Kuna buƙatar daidaitattun sassa na ƙarfe - sauri? Ba "sauri don jefawa ba." Ma'aikatar simintin saka hannun jari cikin sauri yana nufin jujjuya hadaddun, manyan abubuwan haɗin kai kamar AMS 5387 cobalt alloy famfo gidaje daga zane zuwa jigilar kaya cikin ƙasa da kwanaki 21. Wannan ba hanzari ba ne. Yana sake sabunta tsarin lokaci.
Mun isar da batches sama da 1,200 masu saurin juyowa tun daga 2020-mafi yawa bawul ɗin matsa lamba, gidajen famfo na silinda na piston, da na'urorin bututun ci gaba don OEMs na ruwa a duk Arewacin Amurka da Turai. Abin da ya sa ya yi aiki ba gudu kadai ba. Yana da yadda ƙwaƙƙwaran simintin gyare-gyare, injina, da sarrafa ƙarfe ke kulle tare.
Yawancin wuraren da aka kafa suna ɗaukar simintin saka hannun jari azaman tsari ne kaɗai. Suna zuba nau'ikan kakin zuma, harsashi na wuta, simintin gyare-gyare, sannan a mika su zuwa shagon injin-idan ma akwai. Tari na jinkiri: tsarin kula da zafi, ma'aunin ma'auni (CMM) baya, gibin gano kayan abu. Mun ga abokin ciniki ɗaya yana jira kwanaki 47 don tabbatar da kaurin bango akan filogin mai & gas. Takaddun su sun buƙaci ± 0.05 mm haƙuri akan ɓangaren cobalt-nickel diamita 120 mm. Jinkirin ba daga jinkiri ba ne - daga rarrabuwa ne.
Maganinmu yana farawa tare da haɗin kai tsaye-ba azaman kalma ba, amma azaman aikin yau da kullun. Tsarin ƙirar kakin zuma yana faruwa tare da nazarin GD&T. Lokacin ƙonawar Shell ya daidaita tare da wadatar tanderu * da * kisa na ɗaukar nauyi na CNC. An riga an tabbatar da zagayowar maganin zafi don kowane nau'in alloy-AMS 5387, T800, F22 karfe-don haka babu wani tsari da ke jiran bayanin martabar thermal. Kowane cobalt alloy ingot mai shigowa yana ɗaukar cikakkun rahotannin gwajin niƙa; kowane ɓangaren da aka gama yana riƙe da gano matakin matakin kuri'a har zuwa lambar cajin tanderu.
Wannan yana kawar da maki gama gari guda uku a cikin ayyukan simintin gyare-gyare:
- Matsakaicin girman kai tsakanin simintin gyare-gyare da gamawa- an warware ta hanyar riƙe juzu'in simintin simintin zuwa ± 0.3 mm akan fuskoki masu mahimmanci, sannan ta amfani da tabbatarwar CMM a cikin tsari kafin niƙa ta ƙarshe.
- Rashin daidaituwar ƙananan tsarin a cikin manyan simintin gyare-gyare- an gabatar da shi ta hanyar ƙimar sanyaya mai sarrafawa a cikin layin wutar lantarki na ISO 9001 da aka ba da izini na thermocouple na ainihi ta ASTM E2862
- Lalacewar saman yana ba da mamaki yayin dubawa na ƙarshe-An hana shi ta hanyar duban gani na duk kayan kwalliyar harsashi kafin zubawa da taswirar porosity ta atomatik akan 100% na sassan X-rayed
Wasu na iya yin gardama cewa matsatsin haɗin kai yana sadaukar da sassauci. Amma a aikace, akasin haka yana faruwa. Lokacin da ƙera famfo na Turai ya buƙaci sake bita guda shida na bututun cobalt alloy mara daidaitaccen-kowanne yana buƙatar tweaks na geometry da ingantaccen ingantaccen hanyar kwarara - mun gudanar da cikakkun samfuran sake zagayowar cikin kwanaki 11 gaba ɗaya. Me yasa? Saboda injiniyoyinmu sun tabbatar da yuwuwar yin simintin *lokacin* bita na CAD-ba bayan an yanke kayan aiki ba. Babu ja da baya. Babu tarkace. Kawai sake maimaitawa a cikin tsarin iri ɗaya.
Wannan tsarin ya haɗa da ƙarfin mahimmanci guda huɗu waɗanda ke aiki a ƙarƙashin rufin ɗaya: simintin saka hannun jari (don m geometries har zuwa 45 kg), simintin yashi (don manyan gidaje na tsarin), injin CNC mai yawa (5-axis na lokaci ɗaya don kwane-kwane), da kammala aikin farfajiyar - gami da murfin HVOF don lalacewa yankuna da wucewar bakin karfe. Duk an daidaita su zuwa ASME B16.34, ISO 8502-3, da ƙayyadaddun ƙa'idodin gwajin kwastomomi.
Abin da abokan ciniki ke tambaya-kuma abin da muka amsa da farko-ba "Yaya sauri?" Yana da "Za ku iya riƙe 0.002" a kan wannan guntun yayin da kuke kiyaye amincin ƙwayar hatsi ta cikin fillet? Ko "Shin wannan filogi na T800 zai tsira 15,000 psi cyclic loading ba tare da ƙaddamar da microcrack ba?" Ko kuma "Shin kuna da takaddun shaida cewa rukunin AMS 5387 ɗinku ya cika AMS 2301 tensile da buƙatun tasiri?" Muna yi. Kowane lokaci.
Ayyukan bayarwa na ainihi na duniya ya tabbatar da shi: 94.7% na umarni na matsakaici (50-500 pcs) a cikin ± 2 kwanakin kwanan wata. Matsakaicin lokutan jagorar samfuri na kwanaki 14 daga zanen da aka amince da shi zuwa ƙaddamar da labarin farko-tare da cikakken rahoton ƙima, takaddun shaida, da bayanan NDT sun haɗa. Babu add-ons. Babu ware.
Duban gaba, ƙulli ba ƙarfin ba ne - cancanta ne. Ƙarin sassan suna buƙatar takaddun shaida EN 10204 3.2, yarda da PED 2014/68/EU, ko daidaitawar API Q1. Don haka muna fadada iyakokin binciken mu na ɓangare na uku da gina ingantaccen tsarin tsarin gaurayawan kayan aikin simintin simintin gyare-gyare—kamar haɗaɗɗun bawul ɗin da aka jefa zoben wurin zama *a wurin*, sannan a yi tsalle don dacewa da ƙashin tushe.
Idan aikin ku na gaba yana buƙatar daidaitattun sassa na ƙarfe-ba kawai simintin gyare-gyare ba, ba kawai sassa na injina ba, amma abubuwan haɗaɗɗen kayan aikin da aka gina don yin aiki ƙarƙashin matsin lamba-to kuna buƙatar fiye da wurin kafa ko shagon inji. Kuna buƙatar a m zuba jari simintin gyaran kafa factory inda karfe, geometry, da jadawalin ke haduwa. Ba a matsayin alkawari ba. Kamar yadda aka saba yi.
