Xa usiva 'utyalo-mali olulahlekileyo oluchanekileyo', uninzi lucinga ukuba imalunga nokwenza iimilo ezintsonkothileyo. Nantso umphezulu. Ibali lokwenyani likumlo wokuthembeka komgangatho, idabi elichasene nokugqwetha iqokobhe leceramic, kunye nothethathethwano oluqhubekayo phakathi kokuziphatha kwealloyi kunye noxinzelelo lobushushu. Ayingomlingo; luthotho lwezivumelwano ezilawulwayo.
Umdlalo weShell: Apho uKuchaneka Kuphunyelelweyo okanye Kulahlekileyo
Wonke umntu ujonga ipateni ye-wax, kwaye ngokuqinisekileyo, inaliti elungileyo sisiqalo. Kodwa isakhiwo seqokobhe? Nantso ke into ethi cwaka. Ndikhe ndabona iivenkile zigalela imali kwi-high-resolution ye-3D eprintiweyo iipateni kuphela ukuphulukana nayo yonke loo nkcazelo yomphetho kwidyasi yediphu yokuqala. I-viscosity ye-slurry, ubukhulu bengqolowa ye-stucco kunye ne-morphology-fumana oku kungalunganga, kwaye ubhaka ngokugqwetha ukusuka kwimini yokuqala. Iqokobhe alikho nje ukungunda; yi-corset yesakhiwo ngexesha lokuthulula kunye nomqobo ngexesha lokupholisa. Ukuba ukwanda kwayo kwe-thermal akunabudlelwane obuqikelelweyo kunye nentsimbi yakho, usukela umsila wakho ekunyamezeleni.
Thatha i-pitfall eqhelekileyo: ukuthatha iqokobhe elityebileyo lihlala lingcono kuzinzo lwe-dimensional. Ukuphosa intsimbi yecandelo elinzima, mhlawumbi. Kodwa kwi-aerospace enodonga olucekeceke kwi-nickel-based superalloy, iqokobhe elingqongqo kakhulu linokubangela ukukrazuka okushushu njengoko lithintela ukufinyela. Udinga iqokobhe elomeleleyo ngokwaneleyo ukuze ubambe intsimbi, kodwa libenokwaneleyo 'ukupha' kwiqondo lobushushu elifanelekileyo. Kulapho iisistim zobunikazi bokudibanisa kunye nesicelo se-stucco esine-leyared esivela kwi-Foundries enamava zenza umahluko. Yimvakalelo kunye namava, hayi nje iphepha elithile.
Ndikhumbula iprojekthi yendlu yesivamvo se-injini yomoya, apho i-spec yabiza unyamezelo lwe-±0.1mm kumbhobho wangaphakathi. Iwax yayigqibelele. Sasebenzisa idyasi yobuso be-zirconia eqhelekileyo. Ukugalela okokuqala kungena rhoqo kwi +0.15mm. Ingxaki? Idyasi yobuso ibisebenza kakhulu kunye ne-superalloy, idala umaleko wokusabela ongqindilili kunoko bekulindelekile obutshintshe ngokufanelekileyo ubungakanani bomgodi. Sitshintshele kwi-silica-based prime slurry-impendulo encinci, isithintelo esingenasici-kwaye sabuyela ekunyamezeleni. I ngokuchanekileyo olulahlekileyo utyalo-mali lwewax inkqubo igcwele ezi micro-intsebenziswano.
Ukuziphatha kweAlloy: Iqabane elingalindelekanga
Ukuthetha nge-alloys, kulapho ulwazi oluqhelekileyo lusilela khona. Ukwenziwa kotyalo-mali oluchanekileyo ye-304 i-stainless lihlabathi ngaphandle kokuyenza nge-cobalt-based alloy efana ne-Stellite 6 okanye i-nickel-based efana ne-Inconel 718. Ubuninzi babo, i-shrinkage factor, kunye nokugcinwa kobushushu kwahluke kakhulu. Awunakusebenzisa i-gating efanayo kunye nefilosofi ekhulayo.
718, umzekelo, inoluhlu olukhulu lomkhenkce. Ifuna ukwenza i-micro-porosity ukuba awulawuli umkhombandlela wokuqinisa ngamandla. Oku sikufunde kabuhlungu kumsebenzi wangaphambili wesibiyeli se-injini. Isiphelo esihle somphezulu, sadlula iX-reyi, kodwa yasilela kuvavanyo lokudinwa. Ingxaki yabekwa yodwa kwisiphambuka esingondlekanga kakuhle. Isisombululo ibingekokongeza nje isinyithi esingaphezulu (isikhuphusi esikhulu); yayimalunga nokubeka ngokutsha amasango ukwenza iqondo lobushushu eliqhubekayo. Kuye kwafuneka ukuba phantse sicinge ngasemva ukusuka kwimeko eqinileyo ukuya kuthululo lolwelo.
Yiyo loo nto imbali yezinto ze-Foundry ibalulekile. Ivenkile efana I-Qingdao Qiangsenyuan Technology (QSY), ekhankanya amashumi eminyaka kunye ne-alloys ekhethekileyo, ayikho nje uluhlu lwezixhobo. Babonisa ugcino lwedatha oluqokelelweyo lwamaqondo obushushu, iqokobhe lobushushu bangaphambili, kunye nemigaqo yokupholisa yosapho ngalunye. Loo nkumbulo yeziko yiyo ethintela uvavanyo kunye nempazamo exabisa imali eninzi kwiiprojekthi ezintsha.
Ukuxhawula ngesandla ngoMatshini: As-Cast vs. Finished
Akukho nxalenye 'echaneke' ngokwenene ephuma kwiqokobhe. Kuhlala kukho isibonelelo somatshini. Obona buchule bukunciphisa. Injongo kukuhambisa ukuphosa okuzinzileyo, kunye noxinzelelo oluncinci lwentsalela, ukuze xa ibetha umatshini we-CNC, ingahambi ngokungalindelekanga njengoko usike kuyo.
Ndiphikisene nabayili abachaza isibonelelo esincinci esincinci kuyo yonke indawo, njenge-0.5mm. Leyo yingcinga yeejiyometri ezininzi. Ibeka uxinzelelo olungenakwenzeka kwinkqubo yokuphosa kwaye ihlala ikhokelela kwi-scrap ngexesha lomatshini xa isixhobo sincamisa nje indawo etshintshileyo kancinci. Eyona ndlela isebenzayo yeyokusebenzisana: chonga iimpawu ezibalulekileyo zedatha kunye nemiphezulu yokutywina. Bamba unyamezelo oluqine kakhulu kunye nokugqiba kakuhle kwabo bakwinkqubo yokuphosa (ngamanye amaxesha ide imise i-net-shape), kwaye uvumele isibonelelo esinesisa kwimiqulu engabalulekanga. Kulapho amaziko adibeneyo akhanya khona. Imodeli ye-QSY yokunikezela zombini utyalo mali kunye nomatshini we-CNC phantsi kophahla olunye kuthetha ukuba i-loop yempendulo imfutshane. Iqela lomatshini lingaxelela i-Foundry, Heyi, sibona indawo eqinileyo ehambelanayo kule flange, kwaye banokuyilandela emva komcimbi wokupholisa wendawo ekubumbeni.
Sakhe saba nomzimba wevalvu apho abaphathi bentambo be-as-cast babengaphakathi kwe-spec, kodwa ngexesha lokucofa, isixhobo sasizulazula ngamanye amaxesha. Umoni? Ayikokuchaneka komda, kodwa iingqokelela ezincinci ze-micro-porosity ezazingaxinana ngokwaneleyo ukuba ziboniswe kwi-X-reyi kodwa zitshintshe amandla okusika. Ulungiso lwalulungelelanisa ukunyuka kwendawo ukuze kuphuculwe ukuqina okubhekiselele kwabo baphathi. Yayisisisombululo sokuphosa kwingxaki yomatshini.
I-Mindset ye-Tooling: i-Digital ukuya kwi-Physical
Ukufudukela kweshishini ukuya kwi-3D eprintiweyo wax okanye iipateni zeresin yinguquko, kodwa ayiqondwa kakuhle. Kuyamangalisa kwiiprototypes kunye neecores ezintsonkothileyo zangaphakathi. Ukuveliswa komthamo, izixhobo zentsimbi zemveli zokutofa i-wax iseyinkosi yokuhambelana kunye nokugqiba umphezulu. Ingongoma kukukhetha indlela elungileyo.
Umsonto wedijithali ubalulekile, nangona kunjalo. Imodeli egqibeleleyo ye-CAD ayithethi nto ukuba umyili wezixhobo akabali izinto ezicuthekayo ngokuchanekileyo. Kwaye ayisiyiyo ipesenti efanayo. Yi-anisotropic-yahluke kwii-axes ezahlukeneyo ngokusekwe kwinxalenye yejometri kunye nokuthintela kwiqokobhe. Abasunguli abalungileyo basebenzisa izinto eziguquliweyo zokuncipha, rhoqo ukusuka kwidatha yabo yembali kwiimilo ezifanayo kunye nealloys. Bakha imbuyekezo kwisixhobo kwasekuqaleni. Olu lungiso lwangaphambili luphawu lwenyani ukuchaneka elahlekileyo wax umsebenzi.
Ndikhumbula ndivavanya umboneleli ngothotho lweempompo zeempompo. Iisampulu zomthengisi omnye zinemigangatho emihle ye-aerodynamic kodwa ayiphumelelanga kuvavanyo lokuqukuqela. Siye sazibeka imephu kwaye safumanisa ukuba iiprofayili ze-vane zazicinyiwe-ipateni yayilinganiswe ngento enye, efaniswayo yokuncipha. Omnye umthengisi, owayenze umsebenzi ofanayo kwixesha elidlulileyo, wasebenzisa isikali esiguquguqukayo, esenza ipateni ibe ngqindilili ngakumbi kwicala lomqobo wehabhu esembindini. Ukwenziwa kwawo kwenziwa ngokweenkcukacha. Lulwazi olufihliweyo olo.
Umgangatho yiNkqubo, Hayi uHlolo
Okokugqibela, ukuchaneka akuqinisekiswanga ekugqibeleni; yakhelwe ngaphakathi kwinqanaba ngalinye. Yindawo elawulwayo yegumbi le-wax (ubushushu, ukufuma). Kukuphononongwa ngononophelo kweendibano zeqela phambi kokuba kuqhutyelwe iqokobhe. Ligophe lokudubula elibhaliweyo le-autoclave yokukhupha i-waxing kunye neziko lokutshisa. Ukutenxa kwiqondo lobushushu lokudubula kweqokobhe kunokutshintsha ukungeneka kunye namandla, okukhokelela kwimitruns okanye ukuqhekeka kweqokobhe ngexesha lokugalela.
Iinkqubo zasemva kokusaswa zibalulekile nazo. Uwasika njani amalungu omthi? Ivili elirhabaxa linokubangela uxinzelelo kunye neentanda ezincinci ukuba akwenziwanga ngononophelo. Unyango lobushushu yenye indawo yemigodi. Isisombululo esiphatha ukujulwa okuntsonkothileyo ukwenza ngcono iipropathi zealloyi ngaphandle kokubangela i-warpage okanye isikali se-sintering esonakalisa umphezulu yibhalansi ebuthathaka.
Le mbono iphelele yiyo eyahlula umboneleli wenxalenye kwiqabane lemveliso. Xa inkampani ithanda QSY igxininisa iminyaka engama-30 ekujuleni nasekusebenzeni, yikhowudi yokuba uphile kwezi ngxaki zithungelanayo. Bakhe babona ukuba utshintsho kwisanti yeqokobhe luchaphazela njani ukusebenza, okanye indlela i-tweak kunyango lobushushu inokugcina ibhetshi yamalungu anemilinganiselo yomda. Nantso ukuthungwa kwelizwe lokwenyani ngokuchanekileyo olulahlekileyo utyalo-mali lwewax-Ubunzulu, ngamanye amaxesha bumdaka, ubuchwephesha obuhlala buneenkcukacha bokudibanisa ikhulu lezinto eziguquguqukayo ukubetha iphepha elinye, elingaxoleliyo. Ayikhe imalunga newax kuphela.
