Lokacin amfani 3003 Aluminum na aluminum don samar da iyakokin Inminal da gas, Shin za a yiwa wuraren maida hankali na zanen gado a cikin abubuwan da aka yi bayan an kama shi da lanƙwasa?

1. Shigowa da: Darajar aikace-aikacen da kuma tsokanar haɗari na 3003 Tsarin Kera Aluminum Faifai don Kayayyakin Injini

Ƙarshen injina (e.g., Kasa mafita, Hydraulic bawul din end) da jigon jiragen ruwa (e.g., ingin gaskets, shock-absorbing gaskets) da farko amfani 3003 aluminum fayafai a matsayin ainihin albarkatun su. The 3003 aluminum disc tsarin masana'antu don samfuran injiniyoyi yafi hada da “raw aluminum disc yankan → stamping forming (kwankwankwasa / huda naushi) → sarrafa aiki (flanges / goyan bayan gefuna) → bayan aiwatarwa (deburring / annealing) → gama samfurin taro”. Wannan tsari yana lissafin kusan 35% na masana'antar kera injina saboda ta “yanayi mara nauyi da ƙimar cancanta mai girma (≥95%)”.

Duk da haka, matakan stamping da lankwasawa a cikin 3003 aluminum faifai masana'antu tsari na inji kayayyakin sauƙi haifar da damuwa maida hankali a gefuna, sasanninta, da ramuka na ma'ajin ƙarshen iyakoki da gaskets na sashi. Kamar yadda 3003 Aluminum alloy ne wanda ba za a iya warkewa da shi ba Al-Mn gami da babban hankali ga aikin gajiya., gajiyawa yakan fara farawa a waɗannan rukunin yanar gizon. Alkaluma sun nuna haka 60% na gazawar bangaren injiniya ya samo asali ne daga matsalolin gajiya da wannan tsari ya haifar, kuma 80% na tsagewar gajiya suna mayar da hankali a cikin yankunan damuwa da aka kafa ta hanyar stamping da lankwasawa yayin aiwatarwa. Saboda haka, nazarin alakar da ke tsakanin 3003 aluminum faifai masana'antu tsari na inji kayayyakin kuma fashe gajiya yana da mahimmanci don haɓaka amincin samfuran injina.

2. Tasirin 3003 Tsarin Kera Aluminum Faifai don Kayayyakin Injini akan Yanayin Matsi

Matakai guda biyu masu mahimmanci - stamping da lankwasawa - a cikin 3003 aluminum faifai masana'antu tsari na inji kayayyakin kai tsaye canza yanayin damuwa na gida na kayan, kwanciya boye kasada ga gajiya fasa:

(1) Stamping Stage: Canje-canjen Damuwa yayin Buga Holi da Ƙaƙwalwar Kwanewa

A cikin stamping mataki na 3003 aluminum faifai masana'antu tsari na inji kayayyakin, Babban ayyuka shine ɗora ramukan ƙulli a cikin iyakoki na ƙarshen injina da yankan kwane-kwane na gaskets na bracket.:

• A lokacin huda huda (e.g., 10mm ramukan kusoshi a cikin iyakoki na ƙarshe), gefen ramin ya shiga 8%-12% radial shrinkage nakasar filastik, Ƙirƙirar radial residual tensile stress na 80-100MPa (kusa da iyakar gajiya na 3003 aluminum gami, 80-90MPa). This is the primary source of stress concentration in the process;

• A lokacin contour stamping (e.g., rectangular contours na gaskets), kasa fillet radius (R < 1mm) take kaiwa zuwa wani danniya maida hankali factor Kt na 2.5-3.0, aza harsashi don matsananciyar damuwa a cikin matakin lanƙwasawa na gaba. Wannan yana nuna mahimmancin sarrafa sigina a cikin 3003 aluminum faifai masana'antu tsari na inji kayayyakin.

(2) Lankwasawa Stage: Matsayin Damuwa Lokacin Samar da Siffar

A matsayin maɓalli na tsara matakin a cikin 3003 aluminum faifai masana'antu tsari na inji kayayyakin, lankwasawa (e.g., 90° flanges don iyakoki na ƙarshe, 120° goyan bayan gefuna don gaskets) yana ƙara ƙarfafa maida hankali:

• Gefen waje na kusurwar lanƙwasawa yana cikin tashin hankali (elongation kudi 5%-7%), yayin da bangaren ciki yake cikin matsewa (raguwar adadin 3%-5%). Tangential residual tensile stress na 60-80MPa siffofi a kusurwa, tare da hardening aiki (Taurin yana ƙaruwa daga HV45 zuwa HV60), rage ƙarfin nakasar filastik na gida;

• Idan jagororin damuwa na stamping da lankwasawa sun daidaita a cikin 3003 aluminum faifai masana'antu tsari na inji kayayyakin (e.g., haɗe-haɗe da kusurwoyi masu lanƙwasa), damuwa superposition yana faruwa. Ainihin danniya na gida zai iya kaiwa 100-120MPa, nisa ya wuce iyakar gajiya, kai tsaye jawo microcracks.

3. Ƙaddamar da Ƙaddamar da Gajiya Crack a cikin 3003 Tsarin Kera Aluminum Faifai don Kayayyakin Injini

Ragowar damuwa da lahani na sarrafawa wanda 3003 aluminum faifai masana'antu tsari na inji kayayyakin hanzarta juyin halitta na fashe gajiya yayin sabis na samfuran injina (ƙarƙashin madaidaicin lodi), wanda za a iya raba shi zuwa matakai uku:

(1) Ƙaddamarwar Gidan Yanar Gizo: Haɗin kai Tsakanin Lalacewar Tsari da Abubuwan Kaya

Matsayin stamping na 3003 aluminum faifai masana'antu tsari na inji kayayyakin sauƙin samar da burrs a gefuna rami (tsawo 10-20μm), da lankwasawa mataki oyan samar da surface microcracks (zurfin 5-8μm). Wadannan lahani suna haɗuwa tare da Al₆Mn suna haɓaka a iyakokin hatsi na 3003 aluminum gami ya zama gajiya crack shafukan qaddamarwa. Gwaje-gwaje sun nuna cewa rayuwar farawa ta fashe na samfuran rami tare da burrs ne kawai 58% na samfurin burr-free, yana tabbatar da tasirin hanzari na lahani na tsari akan gajiya.

(2) Yadawar Microcrack: Matsakaicin Matsalolin Tsari da Load

Matsakaicin nauyin nauyi yayin sabis na samfuran injina (e.g., R=-1 ɗimbin rawar girgiza don iyakoki na ƙarshe, R=0.1 matsa lamba don gaskets) superimpose tare da ragowar danniya mai saura daga 3003 aluminum faifai masana'antu tsari na inji kayayyakin, yana haɓaka kewayon ƙimar ƙarfin damuwa ΔK. Yawan yaɗuwar fashewa ya biyo bayan daidaiton Paris (m 3.5):

• Superposition na saura tensile danniya (80-100MPa) daga ramukan hatimi a cikin tsari kuma nauyin girgiza yana ƙara ΔK ta 40% idan aka kwatanta da yanayin rashin damuwa, accelerating the propagation rate by 1.8 sau;

• Idan ba a yi maganin jin daɗin damuwa a cikin 3003 aluminum faifai masana'antu tsari na inji kayayyakin, danshi, mai, ko iskar gas a cikin muhalli suna shiga microcracks, haifar da danniya lalata gajiya da kuma kara kara yaduwa kudi ta 2-3 sau.

4. Tabbatar da Gwajin Gajiya a cikin 3003 Tsarin Kera Aluminum Faifai don Kayayyakin Injini

Don ƙididdige tasirin tasirin 3003 aluminum faifai masana'antu tsari na inji kayayyakin a kan gajiyawar tsagewa, an shirya samfurori masu kwaikwaya bisa ga tsari kuma an gwada su:

(1) Misali Shiri: Bayan Haqiqa Matakan Tsari

1. Albarkatun kasa: 3003 aluminum fayafai (3mm kauri, 150mm diamita, H14 zafi), mai yarda da GB/T 3880.2-2012;

2. Kwafiwar tsari:

• • Misali A (karshen hula kwaikwayo): An kammala “10mm rami stamping (ruwa ≤5μm) → 90° flange lankwasawa (R1mm)” a cewar 3003 aluminum faifai masana'antu tsari na inji kayayyakin;

• • Misalin B (gasket kwaikwayo): An kammala “rectangular contour stamping (R2mm) → 120° goyan bayan lankwasawa” bisa ga tsari;

3. Ƙungiyar sarrafawa: Santsi 3003 aluminum zanen gado ban da stamping da lankwasawa matakai na tsari.

(2) Sakamakon Gwaji: Daidaita Tsakanin Matakan Tsari da Rayuwar Gajiya

Sakamako suna nuna cewa matakan tambari da lanƙwasawa a cikin 3003 aluminum faifai masana'antu tsari na inji kayayyakin rage fashewar rayuwar farawar samfurori ta hanyar wuce gona da iri 90%, sanya su ainihin dalilin kasadar gajiya.

5. Dabarun ingantawa don 3003 Tsarin Kera Aluminum Faifai don Kayayyakin Injini

Don magance matsalolin gajiya da ke haifar da tambari da lankwasa a cikin 3003 aluminum faifai masana'antu tsari na inji kayayyakin, ana gabatar da mafita daga bangarori biyu: tsari mataki ingantawa da kuma bayan-aiki:

(1) Inganta Matsayin Tsari: Rage Matsi Matsi

1. Haɓaka hatimi (core inganta a cikin 3003 aluminum faifai masana'antu tsari na inji kayayyakin):

• • karba “zane rami mai tako” don bugun rami (daga 10mm zuwa 12mm, fillet R0.5mm), rage damuwa maida hankali factor Kt daga 2.0 ku 1.3 da saura tensile danniya ta 30%;

• • Ƙara radius na fillet na hatimin kwane-kwane zuwa R≥2mm don guje wa matsananciyar damuwa a cikin lanƙwasawa na gaba..

2. Lankwasawa ingantawa (daidaitawa zuwa halaye na tsari):

• • Amfani “lankwasawa a hankali” domin karshen hula flanges (sauyi a hankali daga 0° zuwa 90°) maimakon mataki daya 90° lankwasawa, Rage danniya saura tensile danniya daga 60-80MPa zuwa 30-40MPa;

• • Daidaita kusurwar lanƙwasawa na gefuna goyon bayan gasket daga 120 ° zuwa 135 °, rage girman nakasar ƙanƙara daga 7% ku 4%.

(2) Tsari Bayan-Processing: Kawar da Ragowar Damuwa da Lalacewa

1. Danniya taimako annealing: Ƙara a “280-320℃ adana zafi don 1-2h” mataki (don GB/T 12608-2023) bayan tambari da lankwasa a cikin 3003 aluminum faifai masana'antu tsari na inji kayayyakin, rage saura tensile danniya zuwa 30-40MPa da kuma kara gajiya rayuwa ta 2-3 sau;

2. Burr iko: Ƙara “electropolishing” (10-15A/dm², 5-10min) zuwa tsari don rage ramukan burrs zuwa ≤1μm, kawar da gajiyarwa fashewa shafukan qaddamarwa;

3. Ƙarfafawar saman: Yi “harbi leƙen asiri” (0.4-0.6MPa, bakin karfe Shots) akan mahimman sassan samfuran da aka gama (ramuka gefuna, lankwasawa kwana) sanya ta hanyar, kafa wani 50-100μm surface compressive danniya Layer don kashe saura tensile danniya.

6. Ƙarshe: Dabarun Gudanar da Hadarin Gaji don 3003 Tsarin Kera Aluminum Faifai don Kayayyakin Injini

Ko da yake 3003 aluminum faifai masana'antu tsari na inji kayayyakin (aluminum disc → tambari → lankwasawa → bayan aiwatarwa) wata ingantacciyar hanya ce don samar da iyakoki na ƙarshen inji da gaskets, matakan stamping da lankwasawa a cikin tsari cikin sauƙi yana haifar da ƙaddamarwar damuwa da fashe gajiya. Ainihin dabaru na gudanarwa shine kamar haka:

1. Daidaita matakan tsari zuwa kaddarorin kayan aiki: Haɓaka radius fillet na ramukan hatimi da kusurwoyi lanƙwasa a cikin tsari bisa ga ƙarancin ƙarancin gajiya. (80-90MPa) na 3003 aluminum gami don hana damuwa daga wuce iyaka;

2. Ƙarfafa bayan aiwatarwa don gyara kurakurai: Ƙara matakan tsukewa da harbe-harbe zuwa tsari don kashe ragowar damuwa da aka gabatar ta hanyar tambari da lankwasawa., da kuma kawar da lahani na sarrafawa;

3. Monitor the process to ensure reliability: Ƙara gwajin damuwa (e.g., X-ray danniya analyzer) a key nodes (bayan tambari, bayan lankwasawa) a cikin 3003 aluminum faifai masana'antu tsari na inji kayayyakin don tabbatar da ragowar damuwa ≤40MPa, sarrafa kasada kasada daga tsari tushen.

Zuwa gaba, “Hasashen siga na AI” za a iya ƙara haɗawa cikin 3003 aluminum faifai masana'antu tsari na inji kayayyakin don daidaita matsa lamba mai ƙarfi da saurin lankwasawa, samun nasarar sarrafa hankali na lokaci-lokaci na damuwa da haɓaka haɓaka samfuran injina zuwa ga “ƙananan kasadar gajiya da tsawon rayuwar sabis”.