Uma abantu abaningi bezwa 'izingxenye zokusakaza ezinembayo', bafanekisela lezo zingxenye ezingenasici, ezicishe zifane nenethi, ngokuvamile ku-aerospace noma izincwajana zezokwelapha. Imboni ithengisa lo mbono wokuphelela, kodwa iqiniso esitolo liwukuxoxisana okuqhubekayo phakathi kokuhle nokufinyelelekayo. Akukhona nje ukwenza ingxenye; imayelana nokuyenza isebenze, ngokunenzuzo nangokuthembekile, iqoqo ngemva kwenqwaba. Ikhono langempela alikho ekulandeleni imanuwali, kodwa ekwazini ukuthi yimaphi amakhona ongakwazi ukuwasika nokuthi yiziphi iziphambeko ongaphila nazo.
I-Illusion of Drop-In Replacement
Enye yemibono eyiphutha enkulu esibhekana nayo, ikakhulukazi evela kumakhasimende amasha emishini ezenzakalelayo noma ekhiqiza amaphampu, ukulindela ingxenye yokusakaza enembile njengento ephelele, yokungena esikhundleni sengxenye eyenziwe ngomshini. Bathumela umdwebo wengxenye ye-billet eyenziwe ngomshini futhi balindele ukuthi inguqulo yabalingisi ingene khona. Akuvamile ukuthi isebenze ngaleyo ndlela. Ifilosofi yokuklama eyisisekelo ihlukile. Ingxenye eyenziwe ngomshini iklanyelwe ukususwa kwezinto; ingxenye yabalingisi yakhelwe ukugeleza kwezinto ezibonakalayo nokuqinisa. Kufanele ucabangele ama-engeli asalungiswa, ukuguquguquka kokuqina kodonga, nezindawo zokungena kusukela emdwebeni wokuqala. Ngichithe amahora amaningi ngichaza ukuthi kungani sidinga ukungeza okusalungiswa okungu-2-degree odongeni oluqondile noma ukuthi kungani ikhona langaphakathi elicijile liyi-hotspot eqinisekisiwe ye-shrinkage porosity. Akuthina ukuba nzima; yi-physics.
Ngikhumbula iphrojekthi ye-hydraulic valve body, ingxenye yephaseji yangaphakathi eyinkimbinkimbi. Idizayini yasekuqaleni yeklayenti yayineziphambanomgwaqo ezinhle, eziyisikwele zamashaneli oketshezi. Kubukeka kukuhle ku-CAD. Sasazi ukuthi kwakuyiphupho elibi. Sihlongoze ukudizayina kabusha ukuphambana kwemigwaqo nge-radii evulekile. I-pushback yayimayelana nokugeleza kwamandla kanye nenjongo yokuklama. Sagcina ngokuqhuba iqoqo lesivivinyo nhlangothi zombili. Inguqulo yethu edizayinwe kabusha ibe nezindleko zamathuluzi zokuqala eziphakeme kancane kodwa iveze izinga lokusakaza umsindo elingu-95%. Inguqulo yabo ephelele yokuklama? Cishe u-40% wezinsalela zezinyembezi ezishisayo namaqoqo ashwabene kulawo makhona acijile. Izindleko zalokho kwethembeka emdwebeni wokuqala zazingokwezinkanyezi. Lelo cala libe yisibonelo esiyisibonelo esisetshenziswa ngaphakathi QSY ukuqeqesha onjiniyela abasha: hlonipha inqubo.
Yilapho okuhlangenwe nakho kwe-Foundry kubaluleke khona ngempela. Indawo efana I-Qingdao Qiangsenyuan Technology Co., Ltd.(QSY), ngeminyaka yabo engamashumi amathathu kugobolondo nokufaka utshalomali, ibone la maphethini ephinda ezimbonini zonkana. Leyo nkumbulo yokusebenza yesikhathi eside iyigugu. Akukhona nje ngokuba ne CNC imishini ikhono lokuqeda ingxenye; kumayelana nokwazi ukuthi isakazwa kanjani ukuze inqubo yokwenza imishini isebenze kahle futhi ingavezi amaphutha angaphansi. Bayaqonda ukuthi uhambo a ingxenye yokusakaza enembile ayiqali emshinini we-CNC, kodwa ekamelweni lephethini ye-wax kanye ne-ceramic slurry tank.
Okubalulekile Akuyona Nje Imenyu Yokudonsela Phansi
Ukukhetha izinto zokwakha ukunemba izingxenye zokulingisa enye indawo egcwele ukwenza lula ngokweqile. Amaklayenti avame ukuza nento ethile evele ithi insimbi engagqwali noma ingxubevange yezinga lokushisa eliphezulu. Lokho kufana nokusho imoto lapho udinga ukukhetha phakathi kwebhayisikili neloli yokulahla. Udeveli usebangeni elithile kanye nokuziphatha kwakhe kokulingisa.
Thatha i-17-4 PH engenasici. Insimbi enhle, eguquguqukayo yemvula-eyenza ibe lukhuni. Kodwa izici zayo zokulingisa zi... finicky. Uma ungalawuli izinga lokuqina kanye nokwelashwa kokushisa okulandelayo ngokunembile, ungase uthole amandla aqinile kodwa uphuthelwe ngokuphelele ukumelana nokugqwala okudingekile noma ukuqina komthelela. Lokhu sikufunde kabuhlungu nge-oda lengxenye yokuqala yasolwandle. Izingxenye ziphumelele izivivinyo zemishini kodwa zaqala ukukhombisa umgodi ongaphezulu ekuhlolweni kwesifutho sikasawoti ngaphambi kwesikhathi esibekiwe. Inkinga ilandelelwa emuva ekulinganisweni kokupholisa okungalingani ekubunjweni kwegobolondo, okuholela kusakhiwo se-microstructure esingafani. Ukulungisa kwakungelona ushintsho olulula lweresiphi; kwakuhilela ukuklama kabusha ukwakheka kweqoqo ukuze kuqinisekiswe isisindo sokushisa esifanayo kanye nokulungisa umjikelezo wokuhlanganisa wesixazululo sangemuva kokusakazwa. Kwakuyisifundo esibizayo sokuthi kungani ukucaciswa kwezinto ezibonakalayo kufanele kube ingxoxo, hhayi umyalo.
Yilapho uhla lwezinto ze-Foundry luba bucayi khona. Lapho inkampani ithanda QSY uhlu ama-alloys asekelwe ku-cobalt futhi ama-alloys asekelwe ku-nickel eceleni kwezinsimbi ezijwayelekile, kukhombisa ikhono lokuphatha izinto ezingavamile. Lezi akuzona izinto ovele uzincibilikise bese uzithela. Zinokusebenza kabusha okuphezulu, izidingo ezithile zokushisa okuphezulu, futhi ngokuvamile zidinga ukuthululwa komkhathi okulawulwayo. Ukusebenza nge-alloy esekelwe ku-nickel ye-turbine blade akufani nokuthela i-carbon steel yegiya. Lonke iketango lenqubo, kusukela ku-crucible material kuya ku-mold preheat lokushisa, likhethekile. Awukwazi ukukhohlisa lelo khono.
I-Gating System: Ingxenye Ongayiboni
Uma ingxenye yokugcina ingumfanekiso oqoshiwe, i-gateing kanye nesistimu yokukhuphuka i-scaffolding. Futhi ngokuvamile yilapho ubunjiniyela bangempela kwenzeka khona. Isistimu yokungena eklanywe kabi izokhipha izingcezu, kungakhathaliseki ukuthi i-alloy yakho noma ikhwalithi yegobolondo inhle kangakanani. Umgomo uwukuphakela insimbi encibilikisiwe endaweni yesikhunta ngokushelela, ngaphandle kwesiyaluyalu (okubangela ukufakwa kwe-oxide), kanye nokuqinisekisa ukuqina okuqondile okuya ngasezikhuphukeni (okusebenza njengamachibi abalulekile ukunxephezela ukushwabana).
Sake sasebenza endaweni ebiyelwe ngensimbi engenasici enezindonga ezincane, elingana nesivalo sebhokisi lezicathulo kodwa enezimbambo eziyinkimbinkimbi ngemuva. Izilingo zokuqala zaziyinhlekelele. Sizothola ama-mistruns (ukugcwaliswa okungaphelele) noma izivalo ezibandayo (ama-seams lapho izinsimbi zensimbi zihlangana khona kodwa zingahlangani). Inkinga ibiwukuthi isango lethu lokuqala belingadlali kakhulu, sizama ukondla sisonqenqemeni olulodwa. Insimbi yayiphola ngokushesha kakhulu njengoba ihamba endaweni enkulu, ezacile. Isixazululo besingelona iqiniso. Esikhundleni sokwengeza ukushisa okwengeziwe noma ukuthulula ngokushesha, empeleni sengeze amasango amaningi, amancane asatshalaliswa kumjikelezo. Lokhu kuvumele izindlela zokugeleza eziningi, ezimfishane. Yandisa umsebenzi wokunqanyulwa kanye nokuqeda kamuva, kodwa yasinika izinga lokugcwalisa elingu-100%. Izindleko zomshini omncane owengeziwe bezingaphansi kakhulu kunezindleko zenani le-scrap engu-50%.
Lolu hlobo lokuxazulula izinkinga luyisinkwa sansuku zonke ukutshala imali. Kuyingxube ye-fluid dynamics, thermodynamics, kanye ne-trial-and-error intuition endala. Ukulingisa isofthiwe kuyasiza manje, kodwa akulona ivangeli. Usadinga ukwenza izivivinyo zomzimba ukuze ulinganisele imodeli ngezimo zakho zesitolo eziqondile—umswakama othinta udaka, umehluko ocashile ku-binder, izici ezishisayo zokusekelwa kwesihlabathi sakho. I ukubunjwa kwegobolondo inqubo emnyombeni wayo iwumsebenzi wezandla.
Lapho Ukunemba Kuhlangana Nesitolo Somshini
Ubudlelwano phakathi kwe-casting foundry nesitolo somshini buyavumelana, ikakhulukazi uma zingaphansi kophahla olulodwa. Isithembiso sika ukunemba kokulingisa iseduze kwe-net-shape, kodwa eduze kunegama elihlobene. Izindawo ezibucayi zedatha, izimbobo ezinentambo, izimbobo eziqinile—lokhu cishe njalo kudinga ukwenziwa ngomshini. Okubalulekile wukubeka ingxenye esimweni esenza lowo mshini wokugcina uzinze, ubikezeleke, futhi ukonga.
Lokhu kusho ukuhlela. Udinga ukushiya isitokwe semishini esanele, kodwa hhayi kangangokuthi umosha izinto ezibonakalayo futhi uhlafuna impilo yamathuluzi. Udinga ukuqinisekisa ukuthi ingxenye inesikhumba esingaguquki, esibikezelwayo ukuze ukusikeka kokuqala kuzinzile. Futhi okubaluleke kakhulu, udinga ukuqinisekisa ukuthi ingxenye izwakala ngaphansi kwaleso sikhumba. Ayikho into embi kuchwepheshe bemishini njengokushaya iphakethe legesi elingaphansi komhlaba noma umgodi wokushwabana phakathi nendawo yokuqedela engxenyeni ebizayo, ecishe iphelele. Ukulahlekelwa okuphelele.
Ngo QSY, ukuhlanganiswa kokulingisa kanye CNC imishini kuyinzuzo yamasu. Ochwepheshe babo bemishini banikeza impendulo eqondile eqenjini labasunguli. Uma behlala bethola indawo eqinile endaweni ethile yobalingisi insimbi ingxenye, ikhomba inkinga yendawo yokupholisa. Uma ukuguga kwamathuluzi kudlulele kunqwaba ye insimbi izingxenye, kungase kubonise inkinga ye-microstructure njengama-carbides eqile. Le mpendulo ye-close-loop iyona eqhuba ukuthuthukiswa kwangempela, okukhulayo kukho ingxenye yokusakaza enembile izinga. Ishintsha ukunemba kwetiyori kube isici esilinganisekayo, esilethwa engxenyeni yokugcina yokuphrinta.
Umdlalo Omude: Ukungaguquguquki Phezu Kwe-Flashy Prototype
Noma ubani angaba nenhlanhla futhi akhiqize ukusakaza kwe-prototype eyodwa ephelele. Ukuhlolwa kwangempela kwe-Foundry kukhiqiza ingxenye engu-10,000 ekuqhutshweni kokukhiqiza ngokuzinza kwe-dimensional efanayo, ukuphela kwendawo, kanye nezakhiwo zemishini njengesampula yokuqala egunyaziwe. Yilapho amasistimu okulawula inqubo, izindlela zokuhlola eziqinile, nokuqapha inqubo yezibalo kwehlukanisa ochwepheshe kwabathanda ukuzilibazisa.
Kubandakanya ukuqapha yonke into: imingcele yomjovo we-wax (izinga lokushisa, ingcindezi, isikhathi) ukuqinisekisa amaphethini afanayo; i-slurry viscosity kanye ne-stucco sand gradation yokuqina kwegobolondo okungaguquki; i-chemistry encibilikayo kanye nokushisa okuthululwayo kukho konke ukushisa; imijikelezo ye-dewaxing kanye ne-sintering. Ukukhukhuleka kunoma yikuphi kwalokhu kungase kudlulele eqoqweni lezingxenye ezingavumelani. Sisebenzisa izindawo zokuhlola kuzo zonke izigaba. Ukuhlolwa kwe-athikili yokuqala (i-FAI) kuphelele, kodwa ukuhlolwa okusekuqhubekeni kwesikhathi eside yikho okuvimbela inhlekelele.
Lokhu kugxila okungapheli kokuphindaphinda yikho okwakha isithunzi. Kungakho inkampani ingasebenza iminyaka engaphezu kwengama-30 kulo mkhakha. Akukhona ngokuba oshibhe kakhulu esicaphuni; imayelana nokuba ngothembeke kakhulu. Lapho iklayenti liklama a ingxenye yokusakaza enembile emkhiqizweni wabo, benza isibopho sesikhathi eside. Kudingeka bazi ukuthi i-supply chain yabo ngeke ibahluleke. Lokho kuthembana kwakhiwe ingxenye nengxenye, iqoqo ngeqoqo, phakathi neminyaka. Umsebenzi othulile, ongenabukhazikhazi we-metrology, ukungena kwedatha, nemibiko yesenzo sokulungisa ekugcineni echaza ikhwalithi yezingxenye ezishiya idokhu. Futhi ekugcineni, yilokho ngempela leli bhizinisi elimayelana—ukuletha hhayi nje ingxenye, kodwa isiqiniseko.
