Lapho abantu abaningi bezwa 'i-precision casting foundry', bafanekisela izingxenye zensimbi ezingenasici, ezicwebezelayo zisuka ebhukwana. Lowo umbono oyiphutha wokuqala. Iqiniso limayelana nokuyekethisa okulawulwayo—ukulawula ukushisa, ingcindezi, nokuziphatha ngendlela ekwenza ube seduze nalokho okufanelekile ngokwezentengiselwano. Akuwona umlingo; kuwukugaya kokulawula inqubo.
Umdlalo Weshell: Ngaphezu Kwesihlabathi Nje
Thatha i-shell mold casting. Igama likwenza kuzwakale kulula, njengokucwilisa iphethini esihlabathini neglu. Kodwa udeveli ekubunjweni kwe-ceramic slurry kanye nokusabalalisa okusanhlamvu kwesihlabathi se-stucco. Yenza i-viscosity ibe yiphutha ngamasekhondi ambalwa enkomishini ye-Zahn, futhi ukujiya kwegobolondo lakho kuyashintshashintsha. Ngike ngabona amaqoqo lapho uhlangothi olulodwa lwegobolondo lwaluphelele, olunye lwabhidlika ngesikhathi sokucwiliswa ngoba ijazi eliyisisekelo alizange lihlangane kahle. Kuyikhono elithintekayo—ufunda ukwahlulela okuxekethile ngendlela econsa ngayo, hhayi nje ngeshidi ledatha.
Yilapho umlando omude wokusebenza ubalulekile khona. Inkampani efana I-Qingdao Qiangsenyuan Technology Co., Ltd. (QSY), esineminyaka engaphezu kwengu-30 ekulingeni nasekwenziweni kwemishini, cishe isishise izinkulungwane zamafomula odaka. Kungenzeka ukuthi bazinzile ekuhlanganiseni okuphathelene nokushintshashintsha komswakama okukhethekile kwe-Qingdao, okungadala umonakalo emijikelezweni yokomisa. Awukutholi lokho esitolo esisha.
Isivivinyo sangempela sinama-cores ayinkimbinkimbi. Ngephaseji yokupholisa yangaphakathi emzimbeni wevalvu, ingqikithi idinga ukumelana nokucindezela kwensimbi kodwa isagoqeka ukuze isuswe. Sake sasebenzisa umgogodla we-silica sand core emsebenzini wensimbi engagqwali. Insimbi yangena phakathi, yakha ukungcola okuxubile okwathatha izinsuku ze-EDM ukuthi isuswe. Ukulungisa? Ukushintshela kumxube wesihlabathi we-zircon ukuze ukhulise ukushisa kwawo okuphansi. Ushintsho oluncane lwezinto ezibonakalayo, izindleko ezinkulu zokuhlenga zigwenywe.
Ukusakaza Kwezimali: I-Wax kanye Nokulinda
Ukutshala imali iyingane yephosta ngokunemba, kodwa ugibe wayo omkhulu isikhathi. Zonke izingqimba zegobolondo le-ceramic zidinga ukoma kahle. Yisheshise, futhi uthole ukuqhuma kwesitimu ngesikhathi sokuthela—okuthiwa 'ukuqhuma kwegobolondo'—okushiya nesikhunta esigcwele izinsimbi ezilahliwe nezinsalela zobumba. Isikhathi somjikelezo singumphathi, hhayi umhleli.
Ukuhlanganiswa kwephethini ye-wax kungenye indlela yobuciko. Ukuze uthole iqoqo le-turbine blade, ukushiselwa kwamasango e-wax kwenziwa ngesandla. Umsebenzisi onethuluzi elishisayo uthinta i-wax; kushisa kakhulu, futhi kuncibilikisa unqenqema oluncane lwensingo; kubanda kakhulu, futhi i-weld ibuthakathaka, okuholela ekuhlukaneni kwephethini ngesikhathi sokwakhiwa kwamagobolondo. Kuyikhono elithatha iminyaka. Ngikhumbula ngivakashela i-foundry floor lapho umshiseli we-wax ongcono kakhulu engenza isihlahla samaphethini angu-72 engxenyeni yesikhathi sokuqasha okusha, ngaphandle kokusebenza kabusha kweqanda. Lokho kusebenza kahle kuhumusha ngokuqondile ukukhiqiza.
I-De-waxing yisinyathelo esibucayi, esivame ukunganakwa. Indlela endala kwakuwukudubula kwe-flash, okubeka engcupheni ukuqhekeka kwegobolondo. Manje, ama-foundries athuthuke kakhulu, kufaka phakathi lawo ahlanganisiwe CNC imishini njenge-QSY, sebenzisa ama-autoclave omusi anengcindezi ephezulu. Iqhinga ijika le-pressure-temperature. Idinga ukuncibilikisa i-wax kusuka ngaphakathi ngaphandle kokudala ukushaqeka okushisayo. Iwebhusayithi yabo, tsngtaocnc.com, ikhuluma ngomsebenzi wabo ngama-alloys asekelwe ku-nickel. Lawa ma-alloy ngokuvamile anezidingo eziqinile zesakhiwo sokusanhlamvu, okusho ukuthi izinga lokushisa lesikhunta sangaphambi kokusakazwa kufanele linembe. I-de-wax enephutha eqhekeka kancane igobolondo ingabangela ukungena kwensimbi, yonakalise indawo engaphezulu futhi yenze imishini yangemuva kokusakazwa ibe yiphupho elibi.
Impahla uMthetho
Awukwazi ukukhuluma nge i-precision casting Foundry ngaphandle kokungena ekujuleni kwe-metallurgy. Insimbi ye-carbon, engagqwali-ziziphatha ngendlela ehlukile. Kodwa ama-alloys akhethekile yilapho kuhlolwa khona ubuchwepheshe bangempela. Thatha ama-alloys asekelwe ku-cobalt, njenge-Stellite. Athelwa emazingeni okushisa aphakeme kakhulu futhi anomkhuba omubi wokwakha izigaba eziqinile, eziphukayo uma zipholile ngokungalungile.
Sibe nephrojekthi yeringi engagugi. Ukuphrinta kubize ubulukhuni obuthile be-Rockwell C. Ukuthululwa kokuqala, kusetshenziswa indlela yokupholisa evamile, kwakuthambile kakhulu noma kuqhekekile. Inkinga yayiwukushisa kwesikhunta. Kwakudingeka siklame amapuleti angokwezifiso okupholisa—izinsimbi zethusi ezibekwe esikhunjeni—ukuze insimbi iqine, okuphoqe ukuthi iphole kusukela esigabeni esibalulekile ukuya ngaphandle. Yasebenza, kodwa yengeza izinsuku ezimbili esikhathini sokwenza isikhunta. Lokhu ukuhwebelana okuqhubekayo: ukunemba uma kuqhathaniswa nezindleko uma kuqhathaniswa nesikhathi sokuhola.
Yilapho umlando wezinto zomphakeli ubalulekile. Isimangalo senkampani sokusebenza ngama-alloys asekelwe ku-nickel siyinto eyodwa, kodwa ukuba nelogi lokuthululelwa okuphumelelayo kwezingxenye ezisendaweni enolaka (cabanga ngama-chemical pump impellers) kungenye. Kusho ukuthi baxazulule izinkinga zokungena nokukhuphuka ezihlukile kulawo maphethini okuncipha kwama-alloys.
I-CNC: Lapho Ukulingisa Kuhlangana Neqiniso
Ayikho ingxenye yabalingisi 'eyi-net-shape' ngomqondo wokunemba okuphezulu. Yilapho kuhlanganiswe khona CNC imishini kuba okungaxoxiswana ngakho. Inzuzo enkulu i-Foundry enomshini wasendlini enayo impendulo. Uma umakhinikhi ebhoboza ekulingeni futhi ethola indawo eqinile noma imbotshana engaphansi komhlaba, lolo lwazi lubuyela emuva ngqo eqenjini elincibilikayo.
Ngikhumbula inqwaba yabakaki be-iron ductile. Babesebenza kahle ngaphandle kwekhona elilodwa kuzo zonke izingxenye lapho ithuluzi lalikhuluma khona. Kuvele ukuhluka okuncane kwezinga lokupholisa kulelokhona lesikhunta, okudala indawo yendawo yokuqukethwe kwe-pearlite ephezulu. Ithimba labasunguli lalungisa amaphiko okupholisa esikhunjeni, futhi inkinga yanyamalala. Ngaphandle komshini ngaphansi kophahla olufanayo, leyo loop yempendulo ithatha amaviki.
Enkampanini efana ne-QSY, enikeza kokubili ukusakaza nokwenza imishini kusho ukuthi bangakwazi ukulawula idatha. Bangakwazi ukufaka amaphedi okuthola indawo noma isitokwe esengeziwe ezindaweni ezinembile bazi kahle ukuthi i-CNC yabo izobamba futhi isike kanjani ingxenye. Lokhu kusebenzisana kubalulekile kumajiyometri ayinkimbinkimbi lapho izibonelelo zemishini kudingeka zibe zincane kodwa zifane ngokuphelele ukuze kugwenywe ukusika odongeni.
Ukwehluleka Okufundisayo
Izikhathi ezifundisa kakhulu zivela ezintweni ezingahambi kahle. Ekuqaleni, besithembele kakhulu ku-software yokulingisa ukuze kuqiniswe. Senze ukulingisa kwendlu yevalvu yethusi, futhi yakhombisa ukuphakela kahle. Ama-casting angempela ayenezimbobo ezinkulu zokushwabana ku-flange ewugqinsi. Ukulingisa akuzange kubalele ukwehluka okuncane ekuphatheni kwangempela kokushisa kwe-alloy yethu. Silahlekelwe yinqwaba. Siyini isifundo? Ukulingisa kungumhlahlandlela, hhayi umprofethi. Usadinga ukusika ukusakazwa kwesihloko sokuqala, usihlukanise, usifake, bese ubheka okusanhlamvu. Akukho okungathatha indawo yokuhlola okulimazayo.
Okunye ukwehluleka okuvamile wukwenza inqubo ngokwedlulele. Sake sazama ukusebenzisa i-ultra-high-purity argon purge yokuncibilikisa insimbi engagqwali ukuze kuncishiswe ukufakwa. Isebenzile, kodwa ukwenyuka kwezindleko kwaba ngama-300%. Ingxenye yayingadingi; ukukhishwa kwegesi okujwayelekile kwakwanele. I-spec yayingeyephampu yezimboni evamile, hhayi ingxenye ye-aerospace. Ukwazi lapho 'okwanele ngokwanele' empeleni 'kuphelele' kuhlelo lokusebenza ukwahlulela okuphrofeshinali okuhlukanisa i-Foundry enolwazi kusukela kwethiyori.
Ngakho, yini ethembekile i-precision casting Foundry kubukeka sengathi? Akuyona leyo enencwajana egqama kakhulu. Yilona elingachaza, ngemininingwane engenalutho, ukuthi kungani basebenzisa izinga lokushisa elithile lokuthulula le-17-4PH elingenabala, noma ukuthi baklama kanjani izihlahla zabo ze-wax ukuze banciphise isiphithiphithi ku-aluminium. Yileyo webhusayithi yayo, njenge-QSY, ibhala ngokuqondile amakhono ayo ayisisekelo—ukubunjwa kwegobolondo, ukutshala imali, ukukhanda, nohlu oluthile lwezinto—ngaphandle kwezimangalo ze-hyperbolic. Iphakamisa ukugxila ekuphindaphindeni phezu kwezimangaliso. Kulokhu kuhweba, yilokho kuphela ukunemba okubalulekile ngempela.
