Xa abantu abaninzi besiva 'iincakuba zomoya', baba nomfanekiso wezi zinto zintle, zimenyezelayo zomoya ezijikeleza kwi-injini yejethi okanye iplanti yombane. Ukungaqondi okuqhelekileyo kukuba konke malunga nokumila kwe-aerodynamic. Ngelixa oko kubalulekile, elona bali lokwenyani-eligcina iinjineli ebusuku-lenzeka kwakudala ngaphambi kokuba libone nakuphi na ukuhamba komoya. Kumalunga nokuphila ngaphakathi kwesihogo sokoqobo: ubushushu obugqithisileyo, amandla aphakathi azama ukukrazula intsimbi, kunye neegesi ezidliwayo. Ukufumana i-geometry ngokufanelekileyo ngumceli mngeni omnye, kodwa ukwenza isiqwenga sesinyithi siphile ngokuthembekileyo kuloo ndawo kulapho amashumi eminyaka ye-foundry kunye ne-machining craft ingena khona. Kulapho ubuchwephesha bokwenyani beenkampani ezinezinto ezinzulu kunye nembali yokucubungula, njengeQingdao Qiangsenyuan Technology Co., Ltd. (QSY), iba yinto engenakuxoxisana. Bebekumdlalo wokusa kunye nokuchaneka komatshini iminyaka engaphezu kwama-30, nto leyo ethetha ukuba babone lonke uhlobo lwe-porosity, ukukrazula okushushu, kunye nokuhamba okubonakalayo onokucinga.
Isiseko: Iqala ngeMold kunye ne-Melt
Awukwazi ukwenza umatshini iblade egqibeleleyo ukusuka ekujuleni okungalunganga. Ilula ngolo hlobo. Ukusebenza okuphezulu iincakuba zomoya, ngakumbi kwi-aerospace okanye i-injini yobushushu obuphezulu bemizi-mveliso, sihlala sithetha malunga nokufakwa kotyalo-mali, okanye ukuphoswa ngundo lweqokobhe. Inkqubo yepateni ye-wax ikufumana imijelo enzima yokupholisa yangaphakathi-ezo ndawo zenyoka ngaphakathi kwe-blade ezingummangaliso wobunjineli bale mihla. Kodwa umlingo, okanye intlekele, iyenzeka ngexesha lokuthulula. Ngezinto ezifana ne-nickel-based superalloys, ukushisa okuthululwayo kunye ne-mold preheat kufuneka ibe kumdaniso ogqibeleleyo. Kubanda kakhulu, kwaye ufumana misruns; kushushu kakhulu, kwaye unokufumana ukusabela kokungunda okanye ukukhula okuziinkozo okugqithisileyo. Ugqaliselo olude lwe-QSY kukungunda kweqokobhe kunye nokufakwa kotyalo-mali kwi-alloys ekhethekileyo ayingomgca wokuthengisa; linyathelo lesiseko. Ndikhumbula iminyaka yeprojekthi emva apho sasinemiba engaguqukiyo kunye ne-micro-porosity kwindawo yengcambu ye-blade-inxalenye evala kwidiski. Kuye kwafumaniseka ukuba uyilo lwenkqubo yokungena kwivenkile yepateni lucime kancinci, lubangela ugcwaliso lwesiphithiphithi kuloo ndawo inoxinzelelo oluphezulu. Kuthathe iiveki zovavanyo kunye noyilo olwahlukileyo lwe-sprue ukuyilungisa.
Emva koko kukho umbandela ngokwawo. Intsimbi estainless ludidi olukhulu, kodwa kwiiblades ezininzi ze-injini yegesi, ufudukela kwi-cobalt okanye i-nickel-based alloys. Ezi ayizizo iintsimbi zakho zemihla ngemihla. Ziba ne-viscous xa zinyibilikisiwe, ziyancipha ngeendlela ezithile, kwaye zinzima kakhulu ekusebenziseni izixhobo kamva. Ukhetho phakathi kokuphosa okuqinisiweyo okuthe gqolo okanye ukuphoswa kwekristale enye sisigqibo esisisiseko seendleko-vs-ukusebenza esenziwe apha. Ukukwazi kwe-Foundry ukulawula umphambili wokuqina kuyo yonke into. Ixesha lenkampani leminyaka engama-30, njengeQSY's, licebisa ukuba bakhe ulwazi olucwangcisiweyo-oluhlobo olungekho kwiincwadana-kwindlela yokusingatha ezi zinyibiliko zinyibilikayo zobukhulu obahlukeneyo bamagqabi kunye nokusetyenziswa.
I-Post-cast, i-check yokuqala ebalulekileyo ayinamlinganiselo. Kukuhlolwa kweradiyo kunye ne-ultrasonic. Ukukhangela ezo ziphene zangaphakathi. Unokuba nencakuba ekhangeleka igqibelele ngaphandle kodwa ineqela le-porosity kanye kumda ophambili. Lixesha lebhombu. I-Foundry kunye nevenkile yomatshini kufuneka ihambelane apha, kuba ukuba i-NDT ifumana isiphene kwindawo ebalulekileyo, inxalenye yi-scrap. Akukho bungakanani bomlingo we-CNC onokulungisa isithuba esingaphantsi komhlaba.
I-Machining Tightrope: Ukubamba ukunyamezela kwiNqanaba eliGqwethiweyo
Kulapho irabha idibana khona nendlela. Iblade yeinjini yeinjini etyhidiweyo engenanto ayiyonto intle, ibhloko yealuminiyam engenaxinzelelo. Yinto egqwethiweyo, emile njengefoyile yomoya eqinile enoxinzelelo olushiyekileyo olusuka ekupholiseni. I-op yokuqala ye-machining, ehlala ingcambu (i-fir-tree okanye i-dovetail), ibeka i-datum yayo yonke into elandelayo. Ukuba awuyisi ireferensi ngokuchanekileyo, yonke iprofayile ye-aerodynamic iya kucima. Sisebenzisa izixhobo ezikhethekileyo ezithi zibambe umphezulu we-airfoil ngaphandle kokuwonakalisa, eliqhinga ngokwalo. Amandla okubamba kufuneka abe ngokwaneleyo ukuwubamba ngokuchasene namandla okusika, kodwa hayi kakhulu ukuba abuye emva kwexesha.
CNC machining ezi alloys yinkqubo ecothayo, ebiza kakhulu. Awuthathi amanxeba anzulu. Imalunga nezantya eziphezulu zokusonta, amaxabiso achanekileyo okutya, kunye neprimiyamu yekhabhide okanye isixhobo se-ceramic esiguga ngokukhawuleza ngokumangalisayo. Isandi sokusikwa sitshintsha xa isixhobo siqala ukuhamba-ufumana i-whine ephezulu. Umchwephesha olungileyo uyawuphulaphula. Uxinzelelo lokupholisa kunye nokubekwa kubaluleke kakhulu, ngakumbi xa usila umphetho obhityileyo wokulandela. Awunako ukuvumela ubushushu ukuba bakheke, okanye ubangele uxinzelelo lwe-thermal olujija inxalenye emva kokukhulula. Ndiyibonile ibhetshi yeeblawudi apho imilinganiselo elandelwayo yayigqibelele kwi-CMM kanye emva komatshini, kodwa yatshintshwa ngabambalwa emva kokuhlala ubusuku bonke. Yayingumba wokuhanjiswa opholileyo lowo; besiyikhukulisa kodwa singawufumani umsinga kanye kwindawo esikiweyo kwelo candelo lincinci.
Eli lixabiso lomboneleli othe nkqo odityanisiweyo. Xa ukuphosa kunye nomatshini we-CNC uphantsi kophahla olunye, njengakumsebenzi we-QSY, i-loop yempendulo imfutshane. Ukuba oomatshini bafumana indawo enzima ehambelanayo okanye ukutshintshwa kwemilinganiselo elandelwayo kwimpawu yokuphosa, banokuhamba babuyele kwi-Foundry kwaye balungise inkqubo. Ukuzama ukwenza oku phakathi kwabathengisi ababini abahlukeneyo kubandakanya iiveki zee-imeyile, ukutshintshwa kwetyala, kunye nokulibaziseka.
Isidima soMphezulu: Ngakumbi kunoBugude nje
Emva komatshini, umphezulu awukalungi. Ukusila kunye nokusila kushiya umaleko omncinci wezinto eziphazamisekileyo, zihlala zineenyembezi ezincinci okanye uxinzelelo olushiyekileyo. Kwinxalenye ephantsi komthwalo we-cyclic, le yindawo ephambili yokuqaliswa kokuqhekeka. Yiyo loo nto iinkqubo ezifana nokuchama kunyanzelekile. Ibhobhoza umphezulu ngemidiya encinci ukuphembelela umaleko woxinzelelo olucinezelayo, ivale ngokufanelekileyo ucango kwiintanda ezingaphezulu. Kodwa kufuneka ilawulwe—ubukhulu, ukugubungela, i-engile. Ukuchama umphetho obhityileyo okhokelayo ngamandla kakhulu unokuwukroba uphume kakuhle.
Emva koko kukho iingubo. I-Thermal Barrier Coatings (i-TBCs) yi-topcoat yeceramic odla ngokuyibona inika iincakuba ezimatte, zirhabaxa kancinane. Kodwa ngaphantsi kwayo ihlala idyasi yebhondi, njenge-MCrAlY (M ibe nickel okanye i-cobalt), isetyenziswe ngesitshizi seplasma okanye i-HVOF. Le dyasi yebhondi yeyona nto ibonelela ngokumelana ne-oxidation kwaye ibambelela kwi-TBC. Ukulungiswa kwale nto yokwaleka lelinye inyathelo elichanekileyo. Umphezulu ufuna inkangeleko erhabaxa ethile (kaninzi ngokuqhunyiswa kwegrit) ukuze incamathele ngoomatshini, kwaye kufuneka icoceke ngokupheleleyo. Nayiphi na intsalela yeoli iya kubangela i-delamination kamva. Ndikhumbula uhlalutyo lokungaphumeleli apho iblade yachitha i-TBC yayo enkonzweni. Oyena nobangela? Utshintsho kwi-solvent yokucoca ngaphambi kokugquma okushiye ifilimu epholileyo, engabonakaliyo. Kwathatha iinyanga ukuyilandela.
Kwezinye iiblade, ngakumbi kumacandelo ashushu, unokuba nemingxuma yokupholisa egrunjwe nge-EDM okanye i-laser. Le mingxuma mincinane, isoloko ineengile, kwaye ukubekwa kwayo kunye nomgangatho wayo ubalulekile ekwenzeni ifilim ekhuselayo yokupholisa phezu komphezulu wencakuba. Ukugrumba umngxuma ogqabhuke kancinane kwindawo ethile kunokuphazamisa loo filimu kwaye wenze indawo eshushu yendawo.
Okwenyani-Ihlabathi lokuNxibelela kunye neendlela zokungaphumeleli
Uyilo lweencwadi zesikhokelo alufane lubekho kunxibelelwano lokuqala nenyani. Urhwebo lwakudala luphakathi kokusebenza kakuhle kwe-aerodynamic kunye nokuveliswa. Umyili unokufuna ifoyile entle ecekethekileyo, eqingiweyo yomoya enerediyasi eqinileyo kumphetho olandelanayo. Injineli ye-Foundry iya kuthi akunakwenzeka ukuphosa ngaphandle kwesantya esiphezulu se-scrap ngenxa ye-mistuns. Umatshini womatshini uya kuthi ubuthathaka kakhulu ukulungisa kunye nomatshini ngaphandle kokuncokola okanye ukugoba. Ukulalanisa kuhlala kuphelela ekubeni licandelo elijiyile kancinane, okanye uyilo loyilo ukuvumela indlela yesixhobo eyomeleleyo. Olu luthethathethwano oluqhubekayo.
Iindlela zokungaphumeleli ziyafundisa. Ukungaphumeleli kokudinwa kudla ngokuqala kwiingcambu okanye ekudibaneni kwe-airfoil kunye neqonga. I-Creep-i-deformation ecothayo, esisigxina phantsi kobushushu kunye noxinzelelo-ibonisa njengokwandiswa kancinci kunye nokungajiki kweblade kumawaka eeyure. Ukhukuliseko olusuka kumasuntswana kumjelo wokutya lunokuphelisa umphetho ophambili, njengokuqhushumba kwesanti. Kodwa enye yezona zinto zichwethezayo kukunxiba okukhathazayo kubuso bonxibelelwano lweengcambu kunye nediski ye-injini. Ukunyakaza kweMicroscopic phantsi komthwalo kubangela ukunxiba, oku kunokukhokelela ekugxininiseni uxinzelelo kunye nokuqaliswa kokuqhekeka. Yiyo loo nto ukuchaneka kwezi mpawu zengcambu, zenziwe yivenkile ye-CNC ekwaziyo, kubaluleke kakhulu-ukunciphisa intshukumo yokuqala encinci.
Ufunda ukuhlonipha lonke ikhonkco. Ukuphosa okugqibeleleyo konakaliswe lulungiselelo olubi lomatshini. I-blade eyenziwe ngokugqibeleleyo ifakwe emngciphekweni yinkqubo yokwambathisa engalawulwayo. Litsheyini elinamakhonkco amaninzi, kwaye ukuthembeka kukonke kulungile kuphela njengelona libuthathaka. Yingakho ukusebenzisana nomthengisi olawula amakhonkco amaninzi, ukusuka kwinyibilika ukuya kwinxalenye egqityiweyo yomatshini, kunciphisa umngcipheko. Ayikokuba lula; imalunga nokuphendula ngenkqubo.
Ukujonga Phambili: Ukutyhala rhoqo
Intsimi ayizange ime ngxi. Kuhlala kukho ukutyhala amandla aphezulu obushushu ukuphucula ukusebenza kakuhle kwe-injini, nto leyo eqhuba uphuhliso olutsha lwealloy kunye noyilo olundlongondlongo lwetshaneli yokupholisa yangaphakathi. Imveliso eyongeziweyo (ushicilelo lwe-3D) ngoku ikumxube weprototyping entsonkothileyo yokupholisa iijiyometri ezingakwaziyo ukuziphosa. Kodwa kumthamo ophezulu, ukuthembeka okuphezulu kwemveliso, utyalo-mali oludityaniswe ngokuchaneka kweCNC machining kuya kuba ngumsebenzi kwixesha elide elizayo. Ulwazi alukho nje kwisoftware okanye kwizixhobo zoomatshini; ikwinkumbulo edibeneyo yeenjineli kunye namagcisa aqhube amawakawaka obushushu, amisela amawaka ezinto ezilungisiweyo, kwaye ahlalutya amakhulu eendawo ezingaphumeleliyo.
Leyo yi-asethi engaphathekiyo. Xa ujonga iprofayile yenkampani, njengaleyo yeQingdao Qiangsenyuan Technology (QSY) kwi-tsingtaocnc.com, umgca ongundoqo awukho nje uluhlu lweenkonzo ezifana nokuphosa utyalo-mali kunye nomatshini we-CNC. Yinxalenye yeminyaka engama-30. Kweli shishini, elo xesha lithetha ukuba baye bajonga le miceli mngeni yezinto, basombulula ezi ngxaki zigqwethekileyo, kwaye bakhe ulawulo oluyimfuneko lomgangatho. Mhlawumbi benze yonke into ukusuka kwiiblawudi ze turbine yamandla amakhulu ukuya kumancinci, antsokothileyo kwiiyunithi ezincedisayo. Loo mava aguqulela ngokuthe ngqo kwizinto ezimbalwa ezingaziwayo kunye nemimangaliso embalwa ngexesha lemveliso-leyo, into ebaluleke kakhulu njenge intsimbi yeinjini, yinto oyihlawulayo ekugqibeleni.
Ngoko kwixesha elizayo xa ubona iblayidi yeinjini yomoya, libala indawo emenyezelayo umzuzwana. Cinga ngohambo: umngundo ochanekileyo we-ceramic, ukugalelwa okulawulwayo kwe-superalloy kubushushu obumfamekisayo, ukucotha, ukususwa ngononophelo kwesinyithi ngenkqubo ye-CNC ukutyhila uhlobo lokugqibela, kunye nonyango lwangaphezulu olusixhobisele imfazwe. Ngumsebenzi ogqwesileyo wesinyithi esisetyenzisiweyo kunye nobuchwephesha bomatshini, apho yonke imicron yokutenxa ibalisa ibali.
