Maitiro Ekugadzirisa Kugadzika Kwemapuratifomu Ekunze eRoller Chain

Maitiro Ekugadzirisa Kugadzika Kwemapuratifomu Ekunze eRoller Chain

Mumasisitimu ekutumira zvinhu mumaindasitiri, maroller chains ndiwo ma "core transmission components", uye mashandiro awo anotarisa zvakananga kushanda zvakanaka kwemuchina uye hupenyu hwebasa rawo. Ma "outer link plates" e "skeleton"cheni inotenderera, inoita basa rakakosha mukutumira mitoro uye kubatanidza macheni. Kugadziriswa uye kunyatsoita magadzirirwo azvo zvinhu zvakakosha zvinokanganisa kunaka kwecheni yeroller. Kuisa stamping, nzira huru yekugadzira maplate ekunze, inoda mitemo yakasimba padanho rega rega, kubva pakusarudza zvinhu zvisina kugadzirwa kusvika pakugadzirwa kwapera, kuve nechokwadi chekuti maplate ekunze ane simba rakakwana, kusimba, uye kururama kwezvikamu. Chinyorwa chino chichapa ongororo yakadzama yemitemo yakazara yekuisa stamping yecheni yekunze yeroller chain, ichipa vashandi veindasitiri ruzivo rwehunyanzvi uye ichibvumira vashandisi vekupedzisira kuti vanzwisise zvakajeka maitiro ekugadzira ari kumashure kwecheni dzemhando yepamusoro dzeroller.

I. Zvivimbiso zveBasa Usati Waisa Stamping: Kusarudzwa kweZvinhu Zvisina Kugadzirwa uye Maitiro Ekugadzirisa Pamberi

Kushanda kwemaplate ekunze kunotanga nezvinhu zvemhando yepamusoro. Maitiro ekugadzika anoisa zvinodiwa zvakajeka zvehunhu hwemuchina uye kuumbwa kwemakemikari echinhu chacho, izvo zvinodiwa kuti maitiro anotevera aitwe zvakanaka. Parizvino, zvinhu zvikuru zveplate dzekunze kusanganisa muindasitiri iyi isimbi dzechimiro che low-carbon alloy (dzakadai se20Mn2 ne20CrMnTi) uye simbi dzechimiro che carbon dzemhando yepamusoro (dzakadai se45 steel). Sarudzo yezvinhu zvinoenderana nekushandiswa kwe roller chain (semuenzaniso, mitoro inorema, kumhanya kwakanyanya, uye nharaunda dzinoparadza). Zvisinei, zvisinei nechinhu chakasarudzwa, chinofanira kusangana nezviyero zvinotevera:

1. Maitiro eKuumbwa kweMakemikari eZvinhu Zvisina Kugadzirwa
Kudzora Zviri Mukati meCarbon (C): Kune simbi 45, huwandu hwekabhoni hunofanira kunge huri pakati pe0.42% ne0.50%. Hunhu hwakawanda hwekabhoni hunogona kuwedzera kuputsika kwechinhu ichi panguva yekudzvanya, nepo huwandu hushoma hwekabhoni hunogona kukanganisa simba rayo mushure mekupisa kwakatevera. Hunhu hwemanganese (Mn) hwesimbi ye20Mn2 hunofanira kuchengetedzwa pakati pe1.40% ne1.80% kuti huvandudze kuomarara uye kusimba kwechinhu ichi, zvichiita kuti maplate ekunze arambe kuputsika pasi pemitoro yekukuvadzwa. Miganhu Yezvinhu Zvinokuvadza: Hunhu hweSulfur (S) nephosphorus (P) hunofanira kudzorwa zvakanyanya pasi pe0.035%. Zvinhu zviviri izvi zvinogona kugadzira macompounds ane low-melting-point, zvichiita kuti chinhu ichi chive "chinopisa" kana "chinotonhora" panguva yekudzvanya, zvichikanganisa goho rezvigadzirwa zvakapedzwa.

2. Maitiro Ekurapa Zvinhu Zvisina Kugadzirwa

Usati watanga kugadzika, zvinhu zvakagadzirwa zvinoitwa matanho matatu ekutanga: kuomesa, kuisa phosphate, uye kuisa mafuta. Danho rega rega rine zvinodiwa zvemhando yepamusoro:

Kunyudza: Uchishandisa 15%-20% hydrochloric acid solution, nyika patembiricha yemumba kwemaminitsi 15-20 kubvisa makwande nengura pamusoro pesimbi. Mushure mekunyudza, pamusoro pesimbi panofanira kunge pasina makwande anooneka uye pasina ngura yakawandisa (pitting), izvo zvinogona kukanganisa kunamira kwe phosphate coating inotevera.

Kusanganisa: Uchishandisa mushonga we zinc-based phosphating, isa pa50-60°C kwemaminitsi 10-15 kuti ugadzire phosphate coating ine ukobvu hwe5-8μm. Kubatanidza phosphate kunofanira kunge kwakafanana uye kwakakora, nekunamatira kusvika paLevel 1 (pasina kukwesha) uchishandisa cross-cut test. Izvi zvinoderedza kukweshana pakati pe stamping die nesimbi, zvichiwedzera hupenyu hwedie uye zvinosimudzira ngura ye outer link plate.

Kuisa mafuta: Pfapfaidza mafuta ekudzivirira ngura (ukobvu ≤ 3μm) pamusoro pe phosphate coating. Firimu remafuta rinofanira kushandiswa zvakaenzana pasina mipata kana kuungana. Izvi zvinodzivirira ngura yeplate yesimbi panguva yekuchengetera uku uchichengetedza kururama kwemabasa anotevera ekutsika.

II. Maitiro eKuisa Stamping Yepakati: Kudzora Kwakarurama Kubva Pakupwanya Chisimbiso Kusvika Pakuumba

Maitiro ekugadzika zvisungo zvekunze zve roller chain anosanganisira matanho mana makuru: kubvisa jira, kupwanya, kugadzira, uye kuchekerera. Magadzirirwo emidziyo, kunyatsoita basa, uye mashandiro edanho rega rega anokanganisa zvakananga kururama kwehukuru uye hunhu hwemakanika ekunze. Mitemo inotevera inofanirwa kutevedzwa zvakanyanya:

1. Maitiro Ekubvisa Blanking Process
Kuvhara simbi kunosanganisira kupinza mapepa esimbi asina kugadzirwa muzvikamu zvinowirirana nehukuru hwakavhurika hwezvisungo zvekunze. Kuve nechokwadi chekuti mativi acho akarurama uye mhando yemucheto wezvikamu izvi zvakakosha pakuita izvi.

Kusarudzwa kweMidziyo: Kudzvanya kwechinhu chimwe chete kwakavharwa kunodiwa (huremu hwematani hunosiyana zvichienderana nehukuru hwechinongedzo chekunze, kazhinji 63-160kN). Kurongeka kwekutsvedza kwechinhu kunofanirwa kudzorwa mukati me ±0.02mm kuti ive nechokwadi chekutsvedza kwakafanana kwechinhu chimwe nechimwe uye kudzivirira kutsauka kwemativi.

Kururama Kwemadhiri: Kupatsanurwa pakati pechibhakera nedhiri redhiri reblanking kunofanirwa kutariswa zvichienderana nehukobvu hwechinhu, kazhinji 5%-8% yehukobvu hwechinhu (semuenzaniso, kune ukobvu hwechinhu hwe3mm, nzvimbo yacho i0.15-0.24mm). Kukombama kwemucheto wekucheka madhiri kunofanira kunge kuri pasi peRa0.8μm. Kusakara kwemucheto kunodarika 0.1mm kunoda kugayiwa nekukurumidza kudzivirira maburrs kuti asaumbwe pamucheto usina chinhu (hurefu hweburr ≤ 0.05mm).

Zvinodiwa pahurefu: Kutsauka kwehurefu husina chinhu kunofanirwa kudzorwa mukati me ±0.03mm, kutsauka kwehupamhi mukati me ±0.02mm, uye kutsauka kwedivi mukati me 0.04mm mushure mekudzima kuti pave nechokwadi chekuti datamu dzakarurama dzematanho ekugadzirisa anotevera.

2. Maitiro Ekurova

Kuboora inzira yekuboora maburi emabhoti nemaburi eroller ekunze kwema link plates kupinda mubepa mushure mekuboora. Kurongeka kwenzvimbo yeburi uye kurongeka kwedhayamita zvinokanganisa zvakananga mashandiro eroller cheni.

Nzira Yokuisa: Kuisa dhatamu mbiri (uchishandisa mipendero miviri iri pedyo yechinhu chisina chinhu sereferensi) kunoshandiswa. Mapini ekutsvaga anofanira kusangana nekururama kweIT6 kuti ave nechokwadi chekuti nzvimbo isina chinhu yakafanana panguva yega yega yekubaya. Kutsauka kwenzvimbo yegomba kunofanira kuva ≤ 0.02mm (zvichienderana nepamusoro pechinongedzo cheplate yekubatanidza). Kururama kwedhayamita yegomba: Kutsauka kwedhayamita pakati pebhoti nemaburi anotenderera kunofanirwa kusangana nezvinodiwa zvekushivirira kweIT9 (semuenzaniso, kune gomba re10mm, kutsauka kuri +0.036mm/-0mm). Kushivirira kwedenderedzwa regomba kunofanirwa kuva ≤0.01mm, uye kushata kwemadziro emaburi kunofanirwa kunge kuri pasi peRa1.6μm. Izvi zvinodzivirira macheni ekubatanidza kuti asasununguke zvakanyanya kana kuti anyatsosimba nekuda kwekutsauka kwedhayamita yegomba, izvo zvinogona kukanganisa kugadzikana kwekutumira.

Kurongeka Kwekurovera: Rova maburi ebhoti kutanga, wozotevera maburi eroller. Kutsauka pakati pemaburi maviri kunofanira kunge kuri mukati me ±0.02mm. Kutsauka pakati nepakati kunotungamira zvakananga mukutsauka kwepitch muroller chain, izvo zvinokanganisa kunyatsoita kwetransmission.

3. Maitiro Ekugadzira Maitiro

Kugadzira kunosanganisira kudzvanya gomba risina chinhu rakaboorwa nedhiraivha muchimiro cheplate yekubatanidza chekunze (semuenzaniso, chakakombama kana kuti chakatsikwa). Maitiro aya anoda kuve nechokwadi chekuti plate yekubatanidza yekunze yakarurama uye kuti idzorerwe nekukasika.

Kugadzira Mould: Chidimbu chekugadzira chinofanira kunge chakapatsanurwa, chine nzvimbo mbiri, dzinotanga kugadzirwa uye dzinozopedzisira kugadzirwa, dzakagadzirwa zvichienderana nechimiro cheplate yekubatanidza yekunze. Nzvimbo yekutanga kugadzira inotanga yadzvanya gomba risina chinhu kuita chimiro chekutanga kuderedza kushushikana kwekushanduka panguva yekuumbwa kwekupedzisira. Kukombama kwepamusoro peplate yekubatanidza yekupedzisira yekugadzira kunofanira kusvika paRa0.8μm kuti ive nechokwadi chekuti pamusoro peplate yekubatanidza yekunze yakatsetseka, isina kupinda mukati.

Kudzora Kumanikidzwa: Kumanikidzwa kwekugadzira kunofanirwa kuverengerwa zvichienderana nesimba rekugadzira rechinhu uye kazhinji ka1.2-1.5 simba rekugadzira rechinhu (semuenzaniso, simba rekugadzira resimbi ye20Mn2 i345MPa; kumanikidzwa kwekugadzira kunofanirwa kudzorwa pakati pe414-517MPa). Kumanikidzwa kushoma kuchaita kuti chiumbwa chisakwane, nepo kumanikidzwa kwakawanda kuchikonzera kushanduka kwepurasitiki zvakanyanya, zvichikanganisa mashandiro ekupisa anotevera. Kudzora Kudzoka Kwemvura: Mushure mekuumbwa, kubhururuka kweplate yekubatanidza yekunze kunofanirwa kudzorwa mukati me0.5°. Izvi zvinogona kugadziriswa nekuisa kona yekutsiva mugomba remold (yakatsanangurwa zvichienderana nehunhu hwekudzoka kwechinhu, kazhinji 0.3°-0.5°) kuti ive nechokwadi chekuti chigadzirwa chapedzwa chinosangana nezvinodiwa zvekugadzira.

4. Maitiro Ekugadzirisa
Kucheka ibasa rekubvisa flash nezvinhu zvakawandisa zvinogadzirwa panguva yekuumbwa kwechinhu kuitira kuti mativi eplate yekubatanidza yekunze atwasanuke.

Kururama kweKucheka Die: Mukana uri pakati pekubaya nekufa kwecheka rekucheka unofanirwa kudzorwa mukati me 0.01-0.02mm, uye kupinza kwemucheto wekucheka kunofanira kunge kuri pasi peRa0.4μm. Iva nechokwadi chekuti mipendero yeplate yekubatanidza yekunze mushure mekucheka haina burr (hurefu hweburr ≤ 0.03mm) uye kukanganisa kwekutwasuka kwemucheto kuri ≤ 0.02mm/m.

Kuchekererana: Chekerera mipendero mirefu kutanga, wozochekerera mipendero mipfupi. Izvi zvinodzivirira kushata kweplate yekubatanidza yekunze nekuda kwekuchekererana kusina kunaka. Mushure mekuchekererana, plate yekubatanidza yekunze inofanira kuongororwa nemaziso kuti ive nechokwadi chekuti hapana zvikanganiso zvakaita semakona akachekwa kana mitswe.

III. Mitemo Yekuongorora Hunhu Mushure meStamping: Kudzora Kwakazara Kwekushanda Kwechigadzirwa Chapera

Mushure mekudhindwa, maplate ekunze anoongororwa nehunhu hwawo nenzira nhatu dzakasimba: kuongororwa kwehukuru, kuongororwa kwemidziyo, uye kuongororwa kwechitarisiko. Zvigadzirwa zvinosangana nezvinodiwa zvese chete ndizvo zvinogona kuenderera mberi nekurapa kupisa uye kugadzira. Mitemo chaiyo yekuongorora ndeiyi inotevera:

1. Mitemo yekuongorora yeDimensional
Kuongororwa kwehukuru kunoshandisa muchina wekuyera wezvikamu zvitatu (kururama ≤ 0.001mm) wakasanganiswa nemageji akasarudzika, uchitarisa pane zviyero zvakakosha zvinotevera:

Pitch: Pitch yekunze yekubatanidza plate (daro riri pakati pemaburi maviri emabhaudhi) inofanira kunge yakaenzana ne±0.02mm, ne cumulative pitch error ye≤0.05mm pazvikamu gumi. Kuchinja-chinja kwepitch zvakanyanya kunogona kukonzera kudedera uye ruzha panguva yekutumira roller chain.

Ukobvu: Kutsauka kweukobvu hweplate yekubatanidza yekunze kunofanirwa kusangana nezvinodiwa zveIT10 tolerance (semuenzaniso, kune ukobvu hwe3mm, kutsauka kuri +0.12mm/-0mm). Kusiyana kweukobvu mukati mebatch kunofanirwa kuva ≤0.05mm kudzivirira mutoro usina kuenzana pamaketani ekubatanidza nekuda kweukobvu husina kuenzana. Kushivirira Nzvimbo yeMaburi: Kutsauka kwenzvimbo pakati pegomba rebhoti negomba reroller kunofanirwa kuva ≤0.02mm, uye kukanganisa kwegomba reroller kunofanirwa kuva ≤0.01mm. Iva nechokwadi chekuti nzvimbo yekupinda nepini neroller inosangana nezvinodiwa zvekugadzira (nzvimbo yekupinda kazhinji 0.01-0.03mm).

2. Mitemo Yekuyedza Zvivakwa zveMechanical

Kuongororwa kwemidziyo yemakanika kunoda kusarudza sampuli 3-5 kubva muchikamu chimwe nechimwe chezvigadzirwa kuti zvionekwe kuti zvine simba rekusimba, kuomarara, uye kuyedzwa kwekukombama.

Simba reKubata: Kana zvaedzwa uchishandisa muchina wekuyedza zvinhu zvese, simba rekubata replate yekubatanidza yekunze rinofanira kuva ≥600MPa (mushure mekupisa kwesimbi 45) kana ≥800MPa (mushure mekupisa kwe20Mn2). Kutyoka kunofanira kuitika munzvimbo isina maburi yeplate yekubatanidza yekunze. Kukundikana pedyo negomba kunoratidza kushushikana panguva yekubaya, uye maparamita edie anofanira kugadziriswa. Kuedza Kuoma: Shandisa Rockwell hardness tester kuyera kuoma kwepamusoro kwemaplate ekubatanidza ekunze. Kuoma kunofanirwa kudzorwa mukati meHRB80-90 (annealed state) kana HRC35-40 (kudzimwa uye tempered state). Kuoma kwakanyanya kunowedzera kusimba kwechinhu uye mukana wekutyoka; kuoma kwakanyanya kunokanganisa kusakara.

Kuedza Kukombama: Peta maplate ekunze ekubatanidza 90° pamwe chete nekureba kwawo. Hapana mitswe kana maburi anofanira kuoneka pamusoro mushure mekukombama. Chitubu chemvura mushure mekuburitsa zvinhu chinofanira kunge chiri ≤5°. Izvi zvinoita kuti maplate ekunze ekubatanidza ave nesimba rakakwana rekutsungirira mitoro yekurovera panguva yekutumira.

3. Maitiro Ekuongorora Chitarisiko

Kuongorora chitarisiko kunoshandisa musanganiswa wekutarisa nekutarisa magirazi ekukudza (10x). Zvinodiwa chaizvo ndeizvi:

Hunhu Hwepamusoro: Nzvimbo yekunze yekubatanidza jira inofanira kunge yakatsetseka uye yakati sandara, isina mavanga (kudzika ≤ 0.02mm), mavanga, kana zvimwe zvisizvo. Fosfeti inofanira kunge yakafanana uye isina mavanga asina kusimba, yero, kana kupwanyika. Hunhu Hwemucheto: Mipendero inofanira kunge isina mavanga (kureba ≤ 0.03mm), mavanga (hukuru hwemavanga ≤ 0.1mm), mavanga, kana zvimwe zvisizvo. Mavanga madiki anofanira kubviswa kuburikidza nepasivation (kunyudzwa mumushonga wepasivation kwemaminitsi mashanu kusvika gumi) kudzivirira mavanga pamushandisi kana zvimwe zvikamu panguva yekuunganidza.
Hunhu hweMadziro eMaburi: Madziro egomba anofanira kunge akatsetseka, asina matanho, mavanga, kushanduka, kana zvimwe zvikanganiso. Kana akaongororwa negeji yekupinda/kusapinda, geji yekupinda inofanira kupfuura zvakanaka, nepo geji yekupinda isingapfuure, zvichiita kuti gomba risvike pakurongeka kwezvinodiwa pakubatanidza.

IV. Nzira dzeKugadzirisa Maitiro eStamping: Kubva paStandardization kuenda kuIntelligence

Nekufambira mberi kuri kuramba kuchiita tekinoroji yekugadzira maindasitiri, mitemo ye roller chain outer link stamping processes iri kuramba ichivandudzwa. Kuvandudzwa kweramangwana kuchave kwakanangana nemaitiro akangwara, egirini, uye epamusoro-soro. Nzira dzekugadzirisa dzakatarwa ndeidzi dzinotevera:

1. Kushandiswa kweMidziyo Yekugadzira Yakangwara

Kuunza michina yeCNC stamping nemarobhoti eindasitiri kuti uwane kudzora otomatiki uye nehungwaru kwemaitiro estamping:

Michina yeCNC stamping: Yakashongedzerwa neservo system yakanyatsogadzirwa, inobvumira kugadzirisa maparameters panguva chaiyo senge stamping pressure uye stroke speed, ine control accuracy ye±0.001mm. Iinewo kugona kuzviongorora, zvichiita kuti zvikwanise kuona matambudziko akadai sekusakara kwemafa uye zvinhu zvisina kumira zvakanaka, zvichideredza huwandu hwezvigadzirwa zvisina kunaka.

Marobhoti emumaindasitiri: Anoshandiswa mukutakura zvinhu zvisina kugadzirwa, kudhinda zvikamu, uye kurongedza zvigadzirwa zvakapedzwa, anotsiva mashandiro emaoko. Izvi hazvingobatsiri chete pakugadzira (zvichibvumira kugadzirwa kwemaawa makumi maviri nemana nguva dzose), asiwo zvinobvisa kutsauka kunokonzerwa nekushanda nemaoko, zvichiita kuti chigadzirwa chive chemhando yepamusoro.

2. Kukurudzirwa kweMaitiro Ekuchengetedza Rusvingo

Kuderedza kushandiswa kwesimba uye kusvibiswa kwezvakatipoteredza uku uchizadzisa zvinodiwa:

Kugadzirisa zvinhu zvechikohwe: Kushandisa chikohwe chakagadzirwa nesimbi inokurumidza (HSS) uye carbide yakagadzirwa nesimende (WC) kunowedzera hupenyu hwechikohwe (hupenyu hwebasa hunogona kuwedzerwa nekatatu kusvika kashanu), kunoderedza kuwanda kwekutsiva chikohwe, uye kunoderedza marara ezvinhu.

Kuvandudzwa kwemaitiro ekurapa usati watanga: Kukurudzira tekinoroji yekubvisa phosphorus isina phosphorus uye kushandisa mhinduro dzekubvisa phosphorus dzisina njodzi kunoderedza kusvibiswa kwephosphorus. Uyezve, kupfapfaidza mafuta anodzivirira ngura nemagetsi kunovandudza kushandiswa kwemafuta anodzivirira ngura (huwandu hwekushandiswa hunogona kuwedzerwa kusvika pamusoro pe95%) uye kunoderedza kuburitswa kwemafuta.

3. Kuvandudza Tekinoroji Yekuongorora Yakanyatsorongeka

Sisitimu yekuongorora maonerwo emuchina yakatangwa kuti ikwanise kuongororwa nekukurumidza uye nemazvo kwemhando yepamusoro kwemaplate ekunze.

Yakashongedzerwa nekamera ine resolution yepamusoro (resolution ≥ 20 megapixels) uye software yekugadzirisa mifananidzo, sisitimu yekuongorora maficha emuchina inogona kuongorora maplate ekunze panguva imwe chete kuti ione kana akarurama, zvisizvo pakuonekwa, kutsauka kwenzvimbo yegomba, nezvimwe zvinhu. Sisitimu iyi ine kumhanya kwekuongorora kwezvikamu zana paminiti, ichiwana kururama kwakapetwa kagumi kupfuura kuongororwa nemaoko. Inogonesawo kuchengetedza nekuongorora data rekuongorora panguva chaiyo, ichipa rutsigiro rwedata rekugadzirisa maitiro.

Mhedziso: Mitemo ndiyo nzira yekubatsira pamhando yepamusoro, uye ruzivo rwakadzama runoratidza kuvimbika kwekutapurirana.

Maitiro ekugadzika ma "roller chain outer link plates" angaita seari nyore, asi mitemo yakasimba inofanira kutevedzwa padanho rega rega—kubva pakudzora kuumbwa kwemakemikari ezvinhu zvakagadzirwa, kusvika pakuona kuti mativi acho akarurama panguva yekugadzika ma "stamp", kusvika pakuongororwa kwakazara kwemhando yechinhu chapera. Kutarisa chero chinhu kunogona kukonzera kudzikira kwekushanda kwe "outer link plate", uye nekudaro, kukanganisa kuvimbika kwe "transmission" ye "roller chain" yese.