Ukuhlaziywa Okuphelele Kwenqubo Yokwakha Ngokuqondile Kwe-Roller Chain: Imfihlo Yekhwalithi Kusukela Kuzinto Ezingavuthiwe Kuya Kumkhiqizo Oqediwe
Embonini yokudlulisa izimboni, ukuthembekaamaketanga okugoqainquma ngqo ukusebenza kahle kanye nokuphila kwemishini yomugqa wokukhiqiza. Njengobuchwepheshe bokukhiqiza obuyinhloko bezingxenye ze-core roller chain, i-precision forging, kanye nenzuzo yayo ecishe ibe yi-net, ifinyelela ibhalansi ephelele phakathi kokunemba kobukhulu bezingxenye, izakhiwo zemishini, kanye nokusebenza kahle kokukhiqiza. Lesi sihloko sizogxila kuyo yonke inqubo ye-roller chain precision forging, sembule izimfihlo ngemuva kwe-roller chain esezingeni eliphezulu.
1. Ukucubungula Ngaphambi Kokucutshungulwa: Ukukhethwa Kwezinto Eziluhlaza Nokwelashwa Ngaphambi Kokucutshungulwa – Ukulawula Ikhwalithi Emthonjeni
Isisekelo sekhwalithi ekwakheni ngokunemba siqala ngokukhethwa okuqinile kwezinto zokusetshenziswa kanye nokwelashwa kwangaphambili kwesayensi. Izingxenye eziyinhloko zamaketanga e-roller (ama-roller, ama-bushing, ama-chain plate, njll.) kumele zikwazi ukumelana nemithwalo eshintshanayo, ukuthinteka, kanye nokuguguleka. Ngakho-ke, ukukhetha kanye nokuphathwa kwezinto zokusetshenziswa kuthinta ngqo ukusebenza komkhiqizo wokugcina.
1. Ukukhetha Izinto Zokusetshenziswa: Ukukhetha Insimbi Ehambisana Nezidingo Zokusebenza
Kuye ngokusetshenziswa kweketanga lama-roller (njengemishini yokwakha, ama-transmission ezimoto, kanye namathuluzi omshini onembile), izinto zokusetshenziswa ezivame ukusetshenziswa yinsimbi yesakhiwo sekhabhoni esezingeni eliphezulu noma insimbi yesakhiwo se-alloy. Isibonelo, ama-roller nama-bushing adinga ukumelana nokuguguleka okuphezulu nokuqina, ngokuvamile kusetshenziswa izinsimbi ze-alloy carburizing ezifana ne-20CrMnTi. Ama-chain plate adinga ibhalansi yamandla nokumelana nokukhathala, ngokuvamile kusetshenziswa izinsimbi zesakhiwo sekhabhoni ephakathi nendawo njenge-40Mn kanye ne-50Mn. Ngesikhathi sokukhethwa kwezinto, ukwakheka kwamakhemikhali kwensimbi kuhlolwa ngokuhlaziywa kwe-spectral ukuqinisekisa ukuthi okuqukethwe kwezinto ezifana nekhabhoni, i-manganese, ne-chromium kuhambisana nezindinganiso zikazwelonke ezifana ne-GB/T 3077, ngaleyo ndlela kugwenywe ukwakha ukuqhekeka noma ukuntuleka kokusebenza okubangelwa ukuphambuka kokwakheka.
2. Inqubo Yokwelapha Ngaphambi Kokwelashwa: “Ukufudumeza” Ukuze Kuhlanganiswe
Ngemva kokungena efektri, izinto zokusetshenziswa zidlula ezinyathelweni ezintathu ezibalulekile zokwelashwa kwangaphambi kwesikhathi:
Ukuhlanzwa Komphezulu: Ukuqhuma kwesibhamu kususa isikali, ukugqwala, kanye namafutha ebusweni bensimbi ukuvimbela ukungcola ukuthi kungacindezelwa endaweni yokusebenza ngesikhathi sokwakha nokudala amaphutha.
Ukusika: Amasaha aqondile noma izikebhe ze-CNC zisetshenziselwa ukusika insimbi ibe yizicucu ezinesisindo esinqunyiwe, ngephutha lokunemba kokusika elilawulwa ngaphakathi kuka-±0.5% ukuqinisekisa ubukhulu bomsebenzi obuhambisanayo ngemva kokwakha.
Ukushisa: I-billet ifakwa esithandweni sokushisa esiphakathi nendawo. Izinga lokushisa kanye nokushisa kokugcina kokubumba kulawulwa ngokohlobo lwensimbi (isibonelo, insimbi yekhabhoni ivame ukushiswa ku-1100-1250°C) ukuze kufezwe isimo sokubumba esifanele "sokubumba okuhle kanye nokumelana nokubola okuphansi" ngenkathi kugwenywa ukushisa ngokweqile noma ukushiswa ngokweqile okungonakalisa izakhiwo zezinto.
II. Ukwakhiwa Kwe-Core: Ukubumba Okunembile Kokuma Okuseduze Ne-Net
Inqubo yokwakha eyinhloko ibalulekile ekufezeni ukukhiqizwa kwezingxenye ze-roller chain "ezinqunyiwe noma ezinganqunyiwe". Kuye ngesakhiwo sezingxenye, i-die forging kanye ne-upset forging kusetshenziswa kakhulu, kusetshenziswa isikhunta esinembile kanye nemishini ehlakaniphile ukuqedela inqubo yokwakha.
1. Ukulungiswa Kwesikhunta: "Indlela Eyinhloko" Yokudlulisa Ngokucophelela
Izikhunta ezisebenza ngokunemba zikhiqizwa ngensimbi esebenza ngokushisa ye-H13. Ngokusebenzisa i-CNC milling, i-EDM machining, kanye ne-polishing, umgodi wesikhunta ufinyelela ukunemba kobukhulu be-IT7 kanye nobukhulu bomphezulu obungu-Ra ≤ 1.6μm. Isikhunta kumele sishiswe ku-200-300°C bese sifuthwa nge-graphite lubricant. Lokhu akugcini nje ngokunciphisa ukungqubuzana nokuguguleka phakathi kwesikhala nesikhunta, kodwa futhi kwenza kube lula ukuqhekeka okusheshayo futhi kuvimbele amaphutha okunamathela. Ngezingxenye ezilinganayo njengama-roller, isikhunta kumele futhi sakhiwe nge-diverter grooves kanye ne-vents ukuqinisekisa ukuthi insimbi encibilikisiwe (isikhala esishisayo) igcwalisa ngokulinganayo umgodi futhi isuse umoya kanye nokungcola.
2. Ukwakha: Ukucubungula Okwenziwe Ngokwezifiso Ngokusekelwe Ezicini Zezingxenye
Ukwakha Ama-Roller: Kusetshenziswa inqubo “yokwakha okugcina okucasulayo” enezinyathelo ezimbili. I-billet efudumele iqala iphazamiseke ku-pre-forging die, okokuqala iguqule ukwakheka kwezinto bese igcwalisa umgodi wangaphambi kokwakha. I-billet idluliselwa ngokushesha ku-final forging die. Ngaphansi kwengcindezi ephezulu yokucindezela (ngokuvamile ukucindezela okushisayo okunamandla angu-1000-3000 kN), i-billet ifakwe ngokuphelele kumgodi wokugcina wokwakha, yakha ubuso obuyindilinga be-roller, i-inner bore, kanye nezinye izakhiwo. Isivinini sokwakha kanye nokucindezela kumele kulawulwe kuyo yonke inqubo ukuze kugwenywe ukuqhekeka ku-workpiece ngenxa yokuguquguquka ngokweqile.
Ukwakha Izikhwama: Kusetshenziswa inqubo ehlanganisiwe "yokubhoboza-ukwandisa". Imbobo engaboni iqale ibhobozwe maphakathi ne-billet kusetshenziswa isibhakela. Imbobo bese inwetshwa ibe yizilinganiso eziklanyelwe kusetshenziswa idayisi yokwandisa, kuyilapho kugcinwa ukubekezelelana kobukhulu bodonga lwezikhwama obufanayo obungu-≤0.1 mm.
Ukwakhiwa Kwepuleti Leketanga: Ngenxa yesakhiwo esiyisicaba nesincane samapuleti eketanga, kusetshenziswa inqubo "yokwakhiwa kwe-die okuqhubekayo eneziteshi eziningi". Ngemva kokushisa, i-blank idlula ezikhungweni zokwakheka kwangaphambili, ukwakheka kokugcina, kanye nokusika, iqedela iphrofayili yepuleti leketanga kanye nokucubungula imigodi ekusebenzeni okukodwa, ngesilinganiso sokukhiqiza sezingcezu ezingu-80-120 ngomzuzu.
3. Ukucubungula Ngemva Kokubumba: Ukuqinisa Ukusebenza Nokubukeka
Umsebenzi owenziwe ngobumba usheshe ucinywe ukushisa okusele noma ukwenziwa kube ngokwejwayelekile kwe-isothermal. Ngokulawula izinga lokupholisa (isb., ukusebenzisa ukupholisa ngamanzi noma ukupholisa ngebhavu le-nitrate), isakhiwo se-metallographic somsebenzi siyalungiswa ukuze kufezwe isakhiwo esifanayo se-sorbite noma se-pearlite ezingxenyeni ezifana nama-rollers nama-bushings, okuthuthukisa ubulukhuni (ubulukhuni be-roller ngokuvamile budinga i-HRC 58-62) kanye namandla okukhathala. Ngesikhathi esifanayo, kusetshenziswa umshini wokusika ngesivinini esikhulu ukususa i-flash nama-burrs emaphethelweni e-forging, ukuqinisekisa ukuthi ukubukeka kwengxenye kuhlangabezana nezidingo zomklamo.
3. Ukuqeda Nokuqinisa: Ukuthuthukisa Ikhwalithi Ngokuningiliziwe
Ngemva kokwakhiwa kwe-core, umsebenzi usuvele unokubukeka okuyisisekelo, kodwa izinqubo zokuqeda nokuqinisa ziyadingeka ukuze kuthuthukiswe ukunemba nokusebenza kwawo ukuze kuhlangatshezwane nezidingo eziqinile zokudluliselwa kwe-roller chain ngesivinini esikhulu.
1. Ukulungiswa Okunembile: Ukulungisa Ukuguquka Okuncane
Ngenxa yokuncipha nokukhululwa kokucindezeleka ngemva kokufakelwa, izinto zokusebenza zingase zibonise ukuphambuka okuncane kobukhulu. Ngesikhathi senqubo yokuqeda, kusetshenziselwa idayisi yokulungisa ngokunemba ukufaka ingcindezi ku-workpiece ebandayo ukulungisa ukuphambuka kobukhulu ngaphakathi kwe-IT8. Isibonelo, iphutha lokuzungeza kobubanzi bangaphandle kwe-roller kumele lilawulwe ngaphansi kuka-0.02mm, kanye nephutha lobubanzi bangaphakathi be-cylindricity yesilive akumele lidlule ku-0.015mm ukuqinisekisa ukudluliswa kweketanga okubushelelezi ngemva kokuhlanganiswa.
2. Ukuqina Komphezulu: Ukuthuthukisa Ukumelana Nokuguguleka Nokugqwala
Kuye ngendawo yokusebenza, izinto zokusebenza zidinga ukwelashwa kwendawo okuqondiswe kuyo:
Ukushiswa Kwekhabhoni Nokucisha: Ama-roller nama-bushing ashiswa ngekhabhoni esithandweni sokushiswa kwekhabhoni ku-900-950°C amahora angu-4-6 ukuze kufinyelelwe okuqukethwe kwekhabhoni engaphezulu okungu-0.8%-1.2%. Bese ayacinywa futhi aqiniswe emazingeni okushisa aphansi ukuze kudalwe isakhiwo esincane se-gradient esibonakala ngokuqina okuphezulu kwendawo kanye nokuqina okuphezulu kwengaphakathi. Ukuqina kwendawo kungafinyelela ngaphezu kwe-HRC60, kanye nokuqina komthelela wengaphakathi ≥50J/cm².
I-Phosphating: Izingxenye ezifana nama-chain plates zihlanganiswa i-phosphate ukuze zakhe ifilimu ye-phosphate enezimbobo ebusweni, okuthuthukisa ukunamathela kwamafutha okulandelayo kanye nokuthuthukisa ukumelana nokugqwala.
Ukuchama Ngesibhamu: Ukuchama Ngesibhamu ebusweni bepuleti leketanga kudala ukucindezeleka okusele kokucindezela ngokusebenzisa umthelela wokuchama ngensimbi esheshayo, kunciphisa ukuqala kokuqhekeka kokukhathala futhi kwandise impilo yokukhathala kweketanga.
IV. Ukuhlolwa Kwenqubo Egcwele: Ukuzivikela Kwekhwalithi Ukuqeda Amaphutha
Yonke inqubo yokwakha ngokunemba ihlolwa ngokucophelela, yakha uhlelo lokulawula ikhwalithi oluphelele kusukela ezintweni zokusetshenziswa kuya kumkhiqizo oqediwe, okuqinisekisa ukuqinisekiswa kwekhwalithi okungu-100% kuzo zonke izingxenye ze-roller chain eziphuma efektri.
1. Ukuhlolwa Kwenqubo: Ukuqapha Kwangempela Kwamapharamitha Abalulekile
Ukuhlolwa Kokushisa: Ama-thermometer e-infrared asetshenziselwa ukuqapha izinga lokushisa lokushisa kwe-billet ngesikhathi sangempela, ngephutha elilawulwa ngaphakathi kuka-±10°C.
Ukuhlolwa Kwesikhunta: Umgodi wesikhunta uyahlolwa ukuthi awugugi yini njalo ezingxenyeni ezingu-500 ezikhiqizwayo. Ukulungiswa kokupholisha kwenziwa ngokushesha uma ukugoba kobuso kudlula i-Ra3.2μm.
Ukuhlolwa Kobukhulu: Umshini wokulinganisa onama-coordinate amathathu usetshenziselwa ukusampula nokuhlola izingxenye ezenziwe ngobumba, ugxile ebukhulu obubalulekile njengobubanzi bangaphandle, ububanzi bangaphakathi, kanye nobukhulu bodonga. Izinga lokuhlola alingaphansi kuka-5%.
2. Ukuhlolwa Komkhiqizo Oqediwe: Ukuqinisekiswa Okuphelele Kwezinkomba Zokusebenza
Ukuhlolwa Kokusebenza Kwemishini: Isampula yemikhiqizo eqediwe ngokungahleliwe yokuhlola ubulukhuni (isihloli sobulukhuni saseRockwell), ukuhlolwa kobulukhuni bomthelela (isihloli somthelela se-pendulum), kanye nokuhlolwa kwamandla okudonsa ukuqinisekisa ukuhambisana nezindinganiso zomkhiqizo.
Ukuhlolwa Okungonakalisi: Ukuhlolwa kwe-Ultrasonic kusetshenziselwa ukuthola amaphutha angaphakathi njengemifantu kanye nemifantu, kuyilapho ukuhlolwa kwezinhlayiya zamagnetic kusetshenziswa ukuthola amaphutha angaphezulu nangaphansi komhlaba.
Ukuhlolwa Kokuhlanganiswa: Izingxenye ezifanelekile zihlanganiswa zibe uchungechunge lwe-roller futhi zihlolwe ukusebenza okuguquguqukayo, okuhlanganisa ukunemba kokudlulisela, izinga lomsindo, kanye nokuphila kokukhathala. Isibonelo, ingxenye ibhekwa njengefanelekile kuphela uma isebenze ngokuqhubekayo ku-1500 r/min amahora ayi-1000 ngaphandle kwezinkinga.
V. Izinzuzo Zenqubo kanye Nenani Lokusetshenziswa: Kungani Ukunemba Kuyisinqumo Esiphambili Semboni?
Uma kuqhathaniswa nenqubo yendabuko "yokwakha + ukusika okubanzi", ukuklama ngokunemba kunikeza izinzuzo ezintathu eziyinhloko zokukhiqiza uchungechunge lwama-roller:
Ukusetshenziswa okuphezulu kwezinto zokwakha: Ukusetshenziswa kwezinto zokwakha kukhuphuke kusuka ku-60%-70% ezinqubweni zendabuko kwaya ngaphezu kuka-90%, okunciphisa kakhulu imfucuza yezinto zokwakha ezingavuthiwe;
Ukusebenza kahle kokukhiqiza okuphezulu: Sisebenzisa imishini yokwakha eqhubekayo yeziteshi eziningi kanye nemishini ezenzakalelayo, ukusebenza kahle kokukhiqiza kuphakeme ngokuphindwe ka-3-5 kunezinqubo zendabuko;
Ukusebenza kahle komkhiqizo: I-Forging isabalalisa isakhiwo sefayibha yensimbi eceleni kwe-workpiece contour, idala isakhiwo esilula, okuholela ekukhuleni kwempilo yokukhathala ngo-20%-30% uma kuqhathaniswa nezingxenye ezisetshenzisiwe.
Lezi zinzuzo ziholele ekusetshenzisweni kabanzi kwamaketanga okugoqa aqinisiwe ngokunemba ekukhiqizweni kwemishini esezingeni eliphezulu, njenge-track drive yemishini yokwakha, izinhlelo zesikhathi zezinjini zezimoto, kanye ne-spindle drive yamathuluzi omshini oqondile. Zibe yizingxenye zamandla eziyinhloko eziqinisekisa ukusebenza okuzinzile kwemishini yezimboni.
Isiphetho
Inqubo yokuqamba ngokunemba kwamaketanga e-roller iwumphumela wendlela ebanzi ehlanganisa isayensi yezinto zokwakha, ubuchwepheshe besikhunta, ukulawula okuzenzakalelayo, kanye nokuhlolwa kwekhwalithi. Kusukela ezindinganisweni eziqinile ekukhetheni izinto zokusetshenziswa, kuya ekulawulweni kokunemba kwezinga le-millimeter ekubumbeni okuyinhloko, kuya ekuqinisekisweni okuphelele ekuhlolweni komkhiqizo oqediwe, inqubo ngayinye imele ubuhlakani kanye namandla obuchwepheshe bokukhiqiza kwezimboni.
Isikhathi sokuthunyelwe: Septhemba-24-2025