Me yasa aluminum da'iran crack

Shigowa da: Me yasa "Cracking" Ya Zama Mafi Girma Bottleneck a Tsarin Aluminum Da'irar

Kamar yadda kayan dafa abinci da masana'antar hasken wuta ci gaba da matsawa zuwa sassauƙan ƙarfe kafa, Jikin Kokon Dricware, Tufafin cooker na ciki, masu haskakawa, fitilu, kuma tasoshin ajiya suna ƙara buƙatu mafi girma akan haɓakar da'irorin aluminum. Duk da haka, a kullum samarwa, fatashin, madadin marufi na rufin blister don samfuran marufi kamar gel ko cream, yawan kunne, lemu-kwasfa mai laushi, da karyewar baki har yanzu yana faruwa akai-akai. Waɗannan lahani suna rage yawan amfanin ƙasa da kashi 20-40% a masana'antu da yawa, mai tsananin tasiri ga daidaiton fitarwa.

Masu masana'anta sukan yi tambaya:

• Me yasa da'irorin aluminum masu gami da kauri iri ɗaya suke yin daban yayin ƙirƙirar?
• Me yasa gefuna sukan fara tsagewa yayin zane mai zurfi?
• Me yasa baka (R-zone) fashe ba zato ba tsammani yayin juyi?
• Menene tsarin tsari don kawar da fashewa daga kayan, shafewa, ya mutu, man shafawa, da sarrafa siga?

Wannan labarin ya bayyana cikin zurfin injiniya hanyoyin da ke bayan da'irar aluminum, abu yana haddasawa, dalilai masu alaka da tsari, da cikakkun mafita daga hangen nesa na samarwa na ƙarshe zuwa ƙarshen.

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Kashi 1 - Me yasa Aluminum Da'irori ke faɗuwa yayin zana mai zurfi ko jujjuyawa? (Binciken Injiniya)

1. Dalilai masu alaƙa da abu

1. Haɗin Gilashin Yana Ƙayyade Ƙarfin Nakasawa

Daban-daban aluminum gami da daban-daban stretchability:

Mafi girma abun ciki na Mn ko Mg ƙara ƙarfi amma rage elongation, yin fatattaka mafi yuwuwa.
Don haka:

• 1050/1060 sune mafi kyawun allo don zane mai zurfi
• 3003 ana iya amfani da shi kawai tare da ingantaccen sarrafa annealing
• 5052 yana da ƙarfin ƙarfi amma yana da haɗari don zane mai zurfi

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2. Kayayyakin Makanikai marasa Uniform (Rashin daidaituwa ko kauri)

Fatsawa na iya faruwa lokacin:

• Rarraba damuwa na ciki bai dace ba
• Rashin kauri yana da girma
• Taurin gefen yana da mahimmanci fiye da cibiyar
• Tauraruwar aikin sanyi ya kasance saboda rashin isassun buguwa

The yankin baki shine mafi yawan raunin rauni.

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3. Ƙaƙƙarfan Hatsi ko Tsawon Hatsi Yana Haɓaka Farkowar Farko

Tsarin hatsi yana ƙayyade tsari:

• Kyakkyawan hatsi = kyakkyawan tsari
• Ƙanƙarar hatsi = ƙaranci mai girma, sauki fatattaka
• Ƙarfin ƙwayar hatsi yana kaiwa zuwa 'yan kunne, damuwa maida hankali, da fasa

Nakasu na ƙarfe na yau da kullun waɗanda ke ƙara haɗarin fashewa:

• M hatsi
• Tsawon hatsi
• Nau'in mirgina mai ƙarfi
• Yawan hazo

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2. Dalilai masu alaƙa da tsari

1. Matsakaicin Matsayin Zane (DR)

Rabon zane mai zurfi (DR):
DR = diamita mara kyau / kofin diamita

• Yaushe DR > 2.1, da'irorin aluminum suna da yuwuwar tsagewa.

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2. Ƙuntataccen Gudun Material = Ƙarƙashin Ƙarƙashin Ƙarƙashin Ƙarƙashin Ƙaƙwalwa

Fatsawa yana faruwa ne lokacin da ƙarfe ba zai iya gudana a hankali cikin rami mai mutuwa ba.

Dalilan gama gari:

• Ƙarfin mai riƙe da komai ya wuce kima
• Rashin isasshen ƙarfin mai riƙe da komai (yana haifar da wrinkles → daga baya yaga)
• Maganin shafawa mara kyau (babban gogayya → tsagewa)

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3. Radius mara kyau (R-darajar)

Ƙananan R-kwangulu shine dalili na 1 na fashewa.

• Ƙananan radius mutu → maida hankali na damuwa → R-zone ya fashe a ciki 90% na lokuta
• Matsakaicin cire naushi-mutuwa
• Kusurwoyin canji ba zato ba tsammani

Ƙimar R da aka ba da shawarar:

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4. Rashin Lubrication Yana haifar da Hawaye

Rashin isasshen man shafawa yana kaiwa zuwa:

• Scratches
• Haushi
• Tsanani mai tsanani
• Yaga a yankin R-zone ko bango

Amfani:

• Babban matsi mai zurfin zane mai zurfi
• Man shafawa na tushen graphite
• Man shafawa na kayan abinci don girki

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5. Rashin Ma'aunin Ƙarfi Mai Alakan Juya

Fashewar juzu'i yakan faru a ciki:

• R-zone
• Wurin miƙa mulki na ƙasa zuwa bango
• Yanki mai ban tsoro

Dalilai:

• Matsin abin nadi mai yawa
• Yawan ciyarwa da sauri
• High localized dumama → aiki hardening
• Kaurin farawa yayi siriri sosai

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3. Dalilan da suka danganci kayan aiki

1. Talauci Daidaicin Injin

• Eccentric ram
• Jijjiga inji
• Rarraba ƙarfi mara daidaituwa
  → Fashewa yayin kafawa.

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2. Mutuwar da aka sawa ko masu riƙe da komai

Wear yana gabatarwa:

• Burs
• Scratches
• Karfe na cikin gida na waje

Yana kaiwa ga fashewa da wuri.

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Kashi 2 - Yadda Ake Hana Fashewa Lokacin Zane Mai Zurfi ko Juyawa

1. Ikon Material (Mafi Muhimman Factor)

1. Zaɓin Alloy ɗin Dama

Ƙarfafa fushi (H14/H24) ba zai iya ba a zurfafa jawo.
Amfani O-sa fushi kawai.

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2. Madaidaicin Annealing (Yana magance 80% na Matsalolin Fatsawa)

Maƙasudin ɓarna:

• Cire taurin aikin sanyi
• Maida ductility
• Daidaita kayan aikin injiniya

Nasiha:

Ƙarƙashin-annealed:

• High gefen taurin
• R-zone yaga
• Alamar Roller

An wuce gona da iri:

• M hatsi
• Orange-kwasfa surface

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3. Kauri da Taurin Sarrafa

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2. Mutuwar Ingantawa

1. Daidaitaccen R-Radius Design

Amfani:

• Punch R ≥ 4t
• mutu R ≥ 6t

Inda t = kaurin takarda.

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2. Tsabtacewa Da Kyau

Nasiha:

• 1.08– 1.12t don zane na farko
• 1.15-1.20t don sake gyarawa

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3. Ƙarfin mai riƙe da komai a ciki

• Yayi yawa → ƙuntataccen kwarara → tsagewa
• Dan kadan → murzawa → daga baya yaga

Yi amfani da na'ura mai aiki da karfin ruwa ko tsarin CNC idan zai yiwu.

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3. Lubrication & Maganin Sama

Kyakkyawan lubrication yana rage gogayya 3-5 ×.

Nasiha:

• Babban matsi mai zurfi-zana mai
• Graphite man shafawa
• Man kayan abinci don samar da kayan dafa abinci

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4. Zurfafa Zane Mai Kyau

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5. Ƙwaƙwalwar Sigogi

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6. Yin amfani da "Pre-forming + Zurfin Zane” Haɗuwa

Matakai:

• Pre-miƙewa
• Pre-lankwasawa
• Zane a matakai biyu
• Matsakaici Annealing

Wannan yana rage tsagewa ta a kan 60%.

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Kashi 3 - Nau'in Cracking gama gari da yadda ake gano su

1. Gefen Fasa (Mafi Yawanci)

Dalilai:

• High gefen taurin
• Rashin isassun annealing
• Rashin kauri

Magani:

• Gwajin taurin gefen
• Tabbatar da cikakken annealing
• Rage ƙarfin mai riƙe da komai

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2. R-Zone Cracking

Dalili:

• Ƙananan R-radius
• Babban gogayya
• Damuwa maida hankali

Magani:

• Yawan mutuwa R
• Inganta man shafawa
• Rage saurin zane

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3. Madaidaicin Layi Cracking

Dalili:

• Nau'in mirgina mai ƙarfi
• Girman hatsi

Magani: Canza zuwa abu mafi inganci.

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4. Ruwan Bawo-Bawo Mai Fassara

Dalili:

• Over-annealing
• M hatsi

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5. Kadi-kade a Yankin Canji

Dalili:

• Rashin daidaiton abin nadi
• Kaurin farawa mai bakin ciki

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6. Faɗakarwa

Dalili:

• Babban canjin kusurwa
• Rashin isasshen kauri

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Kashi 4 - Cikakken Magani-Level (Daga Coil zuwa Samfurin Karshe)

1. Albarkatun kasa (Aluminum nada)

Mabuɗin buƙatun:

• Alloy: 1050/1060-O, 3003-O
• Girman hatsi: 50- 100 μm
• Hakuri mai kauri: ± 0.01 mm
• Bambancin taurin < 5HB

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2. Tsaftacewa da Barci

• Cire mai
• Rigakafin zazzagewa
• Babban madaidaicin da'irar yankan

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3. Annealing

Madaidaici:

• 380-420 ° C
• 4 hours jikewa
• Sannu a hankali

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4. Pre-forming Shiri

• Ko da man shafawa
• Mold preheating
• Duban mai riƙe da komai

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5. Zane mai zurfi

• Na farko zana sarrafawa DR
• Anneal kafin zana na biyu
• Kyakkyawan sautin ƙarfin mai riƙe da komai

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6. Juyawa

• Multi-mataki kafa
• M nadi surface
• Dumama taimako lokacin da ake buƙata

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7. Binciken Ƙarshe

• Duban gani
• Taswirar kauri
• Tsawon kafa
• Gwajin faɗaɗawa

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Kashi 5 - Nazarin Harka Injiniya

Harka 1 - 3003 Da'irorin Aluminum suna Fasa a cikin Kayan girki Mai Zurfi

Batu:

• Babban taurin gefen da 10-15HB
• Ƙarƙashin-annealed

Magani:

• Ƙara lokacin jinƙai
• Ƙara matsakanci annealing kafin zana na biyu
• Rage ƙarfin mai riƙe da komai ta hanyar 15%

Sakamako:

• An rage yawan fashe daga 22% → 1.5%

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Harka 2 - 1060 Da'irori suna Fasa a cikin Murfin Matsakaicin Matsakaicin Zuciya

Batu:

• Rashin daidaiton abin nadi a yankin R-zone
• Kaurin farawa yayi siriri sosai

Magani:

• Madaidaicin matsi na abin nadi
• Ƙara kauri 1.3 → 1.4 mm

Sakamako:

• An rage yawan fashe daga 18% → 0.8%

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Ƙarshe: Ana Bukatar Dabarar-Tsarin Tsari don Kawar da Cracking

Fatsawa yayin zane mai zurfi ko juyi baya haifar da wani abu guda ɗaya. Yana da hadadden sakamako na:

• Tsarin kayan abu
• Annealing daidaici
• Mutuwar zane
• Lubrication
• Tsari sigogi
• daidaiton kayan aiki

Sai kawai lokacin da waɗannan abubuwan suka inganta tare zasu iya warwarewa ta asali da'irar aluminum fasa cikin zane mai zurfi da kuma ƙara yawan yawan amfanin ƙasa.