Lokacin da injiniyoyi suka bayyana a Rollformers shaft abin nadi factory, Ba wai kawai suna yin odar wani sashi ba - suna tabbatar da jujjuyawar kashin baya na babban layin ƙarfe na ƙarfe. Mun ga dakatarwar samarwa da yawa da aka yi ta hanyar abin nadi wanda ya karkata bayan mita 3,000 na ci gaba da ciyarwar coil, ko gazawar binciken taurin saman a 58 HRC. Shi ya sa madaidaicin ba na zaɓi ba ne a nan - shine tushen tushe.
Me yasa Shaft Rollers ya kasa - Kuma Abin da Ake Yi Aiki
Yawancin gazawar sun samo asali ne zuwa tushen tushe guda uku: tsarin ƙarfe mara daidaituwa, jujjuyawar juzu'i yayin hawan keke, da rashin isassun daidaiton saman ƙasa ƙarƙashin murkushe lamba. Standard carbon karfe rollers fashe a karkashin maimaita lankwasawa danniya a rollforming tsaye. Simintin gyare-gyare ba tare da sarrafa sarrafa hatsi suna haɓaka ƙananan fasa ba a kusa da hanyoyin maɓalli. Kuma masu maye gurbin na'ura na CNC galibi suna tsallake sassaucin damuwa bayan injin-don haka suna karkatar da su cikin sa'o'i 48 na shigarwa.
Muna gwada kowane abin nadi don torsional rigidity ta amfani da ka'idojin ASTM E143-kuma mun ƙi duk wani rukunin da ke nuna> 0.012 mm radial runout a 3,000 rpm. Tabbatar da ainihin duniya yana da mahimmanci fiye da ƙayyadaddun bayanai. Ɗaya daga cikin injin niƙa na Arewacin Amurka ya ba da rahoton 47% tsawon rayuwar sabis bayan ya canza daga generic AISI 4140 zuwa AMS 5387 cobalt-nickel alloy rollers, duk da cewa na karshen yana da 2.3 × fiye da gaba. ROI ya zo ne daga kawar da maye gurbin mako-mako da kuma guje wa raguwar lokacin da ba a shirya ba yayin bututun hayaki na mota.
Haɗin Kai tsaye Yana Warware Abin da Outsourcing Ba zai iya ba
Ba za ku iya fitar da ikon sarrafa ƙarfe ba. Lokacin da abokin ciniki ya aika da GD&T zane don 215 mm OD × 1,850 mm dogon winch shaft abin nadi — tare da ± 0.005 mm cylindricity, 62-65 HRC taurin saman, da cikakken ganowa ga MTRs- kuna buƙatar simintin gyare-gyare, machining, da magani mai zafi a ƙarƙashin rufin ɗaya. Babu handoffs. Babu rashin daidaiton tsari.
Kayan aikin mu masu yarda da ISO yana sarrafa duka uku:
- Yin simintin yashi na ductile baƙin ƙarfe da bakin karfe gidaje tare da sarrafa sanyaya rates don hana nodular graphite clustering
- Multi-axis CNC juya da nika na igiyoyi masu taurare-ta yin amfani da tabbatarwar CMM a cikin aiki bayan roughing, Semi-karewa, da wucewa ta ƙarshe
- Taurin-hardening + shigar da taurin saman, ingantacce tare da ma'aunin giciye na Rockwell C kowane 150 mm tare da tsayi
Wannan yana kawar da tsayayyen gibin “gida-zuwa-inji-kanti”: inda ba a ƙididdige raguwar simintin gyare-gyare a cikin alawus ɗin hannun jari, ko kuma inda murɗaɗɗen maganin zafi ke ɓata girman da aka riga aka gama. Mun rage sake yin aiki akan hadadden rollers da kashi 68% tun aiwatar da diyya mai rufaffiyar madauki a cikin shirye-shiryenmu na CNC.
Zaɓin Kayan Kaya Ba Takaicen Motsa Jiki bane
"Bakin Karfe" yana nufin komai ba tare da mahallin ba. Don masu yin na'ura masu aiki da galvanized ko ƙarfe mai rufi, 304SS yana lalacewa cikin ƙasa da sa'o'i 800. Mu T800 na tushen allurai na cobalt sun wuce sama da sa'o'i 5,200-saboda tarwatsawar carbide ɗin su na tsayayya da galling, ba kawai lalata ba. Kuma AMS 5387 ba kawai "cobalt alloy" ba ne -daidaitaccen tsarin Co-Ni-Cr-Mo-W wanda aka yi masa kwaskwarima don riƙe taurin zafi sama da 600°C, mai mahimmanci lokacin da gogaggun ɗumamar spikes yayin haɓakar sauri.
Muna samo danyen ingots ne kawai daga masana'antun da aka tabbatar da su zuwa AMS 2301 da EN 10204 3.1, tare da cikakken yanayin yanayin zafi. Kowane tsari yana jurewa nazarin yanayin kallo kafin yin simintin gyare-gyare-kuma muna riƙe samfuran har tsawon shekaru 10. Idan abokin ciniki ya ba da rahoton lalacewa da wuri, za mu ja MTR na asali, mu kwatanta shi da ainihin ƙananan tsarin (ta hanyar SEM/EDS), kuma mu ware ko batun abu ne, tsari, ko rashin daidaituwar aikace-aikacen.
Dogaro Yana farawa Kafin Yanke Farko
A dogara Rollformers shaft abin nadi factory baya jiran zane ya zo. Yana shiga da wuri-a cikin nazarin ƙira. Mu akai-akai tuta batutuwa kamar radiyoyin fillet marasa girman da ke maida hankali kan kujeru, ko jurewar madaidaicin maɓalli wanda ke haifar da lalacewa. A bara, mun taimaka wa wani OEM na Kudu maso Gabashin Asiya ya sake fasalin lissafi na kafada a kan madaidaicin juzu'i na 12 - yana rage damuwa von Mises da kashi 31% da tsawaita rayuwar gajiya sama da 10.7 hawan keke.
Kwanciyar isarwa yana biye ne daga tsararru - ba alƙawura ba. Muna jera zubin simintin gyare-gyare, kayan aikin zafi, da jadawalin injina a cikin sa'o'i 4. Prototype yayi odar jigilar kaya a cikin kwanaki 18; matsakaicin girma yana gudana yana riƙe da tagogin kwanaki ± 2. Babu saurin kudade. Babu "bisa ga wadatar kayan aiki" jumla. Domin amintacce ba kawai game da abin da ke juyawa gaskiya ba ne - game da abin da ke zuwa akan lokaci, kowane lokaci.
Ga injiniyoyi masu ƙayyadaddun abubuwan da gazawar ta dakatar da layukan samarwa, zaɓin ba tsakanin dillalai ba — yana tsakanin zato da shaida. Madaidaicin madaidaicin rollers suna buƙatar madaidaicin haɗin gwiwa. Wannan yana farawa da ƙarfe za ku iya tantancewa, aiwatar da za ku iya tantancewa, da sakamakon da zaku iya aunawa-ba kawai a cikin microns ba, amma a cikin lokacin aiki.
