Lokacin da famfon na'ura mai aiki da karfin ruwa ya kasa a cikin injin mai na bakin teku - ko bawul ɗin piston ya kama cikin famfon mai ƙarfi mai ƙarfi - tushen tushen ba shi da wuyar ƙira. Yana sawa. Kuma ba kawai duk wani lalacewa ba: yana da micro-pitting, galling, da kuma lalacewa a ƙarƙashin nauyin hawan keke wanda ya wuce 300 MPa. Mun gan shi a kan rukunin yanar gizon a cikin dandamali na Tekun Arewa na Norway da kuma a cikin tasoshin ruwa na kudu maso gabashin Asiya - inda gazawar hannun rigar Stellite ta rufe ayyukan na tsawon awanni 48+. Shi ya sa injiniyoyi ba sa tambayar "Mene ne hannun riga mafi arha?" Suna tambaya, "Wane ne zai iya isar da hannun riga na cobalt na AMS 5387 tare da juriyar juzu'i na mm ≤± 0.015, cikakken yanayin yanayin zafi, da ingantaccen rayuwar filin fiye da sa'o'in aiki 12,000?"
Me yasa "Masana'antar hannun rigar Stellat" ba kalmar bincike ba ce kawai - tace ƙayyadaddun bayanai ne
"Ma'aikatar hannun rigar Stella" tana sigina fiye da iyawar masana'anta. Yana da gajere don horo na ƙarfe, daidaiton injina, da wayar da kan yanayin gazawa. Alloys-musamman Stelite 6 (AMS 5387) da T800-ba a kera su kamar bakin karfe ba. Matrix ɗin su na cobalt-chromium-tungsten yana tsayayya da yankan kayan aikin, aiki-hardens da ƙarfi, kuma yana buƙatar kwanciyar hankali na thermal yayin niƙa. A gaskiya Stellate hannun riga factory dole ne sarrafa nau'ikan masu canji guda uku waɗanda ba za'a iya sasantawa ba: takaddun shaida (rahotanin gwajin niƙa na ASTM F75 ko AMS 5732), taimako na damuwa bayan machining don hana ɗimbin ɗimbin yawa, da tabbatar da amincin saman ƙasa - ba kawai ƙimar Ra ba, amma ganowar microcrack na ƙasa ta hanyar gwajin shigar da kyalli.
Mun bincika sama da masu samar da kayayyaki 30 waɗanda ke da'awar ƙwarewar Stella. Rabin ba zai iya samar da ƙarshen ID mai maimaitawa ƙasa da Ra 0.4 µm akan guntun 120mm ba. Ɗayan da aka ba da hannayen riga tare da 0.08 mm waje-na-zagaye-wanda aka yarda da shi don ƙananan bawuloli, bala'i ga famfo piston axial. Bambancin ya ta'allaka ne a cikin haɗin kai tsaye: sarrafa tsarin simintin hatsi, haɓaka hanyar kayan aikin CNC don kayan aikin cobalt, da bincikar CMM a cikin kowane mataki-ba kawai dubawa ta ƙarshe ba.
Ƙarfi huɗu waɗanda ke raba ƙwararrun masu kera hannun riga na Stellite daga manyan shagunan ƙarfe
Ma'aikatar hannun riga ta Stellite na gaske tana aiki a mahadar fannoni uku: ƙarfe, ingantattun injina, da ingantaccen aiki. Ga abin da muka tabbatar kafin amincewa da mai sayarwa:
- Abubuwan gano abubuwa har zuwa adadin da aka samu-ba kawai lambobi ba, amma ingantattun rahotannin abubuwan sinadaran da suka dace da AMS 5387 ƙayyadaddun bayanai (C: 0.9-1.4%, Cr: 27-31%, W: 3.5-5.5%, Co balance)
- Multi-axis CNC iyawar tare da m-kayan aiki saitin- babu daidaitattun lathes; muna buƙatar Y-axis live tooling da coolant-ta hanyar spindles don sarrafa guntu fitarwa da thermal murdiya
- Haɗin maganin zafi- warware matsalar a 1175 ° C ± 10 ° C tare da saurin sanyaya iska, an tabbatar da taswirar tauri a cikin sassan giciye (HRC 38-44, uniform tsakanin maki ± 2)
- Kayan aikin gwaji na aiki-ba kawai ƙididdigar ƙira ba, amma gwajin sabis na kwaikwayi: Gwajin sawa na sa'o'i 500 akan tauraruwar fuska na 420SS ƙarƙashin nauyin hydraulic 200 MPa
Ba tare da duka huɗun ba, kuna siyan sassa-ba tabbacin aiki ba. Mun ga hannayen riga sun wuce CMM amma sun gaza bayan zagayowar 800 saboda saura damuwa ya haifar da ƙananan walda a wurin zamewa. Sakamakon farashin hannun jari na QINGDAO QIANGSENYUAN TECHNOLOGY CO., LTD. yana shigar da masanan ƙarfe a cikin shirin samarwa-ba a matsayin masu ba da shawara ba, amma a matsayin masu tsari.
Ƙirar ɓoyayyiyar hannun rigar “off-the-shelf” Stellite-da kuma yadda ginshiƙi na al'ada ke ƙara ƙima.
Wasu masu siye suna ɗaukan safofin hannu na Stellite. Ba su ba. Daidaitaccen girman OD/ID sun yi watsi da ƙayyadaddun gaskiyar tsarin: rashin daidaituwar haɓakar zafin jiki tsakanin hannun riga da gidaje, lodin asymmetric a cikin ƙirar famfo na eccentric, ko rawar jiki mai haifar da tashin hankali a haɗin gwiwar flange. Mun taɓa maye gurbin babban hannun riga a cikin famfon mai ma'adinai tare da bambance-bambancen al'ada wanda ke nuna tsangwama mai dacewa da ɗigon iska. Sakamako: 3.2× tsawon rayuwar sabis, sifili yayyan hatimi, da kuma kawar da raguwar lokacin da ba a shirya ba. Farashin "al'ada" ya kasance 18% mafi girma. Menene ROI? $217,000 ana ceto kowace shekara a cikin aiki, kayan gyara, da kuma asarar samarwa.
Gaskiya masana'antun hannun riga na Stellite ba kawai yanke don bugawa ba - suna tambayar aikin. Lokacin da abokin ciniki ya aiko mana da zane na GD&T, tambayarmu ta farko ba "Za mu iya yin shi ba?" "Mene ne mafi munin yanayin gazawar da wannan haƙuri ya hana?" Wannan tunanin yana canza magana daga farashin kowane yanki zuwa farashi a kowace sa'a mai aiki.
Inda madaidaicin ya dace da aminci-da dalilin da yasa yake farawa tun kafin yanke na farko
Masana'antar hannun rigar Stellite tana samun amana ba a ɓangaren da aka gama ba, amma a cikin abubuwan sarrafa ta na sama. A QINGDAO QIANGSENYUAN TECHNOLOGY, karɓar kayan aiki yana farawa tare da nazarin yanayin kowane mashaya cobalt gami mai shigowa. Machining yana amfani da jurewar ISO 2768-mK azaman tushen tushe - ba azaman manufa ba, amma mafi ƙarancin. Kowane hannun riga yana jurewa 100% gwajin ultrasonic don porosity na ciki, sannan profilometry na gani don taswirar saman saman ƙasa a ƙuduri 5-µm. Marufi na ƙarshe ya haɗa da takamaiman takaddun shaida da ke rufe sinadarai, taurin kai, bayanan ƙima, da bayanan gwaji marasa lalacewa-wanda ake iya ganowa zuwa narkewar asali.
Wannan ba aikin injiniya ba ne. Yana da rage haɗari. Domin lokacin da aikace-aikacenku ke gudana akan 15,000 psi tare da ruwa mai ɗauke da yashi, babu dama ta biyu. Kuna buƙatar a Stellate hannun riga factory wanda ke ɗaukar kowane bangare a matsayin manufa-mahimmanci-ba don yana faɗi haka akan gidan yanar gizo ba, amma saboda tsarin su bai bar wurin zato ba. Wannan shine ma'aunin da muke riƙe-kuma injiniyoyi ɗaya ke ƙara buƙata.
