Xa abantu abaninzi kwishishini le-auto besiva 'utyalo-mali lwemoto', bacinga ngamavili e-turbocharger asebenza ngokuphezulu okanye izinto ezintsonkothileyo zothumelo. Yinyani leyo, kodwa kulapho imbono ephosakeleyo iqala khona-ukuba yinkqubo 'yeprimiyamu' yeenxalenye ze-niche. Inyani emhlabeni imdaka kwaye inomdla ngakumbi. Ayikokuntsonkotha nje ngenxa yokuntsokotha; imalunga nokusombulula iingxaki ezithile, zemveliso ye-gnarly ezinye iindlela ezingenakuchukunyiswa ngaphandle kweendleko zokuqhuba okanye ixesha lokukhokela ngophahla. Ndibone uyilo oluninzi lungena apho injineli ichaze utyalo-mali ngenxa yokuba kuvakala ukuba kubuchwephesha obuphezulu, kuphela kuthi kufuneka siyibuyisele kwindibano enesitampu esinesitampu esinexabiso eliphantsi ngama-40% kunye ne-95% elungileyo. Ixabiso lokwenyani alikho kwileyibhile; kusekwazini ngokuchanekileyo ixesha lokuyisebenzisa.
Undoqo weNkqubo: Apho ithiyori idibana ne-Foundry Grime
Incwadi ithi ukuphosa utyalo-mali, okanye ukulahlwa kwewax elahlekileyo, kuzisa umphezulu ogqwesileyo wokugqiba kunye nokuchaneka komda. Eyona nto isoloko ijongwa yincwadi yesikhokelo linani elipheleleyo lezinto eziguquguqukayo ezinokonakalisa eso sithembiso. Iqala ngepateni yewax. Fumana iqondo lobushushu lenaliti okanye uxinzelelo olungalunganga ngomda omncinci, kwaye wazisa uxinzelelo oluthi lubonakale njengokugqwetheka emva kokuba iqokobhe leceramic likhutshiwe kwaye isinyithi sigalelwe. Ndikhumbula iprojekthi yendlu yesivamvo apho sasine-0.3mm dimensional drift batch-to-batch. Kusithathe iveki sileqa—iqondo lokushisa lokungunda? ixesha lokupholisa?—Phambi kokuba siyifumane yayilutshintsho lwexesha lonyaka lokufuma okungqonge i-ambient echaphazela i-wax crystallization. Olu luhlobo lwezandla, phantse ulwazi olubambekayo olufumana kuphela kwimveliso esebenzayo.
Emva koko kukho isakhiwo seqokobhe. Umjikelo wediphu kunye ne-stucco ubonakala uqondile. Kodwa i-viscosity ye-slurry, indawo yokomisa (iqondo lobushushu kunye nokufuma, kwakhona), kunye nebakala lesanti ephikisayo yengubo nganye-yiresiphi ukuba yonke i-Foundry igada ngokusondeleyo. Iqokobhe elibuthathaka kakhulu liyaqhekeka ngexesha lokuthambisa okanye ukugalelwa; enye engqindilili kakhulu ayikhuphi ngokufanelekileyo kwaye ikhokelela ekufakweni. Sake sasebenza kunye ne-zirconia-based prime slurry ye-high-nickel alloy part. Idatha yaselebhu yayigqibelele. Kuhambo lokuqala lokuqhuba, isiqingatha soonokrwece saqhekeka. Ingxaki? I-coefficient yokwandisa i-thermal yayiyiqhezu leepesenti ukusuka kwiingubo zokugcina, ukudala uxinzelelo lwe-shear ngexesha lobushushu obuphezulu be-autoclave dewax. Buyela kwibhodi yokuzoba.
Ukugalela ngokwako sesinye isixa esibalulekileyo. Ngezinto ezinje ngentsimbi engenasici okanye i-nickel-based alloys, ubushushu obuphezulu kunye nesantya sokugalela zibalulekile. Ukucotha kakhulu, kwaye ufumana ukubaleka kwenkungu okanye ukuvalwa okubandayo. Ngokukhawuleza kakhulu, kwaye utshabalalisa igobolondo elithambileyo langaphakathi, ungenisa ukubandakanywa kwe-ceramic kwindawo. Kumalungu eemoto afana ne-exhaust manifolds okanye izindlu ze-turbo, ezibona i-thermal cycling, ukubandakanywa yindawo yokusilela eqinisekisiweyo. Ayikokunyibilika kwesinyithi kuphela; imalunga nokulawula i-thermal dynamics yenkqubo yonke-i-crucible, iqokobhe, umoya ojikelezayo-kwifestile yemizuzwana engama-90.
Ukhetho Lwezinto eziphathekayo: Akunjalo Ngamandla Nje
Ukuthetha ngezixhobo, ukutyhala kwecandelo leemoto kwiinkqubo ezikhaphukhaphu, ezishushu, kunye nezisebenzayo ngakumbi ziye zaphembelela inguquko yendalo. utyalo mali lwemoto. Ngelixa i-iron ductile kunye ne-carbon steels zingamahashe okusebenzela kwizibiyeli kunye neziqwenga zesakhiwo, isenzo sikwii-alloys ezikhethekileyo. Thatha amacandelo e-turbocharger. Bahamba ngaphaya kwamabanga aqhelekileyo e-Inconel ukuya kwii-alloys ezilungelelanisiweyo ezilinganisa ukuxhathisa kokunyuka kunye nobomi bokudinwa okushushu. Kodwa nantsi into yokubambisa: ezi ngxubevange zihambele phambili zihlala zisiba liphupha lokuphosa. Zinoluhlu olumxinwa lokuqiniswa, olubenza ukuba bathande ukukrazuka okushushu. Amanqaku abo aphezulu okunyibilika afuna iinkqubo ezizinzileyo zamaqokobhe. Inkampani eqhube le nto iminyaka, njenge Qingdao Qiangsenyuan Technology Co., Ltd. (QSY), ifumana imbali yayo ende ekwenziweni nasekuchubeni ukwakha olo lwazi lwenkqubo. Yinto enye yokuthulula iqhosha lokuvavanya i-cobalt alloy; yenye ukuvelisa ngokungaguquguqukiyo udonga olucekethekileyo, oluntsokothileyo lwezindlu ze turbine eneendlela ezivuzayo eziqanda.
Utyalo-mali lwe-aluminiyam kwi-automotive lirhamncwa layo. Ityhalwa kakhulu ekunciphiseni ubunzima-cinga imizimba ye-throttle eyinkimbinkimbi okanye izibiyeli zesakhiwo. Inzuzo yinkululeko yoyilo. Unokudibanisa iziteshi zokupholisa, ukukhwela abaphathi, kunye nokuqinisa iimbambo kwisiqwenga esinye. Umceli mngeni yi-porosity. I-Aluminiyam ibamba igesi, kwaye ukuqina ngokukhawuleza kwamacandelo amancinci kunokubambisa. Sichithe iinyanga kwiprototype ye-knuckle elawulayo, silungisa inkqubo yokungena, songeza iindawo ezipholileyo, kwaye sizama iindlela ezahlukeneyo zokukhupha igesi yokunyibilika ngaphambi kokuba sifumane i-X-ray ecocekileyo yokuphosa. Lugxininiso olungayekeleliyo kwiinkcukacha ezahlula ivenkile engumzekelo kumboneleli olungele imveliso.
Emva koko kukho i-post-casting. Abaninzi bacinga ukuba umsebenzi wenziwe nje ukuba inxalenye ikhutshiwe kwiqokobhe. Kude noko. Unyango lobushushu lusoloko lungaxoxiswana. Kwicandelo elibalulekileyo lokhuseleko njenge-brake caliper mount, umsindo othile (ufana ne-T6 ye-aluminiyam) kufuneka ubethwe ngokuchanekileyo kwindawo yonke, enokuba nenkohliso kunye nobukhulu bamacandelo ahlukeneyo. Apha kulapho udibaniso oluthe nkqo lomthengisi, njengendibaniselwano ye-QSY ye utyalo mali kunye ne-in-house CNC machining, ihlawula. Banokuthi bajongane nokugqwetheka okuncinci kodwa okuqikelelweyo ukusuka kunyango lobushushu ukuya kumatshini wabo wokulungisa, ukugcina intloko ebuhlungu ezantsi komsinga. Ukutshiza umphezulu we-as-cast kunye nesitokhwe esiguqukayo yiresiphi yokwaphuka kwesixhobo kunye ne-scrap.
INtengo yeNtengo: Ukuthethelela iNtlawulo yaNyanga le
Oku kukhokelela kumqobo omkhulu kwiimoto: ixabiso. Izixhobo zotyalo-mali (intsimbi iyafa ngenxa yeepateni zewax) iyabiza. Le nkqubo ifuna abasebenzi kunye namandla. Ngoko ke, kufuneka ube nesisombululo esinamandla. Uloyiso lwakudala luyinxalenye yokuhlanganiswa. Ndasebenza kwisibiyeli se-injini ekuqaleni eyayisenziwa ngeziqwenga zentsimbi ezintandathu ezinesitampu nezidityanisiweyo. Siye sayilwa ngokutsha njengotyalo-mali olunye lwe-aluminiyam. Sayiphelisa yonke i-welding, yanciphisa ixesha lokuhlanganisana, sanciphisa ubunzima nge-15%, kunye nokuphucula ukuqina. Ixabiso lokuphoswa ngenxalenye nganye beliphezulu, kodwa ixabiso lilonke lokufika, ukudityaniswa kwe-asembly kunye nolungiselelo lolungiselelo, liphantsi. Nantso indawo emnandi.
Esinye isizathu kukusebenza ezinye iinkqubo azikwaziyo ukunikezela. Iipaseji zokupholisa zangaphakathi kwi-high-performance brake caliper ngumzekelo obalaseleyo. Ungazama ukuwenza ngoomatshini, kodwa kubiza kakhulu ngokweenkwenkwezi. Ungazama ukuphosa isanti, kodwa ukugqitywa komphezulu kunye nokuchaneka kwendlela kuya kuba kubi, kuchaphazela ukusebenza kakuhle kokupholisa. Ukwenziwa kotyalo-mali kuphela kwendlela esebenzayo. Kumalunga nexabiso lenkqubo epheleleyo kunye nokusebenza, hayi nje ixabiso leqhekeza kwisicatshulwa.
Umgibe ubunjineli obugqithisileyo. Ndiwabonile amacandelo anonyamezelwano lwe +/- 0.5mm ecaciswe njengokuphosa kotyalo-mali xa isanti eqhutywa kakuhle inokubamba +/- 0.8mm ngokugqibeleleyo kwiqhezu leendleko. Incoko kufuneka iqale ngomsebenzi: Yeyiphi eyona milinganiselo ibalulekileyo? Zeziphi iimeko zomthwalo? Yintoni umhlwa okanye ubume bobushushu? Rhoqo, indlela ye-hybrid isebenza ngcono-sebenzisa utyalo-mali olubalulekileyo, undoqo wenxalenye, kunye ne-weld okanye ibholithi kumacandelo alula, angabizi kakhulu. Ukuqina ekukhetheni inkqubo yinto yeenjineli zeemoto zodidi ezingenakufikelela.
Iintsilelo zokwenyani zeHlabathi kunye neZifundo
Ufunda ngakumbi kwiintsilelo kuneempumelelo. Kwangoko ngexesha lam lokujongana noku, sasinomyalelo webhetshi yemizimba yevalvu yentsimbi ye-EGR. Iiprinta zazikhangeleka kakuhle. Saqhuba imveliso. Ukuhlolwa kwenqaku lokuqala kuphumelele. Kodwa ngexesha lovavanyo loxinzelelo lomthengi, sibe ne-30% yezinga lokungaphumeleli ukusuka kwi-micro-leaks. Intlekele. Oyena nobangela? Uyilo lwalunotshintsho olubukhali lwe-thermal ukusuka kwi-flange eshinyeneyo ukuya kwinqanaba elincinci lombhobho. Isango lethu elisemgangathweni lidale ukushwabana okuncinci kwe-porosity kulo mmandla wenguqu. Ulungiso ibingeyiyo inkqubo yohlengahlengiso; yayiyi-tweak yoyilo olula-ukongeza i-fillet radius encinci ukukhuthaza ukuqina kwesikhokelo. Sizifunxe iindleko zaloo bhetshi. Isifundo sasingacimekiyo: intsebenziswano yokwenyani phakathi komyili kunye nenjineli esisiseko kwi-DFM (uYilo lokuVelisa) isigaba asiyonto entle ukuba-nayo; kuphela kwendlela yokwenza utyalo mali lwemoto ethembekileyo kwaye inoqoqosho.
Esinye isifundo sivela kwimodeli yokuhanjiswa kwexesha nje. Iimoto ziqhuba kwiishedyuli eziqinileyo. Sasinenkqubo egqibeleleyo yesibiyeli sengalo yokulawula. Emva koko, umboneleli ophambili wemathiriyeli ekrwada yesihluzo sethu se-ceramic (esisetyenziswa kwinkqubo yokungena) wayenomgangatho ophelelweyo. Izihluzi ezitsha bezinophawu lokuhamba olwahluke kancinane. Kwakwanele ukutshintsha iphethini yokuzalisa, ukudala i-turbulence eyakhokelela kwiifilimu ze-oxide kwiindawo ezingabalulekanga kodwa ezibonakalayo ezibonakalayo. Amalungu asebenza ngokuvakalayo, kodwa awabonwayo. Yawumisa umgca. Ngoku sinezinto ezimbini ezibalulekileyo ezinokusetyenziswa kwaye sineeprothokholi zokuhlola ezingenayo zezinto esingazange sicinge ukuzijonga ngaphambili. Ikhonkco lokubonelela yinxalenye yenkqubo.
La mava agxininisa isizathu sokuba ubomi obude kule nkalo bubalulekile. Inkampani esebenze ngaphezulu kweminyaka engama-30, njenge-QSY, ibone le mijikelo-ukunqongophala kwezinto, i-spikes yeendleko zamandla, i-alloy specifications. Loo nkumbulo yeziko yi-asethi ebonakalayo. Kusenokwenzeka ukuba bakhe iisistim ezomeleleyo kunye nezicwangciso zogcino lweendlela zokusilela eziqhelekileyo, ezitolika ngokuthe ngqo ekuthembekeni kubathengi babo beemoto. Ayikokuba nezixhobo nje kuphela; imalunga nokuba nolwazi olumiliselweyo lwento omawuyenze xa, ngokungenakuthintelwa, kukho into engahambiyo.
Ukujonga ezantsi kweNdlela
Uphi utyalo mali lwemoto intloko? Umbane ngumqhubi omkhulu, kodwa kungekhona ngendlela abanye abacinga ngayo. Ewe, inani elikhulu lamalungu okuphoswa linokuhla kwinqwelo yombane yebhetri ngokuchasene nenjini yokutsha yangaphakathi. Azisekho ii-manifolds ezintsonkothileyo zokuthatha okanye iinxalenye zokukhupha. Nangona kunjalo, amalungu aseleyo adla ngokuba nzima ngakumbi. Ubunzima bokukhanya bubaluleke ngakumbi ekunciphiseni ubunzima bebhetri, ukutyhala i-aluminiyam engaphezulu kunye ne-magnesium castings kunye neendonga ezibhityileyo. Iinkqubo zolawulo lwe-thermal yeebhetri kunye neenjini zibandakanya iindlela eziyinkimbinkimbi, ezidityanisiweyo zolwelo ezilungele ukuphosa utyalo-mali.
Ngaphaya koko, ukutyhala iipakethe zebhetri yesakhiwo okanye ezinkulu, ii-subframes zemoto ezidityanisiweyo (megacastings) yeyona ndawo iphantsi koxinzelelo oluphezulu lokuphosa ukufa okanye ukuphosa isanti ngenxa yobukhulu. Kodwa phakathi kwezo ndibano zinkulu, kuya kubakho amancinci, agxininiswe kakhulu, kunye neendawo ezikhohlisayo zejometri okanye izihlanganisi apho utyalo-mali lunokuba sisisombululo esisiso. Ikamva lincinci malunga nomthamo kunye nokunye malunga nexabiso-ukusombulula iingxaki ezithile, ezinzima kakhulu ukuba ezinye iinkqubo eziphezulu zingenako.
Itekhnoloji ngaphakathi kwesiseko nayo iyavela. Ushicilelo lwe-3D lweepateni ze-wax okanye amaqokobhe e-ceramic asusa ezinye izithintelo zesiqhelo zokusebenzisa izixhobo, nto leyo evumela ukudityaniswa koyilo oluqilima ngakumbi kunye neprototyping ekhawulezayo. Kodwa yazisa izinto ezintsha eziguquguqukayo-ukuncamathelisa umaleko, iimpawu zokutshiswa kweresin. Sesinye isixhobo, hayi induku yomlingo. Imigaqo engundoqo ye-metallurgy, ulawulo lwe-thermal, kunye noyilo lwesango lokungena isasebenza. Amava asisiseko ukusuka kumashumi eminyaka yesiqhelo utyalo mali yinto evumela i-Foundry ukuba yamkele ngempumelelo obu buchwepheshe butsha ngaphandle kokuwela kwimigibe emitsha, ebiza kakhulu. Bubuchule obuphindaphindayo, njengokuba bubunzululwazi.
