Ruwa na aluminum yayi amfani da shi a cikin dafa abinci suna iya yiwuwa ga matsaloli kamar “fatashin” kuma “yi wauta” A yayin aiki. Yadda za a hana su?

1. Shigowa da: Industry Pain Points and Impacts of Processing Defects in Aluminum Discs for Kitchenware

Aluminum fayafai don kayan dafa abinci (An yi amfani da shi a cikin tukwane, kwanon soya, kayan abinci, da dai sauransu.) ana yin su da 3003, 5052, kuma 1100 aluminum gami. Their stamping and drawing processes require “thin-wall forming + daidaiton girma + defect-free appearance”—however, “fatashin” (local stress exceeding the material’s tensile strength) kuma “yi wauta” (local accumulation caused by uneven material flow) are two core defects, directly leading to:

1. Reduced pass rate (industry average defect rate: 8%-15%, reaching 20% for deep-drawn kitchenware);

2. Rising costs (raw material waste + mold maintenance costs increase by more than 30%);

3. Performance risks (cracking easily causes deformation during kitchenware use, while wrinkling affects uniform heat conduction).

To formulate practical prevention solutions, the root causes of defects must be accurately analyzed from three dimensions: Abubuwan kayan abu, tsari sigogi, and mold design. A bayyane, Rigakafin matsaloli tare da fayafai na aluminum da aka yi amfani da su a cikin kayan dafa abinci ya zama babban abin da ake mayar da hankali ga masana'antun don haɓaka haɓakar samarwa da ingancin samfur..

2. Babban Dalilan Bincike na “Fatashin” kuma “Yi wauta” Lalacewar

(1) Fatashin: Babban Tasirin Matsalolin Matsi da Rashin isassun Kayan aiki

1. Maɓalli Masu Haɓaka Maɓalli

• • Zaɓin gami mara daidai: Misali, amfani 5052 H18 zafi (karfin jurewa: 260MPa, elongation: 10%) maimakon 3003 Sa fushi (karfin jurewa: 110MPa, elongation: 25%) don tukwane mai zurfi-rashin isassun ductility yana kaiwa ga fashe;

• • Lalacewar kayan ciki: Fayafai na aluminum tare da ratsan birgima (zurfin >0.02mm) ko hadawa (Fe abun ciki >0.7% sauƙi siffofi da wuya barbashi) zama wuraren taro na damuwa yayin zane;

• • Maganin zafi mara kyau: Rashin isassun annealing (e.g., 3003 aluminum fayafai annealed a <340℃ don <1h) yana barin damuwa na ciki ba a kawar da shi ba, haifar da karuwa kwatsam a cikin damuwa na gida yayin zane.

2. Maɓalli na Tsari da Ƙarfafa Masu Alamun Mold

• • Girman rabon zane: rabon zane na farko (gama samfurin diamita/diamita mara kyau) >2.2 (iyaka ga 3003 Sa fushi) da rabon zane na gaba >1.8, yana haifar da raguwar ɓarkewar gida ya wuce gona da iri 35% (ƙima mai mahimmanci don karyewar abu);

• • Ƙananan fillet ɗin ƙura: Punch-die fillet radius R <5t (t = kauri aluminium; e.g., R <10mm lokacin t=2mm), kara yawan damuwa da damuwa daga 1.2 ku 2.5 da kuma ƙara haɓaka haɗarin fashewa;

• • Lubrication gazawar: Man shafawa carbonization (e.g., man shafawa mai tushen mai tare da filashi <180℃) a lokacin high-zazzabi zane (m zafin jiki >60℃), ƙara gogayya coefficient daga 0.05 zuwa 0.15 — tashin hankali na gida ya wuce iyakar ɗaukar kayan.

(2) Yi wauta: Sakamako mara makawa na Gudun Material Mara Daidaituwa da Rashin Isasshen Ƙuntatawa

1. Ma'auni mara daidaituwa

• • Rashin isasshen ƙarfin mariƙin mara komai: Ƙarfin mariƙin mara komai F < K×t×D (K = ma'auni, 1.2-1.5 domin 3003 aluminum; t = kauri; D = blank diamita). Misali, F <3600N lokacin t=1.5mm da D=200mm-babu wani takurawa mai tasiri akan gefen da ba komai, haifar da wuce kima abu kwarara zuwa cikin rami da wrinkling;

• • Gudun zane mara al'ada: Gudu >2m/s (0.5-1.2m/s shawarar don zane mai zurfi) ba ya barin lokaci don nakasar kayan abu na uniform, yana haifar da tarin gida; sauri <0.3m/s cikin sauƙi yana haifar da laushin kayan gida saboda tarukan zafi, yana haifar da rashin daidaituwa.

2. Mold da Blank Design Lalacewar

• • Tsare-tsare mara ma'ana: Tsare-tsare mai gefe guda ɗaya <1.05t (e.g., <2.1mm lokacin t=2mm) yana ƙara juriya kwararar abu; sharewa >1.2t barin rashin isasshen tallafin kayan aiki, haifar da wrinkling;

• • Bangaren juzu'i: Kuskuren zagaye diski na aluminum >0.1mm (e.g., >0.2mm sabawa ga 200mm diamita) yana haifar da damuwa mara daidaituwa yayin zane, tare da >20% bambanci a gefen abu ya kwarara gudun;

• • Shaye mara kyau: Babu ramukan huci (diamita <φ1mm ku) a cikin kogon mold ko katange iska suna haifar da matsa lamba mara kyau (<-0.02MPa) a cikin rami a lokacin zane, hana kwararar abu da haifar da wrinkling na gida.

3. Maganin Rigakafin Tsare-tsare: Haɗin Haɗin Haɓaka Abu, Tsari, da Mold

(1) Ƙarshen Material: Madaidaicin Zaɓi da Kula da Magani (Core Prevention Foundation)

1. Daidaita Aloy-Zazzabi (Nau'in Cookware An Rarraba shi)

2. Mabuɗin Tsarin Magani na Maɓalli

• • Annealing (kawar da damuwa na ciki): 3003 Aluminum fayafai an ware a 340-360 ℃ for 1.5-2h, sai tanderu- sanyaya zuwa <100℃ kafin a sake shi (cire daga tanderu), tabbatar da taurin ≤HV30 (Vickers taurin); 5052 H14 yana buƙatar farawa da farko zuwa fushin O (370-390℃ na 2h), sannan ya kai H14 kamar yadda ake bukata;

• • Maganin saman: Sarrafa kauri na fim ɗin oxide na diski na aluminum a 5-8μm (fim >12μm cikin sauƙi yana haifar da fatattaka), gurbataccen mai ≤5mg/m² (bushewa zafin jiki: 60-80℃ bayan tsaftacewa da sauran ƙarfi), da rashin ƙarfi Ra ≤0.8μm (guje wa juriya mara daidaituwa);

• • Binciken mara komai: Gwajin Eddy na yanzu don haɗa ciki (yankin hada guda ɗaya <0.5mm²), Laser kauri ma'auni don kauri sabawa ± 5% (e.g., ± 0.1mm lokacin t = 2mm), da kuskuren zagaye ≤0.08mm.

(2) Ƙarshen Tsari: Ƙididdiga Ƙididdigar Ƙimar Ƙarfafawa da Ƙa'idar Ƙarfi

1. Ƙididdiga masu ƙididdigewa don Ma'auni na Ƙa'idar Tsari (Dauke 3003 Sa fushi, t=2mm Fayafan Aluminum a matsayin Misali)

2. Dabarun Ƙa'ida Mai ƙarfi

• • Sa ido na ainihi: Yi amfani da firikwensin ƙarfi (daidaito ± 1%) don saka idanu akan ƙarfin stamping; lokacin da karfi nan take ya wuce 1.2 sau da ƙarfin ƙarfin kayan abu, rage saurin zane ta atomatik ta 20%-30%;

• • Maimai da mai: Sake shafa mai kowane 500-800 guda; amfani “fesa + shafa” don zane mai zurfi don tabbatar da kauri na 5-10μm (yawan kauri cikin sauki yana haifar da wrinkling);

• • Tsakanin tsari: Dakatar da aiki don 10 mintuna kowane 2 sa'o'i a ci gaba da aiki don kwantar da mold zuwa kewayon zafin jiki da aka saita (guje wa laushin abu saboda yawan zafi).

(3) Ƙarshen Tsari: Haɓaka Tsari da Gudanar da Madaidaici

1. Mabuɗin Tsarin Tsarin Tsarin Mahimmanci

• • Punch-die fillet: Zane ta “R=5t-8t” (R=10-16mm lokacin t=2mm); amfani da babba iyaka (R=14-16mm) don zane mai zurfi da ƙananan iyaka (R=10-12mm) don zane mai zurfi; tabbatar fillet surface roughness Ra ≤0.4μm (rage damuwa maida hankali);

• • Ikon sharewa: Tsaya mai gefe guda = 1.05t-1.15t (2.1-2.3mm lokacin t=2mm); amfani da babba iyaka (2.2-2.3mm) don zane mai zurfi da ƙananan iyaka (2.1-2.2mm) don zane mai zurfi;

• • Tsarin cirewa: Drill 2-4 φ1.2-1.5mm huda ramukan a iyakar tsinkaya na mold rami, tare da zurfin rami na 5-8mm-tabbatar da matsa lamba ≤-0.005MPa yayin zane (guje wa mummunan matsi mai haifar da toshewar kwarara).

2. Matsakaicin Tsari da Kulawa

• • Madaidaicin masana'anta: Punch-die coaxiality ≤0.02mm, flatness ≤0.01mm / 100mm - kauce wa m abu danniya saboda matalauta tsakiya.;

• • Kulawa na yau da kullun: Bayan sarrafa 1,000 guda, gyara mold fillet tare da lu'u-lu'u nika ƙafafun (cire alamun lalacewa) da tsaftataccen ramuka tare da raƙuman ruwa na ultrasonic (hana aluminum guntu blockage); tabbatar da cewa babu scratches a kan mold surface (zurfin <0.01mm).

A wannan mataki, Rigakafin matsaloli tare da fayafai na aluminium da ake amfani da su a cikin kayan dafa abinci ya dogara kacokan akan daidaita zaɓin kayan, tsari tsari, da haɓaka ƙirar ƙira-kowace hanyar haɗin gwiwa tana cika wasu don rage haɗarin lahani.

4. Tsarin Kula da Ingantaccen Tsari: Lalacewar tsangwama daga Tushen zuwa Ƙarshen Samfur

(1) Duban Kayan Kaya Mai shigowa (Maɓallin Maɓalli)

1. Binciken abun ciki: Yi amfani da spectrometers masu karantawa kai tsaye don gwada Mn (1.0%-1.5%) da Si (≤0.6%) in 3003 aluminum, da kuma Mg (2.2%-2.8%) in 5052 aluminum-tabbatar da yarda da GB/T 3880.2-2022 (Matsayin ƙasa na Jamhuriyar Jama'ar Sin don Aluminum da Aluminum Alloys – Kashi 2: Haɗin Sinadarin Kayan Aiki);

2. Kayan aikin injiniya: Samfuri 5 guda a kowane tsari don gwajin juzu'i (GB/T 228.1-2021); ƙi dukan tsari idan elongation ne 10% ƙasa da daidaitattun ƙimar;

3. Duban bayyanar: Yi amfani da duban gani na CCD (daidaito 0.01mm) don gane karce da kuma haɗawa; sake yin aiki idan ƙarancin ƙarancin ya wuce 2%.

(2) Sa Ido na Gaskiya Lokacin Gudanarwa

1. Binciken kan layi: Shigar da kyamarori na masana'antu (mitar harbi 30 firam/s) don gane wrinkling na ainihi (alagammana tsawo >0.5mm) da fashewa (tsayin tsage >1mm); tsaya nan da nan don daidaitawa idan an sami lahani;

2. Rikodin siga: Store jawo karfi, blank riƙewa karfi, da bayanan sauri don kowane samfur ta hanyar MES (Tsarin Kisa Manufacturing) don samar da sarkar traceability na tsari; fara faɗakarwa idan jujjuyawar siga ta wuce ± 10%.

(3) Ƙarshen Binciken Samfura Kafin Bayarwa

1. Bayyanar: Na gani + dubawa tactile-babu fashewar gani ko wrinkling (protrusion na gida ≤0.2mm), kuma babu burrs a gefuna (tsawo ≤0.1mm);

2. Girma: Yi amfani da na'ura mai daidaitawa don gwada diamita da aka gama (karkacewa ± 0.2mm), zurfin (karkacewa ± 0.1mm), da kaurin bango uniformity (Matsakaicin karkata ≤10%);

3. Tabbatar da injina: Gwajin gwajin gwaji (0.3Matsakaicin MPa yana riƙe da 30s ba tare da nakasar tukwane ba) da sauke gwaje-gwaje (1.2m sauke tsayi ba tare da tsagewa ba).

5. Abubuwan Aikace-aikacen Masana'antu: Ingantawa daga 18% Lalacewar ƙimar zuwa 3%

Harka 1: Tukwane masu Zurfi da 3003 Ya Temper Aluminum fayafai (Zurfin 60mm, t=2.5mm) a cikin wani Factory Kitchenware

1. Matsalolin asali: 12% tsautsayi da kuma 6% Yawan wrinkling-wanda ya haifar da ƙimar zane mai yawa (2.4), ma kananan mold fillet (R=8mm), da rashin isasshen ƙarfi mai riƙe da komai (4,500N);

2. Maganganun ingantawa:

• • Daidaita tsari: Raba rabon zane zuwa matakai biyu (na farko 2.0, sakandare 1.6); ƙara ƙarfin mariƙin zuwa 6,000N (lasafta kamar F=1.5×2.5×200);

• • Kyau ingantattu: Ƙara fillet R zuwa 15mm (7t), saita yarda mai gefe guda zuwa 2.7mm (1.08t), kuma ƙara 4 φ1.5mm ramukan iska;

3. Sakamako: Ƙimar lalacewa ta ragu zuwa 3% (0.8% fatashin, 2.2% yi wauta), ƙimar wucewa ya karu da 15 maki kashi, kuma farashin rukunin ya ragu da 22%.

Harka 2: Shallow-Drawn Frying Pans with 5052 H14 Temper Aluminum Discs (Depth 25mm, t=1.8mm)

1. Original problem: 10% wrinkling rate—caused by insufficient blank holder force (2,000N) and excessive drawing speed (2.5m/s);

2. Maganganun ingantawa: Adjust blank holder force to 2,700N (F=1.0×1.8×150), reduce speed to 1.2m/s, and switch to dry lubricant;

3. Sakamako: Wrinkling rate reduced to 0, and production efficiency increased by 30% (daga 120 pieces/h to 156 pieces/h).

6. Abubuwan da zasu faru nan gaba: In-Depth Integration of Intelligent Technology and Material Innovation

1. Intelligent process regulation: Introduce AI visual inspection (recognition accuracy 0.05mm) + adaptive control systems to real-time adjust blank holder force and speed (response time <0.1s), forming a “defect prediction-parameter self-optimization” rufe madauki;

2. Material upgrading: Ci gaba “3003 + trace Zr” composite aluminum alloys (elongation increased to 28%, tensile strength maintained at 115MPa) to adapt to larger drawing ratios (first drawing ratio 2.4);

3. Ƙirƙirar fasahar ƙira: Ɗauki ƙwanƙwasa 3D bugu (SLM karfen bugu, Rarraba saman Ra ≤0.2μm) don cimma hadedde forming na hadaddun cavities da rage abu kwarara juriya.

Rigakafin matsaloli tare da fayafai na aluminium da ake amfani da su a cikin kayan dafa abinci zai ƙara yin amfani da fasaha na fasaha da sabbin fasahohi don cimma babban inganci da ƙarancin lahani a nan gaba..

7. Ƙarshe

Rigakafin “fatashin” kuma “yi wauta” a cikin tambari da zane na aluminum fayafai don kitchenware cibiyoyin a kan haɗin gwiwar na zaɓin kayan abu da pretreatment, ƙididdige inganta sigogin tsari, da madaidaicin tsarin ƙirar ƙira. Wajibi ne a ɗauka “matching gami Properties tare da aiki bukatun” a matsayin tushe, “tsauri tsari na tsari sigogi” as core, kuma “sarrafa ingancin cikakken tsari” kamar garanti. Mai ma'ana, haɗa fasaha mai hankali da haɓaka kayan aiki za su warware ainihin abubuwan zafi na masana'antu da cimma burin “high pass rate + maras tsada + babban aiki” a sarrafa.