Uma uzwa 'izingxenye zensimbi ezinembayo', izingqondo eziningi zigxuma ziqonde ekubekezeleni nasezitifiketini zezinto ezibonakalayo. Leyo yinkulumo yencwajana. Indaba yangempela, leyo enquma ukuthi ingxenye ethile iyasebenza noma iyahluleka yini esitolo iminyaka, iqala ngemva kokuba ishidi elicacisiwe lisusiwe. Kumayelana nokuyekethisa okungashiwongo phakathi kwejiyomethri ekahle kanye nokuqina, ukuthungwa okucashile kwendawo esakazwayo ethinta impilo yokukhathala, kanye nokusabela kokwelashwa kokushisa kokushisa okuthile kwensimbi okungekho okujwayelekile okuthwebula ngokugcwele. Ngibone imiklamo eminingi kakhulu ebukeka iphelele ku-CAD kodwa eyiphupho elibi ekungeneni nasekukhuphukeni, okuholela ekuncipheni kwangaphakathi okubonakala kuphela ngaphansi kwe-X-ray noma, okubi nakakhulu, enkonzweni. Ukunemba akukhona nje kubukhulu; ishumekwe kulo lonke uchungechunge lwenqubo, kusukela kuphethini yokuqala ye-wax kuya ekuchameni kokugcina kwesibhamu.
I-Illusion of Drop-In Replacement
Ugibe oluvamile, ikakhulukazi lonjiniyela abalungisa izinto, ukuphatha izingxenye ezinembile njengezinto eziqondile, ezifakwa esikhundleni sokubumba noma ukwenziwa kwezinto. Ukuphrinta kobukhulu kungase kufane, kodwa imvilophu yokusebenza ingahluka kakhulu. Thatha impompi elula. Efojiwe inokugeleza okusanhlamvu okulandela i-blade contour, okunikeza ukumelana okukhulu nokuguguleka. A steel ukunemba Casting yomumo ofanayo inesakhiwo sokusanhlamvu esilinganayo. Uma ungakunaki lokhu ekukhetheni kwakho okokusebenza—mhlawumbe ukhetha ibanga eliqinile le-stainless njenge-CA-15 esikhundleni se-304 evamile—uzothola ukwehluleka ngaphambi kwesikhathi kusevisi elimazayo. Ukulingisa kukunikeza ubunkimbinkimbi bomumo obumangalisayo, kodwa uhweba ngamandla athile okuqondisa. Kufanele udizayinelwe inqubo yokulingisa, hhayi nje ngobukhulu bayo.
Lokhu sikufunde kabuhlungu eminyakeni edlule ngengxenye ye-valve yeklayenti. Bekushintshwa ingxenye eyenziwe ngomshini. Sifinyelela kuzo zonke izici sisebenzisa ukusakaza kwe-investimenti. Kodwa kwakuyisicelo se-steam esinengcindezi ephezulu. Ingxenye yokuqala eyenziwe ngomshini yayinemigodi yokukhulula ingcindezi okwakulula ukuyigaya kodwa eyethusayo ukuyisakaza ngaphandle kokudala izindawo ezishisayo. Sayiphonsa njengokuphrinta, futhi yaphumelela ukuhlolwa kwe-hydro. Kodwa ekuhambeni kwamabhayisikili ashisayo, kwaqalwa imifantu emincane kulawo makhona angaphakathi abukhali—ingozi yakudala yesici esasiyihlabe umkhosi kodwa satshelwa ukuthi siqhubeke nayo. Ayizange yehluleke ngendlela eyingozi, kodwa yaqala ukukhala ngemva kwemijikelezo embalwa. Ukulungisa bekungekona ukuthuthukisa ukulingisa; bekuwukuhlala phansi nonjiniyela wabo futhi bahlele kabusha ngobuqili iphrofayela ye-groove ibe irediyasi esakazwa kakhudlwana, idele kancane inhloso yomklamo wangempela ukuze uthole izinzuzo ezinkulu ngokuqina. Lokho ukubambisana okuchaza ukunemba kwangempela.
Yilapho okuhlangenwe nakho kwe-Foundry kuba okungaxoxiswana khona. Isitolo esifana I-Qingdao Qiangsenyuan Technology Co., Ltd. (QSY), ngeminyaka yabo engamashumi amathathu kugobolondo nokutshala imali, ibone lezi zimo zidlala izikhathi eziningi. Inani labo alikho nje ekwenzeni isihlahla se-wax; kusempendulo yokuqala ye-DFM (Design for Manufacturability). Uma bebuka umdwebo, ngokwengqondo bagijima ebhilidini lamagobolondo, ukuthela, izingcindezi zokupholisa. Lokho kuhlola kokuzizwa kwamathumbu, okuzalwe kusukela emashumini eminyaka kwenziwa futhi kulungiswa, yikho okuvimbela amaphutha abizayo. Imayelana nokuqondisa umklami engxenyeni esebenzayo futhi ekhandwayo ngokwemvelo.
Material Akulona nje Ibanga
Icacisa i-316 engenasici ye-a ukunemba kokulingisa ingxenye ibhidi yokuvula nje. Iyiphi 316? Ukuncibilika okujwayelekile? I-316L enekhabhoni ephansi yokumelana nokugqwala ngemuva kokushisela? Noma inguqulo eguquliwe enokulawula okuqinile kokuqukethwe kwe-ferrite ukuze kuvinjelwe i-sigma embrittlement kusevisi yezinga lokushisa eliphezulu? Ukukhethwa kwe-alloy kuba bucayi nakakhulu ngezipesheli. Sibe nephrojekthi yokwakhiwa kwesithando somlilo esidinga ingxubevange esekwe nickel. Ukuphrinta uthe Inconel 625. Ingxubevange enhle. Kodwa engxenyeni ezobona ukushisa okuzinzile ngomthwalo ophakathi nendawo, izinga lokusakaza elijwayelekile elingu-625 belingekho lilungile. Siphushele i-tweak encane kokuqukethwe kwe-aluminium ne-titanium ukuze uthole amandla angcono okucindezeleka, isiphakamiso esivele ngokuqondile ku-metallurgist ku-Foundry esibambisene nayo. Yengeze mhlawumbe u-5% ezindlekweni zezinto ezibonakalayo kodwa yaphinda kabili impilo yesevisi. Lokho ukunemba ezingeni le-athomu.
Bese kuba khona iqiniso langemva kokusakazwa. Ibanga elifanayo kusuka kuma-foundries amabili ahlukene lingaziphatha ngendlela ehlukile ngemva kokwelashwa kokushisa. Kuza phansi umkhuba wokuncibilika, deoxidation, ngisho izinga lokushisa ukuthulula. I-Foundry esebenza ngokukhethekile insimbi cast nama-alloys akhethekile, afana ne-QSY ebalula kububanzi bawo, azoba nezawo zokupheka futhi acime izintandokazi zemidiya ukuze ashaye izakhiwo ezidingekayo zemishini ngokungaguquki. Awukwazi ukuvele ucabange ukuthi ukukhishwa kwensimbi okungu-4140 kuzoshaya i-280 BHN ngemuva kokucisha incwadi kanye nokuthukuthela. Kufanele uyivivinye, usike amakhuphoni kubagijimi, futhi uhlole. Ukunemba kukhiyiwe ekulawuleni inqubo, hhayi nje embikweni wamakhemikhali.
I-Surface iyinjini
Esinye sezici ezishaywe indiva kakhulu ingxenye yensimbi eyi-precision cast wukuphela kwe-as-cast surface. Abantu bakhathazeka kakhulu ngokunemba kwe-dimensional futhi bakhohlwe ukuthi ukuthungwa kwendawo kuphambili kokugqwala, ukukhathala, nokuguga. Ukulingisa okuhle kokutshalwa kwezimali kufanele kuphume kunobushelelezi obungaphezulu kuka-Ra 3.2 μm noma okungcono, buqonde kusuka kugobolondo. Kodwa lokho isilinganiso. Ngaphansi kwe-microscope, ungase ubone ukufakwa kwe-oxide okuncane, i-pitting ebusweni bemizuzu, noma umphumela wekhasi eliwolintshi ovela ku-ceramic slurry. Ngomzimba we-hydraulic valve, lokho kulungile kakhulu. Okwendawo yophawu oluguqukayo noma ingxenye yokukhathala yomjikelezo ophezulu, akunjalo.
Kulapho ukuhlanganiswa nokusebenza ngomshini, okugqanyiswa yi-QSY ngamandla abo e-CNC, kubaluleke kakhulu. Ukugeleza komsebenzi womhlaba wangempela engivame ukukubona ukuthi: sebenzisa i-net-net-shape, shiya isitoko esincane (imvamisa u-0.5mm noma ngaphansi ngisho nangaphansi ezindaweni ezibucayi zedatha), bese kuba umshini. Kodwa iqhinga likukulandelana. Ingabe unciphisa ingcindezi ngaphambi komshini onzima? Ungakubamba kanjani ukulingisa okumise ngendlela eyinqaba ngaphandle kokuyenga ukuhlanekezela? Sake saba nesegimenti yendwangu ye-turbine enezindonga ezincane. Ukulingisa bekukuhle. Kodwa ngesikhathi sokumba i-CNC yokumba imbobo yebhawodi, ukucindezela okuncane kuhlanekezele yonke iphrofayili. Isixazululo kwaba ukuklama into ethambile, evumelanayo esekela yonke indawo yangemuva, into ithimba labamashini elathuthukiswa ngokuhambisana nonjiniyela babalingisi. Lokhu kunikezwa phakathi kokulingisa kanye nokwenza imishini okuhlukanisa ingxenye enhle nenkulu. Ukulingisa okunembayo kukuthola u-95% lapho; ukukhanda okuhlakaniphile nokuqeda isipikili u-5% wokugcina ochaza ukwethembeka.
Lapho Okuhle Kwanele Akukho
Ingcindezi yezentengiselwano ihlale iwukunciphisa izindleko: sebenzisa impahla encane, imijikelezo esheshayo, ama-alloys ashibhile. Kodwa ngezingxenye ezinembayo zangempela, izindleko zokwehluleka ziphezulu kangangokuthi okuhle ngokwanele kuwuphawu oluyingozi. Ngokuvamile kufika ekuhlolweni okungabhubhisi (NDT). I-Radiography (i-X-ray) indinganiso yezingxenye ezibucayi. Kodwa ingabe ubheka izindawo ezifanele? I-Foundry kufanele ikwazi ukukutshela, ngokusekelwe ekwakhiweni kwesango, lapho i-shrinkage porosity ingenzeka khona kakhulu. Yilapho ugxilisa khona izithombe zakho ze-X-ray. Ngokuqhekeka kwendawo, ukuhlolwa kwe-fluorescent penetrant (FPI) kuhle, kodwa kumaphutha angaphansi komhlaba ezingxenyeni ezinobuqotho obuphezulu njengalezo ze-aerospace noma zezokwelapha, ungase udinge ukuhlolwa kwe-ultrasonic.
Ngikhumbula iqoqo lezingxenye ze-cobalt-chromium alloy kudivayisi yezokwelapha. Baphase amasheke okubuka kanye nobukhulu. Kodwa ngesikhathi socwaningomabhuku olujwayelekile, sinqume ukwenza i-FPI ebanzi kakhulu kusampula. Kutholwe ukuqhekeka kwezinwele eduze kwendawo yokukhipha isango ezingxenyeni ezimbalwa. Imbangela? Ukungaguquguquki okuncane enqubweni yokubhaka igobolondo ejikelezayo, okuholela ekudabukeni okuncane okushisayo. Kwakungekona ukwehluleka kwesistimu, kodwa kwabulala inqwaba. I-Foundry idle izindleko, kunjalo, kodwa isifundo esikhulu sasimayelana nezinhlelo zesampula kanye ne-process drift. Noma uneminyaka engu-30 yesipiliyoni, awukwazi ukunethezeka. Konke ukushisa, igobolondo ngalinye, umcimbi omusha. Ukunemba kugcinwa ngesiyalo senqubo esingapheli kanye ne-paranoia enempilo.
Isilinganiso Sangempela Sokunemba
Ngakho-ke, yini inkomba yokugcina yezinga eliphezulu steel ukunemba Casting? Akusona isihloko sokuqala esicwebezelayo etafuleni lengqungquthela. Ukusebenza onyakeni wesi-3, Unyaka wesi-5. Ukungaguquguquki kuwo wonke ukukhiqizwa kwezingcezu ezingu-10,000, lapho ingxenye 1 nengxenye 10,000 zingena emhlanganweni ofanayo nemvume efanayo, zibonisa ukumelana nokugqwala okufanayo, futhi zithwala umthwalo ofanayo. Lokho kungaguquguquki kuzalwa enqubweni evuthiwe, elawulwayo kanye nesiko elingenasici.
Izikhungo eziye zamelana nemijikelezo yebhizinisi eminingi, etshalwe kubuchwepheshe bokulawula inqubo njengeziqapha izinga lokushisa lokuthela nezilawuli zomswakama wegobolondo, futhi, okubaluleke kakhulu, zigcine abenzi bephethini abanekhono nabaqhubi beziko. Uma usebenza nozakwethu ofana ne-QSY, awuvele uthenge uhlu lwemishini yabo. Uthenga inkumbulo ehlangene yaleyo minyaka engama-30—inkumbulo yokuthi yini ebangela inkungu ihambe engxenyeni encane, indlela ingxubevange ethile egeleza ngayo esikhunjeni esiyinkimbinkimbi, kanye nendlela yokulungisa ijika lokuphatha ukushisa kujometri ethile. Lokho ukunemba okungaphatheki ongeke ukubeke eshidini elithile kodwa umehluko phakathi kwengxenye nempahla ethembekile.
Ekugcineni, ingxenye iyi-artifact ebonakalayo. Umkhiqizo wangempela uyisiqiniseko sokuthi uzokwenza. Leso siqiniseko sakhiwe ngokusebenzisana okuqotho, ukuqonda okujulile kwezinto ezibonakalayo, ukuhlonipha amaphutha enqubo, kanye nokwenqaba okwabiwe ukwamukela mhlawumbe kuhle. Kulapho ubuciko beqiniso, kanye nenani langempela, ekubunjweni kwensimbi okunembayo kulele khona.
