Kabhoni & Chirongo cheZvinhu zveMachina zveCNC
Munzvimbo yekugadzira zvinhu zvemazuva ano, michina yeComputer Numerical Control (CNC) inoshanda senzira huru yekugadzira zvinhu, ichigonesa kugadzirwa kwakanyatsojeka uye kwakanaka kwezvikamu zvakaoma mumaindasitiri akadai semotokari, ndege, mafuta negesi, uye zvinhu zvevatengi. Pakati peiyi nzira pane kusarudzwa kwezvinhu zvakakodzera, uko simbi dzakadai sesimbi dzinotonga nekuda kwekushanda kwadzo kwakasiyana-siyana, simba, uye kushanda zvakanaka kwemari. Pakati peizvi, simbi yekabhoni nesimbi ye alloy zvinobuda sezvikamu zviviri zvinonyanya kushandiswa pakugadzira CNC. Zvinhu izvi zvinopa chiyero chehunhu hwemakanika hunoita kuti zvive zvakanaka pakushandiswa kunoda kugara kwenguva refu, kugona kushanda, uye kushanda zvakanaka pasi pekumanikidzwa.
Simbi yekabhoni, inonyanya kushandiswa musimbi nekabhoni ine huwandu hwekabhoni hunotangira pa0.05% kusvika 2% nehuremu, ndiyo musimboti wemashandisirwo akawanda emaindasitiri. Kuve nyore kwayo pakuumbwa—kunyanya simbi nekabhoni, ine zvinhu zvidiki zvakaita semanganese, silicon, phosphorus, sarufa, uye okisijeni—inobvumira kusiyana kwekuomarara, simba, uye ductility zvichienderana nehuwandu hwekabhoni. Semuenzaniso, simbi dzine kabhoni shoma dzinozivikanwa nekugona kwadzo kusveta uye kugadzirwa zvakanaka, nepo mhando dzekabhoni dzakanyanya dzichipa kuomarara kwakanyanya uye kudzivirira kupfeka. Mukugadzira CNC, simbi dzekabhoni dzinokosheswa nekuda kwekukwanisika kwadzo uye nyore kwekugadzirisa, zvichiita kuti dzikwanise kugadzirwa zvakanyanya kwezvikamu zvakaita semashafts, mapini, uye zvisungo.Asi simbi ye alloy inovakwa pamusoro pehwaro hwesimbi yekabhoni nekuwedzera zvimwe zvinhu zve alloying zvakaita se chromium, nickel, molybdenum, vanadium, kana tungsten. Izvi zvinowedzera hunhu hwakasiyana, kusanganisira kuramba ngura, simba rekudhonza, kuomarara, uye kuramba kupisa, pasina kukanganisa zvakanyanya kushanda kwechinhu chepasi.
Simbi dzesimbi dzine alloy dzakakamurwa kuva dzine alloy shoma (dzine zvinhu zvinosvika 8% zvinosanganisa alloy) uye dzine alloy yakawanda, imwe neimwe yakagadzirirwa mamiriro ezvinhu akaomarara. Mumamiriro ezvinhu eCNC, dzinobudirira mukugadzira zvinhu zvinofanirwa kutsungirira mamiriro ezvinhu akaomarara, akadai semagiya, maekisi, uye maburi eturbine.Sarudzo pakati pesimbi yekabhoni neye alloy muCNC machining inotsamira pazvinhu zvakaita sekushandiswa kwechikamu, kusvibiswa kwezvakatipoteredza, hunhu hwemakanika hunodiwa, uye bhajeti shoma. Semuenzaniso, nepo simbi yekabhoni ichigona kukwana zvikamu zvechivakwa mumamiriro ekunze akapfava, simbi ye alloy inowanzo shandiswa munzvimbo dzine kushushikana kwakanyanya kana ngura. Kunzwisisa maumbirwo ezvinhu izvi, hunhu, mamakisi, uye maitiro ekugadzira kwakakosha kune mainjiniya nevagadziri kuti vagadzirise magadzirirwo, kuderedza mitengo, uye kuve nechokwadi chekuti chigadzirwa chicharamba chiripo kwenguva refu.
Chinyorwa chino chinotarisa kuomarara kwesimbi dzekabhoni nedze alloy sezvinhu zveCNC machining. Tichaongorora maumbirwo adzo, hunhu hwadzo, mamakisi akafanana, kufunga nezvekugona kwadzo kugadzira michina, mashandisirwo adzo, uye zvakanakira kuenzanisa. Nekushandisa misimboti yesainzi yezvinhu uye maitiro eindasitiri, chinangwa chedu ndechekupa gwara rakazara kune nyanzvi dziri kutsvaga kushandisa simbi idzi zvinobudirira mumapurojekiti avo. Kunyangwe uri mugadziri anotsanangura zvinhu kana kuti uri nyanzvi yekugadzira mapurogiramu eCNC, kunzwisisa izvi zvakakosha kunogona kutungamira kumhedzisiro yepamusoro mukugadzira nemazvo.
Simbi yeCarbon: Zvivakwa, Magiredhi, uye Kugona Kugadzira CNC
Simbi yekabhoni ndiyo inonyanya kugadzirwa uye kushandiswa pasi rose, ichipa 90% yesimbi yese inoburitswa. Kurongwa kwayo kunonyanya kuenderana nehuwandu hwekabhoni: kabhoni yakaderera (pasi pe0.30%), kabhoni yepakati (0.30% kusvika 0.60%), uye kabhoni yakawanda (pamusoro pe0.60%). Chikamu chimwe nechimwe chine hunhu hwakasiyana hwemakanika hunokanganisa kukodzera kwayo kugadzirwa kweCNC.
Kutanga nesimbi dzine kabhoni shoma, idzi dzinowanzonzi simbi dzisina kabhoni shoma nekuda kwekupfava kwadzo uye kugona kwadzo kuchinjika. Nemazinga ekabhoni ari pakati pe0.05% ne0.25%, dzinoratidza kugona kuumbwa zvakanaka uye kugona kuchinjika. Panyaya yemakanika, simbi dzine kabhoni shoma dzinopa simba rekugadzira rinosvika 350 MPa uye simba rekudhonza rinosvika 420 MPa, nekureba pakutyoka rinosvika 15% kana kupfuura. Kuomarara kwadzo kweBrinell kwakaderera, kunosvika 121, zvichiita kuti dzikwanise kugadzirwa zvakanyanya. Mukushanda kweCNC, simbi dzine kabhoni shoma dzakadai segiredhi 1018 dzinofarirwa nekuda kwekugadzirwa kwadzo kwakapfava uye kusashanda zvakanaka kwezvishandiso. Giredhi 1018, ine kabhoni 0.15-0.20% uye manganese 0.6-0.9%, ine simba rekudhonza rinosvika 65 ksi uye simba rekudhonza rinosvika 48 ksi. Inowanzo shandiswa kumashafts, mapini, uye zvinosungirirwa muzvikamu zvemotokari nemichina, uko kunyatsoita basa uye kushanda zvakanaka kwemari zvinonyanya kukosha.
Simbi dzine kabhoni iri pakati nepakati dzinovhara musiyano uripo pakati pe ductility nesimba, nekabhoni iri pakati pe0.30% kusvika 0.60%. Magiredhi aya anopa kuomarara kwakawedzerwa uye simba rekudhonza ukuwo achichengetedza mashandiro akakodzera. Hunhu hwakajairika hunosanganisira simba rekugonza re415 MPa, simba rekudhonza re620 MPa, uye kureba kwe25%, nekuomarara kweBrinell kunosvika 201. Giredhi 1045 inoratidza chikamu ichi, ichipa chiyero chesimba nekugona kwekudhonza. Nekabhoni iri pa0.43-0.50% uye manganese pa0.60-0.90%, inowana simba rekudhonza re105 ksi uye goho re60 ksi mushure mekupisa. MuCNC machining, simbi dzine kabhoni iri pakati nepakati dzinoda kusarudzwa kwakanyatsonaka kweparameter kudzivirira kupisa kwakanyanya, izvo zvinogona kutungamira mukuoma kwebasa. Dzakanakira zvikamu zve hydraulic, axles, uye magiya uko kunodiwa kuramba kusimba.
Simbi dzine kabhoni yakawanda, dzine kabhoni inodarika 0.60%, dzinonyanya kukosha pakuomarara uye kuramba kupfeka kupfuura ductility. Hunhu pano hunosanganisira simba rekugadzira rinosvika 570 MPa, simba rekudhonza re965 MPa, uye kureba kwakaderera pa9%, nekuomarara kweBrinell kuchisvika 293. Simbi idzi dzinonetsa muchina nekuda kwekuomarara kwadzo uye tsika yekugadzira machipisi akaoma, kazhinji zvichida maturusi ecarbide nemafuta. Magiredhi akafanana se1095 (0.90-1.03% kabhoni) anoshandiswa pakucheka maturusi, masprings, nemapanga. Mukushandiswa kweCNC, simbi dzine kabhoni yakawanda dzinobatsirwa nekunamirwa kwesimbi isati yagadzirwa kuti ivandudze kushanda, zvichiteverwa nekuomesa kuti ishandiswe pakupedzisira.
Kugona kugadzika kwesimbi dzekabhoni kunodzikira sezvo huwandu hwekabhoni huchiwedzera. Mhando dzekabhoni shoma dzinowedzera zvakanyanya (kusvika ku100 panhamba yekushanda), nepo dzine kabhoni yakawanda dzinogona kudzikira kusvika ku50-60. Zvinhu zvinokanganisa mashandiro eCNC zvinosanganisira kukurumidza kwekucheka, mwero wekudyisa, uye kushandiswa kwechinhu chinotonhodza. Semuenzaniso, kumhanya kwakakodzera kwe1018 kunogona kubva pa100-150 m/min nemidziyo yesimbi inomhanya, asi ma carbide inserts anosarudzwa kuti magiredhi akaoma awedzere hupenyu hwemidziyo. Kurapa kupisa kunoita basa guru; kugadzirisa kana kunatsa zvinhu kunonyorovesa kuti zvive nyore kubvisa chip, ukuwo kudzimisa nekudzikamisa zvinhu zvichiwedzera hunhu hwekupedzisira.
Mashandisirwo esimbi yekabhoni mukugadzira CNC akawanda. Muindasitiri yemotokari, magiredhi epasi nepakati ekabhoni anoumba zvikamu zveinjini, zvikamu zvechassis, uye zvinhu zvinomiswa. Aerospace inoashandisa pazvinhu zvisingakoshi, nepo kuvaka kuchibatsirwa nesimba rawo muzvisungo nemabhuraketi. Chikamu chemafuta negasi chinoshandisa simbi dzine kabhoni yakawanda yekuchera maburi nemavharuvhu. Kazhinji, mutengo wakaderera wesimbi yekabhoni—kazhinji kacho uri pasi pe20-30% pane ma alloys—unoita kuti ive chinhu chikuru chekugadzira prototyping uye kugadzira zvinhu zvakawanda.
Pasinei nezvakanakira, pane matambudziko. Simbi dzekabhoni dzinogona kukuvara pasina dziviriro, zvichideredza kushandiswa kwekunze kana mugungwa. Mhando dzekabhoni yakawanda dzinogona kutsemuka panguva yekunamira kana dzisina kupisa, uye kugadzira kunogona kugadzira maburi anoda kubviswa maburi. Kufambira mberi muhunyanzvi hweCNC, senge masisitimu ekudzora anochinjika, kunoderedza izvi nekuvandudza nzira uye kuderedza kudedera.
Simbi yeAlloy: Zvivakwa Zvakavandudzwa zveKuda Kushandiswa kweCNC
Simbi yeAlloy inosimudzira kugona kwesimbi yekabhoni nekuisa zvinhu zvinosanganisa zvinhu zvinogadzirisa hunhu hwayo zvinoenderana nezvinodiwa. Inotsanangurwa sesimbi ine zvinhu zvinowedzerwa nemaune kupfuura kabhoni (kazhinji 1-50% yehuwandu hwealloy), inosanganisira simbi dzine alloy shoma (kusvika ku8% yealloys) uye mhando dzealloy yakawanda. Zvinhu zvakajairika sechromium zvinovandudza kuramba ngura, nickel inowedzera kusimba, molybdenum inowedzera simba rekupisa kwakanyanya, uye vanadium inowedzera kuramba kupfeka.
Simbi dzisina alloy, dzakadai segiredhi 4140 (dzine 0.38-0.43% kabhoni, 0.80-1.10% chromium, uye 0.15-0.25% molybdenum), dzinopa simba rekugadzira rinosvika 655 MPa uye simba rekudhonza rinosvika 950 MPa mushure mekupisa. Kugona kwadzo kugadzira kuri pakati nepakati, kwakayerwa pa65-70, uye dzinopindura zvakanaka pakudzima nekudzikamisa kuoma kwe28-32 HRC. Mukugadzira CNC, simbi idzi dzinoshandiswa pazvikamu zvine simba guru senge crankshafts, magiya, uye ma axles mumotokari nemuchina unorema. Zvinhu zvakawedzerwa zvinoderedza kuputsika kana zvichienzaniswa nesimbi dzakafanana nekabhoni, zvichibvumira kuti dzisanyanya kukuvadzwa.
Simbi dzine alloy yakawanda dzinosanganisira zvinhu zvakawanda, kazhinji dzinopfuura 10% chromium yemhando dzakaita sedzakaita ...
Hunhu hwesimbi dzesimbi dzine alloy hunosiyana zvakanyanya asi kazhinji hunosanganisira simba rakakwirira rekudhonza (kusvika 1,200 MPa), ductility iri nani, uye kudzivirira kupisa kwakanyanya kana tichienzanisa nesimbi dzekabhoni. Semuenzaniso, simbi dzesimbi dzine alloy dzinogona kuchengetedza kusimba patembiricha inodarika 500°C, yakakodzera turbine blades kana petrochemical valves. Kudzivirira ngura kunowedzerwa mu chromium-rich alloys, zvichideredza kudiwa kwekuputira.
Mukugadzira CNC, simbi dzesimbi dzinoda maturusi akasarudzika, akadai secarbide yakaputirwa kana ceramic inserts, kuti dzishande nesimba radzo. Zvimiro zvekucheka zvinogona kusanganisira kumhanya kwe60-100 m/min pakukwesha uye kudyisa kwe0.1-0.2 mm/rev, neflood coolant yekudzima kupisa. Kurapa kupisa usati wagadzira senge annealing kunovandudza kudzora chip, nepo maitiro ekugadzira mushure mekugadzira achivimbisa kugadzikana kwehukuru.
Mashandisirwo anosanganisira zvikamu zvakakosha. Mundege, simbi dzemhando ye alloy dzinoumba ma "engine mounts" nema "structural frames". Indasitiri yemotokari inovimba nadzo kuti dzigadzire zvikamu zve transmission uye masisitimu ekumisikidza. Oiri negasi zvinoshandisa simbi dzemhando ye alloy pamapaipi nema "drill collars", uko kudzivirira kukuvadzwa kuri chinhu chakakosha. Ma "bearings", ma "springs", uye zvikamu zvechimiro muma "electronic enclosures" zvinobatsirwawo nekugara kwenguva refu kwazvo.
Simbi dzezvishandiso, dzakaita sesimbi dzemhando ye alloy, dzinofanirwa kutaurwa nekuda kwekuoma kwazvo (kusvika ku65 HRC) uye kuramba kukwesha. Magiredhi akaita seH13, ane chromium nevanadium, anogadzirwa neCNC kuti agadzire madhiri nemaforoma, kunyangwe achida kumhanya zvishoma nezvishoma uye gadziriro dzakasimba kudzivirira kutsemuka.
Matambudziko ane chekuita nesimbi dzesimbi anosanganisira mitengo yakakwira—kazhinji 50-100% kupfuura simbi dzekabhoni—uye mukana wekukanganiswa panguva yekupisa. Zvisinei, hunhu hwavo hwakawedzerwa hunotsigira mari inoshandiswa mukushandiswa kwesimbi dzesimbi dzemhando yepamusoro.
Kuenzanisa kweCarbon neAlloy Steel muCNC Machining
Pakusarudza pakati pesimbi yekabhoni neye alloy yekugadzira CNC machining, pane zvinhu zvakawanda zvinoshanda. Simbi yekabhoni inopfuura nekureruka kwayo pamutengo uye nyore kwayo, ine kabhoni shoma inopa kugona kusanganisa uye kugadzira zvakanaka. Zvisinei, haina ngura uye haipindi kupisa zvakanyanya, zvichiita kuti isakodzere nharaunda dzakaoma.
Simbi yesimbi, ine zvinhu zvayo zvakagadzirwa, inoita kuti ishande zvakanaka musimba, kusimba, uye kudzivirira, asi zvisingakoshi michina nemutengo. Semuenzaniso, tafura yekufananidza inoratidza:
pfuma | Simbi yeKabhoni (semuenzaniso, 1045) | Simbi yeAlloy (semuenzaniso, 4140) |
|---|---|---|
Goho Simba (MPa) | 415-570 | 655-860 |
Kubata | Pamusoro (70-100) | Pakati nepakati (50-70) |
Kurwisana Kurwisana | Low | Moderate kusvika Kumusoro |
mutengo | Yakadzika-Pakati | Pakati Pakati |
Applications | Zvimiro zvehurongwa | Kushushikana kwakanyanya, kunoparadza |
Mumamiriro ezvinhu eCNC, simbi yekabhoni inokodzera zvikamu zvinokurumidza kugadzirwa uye zvisingakoshi, nepo simbi ye alloy ichinyanya kusarudzwa pazvikamu zvakanyatsonaka zviri pasi pemutoro.
Maitiro ehybrid, sekushandisa carbon steel cores ne alloy coatings, anogona kuwedzera mabhenefiti.
Kusiyana Kwakakosha Pakati Pesimbi yeCarbon neSimbi yeAlloy muCNC Machining
1. Kusiyana kweCore CompositionCE
Musiyano mukuru uri mukugadzirwa kwemakemikari. Simbi yeKabhoni yakagadzirwa nesimbi, ine kabhoni 0.0218% ~ 2.11% sechinhu chikuru chine kusvibiswa kwakaderera. Inorongwa nekabhoni: simbi ine kabhoni shoma (<0.25%, semuenzaniso, Q235) yakapfava uye ipurasitiki; simbi ine kabhoni yepakati (0.25% ~ 0.6%, semuenzaniso, simbi 45#) inoenzanisa simba uye kupfava; simbi ine kabhoni yakawanda (<0.6%, semuenzaniso, T10) yakaoma asi inopfava.
Simbi yeAlloy inogadzirwa nekuwedzera zvinhu zvinosanganisa simbi (chromium, nickel, nezvimwewo, huwandu hwese hwe1% ~ makumi muzana) kusimbi yekabhoni, senge 42CrMo kuti iwedzere simba uye 304 simbi isingatsvedzeri kuti irambe ngura, izvo zvinoshandura mashandiro ayo ekugadzira.
2. CNC Kucheka Kushanda Kwebasa
Kuramba kwekucheka: Kuramba kwesimbi yekabhoni kunoenderana nehuwandu hwekabhoni—simbi ine kabhoni shoma inobvumira kucheka nekukurumidza, kabhoni yepakati inodhura zvishoma, uye kabhoni yakawanda inoda kumhanya kushoma. Kuramba kwesimbi ye alloy kwakakwirira ne20% ~ 50% kupfuura simbi ye kabhoni imwe chete nekuda kwe hard carbides kubva ku alloying elements.
Kupisa: Simbi yekabhoni inofambisa kupisa zvakanaka, zvichiita kuti tembiricha yemuchina ive yakaderera uye kushandiswa kwezvishandiso kunonoka. Simbi ye alloy inoderedza kupisa zvisina kunaka, tembiricha yemumucheto inowanzopfuura 800℃ (semuenzaniso, 304 simbi isingatsvedzi), ichida kutonhodza kwakanyanya kudzivirira kukuvara kwezvishandiso uye kupisa kwezvishandiso.
3. Maitiro Ekusarudza Zvishandiso
Simbi yekabhoni: Zvinodiwa zvishoma—HSS kana kabhoni yakasimwa yesimbi ine kabhoni shoma/yepakati; kabhoni ine kabhoni yakawanda (semuenzaniso, YG8) yesimbi ine kabhoni yakawanda. Zvishandiso zvisina kuputirwa kana kuti TiCN-coated zvinoshandiswa, zvine mipendero yakapinza (<0.1mm) yesimbi ine kabhoni shoma uye mipendero yakakwenenzverwa (0.1~0.2mm) yesimbi ine kabhoni yepamusoro/yepakati.
Simbi yesimbi: Zvinodiwa zvakanyanya—TiAlN/CrN coatings, mipendero yakakwenenzverwa yakasimbiswa (0.2~0.5mm), uye zvishandiso zvinoshanda zvakanyanya kuti zvikwanise kutsungirira kupisa kwakanyanya uye kukanganiswa.
4. Maitiro Ekushandisa uye Mazano Ekusarudza
Simbi isina kabhoni yakawanda (10#, Q235): Yakakodzera mabhaudhi, macasing—mutengo wakaderera, uye inoshanda zvakanyanya.
Simbi yekabhoni iri pakati nepakati (45#): Yakanakira magiya, shafts—kushanda kwakaringana, zvakanyanya
zvinhu zvakajairika zvemuworkshop.
Simbi ine kabhoni yakawanda (T8, T10): Inoshandiswa pakushandisa maturusi, mapundu—inoda kumhanya kunonoka uye kutonhora kwakasimba.
Simbi yesimbi (42CrMo, 304): Inokodzera macrankshaft emotokari, zvikamu zvendege—inosangana nezvinodiwa zvakasimba zvekushanda kunyangwe mutengo wakakwira.
6. pfupiso
Kusiyana kwekushandiswa kwesimbi mbiri idzi kunobva mukusiyana kwekugadzirwa kwadzo. Kuziva kusiyana uku kunogona kuderedza kushandiswa kwesimbi neanopfuura 30% uye kuwedzera kushanda zvakanaka ne20%. Kugadzira dhatabhesi re "zvinhu-zvekushandisa-zvekushandisa" kunobatsira kuwana chiyero chakanaka pakati pemutengo nekushanda zvakanaka mukushandisa CNC kwakanyatsogadzirwa.
Machining Kufunga uye Zvakanakisa Maitiro
Kugadzira simbi dzekabhoni nedzemhando yealloy neCNC zvinobudirira kunoda kutarisisa maturusi, maparameter, uye matekiniki. Maturusi eCarbide ndiwo akajairika kune ese ari maviri, asi alloys angada mhando dzakaputirwa neCVD kuti agare kwenguva refu. Kucheka mvura kunodzivirira kupisa zvakanyanya, kunyanya mumhando dzekabhoni yakawanda kana alloy dzinowanzo shanda nesimba.
Maparamita anosiyana: esimbi dzekabhoni, kumhanya kwakanyanya (120-180 m/min) uye mafeed (0.15-0.3 mm/rev); emhando dzesimbi, kudzika (80-120 m/min) kudzora kupisa. Kugadzika kwemuchina wakasimba kunoderedza kudedera, uye software yeCAM inogadzirisa nzira dzekushanda zvakanaka.
Matambudziko anowanzo sanganisira kudzora machip—kushandisa machip breakers—uye kupedzisa pamusoro, kunogadziriswa nekupolisha. Maitiro ekuchengetedza, sekufefetera kwakakodzera kweutsi, akakosha.
Kufambira mberi kwakaita sekugadzira michina nekukurumidza (HSM) uye kutonhora kwe cryogenic kunovandudza mhedzisiro yezvinhu izvi.
mhedziso
Simbi dzekabhoni nesimbi dzesimbi dzinoramba dzichikosha mukugadzira CNC, zvichipa hunhu hwakasiyana-siyana kubva pakukwanisika uye nyore mumhando dzekabhoni kusvika pakugara kwenguva refu musimbi dzesimbi. Nekunzwisisa maumbirwo adzo, mamakisi, uye maitiro adzo, vagadziri vanogona kusarudza zvakanaka mashandisirwo akasiyana-siyana kubva pazvisungo zvezuva nezuva kusvika kuzvinhu zvemuchadenga. Sezvo tekinoroji ichifambira mberi, zvinhu izvi zvicharamba zvichikurudzira hunyanzvi muinjiniya yemhando yepamusoro, zvichienzanisa mashandiro nekushanda.