Tsarin Tsarin Tambarin Na'urar Naɗa Na'urar Naɗa Na'urar Haɗa Ta Waje

Tsarin Tsarin Tambarin Na'urar Naɗa Na'urar Naɗa Na'urar Haɗa Ta Waje

A tsarin watsawa na masana'antu, sarƙoƙi na naɗawa sune manyan sassan watsawa, kuma aikinsu kai tsaye yana ƙayyade ingancin aiki na kayan aiki da tsawon lokacin sabis. Faranti na haɗin waje, "kwarangwal" nasarkar nadi, suna taka muhimmiyar rawa wajen isar da kaya da haɗin sarkar haɗi. Daidaito da daidaiton tsarin kera su muhimman abubuwa ne da ke shafar ingancin sarkar naɗawa gaba ɗaya. Tambari, babbar hanyar kera faranti na haɗin waje, tana buƙatar tsauraran ƙa'idodi a kowane mataki, daga zaɓin kayan aiki zuwa isar da kayayyaki da aka gama, don tabbatar da cewa faranti na haɗin waje suna da isasshen ƙarfi, tauri, da daidaiton girma. Wannan labarin zai samar da cikakken bincike game da cikakkun ƙa'idodin tsari don tambarin farantin haɗin waje na sarkar naɗawa, yana ba wa masu sana'a na masana'antu ƙwarewa da kuma ba masu amfani da ƙarshen damar fahimtar dabarun aiwatarwa a bayan sarƙoƙin naɗawa masu inganci.

I. Tabbacin Asali Kafin Tattara Tambari: Zaɓin Kayan Danye da Ka'idojin Kafin A Yi Magani

Aikin faranti na haɗin waje yana farawa da kayan aiki masu inganci. Tsarin buga takardu yana kafa ƙayyadadden buƙatu don halayen injina na kayan da kuma abubuwan da suka shafi sinadarai, waɗanda sune abubuwan da ake buƙata don aiwatar da ayyuka masu zuwa cikin sauƙi. A halin yanzu, manyan kayan da ake buƙata don faranti na haɗin waje a masana'antar sune ƙarfe masu ƙarancin carbon (kamar 20Mn2 da 20CrMnTi) da ƙarfe masu inganci na carbon (kamar ƙarfe 45). Zaɓin kayan ya dogara ne akan aikace-aikacen sarkar nadi (misali, kaya masu nauyi, manyan gudu, da muhallin lalata). Duk da haka, ba tare da la'akari da kayan da aka zaɓa ba, dole ne ya cika waɗannan ƙa'idodi masu zuwa:

1. Ka'idojin Haɗin Sinadaran Danye
Kula da Abubuwan da ke cikin Carbon (C): Ga ƙarfe 45, yawan sinadarin carbon zai kasance tsakanin 0.42% zuwa 0.50%. Yawan sinadarin carbon zai iya ƙara karyewar kayan da kuma fashewa yayin da ake tatsa su, yayin da ƙarancin sinadarin carbon zai iya shafar ƙarfinsa bayan an yi amfani da shi a lokacin zafi. Dole ne a kiyaye yawan sinadarin manganese (Mn) na ƙarfe 20Mn2 tsakanin 1.40% da 1.80% don inganta tauri da ƙarfin kayan, don tabbatar da cewa faranti na waje suna tsayayya da karyewa a ƙarƙashin nauyin tasiri. Iyakokin Abubuwan da ke da Cutarwa: Dole ne a sarrafa yawan sinadarin Sulfur (S) da phosphorus (P) a ƙasa da 0.035%. Waɗannan abubuwa biyu na iya samar da mahaɗan da ke da ƙarancin narkewa, wanda ke sa kayan ya zama "mai karyewa mai zafi" ko "mai karyewa mai sanyi" yayin aikin tatsa su, wanda hakan ke shafar yawan kayayyakin da aka gama.

2. Ka'idojin Kayan Danye Kafin A Yi Maganinsu

Kafin a fara aikin tambarin, ana ɗaukar matakai uku kafin a fara yin magani: tsinken tsinkewa, phosphate, da kuma shafa mai. Kowane mataki yana da ƙa'idodi masu kyau:

Tsaftace Tukunyar: Ta amfani da maganin hydrochloric acid mai kashi 15%-20%, a jiƙa a zafin ɗaki na minti 15-20 don cire tsatsa da sikelin daga saman ƙarfe. Bayan an yi tsatsa, dole ne saman ƙarfe ya kasance babu wani siffa da ake iya gani kuma babu tsatsa mai yawa (rami), wanda zai iya shafar mannewar murfin phosphate na gaba.

Yin amfani da sinadarin phosphate: Ta amfani da sinadarin zinc, a shafa a zafin 50-60°C na tsawon mintuna 10-15 don samar da wani sinadarin phosphate mai kauri na 5-8μm. Dole ne murfin phosphate ya kasance iri ɗaya kuma mai kauri, tare da mannewa ya kai Mataki na 1 (ba tare da ɓawon ba) ta amfani da gwajin yankewa. Wannan yana rage gogayya tsakanin manne mai tambari da farantin ƙarfe, yana ƙara tsawon rayuwar mannewa da kuma ƙara juriyar tsatsa na farantin haɗin waje.

Man shafawa: A fesa siririn mai mai hana tsatsa (kauri ≤ 3μm) a saman murfin phosphate. Ya kamata a shafa fim ɗin mai daidai ba tare da wani gibi ko tarawa ba. Wannan yana hana tsatsa a farantin ƙarfe yayin ajiya yayin da yake kiyaye daidaiton ayyukan tambari na gaba.

II. Ka'idoji don Tsarin Tambarin Babban: Tsarin Daidaito daga Tsaftacewa zuwa Tsarawa

Tsarin tambarin hanyoyin haɗin sarkar na'ura mai jujjuyawa ya ƙunshi matakai huɗu na asali: ɓoyewa, hudawa, ƙirƙirawa, da yankewa. Sigogin kayan aiki, daidaiton mutu, da hanyoyin aiki na kowane mataki suna shafar daidaiton girma da halayen injina na hanyoyin haɗin waje. Dole ne a bi ƙa'idodi masu zuwa sosai:

1. Ka'idojin Tsarin Rufewa
Buɗewa ya ƙunshi huda zanen ƙarfe da ba a saka ba zuwa cikin ramuka waɗanda suka yi daidai da girman da ba a saka ba na hanyoyin haɗin waje. Tabbatar da daidaiton girma da ingancin gefen ramukan yana da matuƙar muhimmanci ga wannan tsari.

Zaɓin Kayan Aiki: Ana buƙatar matsi mai maki ɗaya a rufe (tannage ya bambanta dangane da girman mahaɗin waje, gabaɗaya 63-160kN). Dole ne a sarrafa daidaiton bugun zamiya na mashin ɗin cikin ±0.02mm don tabbatar da bugun daidai ga kowane mashin da kuma guje wa karkacewar girma.

Daidaiton Gashi: Ya kamata a tantance iyakar da ke tsakanin naushin da kuma mayafin mayafin da ke rufewa bisa ga kauri, yawanci kashi 5%-8% na kauri na kayan (misali, ga kauri na kayan 3mm, mayafin shine 0.15-0.24mm). Tsananin gefen yanke mayafin dole ne ya kasance ƙasa da Ra0.8μm. Lalacewar gefen da ya wuce 0.1mm yana buƙatar sake niƙawa nan take don hana burrs fitowa a gefen mara komai (tsawon burr ≤ 0.05mm).

Bukatun girma: Dole ne a sarrafa karkacewar tsawon da babu komai a cikin ±0.03mm, karkacewar faɗin cikin ±0.02mm, da karkacewar diagonal cikin 0.04mm bayan an share fage don tabbatar da daidaiton bayanai don matakan sarrafawa na gaba.

2. Ka'idojin Tsarin Hudawa

Hudawa tsari ne na huda ramukan ƙulli da ramukan naɗawa don faranti na haɗin waje cikin sarari bayan an gama buɗewa. Daidaiton wurin ramin da daidaiton diamita yana shafar aikin haɗa sarkar naɗawa kai tsaye.

Hanyar Sanya Hanya: Ana amfani da matsayin bayanai guda biyu (ta amfani da gefuna biyu na maƙwabtaka da na'urar a matsayin ma'auni). Dole ne fil ɗin gano wuri su cika daidaiton IT6 don tabbatar da daidaiton matsayin babu komai a lokacin kowane naushi. Dole ne karkacewar matsayin ramin ya kasance ≤ 0.02mm (dangane da saman farantin mahaɗin waje). Daidaiton Diamita na Rami: Karkacewar diamita tsakanin ramukan ƙulli da na'urar birgima dole ne ya cika buƙatun haƙurin IT9 (misali, ga ramin 10mm, karkacewar shine +0.036mm/-0mm). Ya kamata juriyar zagayen rami ya zama ≤0.01mm, kuma karkacewar bangon rami ya kamata ya kasance ƙasa da Ra1.6μm. Wannan yana hana hanyoyin haɗin sarka su yi sako-sako ko kuma su yi tsauri sosai saboda karkacewar diamita na rami, wanda zai iya shafar kwanciyar hankali na watsawa.

Tsarin Hudawa: Buga ramukan ƙulli da farko, sannan sai ramukan naɗawa. Dole ne karkatar tazara tsakanin ramukan biyu ta kasance cikin ±0.02mm. Tarin karkacewar tazara tsakanin tsakiya da tsakiya zai haifar da karkacewar kusurwoyi kai tsaye a cikin sarkar naɗawa, wanda hakan ke shafar daidaiton watsawa.

3. Tsarin Ka'idojin Tsarin Aiki

Samarwa ya ƙunshi danna maɓalli mara komai ta cikin wani abu mai kama da manne zuwa siffar farantin haɗin waje ta ƙarshe (misali, lanƙwasa ko taki). Wannan tsari yana buƙatar tabbatar da daidaiton siffar farantin haɗin waje da kuma sarrafa springback.

Tsarin Mold: Ya kamata injin ya ɗauki tsarin da aka raba, tare da tashoshi biyu, waɗanda aka riga aka samar da su da kuma waɗanda aka tsara bisa ga siffar farantin haɗin waje. Tashar da aka riga aka samar da su da farko tana danna blank ɗin zuwa siffar farko don rage damuwa ta nakasa yayin ƙirƙirar ƙarshe. Ƙarfin saman ramin da aka samar da ƙarshe dole ne ya kai Ra0.8μm don tabbatar da santsi, ba tare da shiga cikin farfajiyar farantin haɗin waje ba.

Kula da Matsi: Ya kamata a ƙididdige matsin lamba na ƙirƙirar bisa ga ƙarfin kayan kuma gabaɗaya ya ninka ƙarfin kayan sau 1.2-1.5 (misali, ƙarfin yawan amfanin ƙarfe 20Mn2 shine 345MPa; matsin lamba na ƙirƙirar ya kamata a sarrafa shi tsakanin 414-517MPa). Ƙarancin matsin lamba zai haifar da rashin cikawa, yayin da matsin lamba da yawa zai haifar da lalacewar filastik mai yawa, wanda ke shafar aikin maganin zafi na gaba. Kula da Matsi na Matsi: Bayan ƙirƙirar, dole ne a sarrafa matsi na farantin haɗin waje a cikin 0.5°. Ana iya magance wannan ta hanyar saita kusurwar diyya a cikin ramin mold (wanda aka ƙaddara bisa ga halayen matsi na kayan, gabaɗaya 0.3°-0.5°) don tabbatar da cewa samfurin da aka gama ya cika buƙatun ƙira.

4. Ka'idojin Tsarin Gyaran Gilashi
Gyaran gashi shine tsarin cire walƙiya da kayan da suka wuce gona da iri da aka samar yayin ƙirƙirar don tabbatar da cewa gefunan farantin haɗin waje sun miƙe.

Daidaiton Gashin Gashin: Dole ne a sarrafa tazara tsakanin naushi da gashin gashin gashin a cikin 0.01-0.02mm, kuma kaifi na gefen yankan dole ne ya kasance ƙasa da Ra0.4μm. Tabbatar cewa gefunan farantin haɗin waje bayan yankan ba su da ƙura (tsayin ƙura ≤ 0.03mm) kuma kuskuren madaidaiciyar gefen shine ≤ 0.02mm/m.

Tsarin Gyaran Gashi: Da farko a rage dogon gefuna, sannan a rage gajerun gefuna. Wannan yana hana lalacewar farantin haɗin waje saboda rashin tsarin gyaran da bai dace ba. Bayan a gyara, farantin haɗin waje dole ne a duba shi don tabbatar da cewa babu wata matsala kamar kusurwoyi masu yagewa ko tsagewa.

III. Ka'idojin Duba Ingancin Bayan Tambari: Cikakken Ikon Gudanar da Ayyukan Samfurin da Aka Gama

Bayan an yi tambari, faranti na waje suna fuskantar tsauraran matakai guda uku na duba inganci: duba girma, duba kadarorin injiniya, da duba kamanni. Kayayyakin da suka cika dukkan ka'idoji ne kawai za su iya ci gaba zuwa tsarin gyaran zafi da haɗa su. Ka'idojin dubawa na musamman sune kamar haka:

1. Ka'idojin Duba Girma
Binciken girma yana amfani da injin aunawa mai girma uku (daidaitawa ≤ 0.001mm) tare da ma'auni na musamman, yana mai da hankali kan waɗannan mahimman girma:

Fitilar: Fitilar da ke tsakanin ramukan ƙulli biyu dole ne ta kasance mai jurewa ±0.02mm, tare da kuskuren jifa na ≤0.05mm a kowace guda 10. Fitilar da ta wuce gona da iri na iya haifar da girgiza da hayaniya yayin watsa sarkar nadi.

Kauri: Kauri na farantin haɗin waje dole ne ya cika buƙatun haƙurin IT10 (misali, ga kauri na 3mm, karkacewar shine +0.12mm/-0mm). Bambancin kauri a cikin rukuni dole ne ya kasance ≤0.05mm don hana rashin daidaiton kaya akan hanyoyin haɗin sarka saboda rashin daidaiton kauri. Matsayin Rami Juriya: Bambancin matsayi tsakanin ramin ƙulli da ramin abin nadi dole ne ya kasance ≤0.02mm, kuma kuskuren haɗin rami dole ne ya kasance ≤0.01mm. Tabbatar cewa sharewa tare da fil da abin nadi ya cika buƙatun ƙira (sharar gabaɗaya 0.01-0.03mm).

2. Ka'idojin Gwajin Kadarorin Inji

Gwajin halayen injina yana buƙatar zaɓar samfura 3-5 bazuwar daga kowane rukuni na samfura don gwajin ƙarfin tauri, tauri, da lanƙwasa.

Ƙarfin Tashin Hankali: An gwada shi ta amfani da injin gwaji na kayan duniya, ƙarfin taurin farantin haɗin waje dole ne ya zama ≥600MPa (bayan an yi maganin zafi na ƙarfe 45) ko ≥800MPa (bayan an yi maganin zafi na 20Mn2). Karyewar dole ne ta faru a yankin da ba ramin farantin haɗin waje ba. Rashin nasara kusa da ramin yana nuna yawan damuwa yayin aikin huda, kuma dole ne a daidaita sigogin mutu. Gwajin Taurin Hankali: Yi amfani da na'urar gwada taurin Rockwell don auna taurin saman farantin haɗin waje. Dole ne a sarrafa taurin a cikin HRB80-90 (yanayin annealed) ko HRC35-40 (yanayin da aka kashe da kuma yanayin zafi). Taurin da ya wuce kima zai ƙara karyewar kayan da kuma saurin karyewa; ƙarancin taurin da ya wuce kima zai shafi juriyar sawa.

Gwajin Lanƙwasawa: Lanƙwasa faranti na haɗin waje a 90° tare da tsawonsu. Bai kamata a sami tsagewa ko karyewa a saman bayan lanƙwasa ba. Ya kamata springback bayan saukarwa ya kasance ≤5°. Wannan yana tabbatar da cewa faranti na haɗin waje suna da isasshen ƙarfi don jure wa nauyin tasirin yayin watsawa.

3. Ka'idojin Duba Gani

Dubawar kamanni yana amfani da haɗin duba gani da duba gilashin ƙara girma (ƙara girman sau 10). Bukatun musamman sune kamar haka:

Ingancin Fuskar: Dole ne saman farantin haɗin waje ya zama santsi da lebur, ba tare da karce ba (zurfin ≤ 0.02mm), maɓallan da ke ciki, ko wasu lahani. Dole ne murfin phosphate ya zama iri ɗaya kuma ba tare da wani shafi da ya ɓace ba, rawaya, ko ɓarkewa. Ingancin Gefen: Dole ne gefuna su kasance ba tare da ƙuraje ba (tsawo ≤ 0.03mm), guntu (girman guntu ≤ 0.1mm), tsagewa, ko wasu lahani. Dole ne a cire ƙananan burrs ta hanyar passivation (nutsewa cikin maganin passivation na minti 5-10) don hana karce a kan mai aiki ko wasu abubuwan haɗin yayin haɗuwa.
Ingancin Bangon Rami: Bangon ramin dole ne ya kasance mai santsi, ba shi da matakai, ƙagaggu, nakasa, ko wasu lahani. Idan aka duba shi da ma'aunin go/no-go, ma'aunin go dole ne ya wuce cikin sauƙi, yayin da ma'aunin no-go bai kamata ya wuce ba, yana tabbatar da cewa ramin ya cika buƙatun daidaiton haɗuwa.

IV. Umarnin Inganta Tsarin Tambari: Daga Daidaitawa zuwa Hankali

Tare da ci gaba da ci gaban fasahar masana'antu, ana kuma ci gaba da haɓaka ƙa'idodin hanyoyin yin tambarin haɗin yanar gizo na na'ura mai jujjuyawa. Ci gaban nan gaba zai mayar da hankali kan hanyoyin da suka dace, kore, da kuma inganci. Takamaiman hanyoyin ingantawa sune kamar haka:

1. Amfani da Kayan Aikin Samarwa Mai Hankali

Gabatar da injunan tambarin CNC da robots na masana'antu don cimma ikon sarrafa tsarin tambarin ta atomatik da wayo:

Injinan tambarin CNC: An sanye su da tsarin servo mai inganci, suna ba da damar daidaita sigogi na ainihin lokaci kamar matsin lamba da saurin bugun jini, tare da daidaiton sarrafawa na ±0.001mm. Hakanan suna da ikon gano kai, wanda ke ba da damar gano matsaloli kamar lalacewar kayan aiki da kuma rashin daidaituwar kayan aiki akan lokaci, yana rage adadin samfuran da ke da lahani.

Robot na masana'antu: Ana amfani da su wajen loda kayan da aka sarrafa, canja wurin sassan da aka gama, da kuma rarraba kayan da aka gama, suna maye gurbin ayyukan hannu. Wannan ba wai kawai yana inganta ingancin samarwa ba (yana ba da damar samar da kayayyaki na tsawon awanni 24), har ma yana kawar da karkacewar girma da aikin hannu ke haifarwa, yana tabbatar da daidaiton ingancin samfur.

2. Tallafawa Tsarin Kore

Rage amfani da makamashi da gurɓatar muhalli yayin da ake cika ƙa'idodin tsari:

Inganta kayan mold: Amfani da mold mai haɗaka da aka yi da ƙarfe mai sauri (HSS) da simintin carbide (WC) yana ƙara tsawon rayuwar mold (za a iya tsawaita tsawon sabis sau 3-5), yana rage yawan maye gurbin mold, kuma yana rage ɓarnar kayan.

Inganta tsarin kafin a yi magani: Inganta fasahar phosphating mara phosphorus da amfani da maganin phosphating mai kyau ga muhalli yana rage gurɓatar phosphorus. Bugu da ƙari, feshi mai hana tsatsa ta hanyar lantarki yana inganta amfani da mai mai hana tsatsa (ana iya ƙara yawan amfani da shi zuwa sama da kashi 95%) kuma yana rage fitar da hayakin mai.

3. Haɓaka Fasahar Dubawa Mai Inganci

An gabatar da tsarin duba hangen nesa na na'ura don ba da damar yin bincike cikin sauri da inganci na faranti masu haɗin waje.

An sanye shi da kyamarar da ke da babban ma'ana (ƙuduri ≥ megapixels 20) da kuma manhajar sarrafa hotuna, tsarin duba hangen nesa na na'ura zai iya duba faranti na haɗin waje a lokaci guda don ganin daidaiton girma, lahani a bayyanar, karkacewar wurin rami, da sauran sigogi. Tsarin yana da saurin dubawa na guda 100 a minti ɗaya, wanda ya ninka saurin dubawa da hannu sau 10. Hakanan yana ba da damar adanawa da nazarin bayanan dubawa a ainihin lokaci, yana ba da tallafin bayanai don inganta tsari.

Kammalawa: Ma'auni sune tushen ingancin rayuwa, kuma cikakkun bayanai suna tabbatar da ingancin watsawa.

Tsarin tambarin sarkar na'ura mai juyawa na waje na iya zama kamar mai sauƙi, amma dole ne a bi ƙa'idodi masu tsauri a kowane mataki - daga sarrafa sinadaran kayan masarufi, zuwa tabbatar da daidaiton girma yayin aikin tambarin, zuwa cikakken duba ingancin samfurin da aka gama. Kula da kowane bayani na iya haifar da lalacewar aikin farantin haɗin waje, kuma sakamakon haka, yana shafar amincin watsawa na dukkan sarkar na'ura mai juyawa.