Lokacin da kuka ji 'daidaitaccen simintin ƙarfe', yawancin masu hankali suna tsalle kai tsaye zuwa simintin saka hannun jari. Wannan ba laifi ba ne, amma wurin farawa ne wanda sau da yawa ke kewar daji don bishiyoyi. Madaidaicin ainihin ba kawai game da sunan tsari ba; game da tsarin yanayin yanayin gaba ɗaya ne na sarrafawa—daga narkakken sawun yatsa na gami zuwa juriyar na'ura ta ƙarshe. Na ga ayyuka da yawa sun tsaya cak saboda wani ya ayyana 'daidaitaccen simintin' akan zane ba tare da bayyana ainihin abin da hakan ke nufi da aikin sashinsu ba. An gama saman ne? Kwanciyar kwanciyar hankali a ƙarƙashin zafi? Daidaituwar da ke tsakanin batch na guda 10,000? Wannan shubuha ita ce inda aka haifi matsaloli.
Wasan Shell: Fiye da Yashi Kawai
Ɗauki simintin gyare-gyaren harsashi. Ana tara shi tare da sassaƙan yashi wani lokaci, amma wannan rashin aiki ne. Madaidaicin a nan ya fito ne daga ƙera yashi mai ɗaure kanta. Yana da tsauri. Wannan rigidity yana nufin ƙarancin motsin bangon ƙirƙira yayin zubar, wanda ke fassara kai tsaye zuwa ingantaccen girman girman girman. Ba muna magana ne game da riƙe +/- 0.005 inci akan kowane saman ba—wannan don saka hannun jari ne—amma ga wasu geometries, musamman mafi girma, abubuwan da suka dace, yana iya zama daidai da tsada. Dabarar ita ce sanin lokacin da za a yi amfani da shi. Na tuna wani sashi don famfo mai nauyi, siffa mai sauƙi amma tare da ramukan gundura guda biyu. Koren simintin gyare-gyaren yashi ya ba mu bambance-bambance da yawa a cikin ramukan da aka yi amfani da su, wanda ke haifar da lokacin saitin inji. Juyawa zuwa ƙirar harsashi ya gyara ainihin batun motsi kusan gaba ɗaya. Kudin gyaggyarawa ya fi girma, amma mun sami ƙarin ajiya a cikin aikin injina da guntu. Wannan aiki ne madaidaicin simintin ƙarfe yanke shawara.
Inda harsashi na iya cizon ku yana cikin tsammanin ƙarewar saman. Za ku sami kyakkyawan ƙare, tabbas mafi kyau fiye da yashi na al'ada, amma zai sami nau'in nau'in hatsi. Idan ƙayyadaddun ƙayyadaddun ya yi kira ga tsayayyen simintin simintin gyare-gyaren da aka shirya don plating, ƙila ku ji takaici. Yawancin lokaci yana buƙatar fashewar haske ko injina. Na koyi cewa hanya mai wuyar gaske akan aikin farko, tsammanin abokin ciniki zai fahimci yanayin 'as-cast'. Ba su yi ba. Yanzu, sarrafa wannan tsammanin wani bangare ne na bita na farko.
Zaɓin kayan abu kuma yana taka rawa a ciki. Muna sarrafa baƙin ƙarfe da ƙarfe da ƙarfe mai yawa ta hanyar ƙirar harsashi a shagonmu. Tsarin yana ɗaukar girgizar zafin jiki na ferrous gami da kyau. Amma na ga yunƙurin gudanar da manyan allunan nickel ta hanyar saitin iri ɗaya, kuma halayen thermal sun bambanta - yana iya haifar da tsagewar zafi idan ba a daidaita gating da sanyaya ba. Wannan shine nuance. A tsari ba kawai maɓalli da ka latsa; saitin ma'auni ne wanda ya auri kayan zuwa mold.
Yin Simintin Zuba Jari: Zaɓaɓɓen Babba, Tare da Rubuce-rubucen Boye
Zuba jari simintin gyare-gyare ne fosta yaro ga madaidaicin simintin ƙarfe, kuma saboda kyawawan dalilai. Harsashin yumbu da aka kafa a kusa da ƙirar kakin zuma yana ba ku wannan kyakkyawan ƙarshen saman da ikon ɗaukar cikakkun bayanai. Amma 'daidaici' anan ba atomatik bane. Tsarin ƙirar kakin zuma da kansa shine yuwuwar tushen bambancin. Idan sigogin allura na kakin zuma ba a kulle su ba - zafin jiki, matsa lamba, ƙimar sanyaya - ma'aunin ƙima, kuma wannan girgizar yana samun kwafi a cikin kowane harsashi da kowane simintin ƙarshe. Na kwashe makonni ina buga hanyoyin kakin zuma don sabon sashin iyali. Yana da ban sha'awa, aikin tushe wanda ba ya da kyan gani amma yana ƙayyade duk abin da ya biyo baya.
Sannan akwai ginin harsashi. Rigar tsoma, aikace-aikacen stucco. Aikin hannu ne, aikin hannu ko da a cikin kayan aiki na zamani. Ƙwarewar ma'aikacin yin amfani da rigar slurry na farko yana da matukar muhimmanci don ɗaukar cikakkun bayanai. Sirara sosai, kuma kuna haɗarin gazawar harsashi ko shigar ƙarfe. Yayi kauri sosai, kuma kuna iya rasa sasanninta masu kaifi. Mun taɓa samun matsala tare da katangar bakin ciki akan babban bakin karfe. Alamar kakin zuma sun kasance cikakke, amma ƙarfe yana 'wanke' yumbura a wasu wurare yayin zuba. Maganin ba ƙarfi ba ne; yana daidaita danko na rigar slurry na farko da kuma darajar kayan stucco don gina ƙarin juriya, duk da haka har yanzu madaidaici, Layer na farko. Wannan shi ne granularity na sarrafawa wanda ke bayyana ainihin ainihin.
Da raguwa. Kowane mutum ya san game da ba da izini na shrinkage na layi, amma hulɗar tsakanin gami da harsashi yumbura yayin sanyaya yana haifar da ƙuntatawa. Domin hadadden bangare, gami ba ya raguwa daidai gwargwado. Wannan na iya haifar da raguwar damuwa ko, a cikin mafi munin yanayi, fashewar zafi. Muna aiki da yawa bakin karfe da allurai na musamman kamar cobalt na tushen gami don datsa bawul. Waɗannan kayan suna da nasu halaye na ƙanƙantar da nasu na musamman da maƙallan ƙarfi-a-zazzabi. Dole ne a tsara tsarin gating ba kawai don ciyar da ƙarfe ba, amma don ƙyale simintin ya ragu tare da ƙarancin juriya daga harsashi. Rawa ce tsakanin lissafi, ƙarfe, da kimiyyar yumbu. Zuba ƙasa mai tsada a ɓangaren nickel-alloy mai tsada yana koya muku game da wannan rawa fiye da kowane littafi.
Gaggawar Hannun Injin: Inda Aka Tabbatar da Madaidaicin Casting
Babu tattaunawa madaidaicin simintin ƙarfe ya cika ba tare da taba machining ba. Ba za su iya rabuwa ba. Yin simintin gyare-gyare na iya zama kyakkyawa da girman gaske akan CMM, amma idan ba shi da injin aiki ko kuma yana da taurin da bai dace ba, mafarki ne mai ban tsoro a bene na CNC. Wannan shine inda ayyukan haɗin gwiwar, kamar abin da muka gina tsawon shekaru, ke nuna ƙimar su. Madaidaicin martani gajere ne. Idan ƙungiyar mashin ɗin ta gano cewa ɗigon ƙwalƙwalwa sun gaji da sauri akan simintin simintin gyare-gyare, za su iya komawa wurin da aka kafa kuma za mu iya kallon ƙaramin tsari. An kashe adadin sanyi? Shin akwai samuwar carbide da ba zato ba tsammani a cikin wannan zafin na jefa baƙin ƙarfe?
Na tuna wani sashi don toshe na'ura mai aiki da karfin ruwa. Zuba jarin ya kasance kusa-siffar hanyar sadarwa, amma yana da zurfin ramuka guda shida, daidaitattun ramukan jurewa da za'a hakowa da buga su. Batches na farko sun yi kyau. Sa'an nan, wani sabon tsari ya fara haifar da karyewar famfo. Girman simintin gyare-gyare sun kasance iri ɗaya. Batun ya samo asali ne zuwa ɗan bambanci a cikin abun ciki na phosphorus na kayan abinci na bakin karfe, wanda ya sanya kayan ya zama 'stringer' kuma ya yi ƙasa da abokantaka don bugawa. Gyaran shine ƙaramin daidaitawar sinadarai da tweak zuwa zagayowar sake zagayowar bayan simintin gyare-gyare. Ba tare da sarrafa dukkan sarkar ba, za ku yi jigilar simintin gyare-gyaren da abokin cinikin ku ba zai iya na'ura da kyau ba, yana lalata dangantakar. Madaidaicin sakamako ne da aka isar, ba kawai yanayin jigilar kaya ba.
Wannan shine dalilin da ya sa kamfanonin da ke haɗa simintin gyare-gyare da machining a ƙarƙashin rufin daya, kamar Qingdao Qiangsenyuan Technology Co., Ltd. (QSY), suna da fa'ida ta asali don abubuwa masu mahimmanci. Bayan sun yi aiki sama da shekaru 30 da suka gabata, sun fahimci cewa kashe wutar lantarki zuwa CNC ba ciniki ba ne; ci gaba ne. Bukatar mashin ɗin don tsayayye, kayan tushe da za a iya tsinkaya kai tsaye yana sanar da tsarin mai tushe. Lokacin da kuke mu'amala da musamman gami waɗanda suke da tsada da wahalar injin, wannan haɗin kai ba abin jin daɗi ba ne; larura ce don samun abin dogaro, mai tsada madaidaicin simintin ƙarfe sakamakon.
Material shine Saƙo
Ba za ku iya magana daidai ba tare da kayan magana ba. Alloy ba abu ne kawai na layi akan takarda takamammen ba; yana ba da umarni gabaɗayan tsari. Karfe kuma bakin karfe yi daban-daban a cikin mold. Bakin, tare da mafi girman wurin narkewar sa da kuma ruwa daban-daban, sau da yawa yana buƙatar haɓakar yanayin zafi da ƙarin ƙirar gating don guje wa ɓarna ko haɗaɗɗen oxide. Abubuwan da ake kira 'alloys na musamman' - tushen nickel da cobalt na tushen gami- wata duniya ce. Sau da yawa ana zuba su don matsanancin sabis: babban zafin jiki, babban lalata, juriya. Madaidaicin ƙalubalen su galibi shine game da mutunci. Ƙaƙƙarfan ƙaƙƙarfan ƙaƙƙarfan dacewa na iya zama abin karɓa; a cikin injin injin jet da aka jefa daga nickel superalloy, bala'i ne.
Mun yi aiki a kan wani sashi na famfon sarrafa sinadarai, wanda aka ƙayyade a cikin bakin karfe mai duplex. Juriya na lalata ya kasance mafi mahimmanci. Simintin gyare-gyare na farko sun haɗu da ƙayyadaddun bayanai amma sun gaza a gwajin lalata. Matsalar? Ma'auni na ferrite-austenite ya ƙare saboda yawan sanyaya ta cikin kewayon zafin jiki mai mahimmanci ba a sarrafa shi sosai a cikin harsashi yumbura. Samun 'daidaici' yana nufin sarrafa tsarin ƙarfe, ba kawai siffa ta waje ba. Dole ne mu canza abun da ke tattare da harsashi don musanyawan kaddarorin sa masu hana ruwa da aiwatar da ka'idar sanyaya sarrafawa bayan zuba. Ya ƙara matakai, amma ita ce hanya ɗaya tilo don biyan buƙatun aikin kayan aiki, wanda shine ainihin manufar simintin gyare-gyare.
Anan ne manyan abubuwan ganowa suka bugi bango. Karɓar ƙayayyun kayan ba kawai don samun tanderu ba ne wanda zai iya kai ga zafin jiki. Yana da game da sanin yadda wannan gami ke ƙarfafawa, yadda yake amsawa da kayan ƙira daban-daban, da abin da ake buƙatar jiyya na zafi bayan jefawa don fitar da abubuwan da ake buƙata. Yana da zurfi, ilimi na musamman wanda ke haɓaka tsawon shekaru, sau da yawa ta hanyar gwaji da kuskure. Kuna koyo waɗanne allunan ne masu saurin kamuwa da ƙanƙara, waɗanda ke buƙatar zagayowar latsa mai zafi mai zafi (HIP) azaman madaidaicin hanya don ruguje kowane porosity na ciki. Wannan ilimin shine ainihin ɓangaren ma'auni.
Ma'auni na Haƙiƙa: Daidaituwa a cikin girma
A ƙarshe, gwaji na ƙarshe na a madaidaicin simintin ƙarfe tsari ba cikakke samfuri ɗaya bane. Shi ne yanki na 500 a cikin aikin samarwa yana da kyau kamar na farko. Maimaituwa shine sarki. Wannan shine inda takaddun sarrafa tsari, tsauraran jadawalin dubawa, da sarrafa tsarin ƙididdiga (SPC) ke shigowa. Yana da ƙarancin fasaha da ƙari game da kimiyya. Kula da dankowar wanka mai slurry kullum, duba ma'auni na kakin zuma tare da ma'aunin go/no-go kowane ƴan zagayowar, yin gwaje-gwajen ɓarna na lokaci-lokaci akan samfurin simintin gyare-gyare don duba sautin ciki.
Muna ba da kayan aikin simintin gyare-gyare don taron watsa mota. Ƙarfin yana da girma, haƙuri yana da ƙarfi, kuma farashin gazawar yana da yawa. Madaidaicin a nan an bayyana shi ta ƙimar CpK akan ma'auni mai mahimmanci. Don buga waɗannan lambobi akai-akai, kowane mai canzawa a cikin sarkar dole ne a sa ido da sarrafa shi. Yawan zafin jiki na karfe kafin zubawa, zafin jiki na zafin jiki na gyare-gyare, zafi na yanayi a cikin ɗakin bushewa harsashi (yana rinjayar ƙimar bushewa). Tsari ne.
Lokacin da kuke aiki tare da abokin tarayya kamar QSY, shekaru 30 da suka yi a cikin simintin gyare-gyare da injina suna fassara zuwa kafaffen, ingantaccen tsarin don irin wannan daidaitaccen girma. Wataƙila sun ga yanayin gazawar, sun gina wuraren bincike, kuma sun fahimci farashin barin siga. Ga mai siye, wannan balagaggen tsarin tarihi yakan fi sabon inji mai haske. Yana nufin ƙarancin abubuwan mamaki. Kuma a cikin masana'antu, babu wani labari mai kyau. Isar da tsari bayan tsari wanda ya dace da ayyuka kawai - wannan shine shiru, gaskiya mara kyan gani na darajar masana'antu madaidaicin simintin ƙarfe. Ba batun yin gwaninta ɗaya ba ne; game da yin dubu goma iri ɗaya ne, amintattun abubuwan da wani zai iya gina samfuran su ba tare da tunani na biyu ba.
