Uma uthi 'i-cast iron sandcasting', abantu abaningi bafanekisela ibhulokhi elingahluziwe, elisindayo eliphuma embonini yekhulu le-19. Lowo umbono oyiphutha wokuqala. Eqinisweni, kuyinqubo ekhohlisayo eyinkimbinkimbi elinganisa ezomnotho, isayensi yezinto ezibonakalayo, nokusebenza okungokoqobo okungafani nanoma yini enye. Iwumgogodla wezingxenye eziningi zezimboni, hhayi ngoba 'ingcono kakhulu' ngomqondo welebhu, kodwa ngoba imvamisa iyona efanele kakhulu umsebenzi. Iqhinga alikona nje ukwazi ukuthela insimbi esihlabathini; ukwazi ukuthi kufanele uyisebenzise nini ngaphezu kwezinye izindlela ezifana nokubumba igobolondo noma ukufakwa kwe-investimenti, kanye nendlela yokulawula izinkinga zayo ezingokwemvelo—ukuncipha, ama-engeli angakapheli, idizayini yokungena engenza noma yephule ubuqotho bengxenye. Ngibone amadizayini amaningi kakhulu ehluleka ngoba othile ukuthathe njengokungena esikhundleni sensimbi yokwenza izinto.
Isihlabathi Ngokwaso Akukona Nje Ukungcola
Ake siqale ngesisekelo: isihlabathi. Isihlabathi esiluhlaza, isihlabathi se-resin esingabhaki—inketho lapha ibeka yonke into. Ngevolumu ephezulu, elula kakhulu ukuphonsa isihlabathi sensimbi izingxenye, isihlabathi esiluhlaza (inhlanganisela yesihlabathi se-silica, ubumba, namanzi) iyona ehamba phambili. Kushibhile futhi kungasetshenziswa kabusha, kodwa okuqukethwe umswakama kuyimpi eqhubekayo. Kome kakhulu, futhi isikhunta siphelelwa amandla; imanzi kakhulu, futhi uthola ukuqhuma kwesitimu ngesikhathi sokuthulula, okushiya ukukhubazeka kwegesi ngaphansi nje kobuso bokusakaza. Ngikhumbula inqwaba yezindlu zamaphampu lapho saba namagalelo angaphezulu. Kusithathe usuku ukuze sikulandelele ekukhuphukeni komswakamo endaweni yokugcina okuguqule ingxube yesihlabathi. Kunzima lokho.
Ukuze uthole amajiyometri ayinkimbinkimbi noma ukunemba okungcono kohlangothi, sishintshela kumasistimu angabhaki, njenge-furan noma i-phenolic urethane. Isihlabathi sihlanganiswe ne-resin ewuketshezi kanye ne-catalyst, futhi yelaphe kanzima. Ukuqeda kuphakeme, futhi ungakwazi ukufeza izindonga ezincane. Kodwa izindleko ziyeqa, futhi ukubuyiselwa kwesihlabathi kuba bucayi kakhulu—awukwazi ukumane ukujikijele emuva ku-muller. Endaweni efana I-Qingdao Qiangsenyuan Technology (QSY), lapho baphatha khona yonke into kusukela ekubunjweni kwegobolondo kuya ekutshalweni kwezimali, isinqumo sokuthi iyiphi inqubo yesihlabathi okufanele isetshenziselwe a insimbi umsebenzi wehlela esibalweni esinezingqinamba: ingxenye eyinkimbinkimbi, inani, imfuneko yokuqedwa kwendawo, kanye nemvume yomshini. Ayizenzekeli neze.
Imishini yephethini ingenye izindleko ezifihliwe. Esihlabathini esiluhlaza, uvame ukubhekana namaphethini epuleti likamentshisi, i-aluminium noma insimbi, okumba eqolo ukukulungisa. Ngokugijima okufushane noma ama-prototypes, sisebenzise amaphethini e-polystyrene enziwe ngomshini (indlela yegwebu elilahlekile) ngokuqondile esihlabathini esingaboshiwe. Iyasebenza, kodwa ukulawula i-carbon pickup nokugwema izinkinga ezigoqekayo njengoba igwebu lihwamuka kuwubuciko ngokwako. Uthola ingxenye ehloniphekile, kodwa i-metallurgy ayihambisani njengesikhunta esiqinile sendabuko.
Ukuthela Insimbi: Akukhona nje Ngezinga Lokushisa
I-iron empunga, i-ductile iron - ukukhetha kwe-alloy kuyisisekelo. I-iron empunga, nama- graphite flakes, inalawo mandla amakhulu okudambisa amandla kanye nokusebenza kanzima. I-Ductile iron, ne-nodular graphite yayo, iletha amandla aqinile kanye ne-ductility ethile. Umkhuba wokuthulula uyashintsha ngakunye. Ngensimbi ene-ductile, kufanele ulawule ukufiphala kwe-magnesium uma usebenzisa i-ladle eselashiwe; umphumela we-nodularizing uyancipha ngokuhamba kwesikhathi, ngakho-ke kukhona iwindi eliqinile phakathi kokwelashwa nokuthela. Kuphuthelwe, futhi i-microstructure ibuyela emuva, ibulale izakhiwo zemishini.
Izinga lokushisa elithelayo liyinkinga ye-Goldilocks yakudala. Kushisa kakhulu, futhi ukwandisa ukushwabana kwe-porosity kanye nengozi yokuguguleka kwezindonga zesikhunta, ikakhulukazi ezingxenyeni ezincane. Kubanda kakhulu, futhi uthola ama-mistruns, ukuvala okubandayo, nokungabi namanzi okugcwala ukugcwalisa isikhunta. Ukuze uthole insimbi empunga ye-Class 35 ejwayelekile, singaphokophela cishe ku-1370°C kuya ku-1400°C, kodwa lokho kuyisiqalo nje. Ubukhulu besigaba sengxenye ngokwayo bubeka izinga lokushisa elifanele. Ubakaki abawugqinsi, abayizicucu bangathatha izinga lokushisa eliphansi; inqwaba eyinkimbinkimbi, enezindonga ezincane ezidinga yonke ingcosana yoketshezi olunikezwa izinga lokushisa eliphakeme. Ngifunde lokhu kanzima emzimbeni we-hydraulic valve. Sisebenzise izinga lokushisa elijwayelekile lezinto ezibonakalayo, kodwa ingxenye yayinenethiwekhi yamaphaseji amancane angaphakathi. Kugcine ngokulingisa okuhle okungaba ngu-80% kuqedwe—okusele kwaba uchungechunge lwezivalo ezibandayo ezikhungathekisayo ezikwenze kwahlakazeka.
Ukuvuka nokudla kulapho okuhlangenwe nakho kwangempela kubonisa khona. I-ayoni inezinga eliphansi lokushwabana kunensimbi, kodwa isadinga ukuphakelwa njengoba iqina. Ukubeka izikhuphukeli ngokungalungile kudala imigodi enciphayo ezindaweni ezithwala kanzima. Ukupholisa kungenye ithuluzi—ukubeka ngokufanelekile amakhaza ensimbi noma ethusi esibunjeni ukuze kuphoqelelwe ukuqiniswa okuya ngakunye kusukela ekujikijeleni emuva kusikhuphukeli. Kuyindida ye-3D eshisayo oyixazulula ngesipiliyoni futhi kwesinye isikhathi, isoftware yokulingisa. Izinkampani ezinolwazi olunzulu lwe-Foundry, njenge-QSY neminyaka engamashumi amathathu ukukhiqiza kanye nokwenza imishini, bakhe lo mqondo phakathi kwezinkulungwane zemisebenzi, yingakho bekwazi ukukhiqiza ngokuthembekile ukusakazwa komsindo, okuqinile kokufakwa kwephampu namavalvu.
I-Finish Line: Ukuhlanza, Ukukhanda, kanye Nokuhlola Kwangempela
I-Shakeout ingumsebenzi ononya. I-casting iphuma esihlabathini sishisa, inamasango, izikhuphukeli, noqweqwe lwesihlabathi esishile. Ukugaya off okweqile kuyisinyathelo sokuqala. Bese shot blasting ukuhlanza ebusweni. Yilapho iziphambeko ezifihliwe zivame ukuziveza khona: imbobo engaphansi komhlaba evela esihlabathini, umfantu ophuma ekupholiseni ngokushesha okukhulu. Ukuhlola okubonakalayo kuyisiqalo nje.
Yilapho ukuhlanganiswa nemishini kuba okubucayi. I-Foundry ephinde iphathe CNC imishini, njengamasevisi achazwe kusayithi ye-QSY, inenzuzo enkulu. Baklama ukulingisa becabanga ngenqubo yokwenza imishini. Lokho kusho ukungeza isibonelelo sesitoko esingaguquki (hhayi kakhulu, hhayi sincane kakhulu), ukuklama izindawo ze-datum endaweni ukuze zilungiswe, nokuqonda ukuthi ingxenye izobanjwa kanjani ku-chuck noma ku-vise. Ngibone abalingisi abebebukeka bephelele kodwa bengenakuqhathaniswa ngoba ibhobo elibucayi belisendaweni eqinile kusukela ekupholiseni okusheshayo, licekele phansi izinsimbi ezintathu zokubhola i-carbide ngaphambi kokuthi siyeke.
Ubufakazi bokugcina buvame ukuba semhlolweni ongonakali. Ezingxenyeni ezibucayi, singenza ukuhlola kokungena kodayi kokuqhekeka kwendawo noma ukuhlola ingcindezi. Ukwaneliseka kwangempela kuwukubona okuluhlaza ukuphonsa isihlabathi—le nto emahhadlahhadla, emnyama—ishintsha ibe ingxenye eyenziwe ngomshini ngokunemba, izindawo zayo zokukhwelana zibushelelezi, imicu yayo ihlanzekile, ilungele ukubhawuliswa enjinini noma kuhlaka lokucindezela. Yilokho umjikelezo ogcwele, futhi yingakho ukulingisa kungenakuhlukaniswa nemisebenzi engezansi.
Lapho I-Sand Casting Akuyona Isixazululo
Nakho konke lokhu kukhuluma ukuphonsa isihlabathi sensimbi, kubalulekile ukwazi imingcele yakho. Uma udinga izindonga ezizacile kakhulu (ngaphansi kuka-3mm), ingaphezulu elikhethekile qeda liqonde ngaphandle kwesikhunta, noma umumo oseduze nenethi wama-alloys angavamile, abizayo, ezinye izinqubo ziyawina. Yilapho okunye okukhethekile kwe-QSY, ukubunjwa kwegobolondo nokusakazwa kokutshalwa kwezimali, kuqala khona. Ukubumba igobolondo kusebenzisa isihlabathi esimbozwe inhlaka ukuze kwakhe igobolondo elincanyana, eliqinile, elinikeza ukunemba okungcono kanye nesiphetho kunesihlabathi esiluhlaza. Ukutshala imali, indlela ye-wax elahlekile, eyezingxenye eziyinkimbinkimbi kakhulu, ezinemininingwane eminingi.
Okwesilinganiso insimbi izindlu ze-gearbox, ikhanda lesilinda lenjini, noma uhlaka lwesisekelo esisindayo, ukwenza isihlabathi cishe kuyisinqumo esingabizi kakhulu nesisebenzayo. I-tooling iyalawuleka, izinto ezibonakalayo zinhle kakhulu ekusetshenzisweni, futhi ukukala kuyafakazelwa. Kodwa uma othile engilethela idizayini yendlu yenzwa yensimbi eyinkimbinkimbi enamagalari angaphakathi nengaphandle eyisimonyo, cishe ngiwaqondisa egobolondweni noma ngisho nokuxoxa uma insimbi ukukhishwa kwe-investimenti kungase kulingane kangcono naphezu kwezindleko. Inketho yezinto ezibonakalayo—insimbi vs. insimbi vs. a ingxubevange ekhethekile- ihambisana nokukhetha kwenqubo.
Lo mbono ophelele ohlukanisa umphakeli wezingxenye nozakwethu wangempela wokukhiqiza. Umgomo awukona ukuthengisa abalingisi; wukuletha ingxenye esebenzayo, ethembekile, neyongayo. Ngezinye izikhathi leyo ndlela iholela esikhunjeni esinesihlabathi esiklanywe kahle, futhi ngezinye izikhathi ithatha indlela ephambuke. Ukubona umehluko ovela kumdwebo wokuqala yilokho amashumi eminyaka kuleli bhizinisi, njengomlando wenkampani efana ne-Qingdao Qiangsenyuan Technology, ekugcineni ukukufundisa. Kuncane mayelana nokuphoqa isixazululo futhi kumayelana nokuhlanganisa inqubo enkingeni.
Ukuziphendukela Kwemvelo Okungabonakali
Inqubo ayikamile. Isofthiwe yokulingisa yokuqinisa nokuhlaziya ingcindezi isifinyeleleka kalula, okusivumela ukuthi sihlole ukubekwa kwesikhuphukeli futhi sibikezele izindawo ezishisayo ngaphambi kokusika insimbi ukuze senze iphethini. Ukuphrinta kwe-3D kokubunjwa kwesihlabathi kuwukushintsha umdlalo kuma-prototypes kanye nezingxenye eziyinkimbinkimbi eziqhutshwa kanyekanye, okuqeda izindleko zephethini ngokuphelele. Izimiso eziyinhloko ze-metallurgy nokudlulisa ukushisa zisekhona, kodwa amathuluzi okukulawula aya ngokuba bukhali.
Nokho, kubo bonke ubuchwepheshe, kuseza ekhonweni leqembu labasunguli. Ukufunda ukuphuka kwebha yokuhlola ukuze wahlulele isakhiwo se-graphite, ukwazi ukuthi isondo lokugaya lizwakala kanjani lapho lishaya imbobo yokuncipha, ukuqonda ukuthi ukunwebeka kancane kokulingana kwekhabhoni kungathinta kanjani ukusebenza kahle CNC phansi kamuva. Lolu lwazi oluyimfihlo luyimpahla yangempela.
Ngakho, uma ubheka a ukuphonsa isihlabathi sensimbi, ungavele ubone isigaxa sensimbi. Bona uchungechunge lokuyekethisa ngamabomu nezinqumo zochwepheshe—kusuka ekukhethweni kwesihlabathi nokwakheka kwesango kuya ekuzijwayezeni ukuthela kanye nokulungiselelwa komshini. Kuwubufakazi bobunjiniyela obusebenzayo, inqubo emayelana nokuguquguquka okulawulwayo njengoba imayelana nokuphatha okungokwemvelo. Futhi embonini ehlale ijahe isixazululo esilandelayo sobuchwepheshe obuphezulu, ukuba khona kwayo okuhlala njalo kuyisikhumbuzo esithulile sokuthi ukuqina nokusebenza kahle kwezindleko akuphumi esitayeleni.
