Zane mai zurfi: Injiniyan Tsari, Zane Ratio, da Rigakafin Nasara
Key Data Points: Matsakaicin ƙayyadaddun zane na farko shine 2.0:1 don ƙarfe da 1.6:1 don aluminum. Matsakaicin sake fasalin ya ragu zuwa 1.3–1.5:1 a kowane mataki. Gudun zane yana daga 5 zuwa 50 m/min dangane da abu da lissafi. Ƙarfin mariƙin mara komai yawanci yana daidai da 0.5-1.5% na ƙarfin ƙarfin abu × yanki mara komai. Ana sarrafa bakin ciki na bango tsakanin 10-15% na kauri na asali a cikin ingantattun matakai.
Menene Deep Drawing?
Zane mai zurfikarfe formingetal forming tsari a cikin abin da lebur blank aka radially ja a cikin forming mutuwa ta hanyar inji mataki na naushi, samar da sumul, m sassa tare da zurfin da ya wuce diamita. Ba kamar ayyukan hatimi waɗanda da farko yanke ko lanƙwasa abu ba, zane mai zurfi plastically deforms da karfe zuwa sifofi masu girma uku kamar kofuna, gwangwani, harsashi, shinge, da sassan jikin mota.
Kalmar "zurfi" tana nufin ma'aunin zurfin-zuwa-diamita: lokacin da zurfin da aka zana ya zarce diamita na ɓangaren, ana rarraba tsarin azaman zane mai zurfi. Sassan da ke da ma'aunin zurfin-zuwa diamita sama da 1.0 yawanci suna buƙatar matakan zane da yawa (sake zana) don cimma jigo na ƙarshe ba tare da gazawar kayan aiki ba. A Dongguan Chenghui Fasahar fasaha, mu routinely samar da zurfin-zana sassa tare da zane rabo har zuwa guda mataki 2.2 kamar 2. DC04 sanyi-birgima karfe da 304 bakin karfe.
Ana amfani da zane mai zurfi a ko'ina cikin masana'antu - daga mota (man pans, man fetur tankuna, firikwensin gidaje) zuwa lantarki (gwangwani na baturi, harsashi masu haɗawa), na'urorin likitanci (m kayan aiki gidaje), da kuma Aerospace (rukunin gine-gine masu nauyi). Tsarin yana ba da ɓangarorin tare da kyakkyawan ƙarewar ƙasa, juriya mai ƙarfi (± 0.05 mm wanda za'a iya cimma), da daidaiton kaddarorin injin saboda ƙarfin aiki yayin nakasawa.
Tsarin Zane Mai zurfi: Mataki ta Mataki
1. Shiri mara kyau
A tsari fara da blanking takardar (lebur diamita). An ƙaddara diamita mara kyau ta amfani da ka'idar shimfidar wuri akai-akai: farfajiyar ƙasa na blank dole ne ya zama daidai da yanki na yanki na sarari don ƙara girman yanki na ƙasan ƙasa. Don kofin silinda ba tare da flange ba, za a iya ƙididdige ƙarancin diamita D kamar:
D = √(d² + 4dh) - inda d shine diamita na ciki kuma h shine tsayin kofin.
Blanking yawanci ana yin shi akan latsa injina ta amfani da mutuwa mara kyau. Yin amfani da kayan aiki shine maɓalli na farashi a nan; ingantawa nesting zai iya cimma 70-85% amfani kayan aiki don madauwari blanks. Ana shafa man mai a saman da ba komai kafin zana don rage juzu'i da kuma hana ƙumburi.
2. Aikin Zana Farko
Ana sanya babur akan wani rami mai mutuƙar mutuwa, kuma naushi ya sauko, yana tilastawa ƙarfen ya kwarara cikin robobi. A mariƙin komai (wanda kuma ake kira zoben zana ko ɗaure) yana amfani da matsi mai sarrafawa zuwa yankin flange na babu, yana hana wrinkling yayin da yake barin abu ya shiga ciki. Matsakaicin tsakanin naushi da mutu yawanci jeri daga 1.1t zuwa 1.3t (inda t shine kauri na kayan), yana tabbatar da kwararar abu mai santsi ba tare da guga ba.
da iyakance zane rabo (LDR) - matsakaicin rabo na diamita mara nauyi zuwa diamita na naushi wanda za'a iya zana shi a cikin mataki ɗaya ba tare da gazawa ba - yawanci jeri daga 1.8 zuwa 2.2 don gami da ƙarfe, 1.6 zuwa 1.9 don aluminum, da 1.4 zuwa 1. bakin karfe. Wucewa LDR yana buƙatar matakai da yawa.
3. Redrawing and Ironing
Lokacin da zurfin maƙasudin ya wuce matakin LDR guda ɗaya, kofin da aka zana wanda aka zana yana ɗaukar ɗaya ko fiye redrawing ayyuka. Kowane mataki na jan ja yana rage diamita a hankali kuma yana ƙara zurfin. Tsakanin matakai, ɓangaren na iya buƙata process annealing don sauƙaƙe aikin hardening da mayar da ductility - mai mahimmanci ga kayan kamar 304 bakin karfe da zurfin-zana aluminum.5.5 alloys.
Ironing tsari ne mai alaƙa wanda bangon kofin ya baci kuma yana haɓakawa ta hanyar wucewa ta jerin abubuwan da suka mutu tare da ƙarami kaɗan, samar da kauri na bango. Ana amfani da guga da yawa don gwangwani na abin sha da kayan aikin tubular masu sirara.
Jana Ratio, Iyaka, da Dokokin Zane
Fahimtar ma'auni na zane yana da mahimmanci ga ƙirar zane mai zurfi mai nasara. Mahimman sigogi sun haɗa da:
- Zana Rati (β) = D/d - inda D shine diamita mara kyau kuma d shine diamita na naushi. A β na 2.0 yana nufin blank ɗin ya ninka diamita na naushi.
- Rage Rage Ratio (r) = (D - d)/D × 100% - yawancin injiniyoyi sun fi son bayyana raguwa a matsayin kashi.
- Kauri-zuwa Diamita Ratio (t/D) - madaidaici mai mahimmanci: ƙimar sama da 1% yawanci suna ba da izinin ƙima mafi girma.
Don kayan gama gari, matsakaicin matsakaicin matakin zane na matakin farko shine: karfe DC01/DC04: 2.0-2.2, 304 bakin: 1.8-2, 5052 aluminum (O-zafin): 1.8-2.0, da jan karfe C11000: 1.9-2.1. Tsayawa tsaka-tsaki na iya ƙara yawan ma'aunin zane zuwa 3.0 ko sama.
Dokokin ƙira don ɓangarori masu zurfi sun haɗa da: kiyaye mafi ƙarancin radius na 1-2 × kauri abu a Punch hanci da 4-8× kauri a radius shigarwar mutuwa, guje wa sauye-sauye masu kaifi waɗanda ke mai da hankali, da ƙira don kauri na bango sai dai idan an shirya ironing.
gama gari Defections da Rigakafi
Wrinkling (Flange Wrinkles)
Wrinkling yana faruwa a cikin yankin flange lokacin da matsananciyar hoop ya wuce juriya na kayan. Rigakafin: ƙara blank mariƙin ƙarfi (BHF), inganta BHF a ko'ina cikin bugun jini (m BHF tsarin), da kuma tabbatar da dace lubrication a cikin flange zone. Kyakkyawan farawa BHF shine kusan 1.5-2.5% na kayan da yawan amfanin ƙasa ƙarfi sau da flange yankin..
Yage da karaya
Tsagewa yawanci yana faruwa a radius na hanci ko bangon kofin inda kayan ke fuskantar mafi girman damuwa. Tushen abubuwan sun haɗa da: rabon zane mai wuce kima, rashin isasshiyar sharewar mariƙi (kayan tarko), raɗaɗi mai lalacewa, ko rashin isassun man mai a gefen naushi. Rigakafin: tsaya a cikin iyakokin LDR, kula da filaye masu gogewa (Ra ≤ 0.2 μm), da kuma amfani da lubrication na daban - mai mai a cikin yankin flange, ƙaramin mai a kan hancin naushi don haɓaka gogayya da ake buƙata.
Bayar da baya da Dimensional Dimensional Deviation
Bayan naushin ya ja da baya, farfadowa na roba yana sa sashin ya koma baya kadan, musamman a bakin kofi da bango. Springback ya fi fitowa fili a cikin kayan aiki masu ƙarfi da kayan haɗin gwiwar aluminum. Rigakafin: rama mutun lissafi, yi amfani da ƙuntatawa ko ayyukan ƙima, kuma kuyi la'akari da ƙimar ƙarfin samar da kayan samari yayin tsinkayar bazara.
Earing
Earing yana nufin gefuna masu kauri a saman ƙoƙon da aka zana wanda planar anisotropy ya haifar (kayayyaki daban-daban a wurare daban-daban na takardar). Wannan yana haifar da sharar kayan abu yayin datsa. Rigakafin: Yi amfani da kayan takarda tare da ƙananan halayen kunne (misali, aluminium alloys 5052 da 3003), inganta yanayin shimfidar wuri dangane da jagorar mirgina, kuma ba da izinin izinin datsa (5-10% na tsayin kofin).
Kayayyakin Zane Mai Zurfi
Zaɓin kayan aiki kai tsaye yana rinjayar iyawa, rayuwar kayan aiki, da farashin sashi. Mafi yawan abubuwan da aka zana mai zurfi sun haɗa da:
- Low-Carbon Karfe (DC01, DC04, SPCC, SPCD): Madalla drawability, low cost. Zana ma'auni har zuwa 2.2 mataki-ɗaya. Madaidaici don madaidaicin mota, bangarorin kayan aiki, da sassan masana'antu gabaɗaya.
- Bakin Karfe (304, 316L, 430): Juriya na lalata da ƙarfin ƙarfi. Ƙarin ƙalubale don zana saboda aikin hardening; yana buƙatar annealing tsakanin mataki. An yi amfani da shi don nutsewar kicin, na'urorin likitanci, da kayan sarrafa sinadarai.
- Aluminum Alloys (1050, 3003, 5052-O): Haske mai nauyi tare da tsari mai kyau. 5052-O musamman yana ba da kyakkyawar fa'ida mai zurfi. Na kowa a cikin gidaje na lantarki, sifofi marasa nauyi na mota, da kwantena abinci.
- Copper da Bras00 (010C): Kyakkyawan aiki da tsari. Ana amfani da shi don masu haɗin lantarki, kayan aikin famfo, da kayan ado na ado.
Material temper (annealed vs. hard-rolled) significantly impacts drawability — always specify annealed (O-zafin) ko zurfin zane mai inganci (DQ) don ƙirƙirar ayyuka.
Zurfin Zane vs. Sauran Tsarukan Samar da Ƙarfe
Compared to na al'ada bugawa, zane mai zurfi yana haifar da zurfi, mafi hadaddun siffofi mara kyau. Ba kamar ci gaba mutu bugawa wanda ya yi fice a babban ɗakin ɗakin kwana ko lankwasa, zane mai zurfi ya ƙware a cikin shinge mara kyau. Akasin haka Ƙarfe, zurfin zane yana ba da sauri sake zagayowar lokaci (5-20 shanyewar jiki / minti) ƙarar juzu'i da ƙarar juzu'i a cikin mintuna kaɗan. guda 10,000. Idan aka kwatanta da hydroforming, zane mai zurfi yana da ƙananan kayan aiki na kayan aiki da kuma saurin saiti don sassa masu ma'ana.
Don jagora kan zaɓar mafi kyawun tsari don lissafin juzu'in ku, ziyarci karfe bugawa masana’anta shafi ko buƙatar faɗakarwa don sake dubawa na DFM kyauta.
Tambayoyin da ake yawan yi
Menene bambanci tsakanin zane mai zurfi da tambari?
Zane mai zurfi wani takamaiman nau'in tambari ne wanda ke haifar da sarari mara ƙarfi ta hanyar zana karfen takarda a cikin rami mai mutuwa. Duk da yake duk zane mai zurfi yana yin tambari, ba duk zane-zanen zane ne mai zurfi ba - yawancin ayyukan hatimi sun haɗa da yanke, lankwasa, ko ƙira mara tushe. Maɓallin maɓalli shine zurfin-zuwa-diamita rabo: lokacin da ya wuce kusan 0.5, ana ɗaukar tsarin zane mai zurfi.
Menene madaidaicin rabon zane da za a iya cimma?
Don matakin zane guda ɗaya, matsakaicin matsakaicin zane shine yawanci. 2.0-2.2 don m karfe, 1.8-2.0 don bakin karfe, da 1.8-2.0 don aluminium alloys. Tsakanin matakai da yawa tare da ɓarna tsaka-tsakin mataki, ƙididdige ƙididdiga na zane na 3.0-4.0 ana iya samun su. Madaidaicin iyaka ya dogara da kaddarorin kayan aiki, lissafin lissafin mutu, yanayin lubrication, da saurin latsawa.
Yaya kauri zai iya zama mai zurfin ja sassa?
Zane mai zurfi yana ɗaukar kewayon kauri mai faɗi - daga 0.1 mm foil for micro-components (gwangwanin baturi, kofuna na firikwensin) har zuwa 12-16 mm don sassa na tsarin ma'auni mai nauyi (tasoshin matsa lamba, manyan kayan aikin mota). Matsakaicin kauri-zuwa diamita (t/D) shine mahimmin siga maimakon cikakken kauri kaɗai.
Za a iya haɗa zane mai zurfi tare da wasu matakai?
Ee. Ana haɗa zane mai zurfi akai-akai tare da huda (ƙirƙirar ramuka a ɓangaren da aka zana), flanging (mai yin lebe a kusa da ramuka ko gefuna), embossing (ƙirƙirar abubuwan haɓakawa), da threading (mai yin zaren ciki ko na waje). Ana iya haɗa waɗannan ayyuka sau da yawa cikin kayan aiki na ci gaba ɗaya ko canja wuri, rage farashin kulawa na biyu.
Ta yaya zan san ko sashina ya dace da zane mai zurfi?
Aika zanen ɓangaren ku ko ƙirar 3D zuwa ƙungiyar injiniyarmu don free DFM (Design for Manufacturability) review via mu RFQ shafi. Muna kimanta ƙimar zana, radiyon kusurwa, zaɓin kayan abu, da buƙatun haƙuri don ƙayyadadden dabarun ƙirƙira da samar da cikakken rahoton yuwuwar cikin sa'o'i 24.
Albarkatun Labarai
- Jagorar Zana Tambarin Zurfi - Tsari, kayan aiki, da jagororin ƙira don zane mai zurfi.