6. Sanyi & Shakeout: Bari simintin ya yi ƙarfi gaba ɗaya. Saki injin kuma girgiza fitar da busasshiyar yashi, wanda za'a iya sake yin fa'ida don batches na gaba.
7. Kammala Ayyuka: Yanke tsarin gating, cire abin da ya rage, share fage, da yin injina don biyan buƙatun ƙira na ƙarshe.

3. Maɓalli Maɓalli na Fasaha: Haƙuri & Ingancin saman

Simintin kumfa da ya ɓace yana ba da daidaitaccen daidaiton girman girman da ƙare saman ƙasa tsakanin simintin yashi na al'ada da simintin saka hannun jari. Duk dabi'un da ke ƙasa suna nuna ƙa'idodin samar da masana'antu.

• Hakuri Mai Girma: ISO 8062 CT7-CT9; Haƙuri na layi ya kai ± 0.5-1.0 mm don yawancin girma. Ƙarin haƙuri (± 0.5 mm) yana faruwa a kowane haɗin haɗin manne tsakanin sassan kumfa.
• Rawanin Surface (Ra): 6.3-12.5 μm; wani lallausan kumfa mai laushi ya rage akan simintin simintin, mafi santsi fiye da simintin yashi koren amma ƙasa da gogewa fiye da simintin saka hannun jari.
• Mafi qarancin Kaurin bango: 3 mm ga aluminum gami; 4.5 mm don karafa na ƙarfe (simintin ƙarfe da ƙarfe). Ganuwar sirara tana haɗarin haɓakar ƙarfe da bai kai ba da lahani mai sanyi.
• Machining Allowance: 1.5-3 mm da surface; ƙirar kusa-net-nau'i-nau'i sosai yana rage yawan aikin mashin ɗin bayan simintin.
• Bukatun daftarin aiki: Zero daftarin kusurwa da ake bukata. Ganuwar tsaye da sifofin da aka yanke za a iya jefa su kai tsaye ba tare da hane-hane na cire tsari ba.

4. Babban Fa'idodin Batar Kumfa

Simintin kumfa da aka rasa yana ba da fa'idodin tattalin arziki da ƙira don matsakaici-zuwa-manyan simintin simintin gyare-gyare:

• Babu Layin Rarraba ko Flash: Tsarin kumfa mai guda ɗaya yana cire layin tsagawar mold gaba ɗaya. Babu walƙiya don kashewa, yanke aikin gamawa sosai.
• Babu Sand Cores da ake buƙata: Complex cavities na ciki, lankwasa kwarara tashoshi da makafi sassa za a iya hadedde kai tsaye a cikin tsarin kumfa. Matsakaicin ƙayyadaddun ƙayyadaddun ƙayyadaddun lahani an kawar da su gaba ɗaya.
• 'Yancin Zane-zane na Zero Draft: Masu ƙira ba sa buƙatar ƙara daftarin kusurwoyi don fitar da tsari, wanda ke sauƙaƙa sashin lissafi kuma yana haɓaka ƙarfin tsari.
• Karancin Farashin Kayan aiki & ɗan gajeren lokacin jagora: Hanyoyin kumfa EPS suna da arha don samarwa tare da CNC zafi-waya yankan; samfurin gubar lokaci za a iya rage zuwa 1-3 kwanaki ba tare da tsada karfe allura ya mutu.
• Busashen Yashi Mai Maimaituwa: Za a iya sake amfani da busasshen yashi maras ɗaurewa akai-akai bayan girgizawa, yanke farashin albarkatun ƙasa da rage sharar masana'antu idan aka kwatanta da simintin yashi mai ɗaure.
• Babban Tsari: Cikakkiyar ƙyallen ƙura da ƙyallen ƙura yana rage girman bambance-bambancen tsakanin ayyukan samarwa, wanda ya dace da girman batch daga ƙananan samfura har zuwa samarwa da yawa.

5. Iyakance & Nakasu na Musamman a cikin Bacewar Kumfa

5.1 Mahimman Iyakokin Tsarin

Simintin kumfa da aka rasa yana da iyakoki na fasaha waɗanda ba za a iya kawar da su gaba ɗaya ta hanyar daidaitawa ba:

• Madaidaicin ba zai iya daidaita simintin saka hannun jari ba. Ba zai iya cimma makin haƙuri na CT4-CT6 ko saman madubi mai santsi ba.
• Gurɓatar Carbon haɗari ne da ba za a iya gujewa ba ga ƙarfe da simintin ƙarfe, wanda EPS foam pyrolysis ya haifar.
• Abubuwan ɓangarorin bango (ƙasa da ƙaramin kauri na bango) akai-akai suna fama da ɓarna da rashin cikawa.
• Nau'in kumfa na kumfa yana barin ƙwayar da ake iya gani wanda ba za a iya kawar da shi gaba ɗaya ba tare da niƙa mai nauyi ba.
• Tsarin bai dace da babban zafin jiki na superalloys da alloys titanium ba saboda tsananin ɗaukar carbon da samar da iskar gas.

5.2 Mafi yawan lahani na gama gari: Haɗin Carbon & Ƙarfi

Yawancin gazawar simintin kumfa da aka rasa sun samo asali ne daga lahani guda biyu: haɗakar carbon da ƙarancin iskar gas.

Abubuwan Haɗaɗɗen Carbon (Lalacewar Carbon Ƙarfafawa)
Lokacin da kumfa EPS ya ruɓe ƙarƙashin narkakkar zafi na ƙarfe, iskar gas da bai cika ba ya bar ƙaƙƙarfan soot ɗin carbon da ragowar kwalta sun makale da saman simintin. The carbon narke cikin ferrous karfe, haifar da surface carburization, matalauta machinability da rashin daidaito zafi jiyya yi.

Babban abubuwan da ke jawowa: girman kumfa EPS da yawa fiye da kima (sama da 24 kg/m³), ƙarancin zafin jiki, da ƙaramar rufewa mai ƙarancin ƙarfi wanda ke toshe iskar gas.

Gas Porosity
Ana samar da iskar gas mai yawa a lokacin kumfa pyrolysis. Idan iskar gas ba zai iya tserewa ta cikin rufin da yashi cikin sauri ba, kumfa na iskar gas ya zama tarko a cikin ƙarfe mai ƙarfi, yana samar da ramuka na ƙasa da busa. Haɗarin rashin ƙarfi yana ƙaruwa sosai lokacin da matsa lamba bai isa ba ko kuma yuwuwar shafa ya yi ƙasa da ƙasa.

Ƙarin lahani akai-akai sun haɗa da mannewar yashi (ƙonawa), sanyi yana rufewa daga jinkirin cikowar ƙarfe, da rugujewar ƙira yayin tattara yashi.

6. Lost Foam Casting vs Zuba Jari (Lost Wax)

Teburin da ke ƙasa yana kwatanta ainihin ma'aunin fasaha da tattalin arziki don tallafawa zaɓin tsari:

Ƙa'idar zaɓin mahimmanci: Zaɓi simintin kumfa da aka ɓace don manyan simintin gyare-gyare, mai rikitarwa, matsakaici-daidaitaccen simintin ƙarfe tare da hadaddun hanyoyin ciki. Zabi zuba jari don bakin ciki-bango, ƙananan juzu'i na juriya na buƙatar kyakkyawan ƙarewa.

7. Dace Alloys & Hannun Lost Kumfa Simintin sassa

7.1 Ƙarfe Masu Zaɓuɓɓuka

• Mai dacewa sosai: Iron launin toka, ductile iron, carbon karfe, low-alloy karfe, aluminum gami (ƙananan carbon hadarin).
• Amfani mai iyaka: Bakin karfe (matsakaicin yawan kumfa da ake buƙata don guje wa ɗaukar carbon).
• Ba a ba da shawarar ba: Superalloys masu zafin jiki, gami da titanium, da madaidaicin madaidaicin alluran da ba na ƙarfe ba masu saurin kamuwa da carbon.

7.2 Yawancin Rushewar Simintin Kumfa (ɓatattun sassan simintin kumfa)

Ana amfani da wannan tsari ko'ina don ikon ruwa, na'urorin kera motoci da na masana'antu tare da hadaddun cavities na ciki:

1. Jikin famfo, jikin bawul da manifolds na hydraulic tare da tashoshi na ciki mai lankwasa;
2. Tubalan injin, kawunan silinda da ɗimbin abubuwan shaye-shaye don kayan aikin mota;
3. Gidajen ruwa mai nauyi mai nauyi, akwatunan gearbox da kayan aikin bututu;
4. Gidajen damfara da manyan simintin gyare-gyare na inji ba tare da siraran hakarkarinsa ba.

Jagorar tsari: Zaɓi simintin kumfa da aka ɓace don kauri, tsarin bango iri ɗaya. Kauce wa sassan da ke da ƙananan haƙarƙari da yawa da ƙananan sassa, waɗanda ke haifar da lahani.

8. Tambayoyin da ake yawan yi

8.1 Shin ɓataccen simintin kumfa na iya haifar da simintin simintin gyare-gyare tare da layukan rabuwa da sifili?

Ee. Tsarin kumfa guda ɗaya yana kawar da tsagewar ƙura gaba ɗaya, don haka babu layin rabuwa ko walƙiya da ya bayyana akan ƙãre simintin. Sai kawai mahaɗin manne tsakanin sassan kumfa suna barin ƙananan ƙima.

8.2 Me yasa karfen da aka rasa simintin kumfa ke fama da gurɓataccen carbon?

Tsarin kumfa EPS an yi shi da polystyrene (carbon-hydrogen polymer). Pyrolysis yana samar da adadi mai yawa na carbon kyauta. Idan kumfa ba zai iya cika iskar gas ba, ragowar carbon yana ratsa saman narkakkar karfe kuma yana ɗaga abun cikin saman carbon. Haɗarin ya yi ƙasa kaɗan don simintin gyare-gyaren aluminium saboda ƙarancin yawan zafin jiki da ƙarancin narkewar carbon.

8.3 Wanne tsari yayi ƙasa da ƙasa don manyan simintin gyare-gyare na matsakaici: asarar kumfa ko simintin saka hannun jari?

Yin simintin kumfa da ya ɓace yana da ƙananan farashin kayan aiki na gaba da ƙananan farashin samar da raka'a don matsakaita-zuwa-manyan simintin. Simintin saka hannun jari kawai ya zama tattalin arziƙi don ƙananan madaidaicin sassa masu ƙarancin fitarwa na shekara-shekara.

8.4 Menene madaidaicin kumfa EPS don rage lahanin carbon?

Mafi kyawun kewayon yawa shine 22-24 kg/m³ don simintin ƙarfe da ƙarfe. Yawan yawa sama da 26 kg/m³ yana ƙara haɗarin haɗa carbon, yayin da ƙarancin ƙarancin yawa (yawanci ƙasa da 18 kg/m³) yana haifar da haɗarin faɗuwar ƙirar kumfa yayin cika yashi.

9. Ƙarshe & Jagorar Zaɓi

Babban ka'ida don zabar simintin kumfa da aka ɓace ya dogara da daidaita ƙarfin tsari zuwa sashin lissafi, buƙatun haƙuri da ƙarar samarwa:

1. Zaɓi ɓataccen simintin kumfa don matsakaita-zuwa-manyan simintin gyare-gyare tare da hadaddun magudanan ruwa na ciki, buƙatun layin rabuwar sifili, da matsakaicin juriya (CT7-CT9). Yana rage farashin injina kuma yana gajarta lokacin jagorar samfur sosai.
2. Guji wannan tsari don ɓangarorin bango na bakin ciki, ƙaƙƙarfan ƙaƙƙarfan ƙa'idodi, da manyan simintin gyare-gyare masu kula da ɗaukar carbon; zabar zuba jari maimakon.
3. Sarrafa maɓalli na maɓalli uku don rage lahani: kiyaye yawan kumfa EPS tsakanin 22-24 kg/m³, yi amfani da rufin juzu'i mai ƙarfi, da kuma kula da madaidaicin zazzaɓi don tabbatar da cikakkiyar gas ɗin kumfa.
4. Don ɓangarorin simintin kumfa na al'ada, tabbatar da mafi ƙarancin kauri na bango, haƙurin haɗin gwiwa, da ma'aunin carbon carbon tare da ginin ku kafin kammala zanen sashe.