Lapho onjiniyela bayacacisa imboni yokukhipha isihlabathi se-resin izinsiza zezingxenye zensimbi ezinobuqotho obuphezulu, azigcini nje ngoku-oda izingxenye—zivikela ukuqina kohlangothi ngaphansi kokuhamba ngamabhayisikili ashisayo, ukungaguquguquki kwe-microstructural kuwo wonke ama-castings angu-100-kg, kanye nokungabekezeleli i-porosity ezindaweni ezithwala ingcindezi. Kwa-QINGDAO QIANGSENYUAN TECHNOLOGY CO., LTD., senze izindlu zengxubevange ye-cobalt-nickel ezingaphezu kuka-27,000 kusukela ngo-2019—ngayinye ihlolwe ngama-CMM e-Zeiss alinganiselwe ku-ISO 10360-2—futhi safunda ukuthi isihlabathi se-resin akuyona inqubo yokubuyela emuva. Iyona kuphela indlela esebenzayo yamajiyometri ayinkimbinkimbi njengezindlu zesilinda sephampu ye-piston lapho ukufakwa kwe-investimenti kubiza khona usilingi kanye nesihlabathi esiluhlaza sihluleka ekugcineni.
Kungani I-Resin Sand Casting Iwina ku-Mission-Critical Hydraulic & Pump Components
Amaqembu amaningi okuthenga acabanga ukuthi isihlabathi se-resin “asinembe kangako” kunokutshala imali. Ngokwenza, sibona okuphambene: lapho senza imibhobho ye-AMS 5387 ye-cobalt alloy yamaphampu kawoyela aphesheya kwezilwandle, isihlabathi se-silica esiboshwe nge-resin siletha ukubekezelelana komugqa okungu-0.3 mm kumadiamitha angu-420-mm—kuqine kunokuvumela ukuhlukahluka kokuqina kwegobolondo lokutshala imali. Isihluthulelo? Ukulawulwa kokusabela kwe-exothermic ngesikhathi sokwelashwa. Isikhungo sethu sisebenzisa ama-cold-box-cured amine-cured phenolic urethane binder, hhayi ama-furan resins endabuko. Lokho kuqeda i-pickup yesibabule kuma-cobalt alloys, okugcina ukumelana nokugqwala ezindaweni ze-H₂S. Silinganise ukuhlaselwa kwe-intergranular okuphansi okungu-12% kumapulaki asekelwe ku-T800 ngemva kokuhlolwa kwe-NACE TM0177 yamahora angu-72—okuhlanganiswe ngokuqondile nekhemistri ehlanganisayo, hhayi ukwelashwa kokushisa kwangemuva kokusakaza.
Lokhu kubalulekile ngoba imizimba yama-valve e-hydraulic awehluli ephutheni elibi lobukhulu. Zihluleka ukusuka ekushwabaneni okuncane ezimpambanweni eziphakathi kwezingxenye eziwugqinsi nezincane—njengalapho imbobo yokusiza ingcindezi ihlangana ne-flange ekhuphukayo. Onjiniyela bethu be-Foundry yethu benza imephu ye-gradient eshisayo besebenzisa ukulingisa kwe-MAGMASOFT® *ngaphambi* kokugunyazwa kwephethini. Silungisa izilinganiso ze-resin-to-sand ngendawo: i-binder engu-1.8% ekufakweni okuyisisekelo, u-1.2% ezindongeni zesikhunta sangaphandle. Umphumela? Isivuno sokuqala esingu-94% ezindlini zamasilinda wepompo yepiston uma kuqhathaniswa nesilinganiso semboni esingu-71%.
Ukuhlanganisa Okuqondile Kuxazulula Inkinga "Ye-Casting-Machining Handoff".
Ukwehluleka okuningi akwenzeki ekulingiseni noma ekwenzeni imishini—kodwa lapho kuhlangana khona. Ikhasimende lake lasithumelela umdwebo we-winch center shaft roller eno-±0.025 mm roundness spec ku-OD engu-120-mm. Umhlinzeki wabo wangaphambilini wayiphonsa, wabe esethunyelwa esitolo se-CNC esivela eceleni. Irola yasonteka ngo-0.08 mm ngesikhathi sokudambisa ingcindezi ngenxa yokuthi ingcindezi eyinsalela yokulingisa ayizange ifakwe kumephu ngaphambi komshini. Sikwenza ngendlela ehlukile: ama-metallurgists ethu enza izivivinyo eziqinile kukho konke ukuthululwa kweledi, bese siphakela idatha yokuma kwezinhlamvu emishinini yethu ye-Mazak INTEGREX i-200S yama-axis amaningi. Sisebenza ngomshini kungakapheli amahora angu-48 wokunyakazisa—akukho ukubambezeleka kokuguga—sisebenzisa izindlela zamathuluzi ezilandela amavektha okucindezeleka okubangwa ukusakaza. Ukuyindilinga kokugcina: 0.018 mm. Ngokuvumelana.
Lokhu kuhlanganiswa kudlulela ekulandeleleni kwezinto ezibonakalayo. Iqoqo ngalinye le-T800 alloy liphethe ithikithi lokushisa elinekhodi ye-QR elixhumanisa izitifiketi zezinto ezingavuthiwe (ASTM A995 Grade 6A), imibiko yokuhlaziya encibilikayo, namarekhodi okugcina okuhlolwa kwe-ultrasonic. Awekho izingodo zephepha. Akukho okufakiwe mathupha. Uma isisekelo sephampu sihluleka embonini yokukhipha usawoti emanzini yaseNingizimu-mpumalanga ye-Asia, sihlukanisa ncamashi u-3.2 kg wensimbi encibilikisiwe esetshenzisiwe—futhi sidonse umlando waso oshisayo kusukela kungobo yethu yomlando ye-Siemens SIMATIC PCS 7 DCS.
Imikhawulo Yomhlaba Wangempela—Nendlela Esisebenza Ngayo Ngaphakathi Kuyo
Ukubunjwa kwesihlabathi se-resin kunemingcele eqinile. Ngeke sicaphune izingxenye ezinokuqina kodonga ngaphansi kuka-8 mm kuma-cobalt alloys—ingozi yokugcwaliswa kwesikhunta esingaphelele idlula ama-40%. Futhi ngeke samukele ama-callouts e-GD&T adinga indawo yangempela eqine kakhulu kuno-±0.1 mm ezicini ezingaphezu kuka-150 mm ukusuka kuma-datum ngaphandle kokwengeza izindawo zedatha ezenziwe ngomshini kuphethini. Abanye bangase baphikise ukukhiqizwa kwe-CNC kuphela kugwema lezi zingqinamba. Kodwa ukwenza insimbi engu-65 kg kusuka kubha eqinile kubiza u-3.7× ngaphezulu futhi kumoshe u-68% wezinto ezibonakalayo njengama-chips. Indlela yethu eyingxubevange—ukusakaza okunembayo + okuphokophelwe ukuqedwa kwe-CNC—kwehlisa isikhathi sokuhola ngo-40% kumahlanganisela ephampu yezimoto zobunjiniyela kuyilapho kubambe ukucaba okungu-0.05 mm kuzisekelo ezingu-500-mm.
Sibhala konke ukuchezuka. Ngekota edlule, iklayenti laseYurophu licele ubulukhuni bobuso obungu-0.01 mm ebusweni bepulaki ye-cobalt alloy. Abalingisi bethu bokuhlola babonise u-Ra 0.8 µm. Esikhundleni sokwethembisa imiphumela engafinyeleleki, siphakamise ukupholisha nge-electrochemical post-machining—sengeze u-$14.30/ingxenye kodwa ilethe i-Ra 0.05 µm. Ukungafihli kwehlula ithemba ngaso sonke isikhathi.
Ukukhetha Ifekthri Yakho Yokusakaza I-resin Sand Akukona Intengo-Kumayelana Nobunikazi Benqubo
Ilungelo imboni yokukhipha isihlabathi se-resin ungumnikazi wochungechunge olugcwele: isayensi yezinto ezibonakalayo, i-mold physics, ukuqinisekiswa kwe-metallurgical, nokuhlolwa kokusebenza. Kwa-QINGDAO QIANGSENYUAN TECHNOLOGY, siyenqaba imidwebo engenazo izichasiselo ze-GD&T—sizokusiza ukuthi uzihumushe. Sibuyisela impendulo ye-DFM phakathi namahora angu-72, ukuhlaba umkhosi izingozi ezifana nezikhuphukeli eziyimpumputhe ezindaweni ezigqoke kakhulu noma okusalungiswa okwanele eziteshini zokupholisa zangaphakathi. Uhlelo lwethu lwe-ISO 9001:2015 aluwona umsebenzi wamaphepha—lubukhoma ukulandela umkhondo we-Cpk ngobukhulu obubucayi, ngezaxwayiso ezizenzakalelayo lapho amandla okucubungula ehla ngaphansi kuka-1.33.
Amakhasimende omhlaba ayasikhetha ngoba sithumela izingxenye ezisebenzayo—hhayi nje ukusakaza. Yonke i-valve yokucindezela idlula i-100% yokuhlolwa kwe-hydrostatic ku-1.5 × ingcindezi yokusebenza elinganiselwe. Yonke i-cobalt alloy nozzle idlula ukuhlolwa kokungena kodayi nge-ASTM E165 ngayinye. Asicashi “ngokuhambisana.” Sikubonisa umbiko wokuhlola wenombolo yakho yomkhiqizo.
Uma iphrojekthi yakho elandelayo idinga izingxenye zensimbi ezinembayo ezisinda emijikelezweni ye-psi engu-20,000, zimelane nodaka olubi, noma zigcine ukuqondanisa ngemva kweminyaka engu-10 ngaphansi komhlaba—qala ngemboni yokukhipha isihlabathi se-resin ephatha i-metallurgy njengobunjiniyela, hhayi ubuciko.
