Kana vanhu vazhinji vari muindasitiri yemotokari vanonzwa 'kutangisa kwekudyara kwemotokari', vanofunga nezvemavhiri eturbocharger epamusoro kana mavhiri ekutapurirana akaomarara. Ichokwadi, asi ndipo panotangirawo kusanzwisisa kwakajairika-kuti ingori 'premium' maitiro ezvikamu zve niche. Chokwadi chiri pavhu chakashata uye chinonakidza. Haisi yekungooma kunzwisisa nekuda kwekuoma; ndezvekugadzirisa zvakananga, matambudziko ekugadzira gnarly ayo dzimwe nzira dzisingagone kubata pasina mutengo wekutyaira kana nguva yekutungamira nepadenga. Ndakaona dhizaini yakawandisa ichiuya umo mainjiniya akatsanangura kuisa mari nekuti yaitaridza hunyanzvi hwepamusoro, chete kuti isu tifambe navo tichidzokera kugungano rakadhindwa rakachipa 40% uye 95% yakanaka. Hukoshi chaihwo hausi mutsamba; zviri pakuziva chaizvo nguva yekuishandisa.
Iyo Core yeMaitiro: Iko Theory Inosangana neFoundry Grime
Bhuku racho rinoti kukanda kwekudyara, kana kurasika-wax kukanda, kunopa kupedzisa kwepamusoro uye kurongeka chaiko. Izvo izvo bhuku rinowanzo tarisa pamusoro ihuwandu hwehuwandu hwemhando dzinogona kukanganisa vimbiso iyoyo. Inotanga nepatani yewakisi. Tora tembiricha yejekiseni kana kudzvanywa zvisirizvo nechikamu chidiki, uye iwe unounza zvinonetsa zvinongoratidzira sekukanganisa mushure mekunge ganda re ceramic radzingwa uye simbi yadururwa. Ndinoyeuka purojekiti yeimba ye sensor kwataive ne 0.3mm dimensional drift batch-to-batch. Zvakatitorera vhiki yekudzingirira-mold temp? nguva yekutonhodza? — tisati taona kuti yaive shanduko yemwaka muhunyoro hwepamhepo hunokanganisa kupenya kwewakisi. Ndirwo rudzi rwemaoko-pa, runenge ruzivo rwetactile rwaunowana chete kubva mukumhanyisa kugadzira.
Ipapo pane chivakwa chegoko. Dip-and-stucco cycle inoita seyakatwasuka. Asi iyo slurry viscosity, nzvimbo yekuomesa (tembiricha uye humidity, zvakare), uye giredhi rejecha refractory yejasi rega rega-ndiro resipi iyo yega yega foundry varindi pedyo. Deko risina kusimba rinotsemuka panguva yekubvisa wakisi kana kudirwa; imwe yakanyanya kukora haidonhe zvakanaka uye inotungamira kune inclusions. Isu takamboshanda neiyo itsva zirconia-based prime slurry ye-high-nickel alloy chikamu. Iyo lab data yaive yakakwana. Pakumhanya kwemutyairi wekutanga, hafu yemateko akatsemuka. Nyaya yacho? Iyo yekupisa yekuwedzera coefficient yaive chikamu chezana kubva muzana kubva pamajasi ekuchengetedza, zvichiita kuti shear stress panguva yekupisa-yepamusoro autoclave dewax. Dzokera kubhodhi rekudhirowa.
Iyo yekudira pachayo ndiyo imwe nguva yakaoma. Nemidziyo yakaita sesimbi isina tsvina kana nickel-based alloys, tembiricha yekupisa uye kumhanya kwekudira kwakakosha. Kunyanya kunonoka, uye unowana mhute inomhanya kana kutonhora kuvhara. Kukurumidza, uye iwe unobvisa iyo yakapfava goko remukati, uchiunza ceramic inclusions muchikamu. Kune zvinhu zvemotokari senge manifolds eutsi kana turbo housings, iyo inoona kupisa bhasikoro, kusanganisirwa inzvimbo yakavimbiswa yekutadza. Hazvisi zvekungonyungudusa simbi chete; ndezvekutonga kupisa kwesimba kwese system-crucible, shell, ambient air-pahwindo re90-sekondi.
Sarudzo Yezvinhu: Hazvirevi Nezve Simba Chete
Tichitaura nezvezvishandiso, kusunda kwechikamu chemotokari kupinda mukureruka, kupisa, uye nemasisitimu anoshanda zvakanyanya kwakawedzera kushanduka kwe kukanda mari yemotokari. Nepo ductile iron uye kabhoni simbi ari mahosi ebasa emabhuraki uye zvimedu zvechimiro, chiitiko chiri mune akakosha alloys. Tora turbocharger zvikamu. Ivo vari kufamba kupfuura akajairwa maInconel mamakisi kuita alloys akakwenenzverwa anoenzanisa creep kuramba nehupenyu hwekuneta kwekupisa. Asi heino kubata: aya alloys epamberi anowanzo kunetsa kukanda. Ivo vane yakamanikana solidification siyana, zvichiita kuti ive nyore kubvarura kupisa. Nzvimbo dzadzo dzekunyungudika dzakakwirira dzinoda zvakatonyanya kugadzikana masheti emagomba. Kambani yakafambisa izvi kwemakore, senge Qingdao Qiangsenyuan Technology Co., Ltd. (QSY), inosimudzira nhoroondo yayo refu mukukandira uye kugadzira kugadzira iyo nzira ruzivo. Chinhu chimwe chete kudurura bhatani rekuedza re cobalt alloy; ndeimwe kugara ichigadzira yakatetepa-madziro, yakaoma turbine imba ine zero leakage nzira.
Aluminium investment casting yemotokari ndicho chikara chayo. Inosundirwa zvakanyanya kudzikisa uremu - funga yakaomesesa miviri yehuturu kana mabhuraketi ezvimiro. Kubatsira ndiko kusununguka kwekugadzira. Iwe unogona kubatanidza nzira dzekutonhora, kukwira mabhosi, uye kusimbisa mbabvu muchidimbu chimwe. Dambudziko ndere porosity. Aluminium inobata gasi, uye kukurumidza kusimba kwezvikamu zvitete zvinogona kuibata. Takapedza mwedzi tiri pane prototype yekutungamidza, tichigadzira gating system, tichiwedzera mamhepo anotonhorera, uye kunyange kuyedza nzira dzakasiyana dzekubvisa gassing yekunyungudika tisati tawana X-ray yakachena castings. Iko kutarisisa kusingadzoreki kune ruzivo runoparadzanisa prototype shopu kubva kune yakagadzirira-yakagadzirira mutengesi.
Zvadaro pane post-casting. Vazhinji vanofunga kuti basa rinoitwa kana chikamu chazunguzwa kubva mugoko. Kure nazvo. Kurapa kwekupisa kazhinji hakugone kutaurirana. Kune chekuchengetedza-chakakosha chikamu senge brake caliper gomo, iyo chaiyo hasha (seT6 yealuminium) inofanirwa kurohwa chaizvo muchikamu chose, izvo zvinogona kunyengera nekusiyana kwechikamu chakakora. Apa ndipo panosanganisirwa mutengi wakamira, senge QSY musanganiswa we Investment casting uye mu-imba CNC machining, inobhadhara. Ivo vanogona kukonzeresa kushoma asi kunofungidzirwa kukanganiswa kubva mukupisa kupisa kuenda kune yavo machining zvigadziriso, kuchengetedza musoro wakakura kuzasi. Machining an as-cast surface ine variable stock iresiphi yekuputsika kweturusi uye zvimedu.
Mutengo Equation: Kururamisa iyo Premium
Izvi zvinotungamira kune chipingamupinyi chikuru mumotokari: mutengo. Investment casting tooling (simbi inofira mapatani ewakisi) inodhura. Maitiro acho ndeekushanda nesimba. Saka, unoda kururamiswa kwakasimba. Iko kuhwina kwekirasi chikamu chekubatanidza. Ndakashanda pachibhuraketi cheinjini icho pakutanga chakanga chiri kugadzirwa kwezvidimbu zvitanhatu zvakadhindwa uye zvakakandwa. Isu takaigadzira patsva senge imwe aluminium investimendi yekukandira. Isu takabvisa zvese zvekunama, kudzikisa nguva yegungano, kucheka huremu ne15%, uye nekuomarara kwakavandudza. Mutengo wekukanda pachikamu chimwe nechimwe waive wakakwira, asi mari yese yekumhara, yekumisikidza mukugadzira uye kutakura zvinhu, yaive yakaderera. Ndiyo nzvimbo inotapira.
Chimwe chikonzero ndechekuita izvo mamwe maitiro asingakwanisi kuunza. Iyo yemukati yekutonhodza ndima mune yepamusoro-inoshanda brake caliper muenzaniso wakanaka. Unogona kuedza kuzvigadzira, asi zvinodhura zvenyeredzi. Iwe unogona kuedza kukanda jecha, asi kupedzisa kwepamusoro uye kurongeka kwechikamu kungave kwakashata, zvichikanganisa kutonhora. Investment casting ndiyo chete nzira inoshanda. Iyo ndeye yakazara system mutengo uye kuita, kwete chete mutengo wechidimbu pane quote.
Musungo uri pamusoro-engineering. Ndakaona zvinhu zvine kushivirira kwe +/- 0.5mm yakatsanangurwa sekudyara kwekudyara kana jecha rinofambiswa zvakanaka richikwanisa kubata +/- 0.8mm zvakanaka pachidimbu chemutengo. Hurukuro inofanira kutanga nebasa: Ndeapi ari echokwadi akakomba zviyero? Ndeapi makesi ekutakura? Chii chinonzi corrosion kana tembiricha nharaunda? Kazhinji, nzira yakasanganiswa inoshanda zvakanyanya - shandisa kuisa mari kune yakakosha, yakaoma musimboti wechikamu, uye weld kana bhaudhi pazvikamu zvakapfava, zvakachipa. Rigidity mukusarudza sarudzo ndeyeumbozha mainjiniya emotokari haakwanise.
Chaiyo-Nyika Kukundikana uye Zvidzidzo
Unodzidza zvakawanda kubva pakukundikana pane kubudirira. Pakutanga munguva yangu yekubata neizvi, takanga tine odha yebatch yesimbi isina tsvina EGR valve miviri. Maprints aitaridzika zvakanaka. Isu takamhanya kugadzira. Kuongororwa kwechinyorwa chekutanga kwakapfuura. Asi panguva yekumanikidzwa kwemutengi kuyedzwa, isu takave ne30% yekutadza chiyero kubva kudiki-leak. Catastrophic. Chikonzero chikuru? Dhizaini yaive neyakapinza yekupisa yekupisa kubva kune gobvu flange kuenda kune yakatetepa chubhu chikamu. Gedhi redu rakajairwa rakagadzira kushomeka kushoma munzvimbo iyoyo yeshanduko. Kugadzirisa kwanga kusiri maitiro ekugadzirisa; yaive yakapfava dhizaini tweak-inowedzera diki fillet radius kukurudzira kusimba kwekutungamira. Takatora mari yebatch iyoyo. Chidzidzo chacho chakanga chisingadzimiki: kubatana kwechokwadi pakati pemugadziri uye muvambi injiniya muDFM (Design for Manufacture) chikamu hachisi chinhu chakanaka-kuva- nacho; ndiyo chete nzira yekuita kukanda mari yemotokari yakavimbika uye ine mari.
Chimwe chidzidzo chakauya kubva pane-mu-nguva-yekuburitsa modhi. Motokari inomhanya panguva dzakasimba. Isu takanga tine nzira yakakwana yekudzora ruoko bracket. Zvadaro, kiyi yezvigadzirwa zvekushandisa zveceramic sefa (inoshandiswa mugeti system) yaive nekupera kwemhando. Masefa matsva aive nekamwe kakuyerera kakati siyanei. Zvakanga zvakakwana kushandura nzira yekuzadza, kugadzira mhirizhonga yakatungamirira kumafirimu e-oxide munzvimbo dzisina kuoma asi dzinooneka. Mativi acho aishanda zvakanaka, asi zvairambwa. Yakamisa mutsara. Isu ikozvino mbiri-sosi yakakosha yekushandisa uye tine inouya yekuongorora mapuroteni ezvinhu zvatisina kumbofunga kutarisa kare. Iyo yekugovera cheni chikamu chemaitiro.
Zviitiko izvi zvinosimbisa kuti nei kurarama kwenguva refu mundima iyi kuchikosha. Kambani yave ichishanda kweanopfuura makore makumi matatu, seQSY, yakaona matenderedzwa aya - kushomeka kwezvinhu, mari yemagetsi, kushandura alloy yakatarwa. Chiyeuchidzo ichocho chesangano chinhu chinobatika. Vanogona kunge vakavaka masisitimu akasimba uye zvirongwa zvekuchengetedza zveakajairwa kutadza modes, ayo anodudzira zvakananga kuvimbika kune avo emotokari vatengi. Hazvisi zvekungova nemidziyo chete; ndezvekuva neruzivo rwakadzama rwezvekuita kana, zvisingadzivisiki, chimwe chinhu chikaenda kunze-script.
Kutarisa Pasi Mugwagwa
Kupi kukanda mari yemotokari musoro? Electrification ndiye mutyairi mukuru, asi kwete nenzira iyo vamwe vanofunga. Ehe, iyo sheer nhamba yezvikamu zvakakandwa zvinogona kudzikira mubhatiri-yemagetsi mota inopesana neiyo yemukati yekupisa injini. Hapasisina yakaoma manifolds ekutora kana exhaust zvikamu. Zvisinei, zvikamu zvasara zvinowanzoda zvakawanda. Kureruka kunonyanya kukosha kudzikamisa huremu hwebhatiri, kusundira kune imwe aluminium uye magnesium castings nemadziro akatetepa. Iwo anopisa manejimendi masisitimu emabhatiri nemamotor anosanganisira akaoma, akabatanidzwa emvura nzira dzakanakira kukanda mari.
Uyezve, iyo yekusundidzira yezvimiro zvebhatiri mapaketi kana hombe, akasanganiswa emota subframes (megacastings) ndiyo inonyanya dura rekukanda-kudzvanya kufa kukanda kana kukanda jecha nekuda kwehukuru. Asi mukati meaya magungano makuru, pachange paine madiki, akanyanya kusimbiswa, uye geometrically anonyengera nodhi kana majoini uko kukanda mari kunogona kuve mhinduro yakakwana. Ramangwana harina kuderera pamusoro pehuwandu uye huzhinji pamusoro pekukosha-kugadzirisa zvakananga, matambudziko makuru ayo mamwe maitiro epamusoro-soro asingagoni.
Iyo tekinoroji mukati meiyo foundry iri kubuda zvakare. Kudhinda kwe 3D kwewakisi mapatani kana kunyange magomba eceramic kuri kubvisa zvimwe zvechinyakare zvipingaidzo zvekushandisa, zvichibvumira kubatanidzwa kwakanyanya kwedhizaini uye nekukurumidza prototyping. Asi inosuma mitsva mitsva — kunamatira kwelayer, resin burnout maitiro. Icho chimwe chishandiso, kwete chemashiripiti wand. Iwo musimboti wemisimboti yemetallurgy, thermal manejimendi, uye gating dhizaini ichiri kushanda. Iyo yekutanga chiitiko kubva kumakumi emakore ezvakajairwa Investment casting ndiyo inobvumira muvambi kuti abudirire kutora matekinoroji matsva aya pasina kuwira mumakomba matsva, anodhura. Inyanzvi yekudzokorora, sekunge iri sainzi.
