Uma abantu abaningi bezwa 'i-wax aluminium casting elahlekile', bafanekisela ingxenye engenasici, eseduze nenetha, elungele ukusebenza. Lelo iphupho lokumaketha. Iqiniso, lelo olifunda esitolo kuphela, izingxoxo eziqhubekayo phakathi kokungabi namanzi, ukuncipha, kanye nokuphishekela ngokungaphezi kwesakhiwo esizwakalayo sangaphakathi. Akukhona nje ukwenza umumo; imayelana nobunjiniyela umcimbi wokuqinisa uqobo. Abaningi kakhulu bakuthatha njengobuciko obumnyama noma, okubi nakakhulu, enye nje into ohlwini lokuthengwa kwempahla. Iqiniso liwukuthi, uma ungacabangi ngesakhiwo sokusanhlamvu kusukela ngesikhathi uklama iphethini ye-wax, usuvele ungemuva.
Umbono Oyiphutha Obalulekile: Konke Kumayelana Nokunemba Kobukhulu
Amaklayenti amasha, ngisho nonjiniyela abangomakadebona, bafika belungisiwe ngenxa yokubekezelelana okuqinile. Bafuna ukunemba kwe-dimensional investment casting okudume ngakho. Futhi ngokuqinisekile, kubakaki abalula, lowo umgomo oyinhloko. Kodwa nge-aluminium, ikakhulukazi izingxenye ezingaphansi kwengcindezi eshisayo noma yemishini, ingxoxo kufanele ishintshe. Inani langempela le- inqubo ye-wax elahlekile ngoba i-aluminium akukhona nje ukuthi ingabamba ukubekezelelana okungu-+/- 0.005. Ukuthi ungathonya indlela insimbi eqanda ngayo. Ungakwazi ukuqondisa ukushwabana kusiphakeli, hhayi odongeni olubalulekile. Lowo umehluko phakathi kwengxenye ebukeka ilungile nehlala njalo.
Ngikhumbula iphrojekthi yendawo yokuhlala ye-drone. Imodeli ye-CAD yayiyinhle, inezindonga ezincane kanye nemigudu yangaphakathi eyinkimbinkimbi yokupholisa. Ama-prototypes okuqala aphume aphelele kakhulu. Uphumelele isheke le-CMM ngemibala endizayo. Kodwa ekuhlolweni kokudlidliza, behlulekile esisekelweni—ukuphuka okuqinile. Inkinga? I ukufakwa kwe-aluminium iqiniswe ngendlela ebheke kakhulu, idala ukwakheka kwezinhlamvu zekholomu khona kanye endaweni yokucindezeleka. I-geometry yayikhuthaza. Kwadingeka sibuyele emuva, hhayi ohlelweni lwe-CNC, kodwa ekwakhiweni kwesihlahla se-wax. Sengeze izimbobo zokupholisa ezicashile kugobolondo le-ceramic ezindaweni ezithile ukuze sikhuthaze ukwakheka okusanhlamvu okulinganayo lapho. Yengeze izinsuku ezimbili esigabeni sephethini, kodwa yashintsha ingxenye isuka kukhandidethi yenqwaba ye-scrap yaba ingxenye ethembekile.
Yilapho ama-generic foundries akhubeka khona. Bazobethela isipikili esingaphezulu kodwa baphuthelwe yi-metallurgy. Inkampani ethola lokhu, njenge-QSY (Qingdao Qiangsenyuan Technology Co., Ltd.), ayithengisi nje ukulingisa; bathengisa inqubo yokuqinisa elawulwayo. Ngesizinda sabo sama-alloys akhethekile, bayaqonda ukuthi ukuphatha okushisayo yikho konke, noma ngabe uthela ama-superalloy noma i-aluminium ye-A356. Lowo mqondo ubalulekile.
I-Wax Stage: Lapho Impi Iwiniwe Ngempela (noma Ilahlekile)
Konke kuncike kuphethini ye-wax. Izinga layo, ukungaguquguquki kwayo, izinga lokushisa layo ngesikhathi sokuhlangana. Umthungo omncane, ukuhluka okuncane kwengcindezi yomjovo—lokhu akuthinti nje ukuphela kwendawo; bakha izindawo ezibuthakathaka egobolondweni le-ceramic elingaholela ekugijimeni noma emafeni ngesikhathi sokuthulula. Sisebenzisa i-wax yethu ekushiseni okuthe xaxa kunalokho okushiwo incwadi. Igeleza kangcono emininingwaneni emihle yesikhunta, inciphisa isiyaluyalu, futhi inikeze iphethini eliminyene. Ukuhwebelana kuyisikhathi eside somjikelezo kanye nokuphathwa ngokucophelela. Kodwa ngezingxenye eziyinkimbinkimbi, akuxoxiswana.
Ukuhlangana, noma ukutshala izihlahla, kungobunye ubuciko. Indlela obeka ngayo amaphethini, ububanzi be-wax sprue—lokhu kunquma ukugeleza kwe-aluminium encibilikisiwe. Ufuna ukugcwaliswa okuqhubekayo, okuzolile, hhayi ukuchaphaza okunesiyaluyalu. Ngike ngabona ukuthululwa kucekeleke phansi ngenxa yokuthi isihlahla besime kakhulu, okwenza insimbi yehle phakathi nendawo futhi ivale igesi emigodini engaphandle. Manje, siklama izihlahla ezinesakhiwo esincane se-helical. Kubonakala kuncane, kodwa kukhuthaza ukugcwala okuzungezayo okuthambile. Ngomunye waleyo mininingwane emincane, engathandeki ongeke uyithole ebhukwini lokufunda, ezalwa ngokubuka amakhulu okuthululwa nokusika izilahliwe.
Ukulawula imvelo ye-wax kuyimpi eqhubekayo. Umswakama ehlobo ungabangela ukuba amaphethini ajuluke, okuholela ezindabeni zokunamathela kwegobolondo. Sake saba nenqwaba yabakaki be-aerospace lapho igobolondo lalilokhu liqhekeka phakathi nokukhipha i-waxing. Kusithathe iviki ukuyilandelela emuva ekushintsheni okucashile, kwesizini kokuqukethwe kwe-polymer ye-wax kusuka kumnikezeli wethu, okushintshe i-coefficient yayo yokunweba okushisayo. Umjikelezo we-autoclave ubunolaka kakhulu kuleyo nqwaba. Manje, sisebenzisa igobolondo elincane lokuhlola kukho konke ukulethwa kwe-wax okusha. Kungukuhlupheka, kodwa ishibhile kunokwehluleka ukukhiqiza okugcwele.
Igobolondo: I-Ceramic Ayiyona Nje I-Ceramic
Imininingwane eminingi ivele ibize i-slurry eyisisekelo esekwe ku-zircon kanye nesipele se-silica esihlanganisiwe. Leyo yincwadi yokudlala ejwayelekile. Kodwa udeveli usemijikelezweni yediphu kanye ne-stucco gradation. Ngokusakazwa kwe-aluminium enezindonga ezincane, udinga igobolondo eliqine ngokwanele ukumelana nokucindezela kwensimbi kodwa elingeneka ngokwanele ukuvumela umoya uphume. Amajazi amaningi ayisipele, futhi ubeka engcupheni i-porosity yegesi; ambalwa kakhulu, futhi ubeka engcupheni yokuphuka kwegobolondo noma ukudabuka okushisayo ekubumbeni.
Sithuthele enqubweni elungisiwe yomsebenzi wethu we-aluminium wobuqotho obuphezulu. Sisebenzisa i-stucco esicolekile, esinezikhala ezingama-200 ejazini lesibili nelesithathu esikhundleni sokugxuma siqonde ezintweni ezimahhadla. Yakha ukujiya okufanayo kanye nesiphetho esingcono sangaphezulu ezindaweni ezijulile. Futhi, sitholile, kunciphisa i-veining - lawo ma-ceramic fins acasulayo aphuka futhi ashunyeke endaweni yokuphonsa. Yengeza umjikelezo we-dip owengeziwe, ngakho-ke kubiza kakhulu, kodwa wehlisa kakhulu isikhathi sokuqeda ukusakaza kwangemuva. Ngokusebenzisa izingxenye ezingamakhulu ambalwa, izibalo zisebenzela thina.
Ukomisa ukuguquguquka okuthulile. Ukusheshisa ukomiswa phakathi kwamajazi kuwumgodi ovame kakhulu esitolo esimatasa. Ukomiswa okungaphelele kuholela kumagobolondo anezingqimba anokuhlanganiswa kwejazi elimpofu. Ngesikhathi sokushiswa kwezinga lokushisa eliphezulu, umfutho we-steam ovela kumswakama osele ungasusa igobolondo ngaphakathi. Siqale umthetho onzima: umswakamo we-ambient ngaphezu kuka-70%? Isandiso samahora angu-4 esizenzakalelayo ngesikhathi sokumiswa kwawo wonke amajazi. Azikho izingxabano. Kwehlise ukuhlela kodwa kwasusa sonke isigaba sokuhluleka kwegobolondo okungaqondakali.
Thela: Ngaphezu Kokugcwalisa Isikhunta
Ukuthela i-aluminium ku-a ukukhishwa kwe-wax elahlekile inqubo ayifani nokugcwalisa isikhunta sesihlabathi. Igobolondo le-ceramic liyashisa, lilinganiselwa ku-1000°C, futhi insimbi iphola ngokushesha. Unefasitela mhlawumbe lamasekhondi angu-10-15 oketshezi olusebenzayo lokutshalwa kwezimali okujwayelekile. Isistimu yokugenca kufanele isebenze kahle. Sihlala sishisa izitsha zethu. Iladi elibandayo lingehlisa izinga lokushisa lensimbi libe ngu-20-30°C ngesikhathi nje sokudlulisa, libulale uketshezi lwalo ngaphambi kokuba lishaye ngisho nenkomishi ye-sprue.
Ukuthela ngokwako kufanele kube umfudlana oqhubekayo, ozinzile. Akukho ukuma, akukho ukuthela, akukho ukugxusha. Ufuna ukugcina ingcindezi ye-metallostatic engaguquki ukuze usunduze insimbi ezindaweni ezikude kakhulu zesikhunta. Siqeqesha ithimba lethu lokuthela ukuze libuke ingcindezi e-back- cup sprue. Uma ikhuphuka ngokushesha kakhulu, kusho ukuthi isikhunta sigcwalisa ngokuhlukumezeka. Kwesinye isikhathi, kufanele wehlise izinga lokuthela phakathi nokusakaza, okuzwakala kuphambene. Kuyikhono lokuthinta. Ngime lapho nochwepheshe abasha, ngibaqondisa: Uyakuzwa lokho? Inkomishi isinda ngokushesha. Susa kalula... manje kuzinzile.
Ngemva kokuthela, sasivame ukuvumela isikhunta sipholile emoyeni ozungezile. Iphutha elikhulu kumajiyometri athile. Sibe nezinkinga ngokuklebhuka okushisayo kwezingxenye ezinezinguquko ezinkulu zesigaba. Izingxenye ezincane zaziyoqina futhi zifinyele, zihlukanise izingxenye ezisancibilikile, eziwugqinsi. Manje, sinamabhokisi afakiwe agcwele i-vermiculite. Sidlulisela isikhunta esishisayo ngqo kuzo ukuze silawule, sipholile kancane. Yengeza esinye isinyathelo, kodwa empeleni iwukwelashwa kokushisa okusesikhunjini okudambisa lokho kucindezeleka. Kuxazululwe cishe u-80% wezinkinga zethu ezishisayo zezinyembezi ngobusuku obubodwa.
Imachining & Ubambiswano Nezitolo Njenge-QSY
Yilapho irabha ihlangana khona nomgwaqo. A ephelele ukutshala imali kwe-aluminium kuhle kuphela njengesitolo somshini esiwuqedayo. Kungakho imodeli ye-Foundry nayo eyenza imishini ye-CNC engathi sína, njengale oyibona kuyo Ukusebenza kwe-QSY, inamandla kakhulu. Baluqonda lonke uhambo. Uma siklama ukulingisa, sesivele sicabanga ngamaphoyinti okulungisa, isibonelelo sesitoko, kanye namandla okusala kwengcindezi angase asonte ingxenye uma isiboshiwe futhi isikiwe.
Kunenkinga yakudala: ukulingisa kuphuma kunobukhulu obuhle, kodwa lapho umakhi wemishini ethatha ukusika kokuqala, ukuthungwa kwendawo kuyashintsha noma ithuluzi liyaxoxa. Ngokuvamile, i-subsurface shrinkage porosity noma indawo epholile kancane leyo probe ye-CMM engakaze ithintwe. I-Foundry esebenza ngokusakaza kuphela izosola imingcele yemishini. Isitolo semishini ukuthi imishini kuphela ezosola ikhwalithi yokulingisa. Umhlinzeki ohlanganiswe ngokuqondile kufanele akuxazulule ngaphakathi. Bangakwazi ukuhlobanisa okudidayo komshini babuyisele izinga lokushisa lokuthulula noma igobolondo lishisa ngaphambili kusukela kuleyo nqwaba ethile. Leyo ndlela yempendulo ibalulekile.
Isibonelo, okuhlangenwe nakho kwe-QSY nge-hard-machining cobalt nama-nickel alloys ahumusha ngokuqondile ku-aluminium. Ingqondo yabo imayelana nokukhipha izinto ezibikezelwayo kusuka ku-substrate enobuqotho obuphezulu. Bayazi ukuthi ekubunjweni okuhloselwe umshini wokugaya i-axis engu-5, ungase udinge ukungeza iphedi elincane, lomhlatshelo ebusweni obungabalulekile ukuze nje uzinze ngesikhathi somshini, into ethile i-pure-play Foundry ingase yenqabe njengesici esingadingekile. Yilo mbono wokuphela ukuya ekupheleni oguqula indlela ye-prototyping ibe inqubo yokukhiqiza esebenzayo. Awuthengi nje ukulingisa; uthenga isiqinisekiso sokuthi izoziphatha ngokubikezela ngaphansi kwethuluzi lokusika.
Umcabango Wokugcina: Kuyinqubo, Hhayi Umkhiqizo
Ngakho-ke, uma ususa into eyodwa, makube yilokhu: i-wax aluminium casting elahlekile iwuchungechunge lwezinqubo ezincikene. Ukuthuthukisa isixhumanisi esisodwa ngokuhlukaniswa kuvame ukwephula esinye. I-wax ithinta igobolondo, igobolondo ithinta ukugcwaliswa, ukugcwaliswa kuthinta isakhiwo sokusanhlamvu, futhi isakhiwo sokusanhlamvu sithinta yonke into ezayo ngemva. Impumelelo itholakala ngokuyibuka njengohlelo olulodwa, oluqhubekayo.
Izinkampani eziphumelelayo kulesi sikhala, lezo ongathembela kuzo ngaphezu kokucaphuna nje okulula, yizo ezifake ngaphakathi kwalokhu kucabanga kwezinhlelo. Banezibazi zokungaphumeleli kwesikhathi esidlule—amagobolondo aqhekekile, izimbotshana ezinezimbotshana, omshini osontekile—futhi baye bakhela izimiso zabo kulezo zifundo. Amawebhusayithi abo, njengaleyo ye-Qingdao Qiangsenyuan Technology Co., Ltd., angase afake ohlwini lwezinsizakalo ezifana nokusakazwa kwesikhunta segobolondo kanye nomshini we-CNC ngokuhlukana, kodwa inani langempela liwukuthi baphoqeleka kanjani ukuthi bazihlanganise. Yilokho okuletha ingxenye engahlangani nje nokuphrintiwe, kodwa eyenza emhlabeni wangempela. Kungcolile, kuyaphindaphinda, futhi kugcwele ukuvumelana. Kodwa uma ichofoza, ayikho indlela engcono yokwenza ingxenye ye-aluminium eyinkimbinkimbi, esebenza kahle kakhulu.
