Ingantaccen Tsarin Tsinkaya na 5083 Aluminum fayafai: Daga 3 ku 4 Wucewa don rage girman kayan da ba daidai ba da kuma bel mai rubutun orange a cikin tankokin jirgin sama

1. Shigowa da: Bukatun fasaha don tanki na jirgin ruwa da kuma hauka a ciki 5083 Alloy Spinning

Shugaban tankin iskar manyan motoci (Kula da matsin lamba 0.8-1.2PA, matsakaici: A iska) muhimmin sashi ne mai ɗaukar matsi wanda dole ne ya dace da ma'auni guda biyu: ① Daidaiton Girma (kaurin bango ≤± 0.3mm, kamar yadda aka bayyana a GB/T 150.4-2011 Ruwan Matsi – Kashi 4: Manufacturing, Dubawa da Karɓa); ② Ingancin ƙasa (babu lahani kamar nau'in kwasfa na orange ko fasa, Rarraba Ra ≤1.6μm).

A bayyane, 5083 aluminum fayafai ga manyan tankuna na iska (Mg abun ciki 4.0%-4.9%, Mn abun ciki 0.4%-1.0%) sun zama kayan tushe da aka fi so don kawunan tanki saboda kyawawan kaddarorin su: Ƙarfin yawan amfanin ƙasa ≥270MPa, elongation ≥12%, da kuma m danniya lalata juriya. Juyawa kafa (na al'ada kadi tsari, inda mandrel ke motsa diski don juyawa kuma abin nadi yana ciyar da radially don cimma nakasar filastik) yana ba da fa'idodi kamar “kusa-net-tsari da babban amfani da kayan aiki (>90%)”. Duk da haka, da “3-wuce kadi” Tsarin da aka saba amfani dashi a masana'antar a halin yanzu yana da manyan batutuwa biyu:

1. Wuce kima kaurin bango sabani: Bambancin kauri na bango tsakanin saman kai, yankin mika mulki, kuma madaidaiciyar gefen ya kai 0.4-0.6mm, ƙetare kewayon izini na ± 0.3mm;

2. Surface “lemu kwasfa”: Riga-kafi na lokaci-lokaci suna bayyana akan saman (Ra=2.5-3.2μm), wanda ba wai kawai yana shafar bayyanar ba amma kuma yana iya zama tushen tattara damuwa, rage gajiyarwa.

Wannan ya haifar da tambaya mai mahimmanci: Zai iya ƙara adadin wucewar juyawa daga 3 zuwa 4 - ta hanyar rage raguwar ƙimar kowane fasinja - sarrafa karkatar da kauri na bango kuma kawar da nau'in kwasfa na orange a cikin shugabannin da aka zagaya daga. 5083 aluminium fayafai don manyan tankunan iska? Wannan yana buƙatar zurfafa bincike daga bangarori uku masu haɗin gwiwa: “sanadin matsaloli – tsarin wucewa daidaitawa – tabbaci na gwaji”.

2. Abubuwan da ke haifar da Matsaloli a cikin 3-Pass Spinning: Bincike Bisa Halayen Nakasa 5083 Fayafai na Aluminum don Tankunan Jirgin Sama

Asali, nakasar filastik na 5083 aluminium fayafai don manyan tankunan iska a lokacin daki-zazzabi ana jujjuyawa a “farfadowa mai ƙarfi-mamaye” inji (babu tsauri recrystalization, kamar yadda abubuwan Mg ke hana ƙaura). Rashin lahani a cikin juzu'i mai wucewa 3 ya samo asali ne daga batutuwa biyu masu alaƙa: “rashin daidaituwa” kuma “rashin daidaituwa tsarin siga”, musamman kamar haka:

(1) Muhimman Abubuwan Da Yake Keɓancewar Kaurin bango (>± 0.3mm)

Na farko, ƙetare kauri bango ya taso daga sarrafa kwararar ƙarfe mara kyau, abubuwa guda biyu ne ke tafiyar da su:

1. Matsakaicin girman raguwar ƙimar kowane fasinja yana haifar da rashin daidaituwar ƙarfe

Jimlar raguwar ƙimar juzu'i mai wucewa 3 yawanci 60%-65% (daukan a 5083 Aluminum diski don manyan tankunan iska tare da φ600mm × 12mm a matsayin misali, matsakaicin matsakaicin kauri na ƙarshe shine 4.2-4.8mm), tare da matsakaicin raguwar ƙimar kowane fasinja na 25%-20%-20% (Tebur 1). Ƙarfin nakasar filastik na waɗannan fayafai na aluminium na farko yana ƙaruwa sannan kuma yana raguwa tare da haɓakar raguwa. Yaushe raguwar fasinja ɗaya ya wuce 20%, karfe yana da wuyar gaske “tarawar gida” ƙarƙashin aikin abin abin nadi:

• A cikin yankin canji (inda kai curvature ya canza), Radial damuwa maida hankali yana haifar da wuce gona da iri na karfe zuwa madaidaici, yana haifar da kaurin bangon bakin ciki a cikin yankin canji (0.3-0.4mm bakin ciki fiye da ƙimar ƙira);

• Madaidaicin gefen ya zama mai kauri saboda tara ƙarfe (0.2-0.3mm mai kauri fiye da ƙimar ƙira), A ƙarshe yana haifar da juzu'i na gaba ɗaya wanda ya wuce ± 0.3mm.

2. Rashin daidaituwa tsakanin saurin igiya da ƙimar ciyarwa

Don biyan ingancin samarwa, 3-wuce kadi sau da yawa rungumi “high spindle gudun (80-100rpm) + high ciyar kudi (50-60mm/min)”, haifar da “nakasar adadin” (matsawar radial kowane lokaci naúrar) na 5083 aluminium fayafai don manyan tankunan iska don isa 0.8-1.0mm/r-nisa ya zarce ƙimar farfadowarta mai ƙarfi (0.6mm/r). Ƙarfe ba zai iya cika damuwa na ciki ba, kafa wani “filin rashin daidaituwa” wanda ke kara tsananta kaurin bango.

(2) Tsarin Samar da Tsarin Sama “Lemu Peel Texture”

Bayan kaurin bango rashin daidaituwa, saman “lemu kwasfa” wani babban lahani ne a cikin jujjuyawar 3-pass, da gaske sakamakon “saman rashin zaman lafiya” na 5083 aluminium fayafai don manyan tankunan iska a lokacin nakasawa. Wannan rashin kwanciyar hankali yana faruwa ne sakamakon abubuwa biyu masu alaƙa:

1. Matsakaicin saurin lalacewa na gida yana haifar da rashin daidaituwar hatsi

Babban ƙimar ciyarwa a cikin juzu'i na 3-pass yana haifar da nakasar adadin ƙarfe a cikin wurin tuntuɓar abin nadi don isa 15-20s⁻¹, wanda ya fi na “tsauri dawo da kudi” na waɗannan fayafai na aluminum (8-12s¹). Hatsi ba za su iya samun daidaitawa iri ɗaya ta hanyar ɓata wuri ba, kuma “makada mai ƙarfi” tsari na gida - yana bayyana azaman rashin daidaituwa na lokaci-lokaci (tsawon 0.5-1.0mm, girman girman 0.05-0.1mm).

2. Rashin isassun man shafawa yana haifar da lahani mai alaƙa da gogayya

Ƙarƙashin raguwa mai yawa, matsin lamba tsakanin abin nadi da kuma 5083 aluminium fayafai don manyan tankunan iska ya kai 800-1000MPa. Idan man shafawa (yawanci tushen graphite) fim karya, kai tsaye karfe lamba haddasawa “m lalacewa”, wanda ke kara kara girman bawon bawon lemu (Ra yana ƙaruwa daga 2.5μm zuwa 3.2μm).

3. Haɓaka Tsarin Ƙarfafa Ƙaddamarwa zuwa 4: Ingantawa daga “Daidaita Nakasawa” ku “Ingancin ƙasa”

Don magance lahanin da aka ambata a cikin jujjuyawar 3-pass, ƙara yawan kadi wucewa daga 3 ku 4 yana ba da mafita mai niyya - mai da hankali kan “rage raguwar raguwar wuce-wuri ɗaya da tsawaita lokacin nakasa” don daidaitawa zuwa halaye na farfadowa mai ƙarfi na 5083 aluminium fayafai don manyan tankunan iska. Ƙididdiga ta musamman na haɓakawa yana aiki akan maɓalli biyu:

(1) Sarrafa Kaurin bango: Haɓaka Rage Girman Girmamawa

Dangane da jimlar raguwar adadin 62% (kauri daga 5083 aluminium fayafai don manyan tankunan iska daga 12mm zuwa matsakaicin kauri na kai na 4.56mm), da rage rates for 4 wucewa ana sake rarrabawa (Tebur 1). Babban dabarun yana cikin “rage gudu da rage kaya a cikin wucewa biyu na farko don tabbatar da nakasar iri ɗaya, da mai da hankali kan kammalawa a cikin wucewa biyu na ƙarshe don daidaita kauri”:

• Wuce 1: Rage yawan raguwa daga 25% ku 20%, da farko don “na farko forming”-danna diski na aluminium zuwa siffa ta farko (kauri 9.6mm) don guje wa tarawar ƙarfe wanda ya haifar da babban nakasar farko;

• Wuce 2: Rage yawan raguwa daga 20% ku 18% don ƙarin siffa (kauri 7.87mm). By rage yawan ciyarwar abinci (daga 60mm/min zuwa 45mm/min), Karfe kwarara ya zama mafi karko, rage girman damuwa na gida;

• Wuce 3-4: Raba asali 20% rage raguwa cikin 12% kuma 10%, mai da hankali kan “bango kauri karewa”. Amfani ƙananan raguwar ƙima yana ba da damar gyara daidai kaurin bangon gida (e.g., kayan cikawa a cikin yankin canji, bakin ciki madaidaiciya), a ƙarshe yana sarrafa karkatar kauri na bango tsakanin ± 0.2mm.

Tebur 1: Kwatanta Rarraba Rarraba Tsakanin 3-Pass da 4-Pass Spinning

(2) Kawar da Bawon Lemu: Haɗin kai Tsakanin Ƙimar Lalacewa da Farfaɗo Mai Sauƙi

Baya ga sarrafa kaurin bango, 4-wuce kadi kuma yadda ya kamata gusar orange kwasfa rubutu ta samar da isasshen lokaci domin tsauri dawo da 5083 aluminium fayafai don manyan tankunan iska- cimma ta “raguwa biyu” (rage girman nakasar ta-wuce-wuri da saurin igiya):

1. Rage yawan nakasawa: Rage ƙimar ciyarwa daga 60mm/min zuwa 45mm/min da saurin igiya daga 100r/min zuwa 80r/min, rage girman nakasar daga 15s⁻¹ zuwa 8s⁻¹-daidai daidai da ƙimar farfadowa mai mahimmanci na waɗannan fayafai na aluminum.. Hatsi suna samun gyare-gyare iri ɗaya ta hanyar ɓata wuri, rage yuwuwar samar da bandeji mai ƙarfi ta 80%. Saboda, tsayin tsayin kwas ɗin lemu yana ƙaruwa daga 0.5mm zuwa 1.5mm, amplitude yana raguwa daga 0.1mm zuwa 0.02mm, kuma ragi na saman Ra yana raguwa daga 2.5μm zuwa 1.2μm.

2. Ingantattun yanayin lubrication: Tsawaita lokacin sarrafawa na juyi mai wucewa 4 (daga 30 zuwa 45 min) damar “segmented lubrication” (sake shafa man shafawa kafin kowace wucewa), hana lubricating fim karya. Sakamakon haka, Matsakaicin lamba tsakanin abin nadi mai jujjuyawa da fayafai na aluminum yana raguwa daga 1000MPa zuwa 800MPa, rage lalacewa ta hanyar 60% da kuma kara inganta ingancin surface.

4. Tabbatar da Gwaji: Kwatancen Ayyuka Tsakanin 3-Pass da 4-Pass Spinning

Don tabbatar da gaskiya ko haɓaka wucewa zuwa 4 yadda ya kamata ya rage abubuwan da aka gano, wani maƙerin jirgin ruwa mai matsa lamba ya gudanar da gwaje-gwajen sarrafawa ta amfani da 5083-Fayafai na aluminium masu fushi don tankunan iska da φ600mm × 12mm. An kafa ƙungiyoyin gwaji guda biyu (bambanta kawai a cikin adadin wucewa), tare da wasu sigogi gyarawa: G-60 na tushen mai mai graphite, da mandrel kayan: kashe 45# karfe. Sakamakon gwajin kamar haka:

(1) Gwajin Kaurin bango (Yin amfani da ma'aunin kauri na Ultrasonic, Daidaitaccen 0.01mm)

Na farko, An auna kaurin bango a maɓalli masu mahimmanci (saman kai, yankin mika mulki, madaidaiciya baki) don tantance daidaiton girma. An gabatar da sakamakon a cikin tebur da ke ƙasa:

Ƙarshe: Ana sarrafa kauri kauri na bangon juzu'i na 4-pass a cikin ± 0.23mm, cikakken cika daidaitattun bukatu; da bambanci, tsarin 3-pass yana nuna tsananin kauri a saman kai (-0.48mm), yana haifar da karkatacciyar hanya.

(2) Gwajin ingancin saman (Amfani da Laser Confocal Microscope, Daidaitaccen 0.001μm)

Daga baya, An kimanta ingancin saman don ƙididdige kawar da nau'in kwasfa na orange, tare da ma'auni masu mahimmanci ciki har da rashin ƙarfi, girma, da rashin lahani:

Ƙarshe: Filayen Ra na jujjuyawar 4-pass yana raguwa zuwa 1.2μm, girman kwasfa na orange shine ≤0.02mm, kuma adadin lahani ya ragu daga 15% zuwa 2% - yana nuna ingantaccen ingancin saman sama fiye da juzu'i 3.

(3) Gwajin Kayayyakin Injini (Amfani da Injin Gwajin Tensile, GB/T 228.1-2021)

Daga karshe, An gwada kaddarorin injina don tabbatar da cewa haɓakar wucewa baya lalata aikin kayan (m ga aikace-aikace masu ɗaukar nauyi):

Ƙarshe: Saboda ƙarin nakasar uniform na 5083 aluminium fayafai don manyan tankunan iska, 4-wuce kadi yana samun isasshen aiki hardening, yana haifar da ingantattun kaddarorin inji ba tare da wani lalacewar aiki ba.

Gaba ɗaya, waɗannan gwaje-gwajen sun tabbatar da cewa haɓaka haɓaka zuwa 4 yadda ya kamata warware duka bango kauri sabawa da orange kwasfa rubutu al'amurran da suka shafi.

5. Taimakawa Haɓaka Tsari Bayan Canjin Canjawa: Ɗaukaka Tasirin Ingantawa

A bayyane, karuwar adadin wucewa kadai bai isa ba don inganta aikin juyi gabaki daya; tsarin rufaffiyar madauki “daidaita ma'auni, mold ingantawa, da kuma bayan aiwatarwa” ake bukata don daidaitawa tare da kadi halaye na 5083 aluminium fayafai don manyan tankunan iska. Mahimman matakan tallafi sun haɗa da:

(1) Sake daidaita ma'aunin kadi

Na farko kuma mafi mahimmanci, sake daidaita saurin igiya da ƙimar ciyarwa a cikin wucewa yana tabbatar da daidaiton nakasu:

1. Gudun Spindle da Girman Girman Ciyarwa: 4-wuce kadi ya dauko a “rage jinkiri – daidaita – gama” dabarun sauri (Wuce 1: 80r/min → Wucewa 2-3: 70r/min → Wuce 4: 60rpm), tare da daidaita farashin ciyarwa (45→40→35→30mm/min). Wannan tsari yana tabbatar da ingancin fayafai na aluminium ana kiyaye su sosai a 8-10s⁻¹ kowace fasfo., nisantar ɓarnawar ɓarna da ƙari;

2. Haɓaka Ƙaƙwalwar Ƙwaƙwalwar Ƙaƙwalwa: Daidaita kusurwar aiki na abin nadi daga 30° zuwa 35°, ƙara wurin lamba tare da fayafai na aluminum (daga 20cm² zuwa 25cm²). Wannan daidaitawa yana rage matsin lamba na gida, rage girman mannewa karfe da kuma kara danne lahani.

(2) Sarrafa Madaidaicin Ƙira

Baya ga gyare-gyaren siga, daidaitaccen mold yana tasiri kai tsaye ingancin saman da daidaiton girma:

1. Mandrel Surface Jiyya: Wurin da aka yi masa chrome plated ne (kauri 50μm) kuma goge (Ra ≤0.4μm), rage gogayya coefficient tare da 5083 aluminium fayafai don manyan tankunan iska daga 0.15 ku 0.10. Ƙananan gogayya yana hana manne abu da karce samuwar;

2. Gyaran Roller Edge: Ƙara radius fillet na gefen abin nadi daga R2mm zuwa R3mm. Wannan gyara yana guje wa kaifi-kaifi a saman fayafan aluminum, kara murkushe kwasfa orange.

(3) Maganin Zafin Bayan Kaya

A ƙarshe, Maganin zafi na baya-baya yana tabbatar da kayan aiki da girma:

5083 aluminium fayafai don manyan tankunan iska yin aiki tuƙuru bayan kadi (Taurin yana ƙaruwa daga HV80 zuwa HV110), wanda zai iya haifar da saura damuwa. A “rage yawan zafin jiki danniya annealing” shiga jerin gwano (120℃ don 1.5h) don haka ana buƙatar - rage damuwa na ciki daga 350MPa zuwa 150MPa da daidaita girman kauri na bango. (juzu'i na raguwa yana raguwa daga ± 0.05mm zuwa ± 0.02mm).

6. Kammalawa da Outlook

a takaice, a lokacin da kadi shugabannin daga 5083 aluminium fayafai don manyan tankunan iska, ƙara yawan kadi wucewa daga 3 ku 4 yana ba da ci gaba guda biyu ta hanyar daidaita tsarin nakasa:

1. Ana sarrafa kauri kauri daga ± 0.45mm zuwa ± 0.23mm, cikakken cika buƙatun ≤± 0.3mm na GB/T 150.4-2011;

2. An kawar da nau'in kwasfa orange saman, tare da Ra yana raguwa daga 2.8μm zuwa 1.2μm kuma ƙimar lahani na faduwa daga 15% ku 2%.

Yana da mahimmanci a lura dole ne a haɗa canjin izinin wucewa tare da “daidaita ma'auni (Madaidaicin ƙimar saurin gudu-feed), mold ingantawa (mandrel polishing), da kuma bayan-spining annealing” don haɓaka tasirin haɓakawa - keɓancewar izinin haɓaka ba zai warware matsalolin ba.

Daura, Hanyoyi guda uku masu mahimmanci za su ci gaba da aiwatar da aikin jujjuyawar manyan tankunan iska:

1. Tsarin Kadi Mai Hankali: Haɗa duban gani na AI (saka idanu na ainihi na bangon kauri da ingancin farfajiya) don daidaita yawan raguwa a kowane fasinja, rage dogaro da ƙwarewar hannu;

2. Tsarin Juya Dumi: Ƙara yawan zafin jiki na juyawa zuwa 150-200 ℃ don ƙara inganta filastik na waɗannan fayafai na aluminum., mai yuwuwar rage yawan wucewa (e.g., daga 4 ku 3) don daidaita inganci da daidaito;

3. Haɓaka Rufin Mold: Karɓar carbon kamar lu'u-lu'u (DLC) rufi a kan mandrels da kadi rollers don ƙara rage juzu'i coefficient, haɓaka ingancin ƙasa da haɓaka rayuwar kayan aiki.

Daga karshe, core qa'ida shiryar da tsari zane ga kadi shugabannin daga 5083 aluminum fayafai ga manyan tankuna na iska shine ku “dauki alloy nakasawa halaye a matsayin tushe, wuce rarraba a matsayin ainihin, da ma'auni da yawa a matsayin garanti”. Wannan hanya tana daidaita daidaito, iya aiki, da tsada, tabbatar da bin ka'idodin aminci na manyan tankunan iska na manyan motoci.