Thaum cov neeg feem coob hauv kev lag luam pib hnov 'automotive peev casting', lawv xav txog kev ua haujlwm siab turbocharger log lossis cov khoom sib txuas sib txuas. Qhov ntawd yog qhov tseeb, tab sis nws kuj yog qhov uas qhov kev xav tsis zoo pib - tias nws tsuas yog 'premium' txheej txheem rau niche qhov chaw. Qhov tseeb hauv av yog messier thiab nthuav ntau dua. Nws tsis yog hais txog kev nyuaj rau kev nyuaj siab xwb; nws yog hais txog kev daws cov teeb meem tshwj xeeb, gnarly ntau lawm uas lwm txoj hauv kev tsis tuaj yeem kov yam tsis muaj nqi tsav tsheb lossis lub sijhawm ua haujlwm los ntawm lub ru tsev. Kuv tau pom ntau tus qauv tuaj rau hauv qhov chaw uas tus kws tshaj lij tau teev cov peev txheej casting vim tias nws ua suab nrov, tsuas yog rau peb yuav tsum tau taug kev rov qab mus rau lub rooj sib txoos-welded uas yog 40% pheej yig dua thiab 95% zoo. Tus nqi tiag tiag tsis nyob hauv daim ntawv lo; nws yog nyob rau hauv paub meej thaum twg yuav siv nws.
Lub hauv paus ntawm tus txheej txheem: Qhov twg Txoj kev xav ntsib Foundry Grime
Phau ntawv qhia hais tias peev casting, los yog poob-wax casting, muab cov khoom nto tiav thiab qhov tseeb qhov tseeb. Dab tsi hauv phau ntawv kawm feem ntau glosses tshaj yog tus lej ntawm cov hloov pauv uas tuaj yeem rhuav tshem cov lus cog tseg. Nws pib nrog cov qauv siv quav ciab. Tau txais qhov kev txhaj tshuaj kub lossis siab tsis zoo los ntawm cov npoo me me, thiab koj qhia cov kev ntxhov siab uas tsuas yog tshwm sim raws li kev cuam tshuam tom qab lub plhaub ceramic raug rho tawm haujlwm thiab cov hlau yog nchuav. Kuv nco qab txog qhov project rau lub tsev nyob qhov twg peb muaj 0.3mm qhov ntev drift batch-rau-batch. Coj peb ib lub lim tiam ntawm caum-pwm temp? Lub sijhawm txias?—Ua ntej peb pom tias nws yog lub caij hloov pauv ntawm cov av noo nyob ib puag ncig cuam tshuam rau cov wax crystallization. Qhov ntawd yog hom kev siv tes ua, yuav luag tactile paub koj tsuas yog tau txais los ntawm kev khiav ntau lawm.
Tom qab ntawd muaj lub plhaub tsev. Lub voj voog dip-thiab-stucco zoo li ncaj nraim. Tab sis lub slurry viscosity, qhov ziab ib puag ncig (kub thiab av noo, dua), thiab qib ntawm cov xuab zeb refractory rau txhua lub tsho tiv no - nws yog ib daim ntawv qhia uas txhua qhov chaw tiv thaiv ze ze. Lub plhaub uas tsis muaj zog heev tawg thaum lub sij hawm dewaxing los yog pouring; ib qho uas tuab heev tsis tso dej kom zoo thiab ua rau muaj kev cuam tshuam. Peb ib zaug ua hauj lwm nrog ib tug tshiab zirconia-raws li prime slurry rau ib tug high-nickel alloy feem. Cov ntaub ntawv lab tau zoo tag nrho. Ntawm thawj tus tsav khiav, ib nrab ntawm lub plhaub tawg. Qhov teeb meem? Lub thermal expansion coefficient yog ib feem ntawm ib feem pua ntawm cov tsho tiv no, tsim kev ntxhov siab thaum lub sij hawm kub-kub autoclave dewax. Rov qab mus rau daim duab kos duab.
Lub ncuav nws tus kheej yog lwm qhov tseem ceeb juncture. Nrog cov ntaub ntawv zoo li stainless hlau los yog npib tsib xee-raws li alloys, lub superheat kub thiab pouring ceev yog qhov tseem ceeb. qeeb dhau, thiab koj tau txais huab cua khiav los yog txias kaw. nrawm dhau, thiab koj erode lub ilv plhaub sab hauv, qhia ceramic inclusions rau hauv ib feem. Rau automotive Cheebtsam xws li tso pa manifolds los yog turbo vaj tse, uas pom thermal cycling, ib qho kev koom tes yog ib tug guaranteed tsis ua hauj lwm point. Nws tsis yog tsuas yog melting hlau; Nws yog hais txog kev tswj cov thermal dynamics ntawm tag nrho cov system - crucible, plhaub, ambient cua - nyob rau hauv lub qhov rais 90-thib ob.
Kev xaiv cov khoom: Nws tsis yog hais txog lub zog xwb
Hais lus ntawm cov ntaub ntawv, lub tsheb sector thawb mus rau hauv lub teeb, kub, thiab ntau npaum systems tau ncaj qha mus rau lub evolution ntawm automotive peev casting. Thaum cov hlau nplaum thiab cov pa roj carbon steel yog workhorses rau brackets thiab structural pieces, qhov kev txiav txim yog nyob rau hauv tshwj xeeb alloys. Siv cov khoom siv turbocharger. Lawv tab tom txav mus dhau cov qib Inconel rau hauv cov khoom sib xyaw ua ke uas sib npaug ntawm kev nkag siab nrog thermal qaug zog lub neej. Tab sis ntawm no yog qhov ntes: cov alloys siab heev no feem ntau yog npau suav phem rau nrum. Lawv muaj qhov nqaim solidification ranges, ua rau lawv nquag kub tearing. Lawv cov ntsiab lus melting siab xav tau ntau lub plhaub ruaj khov. Ib lub tuam txhab uas tau navigated no rau xyoo, zoo li Qingdao Qiangsenyuan Technology Co., Ltd. (QSY), leverages nws cov keeb kwm ntev hauv casting thiab machining los tsim cov txheej txheem kev paub. Nws yog ib qho uas yuav tsum tau nchuav ib lub pob ntsuas ntawm cobalt alloy; Nws yog lwm qhov ua kom tsis tu ncua tsim cov phab ntsa nyias nyias, cov vaj tsev turbine complex nrog xoom to.
Aluminium peev casting rau tsheb yog nws tus tsiaj nyaum. Nws raug thawb hnyav heev rau kev txo qhov hnyav-xav tias lub cev tsis sib haum xeeb lossis cov khoom sib dhos. Qhov txiaj ntsig yog tsim kev ywj pheej. Koj tuaj yeem sib xyaw cov cua txias, mounting bosses, thiab ntxiv cov tav hauv ib thooj. Qhov kev sib tw yog porosity. Aluminium tuav cov pa roj, thiab qhov ceev ceev ntawm cov ntu nyias tuaj yeem dai nws. Peb tau siv ntau lub hlis ntawm tus qauv tsim qauv, tweaking lub rooj vag system, ntxiv cov cua txias, thiab txawm tias sim nrog cov txheej txheem de-gassing sib txawv rau cov yaj ua ntej peb tau txais X-ray huv castings. Nws yog ib qho kev mob siab rau kev nthuav dav uas cais lub khw muag khoom los ntawm tus neeg muag khoom npaj txhij.
Tom qab ntawd muaj kev tshaj tawm. Coob leej xav tias txoj haujlwm tiav lawm ib feem yog shaken tawm ntawm lub plhaub. deb ntawm nws. Kev kho cua sov feem ntau tsis sib tham. Rau kev nyab xeeb-tseem ceeb tivthaiv zoo li tus nres caliper mount, lub temper tshwj xeeb (xws li T6 rau txhuas) yuav tsum raug ntaus precisely thoob plaws tag nrho ib feem, uas yuav ua tau yooj yim nrog txawv seem thicknesses. Qhov no yog qhov uas tus neeg muag khoom sib koom ua ke ntsug, zoo li QSY kev sib xyaw ua ke ntawm peev casting thiab hauv tsev CNC machining, them tawm. Lawv tuaj yeem cuam tshuam rau qhov tsawg kawg nkaus tab sis tuaj yeem pom qhov txawv txav los ntawm kev kho cua sov rau hauv lawv cov machining fixtures, txuag lub taub hau loj hauv qab. Machining qhov chaw li-cam khwb cia nrog cov khoom sib txawv yog ib daim ntawv qhia rau cov cuab yeej tawg thiab cov khoom seem.
Tus nqi sib npaug: Justifying tus hwm
Qhov no ua rau qhov teeb meem loj tshaj plaws hauv tsheb: tus nqi. Kev nqis peev casting cuab yeej (cov hlau tuag rau cov qauv siv quav ciab) yog kim. Cov txheej txheem yog siv zog thiab siv zog ntau. Yog li ntawd, koj xav tau ib tug muaj zog justification. Classic yeej yog ib feem consolidation. Kuv ua hauj lwm ntawm lub cav bracket uas yog Ameslikas tsim ntawm rau stamped thiab welded steel daim. Peb redesigned nws raws li ib tug tib aluminium peev casting. Peb tshem tawm tag nrho cov vuam, txo lub sij hawm sib dhos, txiav qhov hnyav los ntawm 15%, thiab txhim kho nruj. Tus nqi ntawm ib feem casting yog siab dua, tab sis tag nrho cov nqi tsaws, kev tsim khoom hauv kev sib dhos thiab kev xa khoom, qis dua. Qhov ntawd yog qhov chaw qab zib.
Lwm qhov kev txiav txim siab yog kev ua haujlwm uas lwm cov txheej txheem tsis tuaj yeem xa. Cov cua txias sab hauv hauv kev ua haujlwm siab nres caliper yog qhov piv txwv tseem ceeb. Koj tuaj yeem sim tshuab lawv, tab sis nws yog astronomically kim. Koj tuaj yeem sim xuab zeb casting, tab sis qhov ua tiav saum npoo thiab qhov tseeb ntawm txoj kev yuav tsis zoo, cuam tshuam rau kev ua kom txias. Kev nqis peev casting tsuas yog txoj kev siv tau xwb. Nws yog hais txog tag nrho cov nqi thiab kev ua haujlwm, tsis yog tus nqi ntawm ib qho kev tsocai xwb.
Lub ntxiab yog over-engineering. Kuv tau pom cov khoom siv nrog kev ua siab ntev ntawm +/- 0.5mm teev raws li peev casting thaum lub xuab zeb casting zoo tuaj yeem tuav +/- 0.8mm zoo kawg nkaus rau ib feem ntawm tus nqi. Kev sib tham yuav tsum pib nrog txoj haujlwm: Dab tsi yog qhov tseem ceeb ntawm qhov tseem ceeb? Dab tsi yog cov ntaub ntawv load? Dab tsi yog qhov corrosion lossis kub ib puag ncig? Feem ntau, kev sib xyaw ua ke ua haujlwm zoo tshaj plaws-siv peev casting rau qhov tseem ceeb, txoj haujlwm tseem ceeb ntawm qhov, thiab vuam lossis ntsia liaj qhov rooj ntawm cov khoom yooj yim, pheej yig dua. Rigidity hauv cov txheej txheem xaiv yog cov khoom kim heev automotive engineers tsis tuaj yeem them taus.
Tiag tiag-lub ntiaj teb no Failures thiab Lessons
Koj kawm ntau dua los ntawm kev ua tsis tiav ntau dua li kev ua tiav. Thaum ntxov ntawm kuv lub sijhawm cuam tshuam nrog qhov no, peb tau txiav txim rau ib pawg ntawm stainless hlau EGR valve lub cev. Cov ntawv luam zoo li zoo. Peb khiav ntau lawm. Thawj tsab ntawv tshuaj xyuas dhau lawm. Tab sis thaum lub sij hawm tus neeg siv lub siab ntsuas, peb muaj 30% tsis ua hauj lwm tus nqi los ntawm micro-leaks. Kev puas tsuaj. Lub hauv paus ua rau? Cov qauv tsim tau muaj kev hloov pauv ntawm lub ntsej muag tuab ntawm lub flange mus rau ib lub raj nyias. Peb lub rooj vag txheem tsim tau me ntsis shrinkage porosity nyob rau hauv qhov kev hloov chaw. Qhov kho tsis yog txheej txheem overhaul; nws yog ib qho yooj yim tsim tweak-ntxiv me ntsis fillet radius los txhawb kev taw qhia solidification. Peb absorbed tus nqi ntawm cov batch ntawd. Cov lus qhia tsis raug muab tshem tawm: kev sib koom tes tiag tiag ntawm tus tsim qauv thiab cov kws tsim qauv tsim hauv DFM (Tsim rau Kev Tsim Kho) theem tsis yog qhov zoo-rau-muaj; nws yog tib txoj kev ua automotive peev casting txhim khu kev qha thiab kev lag luam.
Lwm zaj lus qhia yog los ntawm tus qauv xa khoom raws sij hawm. Automotive khiav ntawm lub sijhawm nruj. Peb muaj cov txheej txheem zoo meej rau kev tswj tuav caj npab. Tom qab ntawd, cov khoom siv raw khoom tseem ceeb rau peb cov lim dej ceramic (siv hauv lub rooj vag system) tau muaj qhov tsis zoo. Cov lim dej tshiab muaj qhov sib txawv me ntsis ntws yam ntxwv. Nws yog txaus los hloov cov qauv sau, tsim kom muaj kev kub ntxhov uas ua rau cov yeeb yaj kiab oxide nyob rau hauv qhov tsis tseem ceeb tab sis pom qhov pom tseeb. Cov khoom tau ua suab nrov, tab sis pom qhov tsis lees paub. Nws nres txoj kab. Peb tam sim no dual-qhov tseem ceeb consumables thiab muaj kev soj ntsuam raws tu qauv rau tej yam uas peb tsis tau xav mus kuaj ua ntej. Cov saw hlau yog ib feem ntawm cov txheej txheem.
Cov kev paub dhau los no qhia tias vim li cas kev ua neej nyob ntev hauv daim teb no tseem ceeb. Ib lub tuam txhab uas tau ua haujlwm rau ntau tshaj 30 xyoo, zoo li QSY, tau inevitably pom cov voj voog no-cov khoom siv tsis txaus, cov nqi hluav taws xob, kev hloov pauv cov ntsiab lus alloy. Lub koom haum nco ntawd yog ib yam khoom muaj nqis. Lawv tau zoo li tsim cov tshuab muaj zog thiab cov phiaj xwm thaub qab rau cov hom tsis ua haujlwm, uas txhais ncaj qha rau kev ntseeg siab rau lawv cov neeg siv tsheb. Nws tsis yog tsuas yog muaj cov khoom siv; nws yog hais txog kev muaj kev paub txog dab tsi yuav tsum ua thaum, inevitably, ib yam dab tsi mus off-script.
Saib Txoj Kev
Nyob qhov twg automotive peev casting taub hau? Kev siv hluav taws xob yog tus tsav tsheb loj, tab sis tsis yog raws li qee tus xav. Yog lawm, tus naj npawb ntawm cov cam khwb cia yuav txo qis hauv lub tsheb roj teeb hluav taws xob piv rau lub tshuab hluav taws xob sab hauv. Tsis muaj ntau txoj kev noj manifolds lossis cov khoom tso tawm. Txawm li cas los xij, cov seem seem feem ntau xav tau ntau dua. Lub teeb yuag yog qhov tseem ceeb tshaj plaws rau offset roj teeb hnyav, thawb rau ntau aluminium thiab magnesium castings nrog cov phab ntsa nyias. Lub thermal tswj tshuab rau roj teeb thiab lub cev muaj zog koom nrog txoj hauv kev, kev sib xyaw ua kua dej uas zoo tagnrho rau kev nqis peev casting.
Tsis tas li ntawd, lub laub rau cov khoom siv roj teeb pob lossis loj, kev sib xyaw ntawm lub tsheb subframes (megacastings) feem ntau yog cov npe ntawm high-pressure tuag casting lossis xuab zeb casting vim qhov loj. Tab sis nyob rau hauv cov rooj sib txoos loj, yuav muaj me me, muaj kev ntxhov siab heev, thiab cov duab geometrically tricky nodes los yog connectors uas peev casting yuav yog qhov kev daws teeb meem zoo. Lub neej yav tom ntej yog tsawg dua ntawm ntim thiab ntau ntxiv txog tus nqi - daws cov teeb meem tshwj xeeb, nyuaj nyuaj uas lwm cov txheej txheem ntim siab ua tsis tau.
Cov thev naus laus zis hauv qhov chaw tsim khoom kuj tseem hloov zuj zus. 3D luam ntawv ntawm cov qauv siv quav ciab lossis txawm tias cov plhaub ceramic yog tshem tawm qee qhov kev txwv ib txwm siv ntawm cov cuab yeej, tso cai rau kev tsim ntau tshaj radical consolidation thiab sai prototyping. Tab sis nws qhia txog kev hloov pauv tshiab - txheej adhesion, resin burnout yam ntxwv. Nws yog lwm lub cuab yeej, tsis yog khawv koob wand. Cov ntsiab cai tseem ceeb ntawm metallurgy, kev tswj xyuas thermal, thiab kev tsim rooj vag tseem siv tau. Lub hauv paus kev paub los ntawm kaum xyoo ntawm cov pa peev casting yog dab tsi tso cai rau lub chaw tsim khoom kom ua tiav cov thev naus laus zis tshiab no yam tsis tau poob rau hauv qhov tshiab, kim pitfalls. Nws yog ib qho khoom siv tes ua rov qab, ntau npaum li nws yog kev tshawb fawb.
