Tsarin sarrafa gear, sigogin yankewa da buƙatun kayan aiki idan gear ɗin yana da wuyar juyawa kuma ingancin injin yana buƙatar ingantawa

Gear shine babban abin da ke samar da wutar lantarki a masana'antar kera motoci. Yawanci, kowace mota tana da hakora 18-30. Ingancin kayan aiki yana shafar hayaniya, kwanciyar hankali da tsawon rayuwar motar. Injin sarrafa kayan aiki tsarin kayan aiki ne mai rikitarwa kuma muhimmin kayan aiki ne a masana'antar kera motoci. Ƙungiyoyin kera motoci na duniya kamar Amurka, Jamus da Japan suma suna da ƙarfin kera kayan aikin injin sarrafa kayan aiki. A cewar kididdiga, sama da kashi 80% na kayan aikin mota a China ana sarrafa su ta hanyar kayan aikin kera kayan aiki na cikin gida. A lokaci guda, masana'antar kera motoci tana cinye fiye da kashi 60% na kayan aikin injin sarrafa kayan aiki, kuma masana'antar kera motoci koyaushe za ta zama babban abin da ake amfani da kayan aikin injin.

Fasahar sarrafa kaya

1. yin siminti da kuma yin fanko

Ƙirƙirar hot die har yanzu tsari ne da ake amfani da shi sosai wajen ƙera kayan aikin mota. A cikin 'yan shekarun nan, an haɓaka fasahar birgima mai faɗi a cikin injin shaft. Wannan fasaha ta dace musamman don yin billets don ƙofofi masu rikitarwa. Ba wai kawai tana da daidaito mai kyau ba, ƙaramin izinin injina na gaba, har ma tana da ingantaccen aiki mai yawa.

2. daidaita

Manufar wannan tsari ita ce a sami taurin da ya dace da yanke gear na gaba da kuma shirya ƙaramin tsari don maganin zafi na ƙarshe, don rage lalacewar maganin zafi yadda ya kamata. Kayan ƙarfen gear da ake amfani da shi yawanci shine 20CrMnTi. Saboda babban tasirin ma'aikata, kayan aiki da muhalli, saurin sanyaya da daidaiton sanyaya kayan aikin suna da wahalar sarrafawa, wanda ke haifar da babban watsawar tauri da rashin daidaiton tsarin ƙarfe, wanda ke shafar yanke ƙarfe da maganin zafi na ƙarshe kai tsaye, wanda ke haifar da babban nakasar zafi da rashin daidaituwa da ingancin ɓangaren da ba za a iya sarrafawa ba. Saboda haka, an ɗauki tsarin daidaita isothermal. Aiki ya tabbatar da cewa daidaita isothermal na iya canza rashin daidaiton daidaituwa gabaɗaya yadda ya kamata, kuma ingancin samfurin yana da karko kuma abin dogaro.

3. juyawa

Domin biyan buƙatun matsayi na sarrafa kayan aiki masu inganci, duk ana sarrafa guraben gear ta hanyar amfani da na'urorin CNC, waɗanda ake manne su ta hanyar injiniya ba tare da sake niƙa kayan aikin juyawa ba. Ana kammala sarrafa diamita na ramin, ƙarshen fuska da diamita na waje tare da haɗin gwiwa a ƙarƙashin matsewa sau ɗaya, wanda ba wai kawai yana tabbatar da buƙatun tsaye na ramin ciki da ƙarshen fuska ba, har ma yana tabbatar da ƙaramin girman watsawar guraben gear. Don haka, daidaiton guraben gear yana inganta kuma an tabbatar da ingancin injinan gear na gaba. Bugu da ƙari, ingantaccen injinan lathe na NC kuma yana rage yawan kayan aiki sosai kuma yana da kyakkyawan tattalin arziki.

4. hobbing da gear structing

Ana amfani da injinan hobbing na yau da kullun da masu gyaran gear don sarrafa gear. Duk da cewa yana da sauƙin daidaitawa da kulawa, ingancin samarwa yana da ƙasa. Idan an kammala babban ƙarfin aiki, ana buƙatar samar da injuna da yawa a lokaci guda. Tare da haɓaka fasahar rufi, yana da matukar dacewa a sake shafa hobs da plungers bayan niƙa. Rayuwar sabis na kayan aikin rufi za a iya inganta ta sosai, gabaɗaya da fiye da kashi 90%, wanda ke rage yawan canje-canjen kayan aiki da lokacin niƙa, tare da fa'idodi masu yawa.

5. aski

Ana amfani da fasahar aske gear ta radial sosai wajen samar da kayan aiki na motoci saboda ingancinta da kuma sauƙin fahimtar buƙatun gyare-gyare na tsarin haƙori da kuma alkiblar haƙori. Tun lokacin da kamfanin ya sayi injin aske gear na musamman na kamfanin Italiya don sauya fasaha a shekarar 1995, ya girma a aikace-aikacen wannan fasaha, kuma ingancin sarrafawa yana da karko kuma abin dogaro.

6. maganin zafi

Giyayen motoci suna buƙatar yin amfani da carbon da quenching don tabbatar da kyawawan halayen injina. Kayan aikin gyaran zafi masu ɗorewa da aminci suna da mahimmanci ga samfuran da ba sa fuskantar niƙa gear bayan an yi amfani da zafi. Kamfanin ya gabatar da layin samar da carburizing da quenching na German Lloyd's, wanda ya sami sakamako mai gamsarwa na maganin zafi.

7. niƙa

Ana amfani da shi galibi don kammala ramin ciki na gear da aka yi wa zafi, fuskar ƙarshe, diamita na waje na shaft da sauran sassa don inganta daidaiton girma da rage haƙurin geometric.

Tsarin sarrafa gear yana ɗaukar kayan aiki na da'irar zagaye don sanyawa da ɗaurewa, wanda zai iya tabbatar da daidaiton injin haƙori da kuma ma'aunin shigarwa yadda ya kamata, da kuma samun ingancin samfurin da ya gamsu.

8. kammalawa

Wannan don duba da tsaftace ƙuraje da ƙuraje a kan sassan gear na gatari na watsawa da tuƙi kafin haɗawa, don kawar da hayaniya da hayaniya mara kyau da suka haifar bayan haɗawa. Saurari sauti ta hanyar haɗakar biyu ko kuma lura da karkacewar haɗin gwiwa akan cikakken mai gwadawa. Sassan haɗin gwiwar watsawa da kamfanin kera ya samar sun haɗa da gidan kama, gidan watsawa da gidan bambance-bambance. Gidan kama da gidan watsawa sassa ne masu ɗaukar nauyi, waɗanda galibi ana yin su ne da ƙarfe na aluminum mai siminti ta hanyar siminti na musamman. Siffar ba ta dace ba kuma mai rikitarwa. Tsarin gabaɗaya shine niƙa saman haɗin gwiwa → ramukan aiwatar da injina da ramukan haɗawa → ramukan ɗaukar nauyi masu ban sha'awa → ramukan ɗaukar nauyi masu ban sha'awa da gano ramukan fil → tsaftacewa → gwajin zubewa da ganowa.

Sigogi da buƙatun kayan aikin yanke gear

Gears suna da matuƙar lalacewa bayan an yi carburizing da quenched. Musamman ga manyan gears, girman canjin da'irar waje da aka yi carburized da quenched da ramin ciki gabaɗaya yana da girma sosai. Duk da haka, don juyawar da'irar waje ta carburized da quenched gear, babu wani kayan aiki da ya dace. Kayan aikin bn-h20 da "Valin superhard" ya ƙirƙira don juyawa mai ƙarfi na ƙarfe mai katsewa ya gyara nakasar da aka yi carburized da quenched gear na waje ramin ciki da fuskar ƙarshe, kuma ya sami kayan aikin yankewa mai dacewa, Ya sami ci gaba a duk duniya a fannin yankewa mai katsewa tare da kayan aikin da suka yi tsauri.

Nau'in Carburizing da Kashewa na Gear: Nau'in Carburizing da Kashewa na Gear yana faruwa ne sakamakon haɗakar matsin lamba da aka samu yayin aikin injin, damuwa ta zafi da damuwa ta tsarin da aka samu yayin maganin zafi, da kuma nau'in kayan aikin. Musamman ga manyan zoben gear da gear, manyan zoben gear suma za su ƙara nau'in bayan ƙonawa da kashewa saboda babban modulus ɗinsu, zurfin carburizing Layer, dogon lokacin carburizing da nauyin kansu. Dokar Canzawa na babban shaft: diamita na waje na da'irar ƙari yana nuna yanayin matsewa a bayyane, amma a cikin alkiblar faɗin haƙori na shaft gear, tsakiya yana raguwa, kuma ƙarshen biyu suna ɗan faɗaɗa kaɗan. Dokar Canzawa na zoben gear: Bayan Carburizing da Kashewa, diamita na waje na babban zoben gear zai kumbura. Lokacin da faɗin haƙori ya bambanta, alkiblar faɗin haƙori zai zama ganga mai siffar ko kuma kugu.

Juyawar gear bayan yin carburizing da kashewa: ana iya sarrafa shi kuma a rage shi zuwa wani mataki, amma ba za a iya kauce masa gaba ɗaya ba. Don gyaran nakasa bayan yin carburizing da kashewa, ga taƙaitaccen bayani game da yuwuwar kayan aikin juyawa da yankewa bayan yin carburizing da kashewa.

Juya da'irar waje, ramin ciki da kuma ƙarshen fuska bayan yin carburizing da kashewa: juyawa ita ce hanya mafi sauƙi don gyara nakasar da'irar waje da ramin ciki na kayan aikin zobe masu carburized da kashewa. A da, duk wani kayan aiki, gami da kayan aikin superhard na ƙasashen waje, ba zai iya magance matsalar yanke da'irar waje mai ƙarfi na kayan aikin da aka kashe ba. An gayyaci Valin superhard don gudanar da bincike da haɓaka kayan aiki, "Yanke ƙarfe mai tauri akai-akai koyaushe matsala ce mai wahala, ba tare da ambaton ƙarfe mai tauri na kusan HRC60 ba, kuma izinin nakasar yana da girma. Lokacin juya ƙarfe mai tauri a babban gudu, idan kayan aikin yana da yankewa akai-akai, kayan aikin zai kammala aikin da girgiza sama da 100 a minti ɗaya lokacin yanke ƙarfe mai tauri, wanda babban ƙalubale ne ga juriyar tasirin kayan aikin." Masana ƙungiyar wukake ta China sun ce haka. Bayan shekara guda na gwaje-gwaje da aka maimaita, Valin superhard ya gabatar da alamar kayan aikin yankewa mai tauri don Juya Karfe Mai Tauri tare da katsewa mai ƙarfi; Ana gudanar da gwajin juyawa akan da'irar waje bayan yin carburizing da kashewa.

Gwaji kan juya gear ɗin silinda bayan an yi amfani da carburetion da kuma kashewa

Babban gear (gear zobe) ya lalace sosai bayan an yi carburizing da kashewa. Nauyin da'irar waje ta gear zobe ya kai 2mm, kuma taurin bayan kashewa ya kai hrc60-65. A wancan lokacin, yana da wahala ga abokin ciniki ya sami babban niƙa mai diamita, kuma izinin injin yana da girma, kuma ingancin niƙa ya yi ƙasa sosai. A ƙarshe, an juya gear ɗin da aka yi carburized da wanda aka kashe.

Gudun yanke layi: 50–70m/min, zurfin yankewa: 1.5–2mm, nisan yankewa: 0.15-0.2mm/ Juyin Juya Hali (an daidaita shi bisa ga buƙatun ƙazanta)

Lokacin da ake juya gear ɗin da aka kashe, ana kammala aikin injin a lokaci guda. Ana iya sarrafa kayan aikin yumbu na asali da aka shigo da su sau da yawa kawai don yanke lalacewar. Bugu da ƙari, rugujewar gefen yana da tsanani, kuma farashin amfani da kayan aikin yana da yawa sosai.

Sakamakon gwajin kayan aiki: yana da juriya ga tasiri fiye da kayan aikin yumbu na silicon nitride na asali da aka shigo da su, kuma tsawon aikinsa ya ninka na kayan aikin yumbu na silicon nitride sau 6 idan zurfin yankewa ya ƙaru sau uku! Ingancin yankewa yana ƙaruwa sau 3 (a da yana yin yanka sau uku, amma yanzu an kammala shi sau ɗaya). Rashin kyawun saman kayan aikin shima ya cika buƙatun mai amfani. Abu mafi mahimmanci shine cewa nau'in gazawar ƙarshe na kayan aikin ba shine gefen da ya karye ba, amma lalacewar fuskar baya ta yau da kullun. Wannan gwajin gear mai kashewa na juyawa akai-akai ya karya tatsuniya cewa ba za a iya amfani da kayan aiki masu ƙarfi a masana'antar don ƙarfe mai ƙarfi na juyawa akai-akai ba! Ya haifar da babban abin mamaki a cikin da'irar kayan aikin yanke ilimi!

Ƙarshen saman ramin ciki mai tauri na juyawa bayan kashewa

Idan aka ɗauki yanke ramin ciki na gear lokaci-lokaci tare da ramin mai a matsayin misali: tsawon lokacin aikin yankewa na gwaji ya kai sama da mita 8000, kuma ƙarshen yana cikin Ra0.8; Idan aka yi amfani da kayan aiki mai ƙarfi tare da gefen gogewa, ƙarshen juyawa na ƙarfe mai tauri zai iya kaiwa kusan Ra0.4. Kuma ana iya samun ingantaccen tsawon lokacin kayan aiki.

Machining ƙarshen fuskar kayan aiki bayan carburizing da kashewa

A matsayin aikace-aikacen da aka saba amfani da shi na "juyawa maimakon niƙa", an yi amfani da ruwan cubic boron nitride sosai a cikin aikin samar da jujjuyawar ƙarshen gear bayan zafi. Idan aka kwatanta da niƙa, juyawar tauri yana inganta ingantaccen aiki sosai.

Ga gears masu kauri da waɗanda aka kashe, buƙatun masu yankewa suna da yawa. Da farko, yankewa lokaci-lokaci yana buƙatar tauri mai yawa, juriyar tasiri, tauri, juriyar lalacewa, ƙaiƙayin saman da sauran kaddarorin kayan aikin.

taƙaitaccen bayani:

Don juyawa bayan yin carburizing da kashewa da kuma juyawar fuska ta ƙarshe, an shahara da kayan aikin nitride na cubic boron nitride na yau da kullun. Duk da haka, don canjin girma na da'irar waje da ramin ciki na babban zoben carburized da kashewa, koyaushe matsala ce mai wahala a kashe nakasuwa da adadi mai yawa. Juyawa lokaci-lokaci na ƙarfe mai kashewa tare da kayan aikin Valin superhard bn-h20 cubic boron nitride babban ci gaba ne a masana'antar kayan aiki, wanda ke taimakawa wajen haɓaka tsarin "juyawa maimakon niƙa" a masana'antar gear, kuma yana samun amsar matsalar kayan aikin juyawa na silinda na gear mai tauri wanda ya daɗe yana rikicewa. Hakanan yana da matukar mahimmanci a rage zagayowar kera zoben gear da rage farashin samarwa; An san masu yanke jerin Bn-h20 a matsayin samfurin duniya na ƙarfe mai kauri mai kashewa a cikin masana'antar.