Xa abantu abaninzi besiva 'isiseko sesanti ye-aluminiyam', baba nomfanekiso wenkqubo esisiseko, ephantse ibe yakudala yokwenza iindawo ezilula, ezirhabaxa. Leyo yimbono yokuqala ephosakeleyo. Ubunyani bunobunzima ngakumbi; yindlela esisiseko ethi, xa isenziwa ngokuchanekileyo nangokuqonda, ikhuphisane kwizithuba obungalindelanga ukuba uzilindele. Asikokulahla nje isinyithi emngxunyeni wesanti. Imalunga nokulawula izinto eziguquguqukayo-intlabathi, ukufuma, iisistim zokubopha, uyilo lwe-gating, ulawulo lokuqinisa-olwahlula ukuphosa okusebenzisekayo kwinxalenye ye-scrap. Ndibone iiprojekthi ezininzi zisilela ngenxa yokuba uyilo lwaphoswa phezu kodonga kwisiseko ngaphandle kokuqwalasela ezi zinto zisisiseko. Ukukhethwa kwe-Foundry kaninzi kubilisa ekubambeni kwabo ezi nkcukacha, kungekhona nje uluhlu lwabo lwezixhobo.
Undoqo weNkqubo: Yonke into iseSantini
Masingene kwigrit. Ngokoqobo. 'Intlabathi' ekugalweni kwesanti ayilohlobo lwasemva kwendlu yakho. Ngumxube owenziwe ngobunjineli, ngokwesiqhelo i-silica, i-zircon, okanye ichromite, edityaniswe nodongwe (isanti eluhlaza) okanye izibophelelo zekhemikhali (ezifana ne-furan okanye i-phenolic resin yokubumba okungabhaki). Umahluko bubusuku nemini. Kwi-aluminiyam, ndingqiyama kwisanti ebotshelelwe ngamachiza kwiijometri ezintsonkothileyo okanye ukunyamezelana okungqongqo. Isanti eluhlaza iyakhawuleza kwaye inexabiso eliphantsi kumthamo ophezulu, iimilo ezilula, kodwa uthengisa ngomphezulu kunye nozinzo lwedimensional. Ubuchule kukukhetha inkqubo efanelekileyo yomsebenzi. Umgibe oqhelekileyo? Kucingelwa ukuba yonke isanti iyafana. Ndineendawo eziye zaphuma zinemithambo eyoyikekayo yomphezulu ngenxa yokuba ukwanda kwe-thermal yentlabathi bekungafanelekanga kwipateni yokuqina kwealluminiyam. Kuthathe iiveki zokuzama kunye nempazamo ngamabakala esanti ahlukeneyo kunye nemilinganiselo yokubopha ukuyilungisa.
Ukwenza ipateni bobunye ubugcisa obuchuliweyo. Iipateni zokhuni zilungile kwiiprototypes okanye ukubaleka okufutshane, kodwa kuyo nayiphi na into ezinzileyo, udinga iipateni zetsimbi okanye ze-epoxy. I-angle eyidrafti, ukugqiba, isibonelelo sokunciphisa-i-alloy nganye iyancipha ngesantya esahlukileyo-yonke iyakhiwa kuloo pateni. Ukubalwa kakubi kweepesenti ezimbalwa ekuncipheni kunokunika ibhetshi epheleleyo ngaphandle kokucaciswa. Ndikhumbula ibhetshi yezindlu zempompo apho sasisebenzisa umgaqo wokuncipha oqhelekileyo we-aluminiyam ye-A356, kodwa uhlengahlengiso oluthile kunye nobushushu obuthululwayo buyitshintshile ngokwaneleyo ukuze kubangele umba ofanelekileyo ngenxalenye yomatshini wokudibanisa. Kwafuneka sihlengahlengise ipateni, esisifundo esidla imali eninzi nesithabatha ixesha.
Emva koko kukho isango kunye nokunyuka. Apha kulapho amava e-Foundry ebonisa ngokwenene. Uyila imijelo etyisa i-aluminiyam etyhidiweyo kwindawo yokungunda kunye neendawo zokugcina amanzi ezondla ukucutheka njengoko iphola. Ukungangeni kakuhle kukhokelela kwisiphithiphithi, esibangela ukubandakanywa kwe-oxide kunye neendawo ezibuthathaka. Ukwenyuka okungonelanga kukhokelela ekuncipheni kwe-porosity. Asiyothiyori yeencwadi nje kuphela; yimvakalelo ephuhlisiwe ekujongeni amawaka emidlalo yokuxheshiswa. Injineli elungileyo ngamanye amaxesha iya kubeka isikhuphukeli esincinci apho isoftware yokulinganisa ingawubheki umba, ngokusekwe kwi-hunch evela kumsebenzi ofanayo wangaphambili. Kwaye basoloko benyanisile.
Apho iAluminiyam yeSanti yokuphosa ingena khona (kwaye apho ingayi)
Le nkqubo ayisiyiyo yonke into. Kwivolumu ephezulu, enodonga olucekethekileyo, iindawo ezintsonkothileyo njengeeblade ze-iturbine, ungajonga utyalo mali okanye ukuphosa ukufa. Kodwa kwimithamo ephantsi ukuya kwephakathi, iinxalenye ezinkulu (cinga iibhlokhi ze-injini, iimeko zothumelo, izibiyeli ezinkulu zesakhiwo), kwaye apho ukuguquguquka koyilo kubalulekile, ukuphosa isanti kubiza kakhulu. Ixabiso lezixhobo liqhekeza le-die casting. Eyona ndawo imnandi yeyokuba enye, iiprototypes, kunye namacandelo anzima. Ndikhe ndasebenza kumacandelo ezixhobo zaselwandle ezinobunzima obungaphezulu kwama-200 kg ebezifanelekele ngokugqibeleleyo ukujula kwesanti. Ukuzama ukwenza oko njengokuphosa ukufa kuya kuba kubiza kakhulu.
Nangona kunjalo, umsebenzi we-post-casting ubalulekile. An isiseko sesanti ye-aluminiyam ekwabonelela ngomatshini wokwenza in-house inzuzo enkulu. Iqinisekisa ukuba bayaluqonda ulwakhiwo lokuphosa kwaye banokucwangcisa iidatum zoomatshini kunye nezibonelelo kwasekuqaleni. Le ndlela idityanisiweyo ithintela amaphupha amabi apho inxalenye iphosa kakuhle kodwa ingakwazi ukubanjwa ngokufanelekileyo kumsebenzi we-CNC, okanye apho umphezulu wokutywina obalulekileyo uphelela kwindawo enemingxuma yokuphosa. Imalunga nokulawula inkqubo ukusuka kubumba ukuya kwindawo egqityiweyo.
Yiyo loo nto ububanzi besakhono senkampani bubalulekile. Thatha i-firm like Qingdao Qiangsenyuan Technology Co., Ltd. (QSY). Ngaphezulu kweminyaka engama-30 yokuphosa kunye noomatshini, bafumana eli khonkco. Iwebhusayithi yabo, tsngtaocnc.com, ibonisa ukuba baphatha iinkqubo ezininzi. Ngelixa bedwelisa iqokobhe ngundo ukuphosa kwaye utyalo mali njengezinto ezikhethekileyo, imigaqo yokwenza umngundo kunye nesinyithi iguqulela. I-Foundry eqonda ngokuchaneka kokungunda kweqokobhe iya kuba nendlela eqeqeshekileyo yolawulo lwesanti kunye nokusetyenzwa kwamaxwebhu azuzisa umsebenzi wabo wokuphosa isanti. Umsebenzi wabo onama-alloys akhethekileyo afana ne-nickel-based based principles ubunzulu bobuchule be-metallurgical, obuxabiseke kakhulu xa ujongene ne-alloys ye-aluminium eyinkimbinkimbi efana ne-silicon ephezulu okanye i-high-magnesium amabakala akhohlisayo ukuphosa ngaphandle kokukrazula okushushu.
UMtyholi kwiiNkcukacha: I-Porosity, Ukugqiba, kunye ne-Real-World Compromises
I-Porosity yidabi elingunaphakade kwi-aluminium casting. Ingaba yi-gas porosity evela kumswakama kwintlabathi okanye i-hydrogen kwi-melt, okanye i-shrinkage porosity ekungondlini okungonelanga. I-Foundry enobuchule iya kuba neenkqubo zokususa igesi (njenge-rotary degassing ene-argon) kunye nolawulo olungqongqo lokumisa isanti. Kodwa ngamanye amaxesha, kufuneka wamkele inqanaba elithile. Into ephambili kukuyichaza ngokwekhontrakthi-usebenzisa i-ASTM okanye imigangatho efanayo yokuhlola iradiyographic-kunye nokuqinisekisa ukuba ayikho kwimimandla ebalulekileyo. Ndikuvumile ukuphoswa nge-porosity ekwanti kwiindawo ezingezizo ezolwakhiwo ukugcina ixesha leprojekthi, kodwa ungaze usondele kumngxuma odityanisiweyo okanye itywina loxinzelelo.
Ukugqitywa komphezulu wolunye uqwalaselo olusebenzayo. Imiphezulu ye-As-cast evela kwi-molds yesanti ineempawu ezibonakalayo. Ukuba ufuna ukugqiba okugudileyo, kufuna ukuqhushumba (ukudubula okanye isanti) okanye ukucola. Oku kongeza iindleko. Uyilo kufuneka luchaze ukuba yeyiphi imiphezulu 'enjenge-cast' kwaye yeyiphi 'engoomatshini'. Ndiyibonile imizobo ebiza i-3.2 μm Ra engenakwenzeka kumphezulu wokuphoswa-akunakwenzeka. Unxibelelwano olucacileyo apha lugcina ukuphoxeka okukhulu kamva.
Unyango lobushushu luphantse lunikezelwe kuninzi lobunjineli bebakala lokugalelwa kwesanti yealuminiyam efana ne-A356 okanye i-A357. Yenziwa ukufezekisa umsindo ofunekayo (i-T6 iqhelekile). Kodwa ubudlelwane be-Foundry kunye nesixhobo sokufudumala sibalulekile. Ukuba zingamaqumrhu ahlukeneyo, ukugqwetheka kunokuba ngumdlalo onetyala. Ngaba yayiluxinzelelo olushiyekileyo lokuphosa okanye ukulungiswa ngexesha lonyango lobushushu besisombululo? Isibonelelo esihlanganisiweyo, okanye ubuncinci intsebenziswano elawulwa ngokuqinileyo, yenza oku kube lula. Injongo yindawo ezinzileyo, egcwele ubushushu ngokupheleleyo elungele ukwenziwa komatshini wokugqibela.
Imeko ekwiNqaku: Ukufunda kwi-Near-Miss
Makhe ndichaze imeko yokwenyani, engachazwanga kancinane. Sasinendawo ye-chassis yesithuthi esikhethekileyo. Idizayini yayintsonkothile, inobunzima bodonga olwahlukeneyo kunye neepaseji ezineentambo. Sahamba nomntu ohloniphekileyo isiseko sesanti ye-aluminiyam. Isampulu yokuqala iphumelele iitshekhi ezibonwayo nezinemilinganiselo. Kodwa ngexesha lendibano yeprototype, indlebe ephakamayo yaqhawulwa ngexesha le-torque-down. Uphononongo lokungaphumeleli lubonise ukuvala okubandayo-ukuyeka apho imisinga yentsimbi emibini idibanela kodwa ingadibani kakuhle-kanye kwingcambu yoxinzelelo oluphezulu lwendlebe.
Oyena nobangela? Idizayini yokungena yazalisa elo candelo lokungunda okokugqibela, kwaye intsimbi yayilahlekelwe bubushushu obuninzi. Ukulinganisa kokuqala kwe-Foundry kuye kwabonisa umcimbi onokwenzeka, kodwa kwathathwa njengomngcipheko ophantsi. Ukulungiswa kwakungekokongeza nje isinyithi esingakumbi; yayiyila ngokutsha i-gating ukuze itshintshe ipateni yokuzalisa kunye nokulungelelanisa ubushushu bokugalela loo bhetshi ye-alloy ethile. Yalibazisa lo msebenzi kangangenyanga. Isifundo sasintlu-mbini: ungaze uzihoye nezilumkiso zokulinganisa ezincinci, kwaye soloko ukhankanya kwaye wenze uvavanyo lwe-radiographic kwiindawo ezinoxinzelelo oluphezulu kuhlolo lwenqaku lokuqala, nokuba alikho kwi-spec eqhelekileyo.
Apha kulapho inkcubeko yokusonjululwa kwengxaki ye-Foundry ivavanywa khona. Ezilungileyo azikhuseli. Bangena ngaphakathi, banqumle ukuphosa, bahlalutye isiphene, kwaye bacebise isisombululo esiqinisekisiweyo. Bayiphatha njengomngeni wobunjineli odibeneyo. Ababi bakhomba iminwe kumthengisi we-alloy okanye uyilo. I-Foundry esebenza njengeqabane ixabisa ubunzima bayo kwigolide.
Ukujonga Phambili: I-Niche ikhuselekile
Ngayo yonke intetho malunga noshicilelo lwe-3D lokubumba kunye noshicilelo lwesinyithi oluthe ngqo, luyi ukugalelwa kwesanti yealuminiyam iphelelwe lixesha? Kude noko. Kwimiyinge yemveliso engaphaya kwesandla, isenoqoqosho kakhulu. Itekhnoloji iyadibana, nangona kunjalo. Ndibone iindlela ezixubeneyo apho i-3D-printed cores yesanti isetyenziselwa iipaseji ezintsokothileyo zangaphakathi ngaphakathi kokungunda kwesanti yemveli. Oku kuvula inkululeko yoyilo olutsha ngelixa ugcina ubuninzi benkqubo ngeendleko.
Ikamva le-Foundry eyimpumelelo ilele kolu hlobo lokuguquguquka. Ukudibanisa ubugcisa bemveli-imvakalelo yesanti, iliso lokuqina-kunye nokulinganisa kwale mihla, ukubekwa esweni kwenkqubo, kunye nobuchwepheshe obuxhasayo obufana nomatshini we-CNC. Imalunga nokunikezela ngesisombululo esipheleleyo. Inkampani ethe yavela kwisiseko esisulungekileyo ukuya kumvelisi odibeneyo, njenge-QSY kunye namashumi eminyaka achaziweyo kuzo zombini ukuphosa kunye noomatshini, ibekwe kule nto. Bayaqonda ukuba ukuphosa kudla ngokuba linyathelo lokuqala lokuhambisa icandelo elisebenzayo.
Ngoko ke, xa uvavanya i isiseko sesanti ye-aluminiyam, khangela ngaphaya kwexabiso ngekhilogram. Jonga ivenkile yabo yepateni, ilebhu yabo yesanti, iiprothokholi zabo zolawulo lomgangatho wokunyibilika kwekhemistri kunye novavanyo lomatshini, kwaye ngokubalulekileyo, ukuzimisela kwabo ukuzibandakanya kwinkqubo yoyilo kwangoko. Cela uphononongo lwamacandelo acela umngeni. Umsebenzi ongcono kakhulu uvela kwiziseko ezizibonayo kungekhona njengezigaleli zetsimbi, kodwa njengamaqabane okuvelisa asombulula ijometri kunye nengxaki yezinto eziphathekayo. Loo ndlela yokucinga yenza wonke umahluko phakathi kwenxalenye esebenzayo kunye nephela njengenkunkuma ebizayo.
