Blanking yana ɗaya daga cikin mahimman ayyuka na tambarin ƙarfe. Yana jujjuya ƙarfe mai lebur ko na'ura zuwa sassa daban-daban - da ake kira blanks - ta hanyar yanke kayan tare da rufaffiyar kwane-kwane ta amfani da naushi kuma ya mutu. Ko kuna ƙera brackets, shinge, lambobin lantarki, ko fale-falen mota, tsarin ɓoyayyiyar yana saita tushe don sashin lissafi, ingancin gefuna, da ƙirƙirar ayyukan ƙasa.
Wannan jagorar ta ƙunshi makanikai na blanking, yadda ya bambanta da naushi, manyan hanyoyin da ake amfani da su na blanking, amfani da kayan aiki dabarun, lahani na gama gari da gyaran su, da lissafin ton ɗin da kuke buƙatar zaɓin latsa.
Menene Tsari Tsari?
A cikin buga tambarin ƙarfe, blanking aikin shearing ne wanda ake yanke ɓangaren da ake so daga cikin takardar kuma ya faɗi ta wurin buɗewar mutu kamar yadda aka gama. Abubuwan da ke kewaye - kwarangwal ko gidan yanar gizo - ya zama guntu. Wannan ita ce sifa mai ma'ana wacce ke raba blanking da naushi (hudawa), inda slug ɗin da aka cire ya zama guntu kuma takardar tana riƙe da rami.
Yadda Shearing Aiki
Lokacin da naushin ya sauko kuma ya tuntubi karfen takardar, shearing yana ci gaba ta matakai daban-daban guda hudu:
- nakasar roba - Kayan yana matsawa kadan a ƙarƙashin tip ɗin naushi; babu wani canji na dindindin da ya faru tukuna.
- Nakasar filastik - Punch ɗin ya shiga cikin kayan, yana fara yanke band ɗin da aka ƙone (mai laushi) a gefen mafi kusa da naushi.
- Karya - Cracks sun samo asali ne daga naushi kuma suna yanke gefuna kuma suna yada ciki. Inda yankunan karaya biyu suka hadu, kayan sun rabu.
- Rabuwa - Bangon yana share buɗewar mutu. Fitattun fitilun wuta ko masu tsiri suna tura sashin ko kwarangwal kyauta.
Sakamakon giciye-ɓangarorin da ba kowa a ciki yana nuna sifofi guda huɗu: rollover (shear band a saman), da burnish zone (mai santsi a tsaye), da yankin karaya (m angled surface), da burr (a gefen kasa mai kaifi).
Tsare-tsare: Mafi Muhimman Ma'auni
Die yarda - da rata tsakanin naushi yankan baki da mutu yankan gefen auna ta gefe - kai tsaye iko gefen ingancin, burr tsawo, da kuma kayan aiki rayuwa.
| Tsare kowane gefe (% na kauri abu) | Sakamako na yau da kullun |
|---|---|
| 3–5 % | Daidaitacce; kadan rollover; mafi girma naushi lalacewa; ana amfani da shi a cikin madaidaicin blanking |
| 5–8 % | Standard don yawancin karafa; Kyakkyawan ƙona-zuwa-karya rabo |
| 8–12 % | Wider ga mafi girma rollover da burr; ƙananan ton; dace da taushi aluminum gami |
| > 12 % | Burge mai yawa da nakasa; gabaɗaya mara yarda don samarwa |
Dokokin babban yatsan hannu: Don ƙarfe mai laushi (har zuwa 3 mm lokacin farin ciki), yi amfani da izinin 5-7% a kowane gefe. Don aluminum, 6-8%; don bakin karfe, 7-10%. Koyaushe tuntuɓi ƙayyadaddun ƙayyadaddun ƙayyadaddun ƙayyadaddun ƙayyadaddun kayan aiki da gwadawa akan ɓangarorin samfurin kafin ƙaddamar da kayan aikin samarwa.
Burr shugabanci a blanking ana iya tsinkaya: burr koyaushe yana farawa akan goge gefe - gefen kishiyar naushi. A cikin blanking, saboda haka burr yana kan gefen ƙasa na ƙarancin da aka gama (gefen mutuwa). Idan ana buƙatar gefen da ba shi da burar a kan takamaiman wuri, daidaita sashin da ke cikin mutu daidai.
Blanking vs. Punching (Soki): Menene Bambanci?
Sharuɗɗan sau da yawa suna rikicewa, amma bambance-bambancen injin yana madaidaiciya:
| Feature | Blanking | Huda (Huda) |
|---|---|---|
| Manufar | Samar da yanki kamar yadda aka gama | Ƙirƙirar rami a cikin takardar; slug shine juzu'i |
| Bangaren Amfani | Yankin da ya faɗo ta cikin mutu | Takardun da ya rage akan mutu |
| Die profile | Wanda aka siffata zuwa sashin shaci | Zagaye ko siffa zuwa ga ramin lissafi |
| Punch profile | Yana bin tsarin sashin (dan kadan saboda sharewa) | Yayi daidai da siffar rami |
| Scrap | kwarangwal (web) da ya saura akan tsiri | Slug ɗin da aka buga |
| Aikace-aikace na yau da kullun | Flat blanks, brackets, gaskets, shims | Ramukan hawa, ramukan samun iska, shiga cutouts |
A cikin ci gaba da yin tambari, duka ayyukan biyu suna faruwa akan tsiri ɗaya a cikin tashoshi daban-daban - suna bacewa a tashar ƙarshe, suna buga na farko.
Nau'in Blanking: Kwatanta
Ba duk ayyukan banza ke haifar da sakamako iri ɗaya ba. Zaɓin hanyar ya dogara da jure juzu'i, buƙatun ingancin gefen, ƙarar samarwa, da ƙarancin farashi.
Blanking na al'ada (Standard Blanking)
Hanyar gama gari. Punch guda ɗaya yana yin shears ta cikin kayan tare da daidaitaccen sharewa (5-8% kowane gefe). Yankunan karaya daga naushi da bangarorin mutu sun hadu a kusurwa, suna haifar da layin hutu mai gani a gefen yanke.
- haƙuri: ± 0.1 - 0.3 mm (na al'ada don karfe)
- Edge gama: Matsakaici; yankin ƙonawa = 30-50% na kauri na kayan abu
- Gudun: Babban; 100-800+ SPM akan manyan latsawa masu sauri
- Cost: Ƙananan farashin kayan aiki; mafi ƙasƙanci na kowane sashi a babban girma
- Mafi kyawun for: Maƙasudin maƙasudin gabaɗaya inda gefen da ba shi da mahimmanci ba shi da mahimmanci
Fine Blanking (Madaidaicin Blanking)
Fine blanking yana amfani da latsa sau uku-aiki: V-ring (stinger) indents takardar don hana kwararar kayan aiki, kushin-matsa lamba yana riƙe da lebur mara kyau, kuma ƙulli 1 yana saukowa tare da. Sakamako shine cikakken gefuna tare da kusan 100% kuna da ƙarancin jujjuyawa.
- haƙuri: ± 0.02 - 0.05 mm
- Edge gama: Madalla; 90-100% kone; tsayin burr <0.05 mm
- Gudun: Ƙananan; 20-80 SPM
- Cost: Babban farashin kayan aiki; ana buƙatar latsa na musamman
- Mafi kyawun for: Gear blanks, sprocket faranti, mota wurin zama aka gyara, sassa na bukatar machined-baki ingancin ba tare da sakandare ayyuka
Progressive Blanking (mutu mai ci gaba bugawa)
An kafa blank ɗin ta tashoshi da yawa akan mutuƙar ci gaba guda ɗaya, kowanne yana yin takamaiman aiki (bincike ramukan matukin jirgi, notching, forming, kuma a ƙarshe blanking). An yiwa tsiri a gaba ta hanyar farar daidai da tazarar tasha.
- haƙuri: ± 0.05 - 0.15 mm (dogara ta tashar)
- Edge gama: Daidai da na al'ada don tashar blanking; na iya haɗa ƙira da ƙira
- Gudun: 100-1000+ SPM
- Cost: Babban tsadar mutuwa; farashi mafi ƙasƙanci na kowane ɓangare a babban kundi (> sassa 100,000)
- Mafi kyawun for: Babban adadin hadaddun sassa; abubuwan da ke buƙatar ayyuka da yawa a cikin wucewa ɗaya
Teburin Kwatanta
| Siga | Blanking na al'ada | Fine Blanking | Ci gaba Blanking |
|---|---|---|---|
| Haƙuri mai girma | 30-50 % kuna | 90-100% kuna | 30-50 % kuna (tasha mara nauyi) |
| Haƙuri | ± 0.1-0.3 mm | ± 0.02-0.05 mm | ± 0.05-0.15 mm |
| Burr tsayi | 5-15% na kauri | <3 % na kauri | 5-15% na kauri |
| Latsa nau'in | Mechanical/na'ura mai aiki da karfin ruwa | Na'ura mai aiki da karfin ruwa sau uku | Na'ura mai sauri |
| kewayon SPM | 100–800+ | 20–80 | 100–1000+ |
| Material kauri | 0.3-12 mm | 0.5-16 mm | 0.3-6 mm |
| Kayan aiki farashi | Ƙananan-matsakaici | Babban | Babban |
| Kudin kowane bangare | Low | Matsakaici-high | Ƙananan ƙananan (ƙarashin girma) |
| Mafi kyawun kewayon girma | 10,000–500,000+ | 5,000–500,000 | 100,000-miliyoyin |
Yin Amfani da Kayayyaki da Haɓaka Ƙungiya
Farashin kayan aiki yawanci 50-70% na jimlar kuɗin sashi mai hatimi. Haɓaka shimfidar sarari (wuri) akan tsiri yana ɗaya daga cikin mafi girman ayyukan aiki a cikin ɓarna.
Dabarun Nesting Maɓalli
- Layi layi - Sassan da suka daidaita a cikin layuka kai tsaye a fadin faɗin tsiri. Mai sauƙi don tsarawa; Amfani yawanci 55-70%.
- Matsakaicin gida - Madadin layuka wanda aka daidaita da rabin sashe na farar. Yana haɓaka amfani da kashi 5-15% sama da sahu na layi na rectangular ko elongated.
- Juyawa mai jujjuyawa - Sassan suna juyawa a kusurwoyi mafi kyau (sau da yawa 30°, 45°, ko al'ada) don haɓaka adadin sassa kowane tsiri. Siffofin da ba bisa ka'ida ba sun fi amfana da wannan hanya.
- Layi gama gari - Abubuwan da ke kusa suna raba layin yanke guda ɗaya, suna kawar da yanar gizo tsakanin su. Za a iya ƙara amfani da kashi 10-20%, amma yana buƙatar ƙirar kayan aiki a hankali kuma yana iya haɓaka lalacewa a gefen da aka raba.
- mara amfani (marasa kwarangwal) - Ana amfani da shi don ci gaba da tube iri ɗaya (misali, lambobin lantarki) inda aka rage ko kawar da kwarangwal.
Yadda ake lissafta Amfani
Amfani da kayan aiki (%) = (Jimlar yanki mara kyau a kowane yanki / yanki mai shinge) × 100
Ko kuma daidai:
Amfani (%) = (Yawan blanks da bugun jini × Single blank area) / (Tsari nisa × Pitch) × 100
Amfani da niyya na 70-85 % yana yiwuwa ga yawancin geometries tare da ƙayataccen gida. Kasa da 60 % yana ba da garantin sake fasalin kayan aiki ko shimfidawa.
Nasihu masu Aiki
- Haɗa injiniyoyin kayan aiki da wuri - ƙaramin tweak na lissafi (ƙara radius, daidaita kusurwa) na iya buɗe gida mafi inganci.
- Yi la'akari da ƙuntatawa na coil nisa - daidaitaccen girman nada mm, 300 mm (misali, 300 mm, misali, 300 mm). samar da mafi kyawun farashi fiye da faɗin tsaga-tsage.
- Yi amfani da software na gida (misali, Sigmanest, Lantek, AP100) don hadaddun sifofi don kimanta kusurwoyi da dama na fuskantarwa cikin sauri.
Magani na gama gari
Ko da tsararren aikin blanking na iya haifar da lahani. Teburin da ke ƙasa ya ƙunshi batutuwa masu yawan gaske, tushen su, da ayyukan gyara.
| Lalacewa | Bayyanar | Tushen Tushen | Magani |
|---|---|---|---|
| Burge mai yawa | Kaifi, daga lebe a gefen mara komai | Sawa yankan gefuna; wuce gona da iri; abu yayi laushi | Sake buga naushi ya mutu; rage izini; yi amfani da kayan aiki mai wuyar ƙarfe ko sutura |
| Rollover (die-gefe rollover) | Mai lanƙwasa bakin ciki a gefen shigarwa mara kyau | Tsaftacewa mai yawa; rashin isasshen kayan riƙe-ƙasa; abu mai laushi | Tsabtace izini; ƙara ƙarfin riƙe da komai; ƙara V-zobe don m blanking |
| Karɓar yanki roughness | Jagged, band mara daidaituwa | Tsare-tsare sosai (fashe ba sa saduwa da tsabta); jagoran hatsi ba daidai ba | Inganta yarda; juya juzu'in juzu'i dangane da mirgina shugabanci |
| Edge cracking | Fashewar da ke haskakawa daga gefen da ba komai a ciki zuwa sashin | Karɓar kayan abu; burr gefen karkashin tashin hankali a cikin m forming; baki mai kaifi yana aiki azaman mai ƙaddamarwa | Deburr kafin kafa; gefen burr gefen gabas zuwa yankin matsawa; yi amfani da bargo mai kyau don gefuna masu mahimmanci |
| Bambancin girma | Girman mara daidaituwa a tsakanin samarwa yana gudana | Tool wear; latsa karkacewa; rashin daidaituwar ciyarwa | Aiwatar da kayan aiki da aka tsara; tabbatar da daidaitawar latsa; duba daidaiton feeder |
| karkatarwa / baka | Faɗaɗɗen ɓoyayyiya ko murɗawa bayan blanking | Rashin daidaituwa; geometry na nau'in asymmetric; saura danniya a cikin nada stock | Sake tsakiya ku mutu; bincika daidaiton kayan aiki; kayan rage damuwa kafin yin komai |
| Slug ja | Slug slug ya koma cikin mutuwa akan bugun jini | Vacuum karkashin naushi; rashin isasshen ƙarfin tsiri; rashin isasshen izini | Ƙara tashar jiragen ruwa na hutu; ƙara tsiri spring matsa lamba; yi amfani da sutura masu riƙe da slug don naushi fuska |
| Galling | Abubuwan shafa akan naushi/mutu | Adhesion tsakanin kayan aiki da kayan aiki; rashin isasshen lubrication; ba daidai ba kayan aiki karfe sa | Aiwatar da suturar TiN/CrN; amfani da kayan aikin carbide; ƙara yawan kwararar mai |
| Die chipping | Ƙananan karaya akan yankan yankan | Tasirin gajiya; rashin kuskuren taurin karfe; Amincewa sosai don kayan wuya | Yi amfani da ƙarfe mai ƙarfi (misali, D2 zuwa M2 miƙa mulki); ƙara shigarwa taper ya mutu; inganta yarda |
Tonnage Lissafi don Blanking
Daidaita ƙididdige yawan latsawa da ake buƙata yana da mahimmanci don zaɓar madaidaicin latsawa da guje wa matsalolin ƙananan-ko fiye (lalacewar ɓangaren, lalacewar latsa, ko ɓata kuzari).
Standard Formula
Blanking karfi (tons) = (Perimeter × Kauri × Karfin ƙarfi) / 2000
Inda:
– Perimeter = jimlar tsayin tsinken kwandon (inci)
– Kauri = kauri (inci)
– Ƙarfin ƙarfi = Ƙarfin Ƙarfin Ƙarfi (PSI)
– 2000 = factor factor (2000 lbs = 1 ton)
Siffar awo
Ƙarfin ƙarfi (kN) = Matsakaicin (mm) × Kauri (mm) × Ƙarfin ƙarfi (MPa) / 1000
Ƙarfin Ƙarfin Ƙarfin Ƙarfin Ƙarfi
| Material | Ƙarfin Tensile (MPA) | Kimanin ƙarfin ƙarfi (MPa) |
|---|---|---|
| Ƙarfe mara nauyi (AISI 1008-1020) | 300–420 | 250–350 |
| Bakin Karfe (304) | 515–620 | 400–500 |
| Aluminum 5052-H32 | 228–275 | 150–185 |
| Aluminum 6061-T6 | 290–310 | 200–220 |
| Copper C11000 | 210–380 | 170–250 |
| Brass C26000 | 300–400 | 220–300 |
TukwiciƘarfin Ƙarfin Ƙarfin Ƙarfin Ƙarfin Ƙarfin Ƙarfin Ƙarfin Ƙarfin Ƙarfi na 6. ƙarfi ga mafi yawan ductile karafa.
Ƙara Margin Tsaro
Koyaushe ƙara 20-30 % ma'auni na aminci don lissafin:
- Bambance-bambancen kayan abu (zafi-zuwa-zafi)
- Blunt kayan aiki tsakanin resharpening
- Rashin daidaituwar ciyarwa yana haifar da yanke juzu'i
- Ayyuka na lokaci ɗaya (idan an haɗa su da blanking)
Misali lissafin: Blanking wani 100 mm × 50 mm rectangular blank daga 2 mm m karfe (ƙarfin ƙarfi = 300 MPa):
Perimeter = 2 × (100 + 50) = 300 mm
Force = 300 × 2 × 300 / 1000 = 180
Tare da 25 % tsaro gefe: 1.80 × 180 225 kN ≈ 23 ton
Rage Ragewar Tonnage: Shear Angles
Ƙara kusurwar shear (rake) zuwa naushi ko mutu yana girgiza layin tuntuɓar a cikin kayan, yana rage kololuwar ton ta yada yanke akan lokaci. Madaidaicin kusurwa na 1° – 3° a kowane gefe (daidai da 5 – 15% na kaurin abu a fadin fuskar naushi) na iya rage girman ton da kashi 30 – 50 % ba tare da ya shafi juzu’i ba.
Mafi kyawun Ayyuka don Samar da Blanking
- Ƙayyade gefen burar akan zane. Tunda burr shugabanci yana da tsinkaya a cikin ɓarna, ƙara shi zuwa ɓangaren zane don haka masu aiki su daidaita daidai.
- Jadawalin kiyaye kayan aiki ta ƙididdigar bugun jini. Edge lalacewa yana sannu a hankali; jadawalin sake fasalin kowane bugun jini na 50,000-200,000 (abin da ya dogara da kayan aiki da shafi) maimakon jiran lahani na bayyane.
- Yi amfani da kayan aiki mai rufi don kayan abrasive. TiN, TiAlN, da CrN shafi na iya tsawaita rayuwar kayan aiki 2-5× lokacin da bacin bakin karfe, ƙaramin ƙarfi mai ƙarfi (HSLA), ko samfuran galvanized.
- Sarrafa nada flatness. Wavy ko cambered tsiri yana haifar da rashin daidaituwa a cikin yanke, yana haifar da tsayin burr mai canzawa da girman sarari. Matakin tsiri kafin tashar da babu komai idan an buƙata.
- Saka idanu mara nauyi azaman wakili mai inganci. Auna samfurin blanks kowane motsi bincike ne mai sauri, mara lalacewa don tuƙi mai girma ko lalacewa kayan aiki.
Tambayoyin da ake yawan yi
Menene bambanci tsakanin blanking da yankan a cikin takarda?
Blanking wani aiki ne na musamman na shearing inda gunkin da aka buga shine ɓangaren da ake so kuma abin da ke kewaye ya zama guntu. Yanke lokaci ne mai faɗi wanda ya haɗa da ɓarna, naushi, datsa, da tsagawa. A cikin ɓarna, buɗewar mutun ya dace da siffar ɓangaren; a cikin naushi (hudawa), mutuƙar ta yi daidai da siffar rami kuma an zubar da lallausan.
Ta yaya ake ƙididdige ƙyalli?
Blanking share ana bayyana shi azaman kaso na kauri na abu, wanda aka auna kowane gefe tsakanin naushi da yankan gefuna. Alal misali, tare da kauri 2 mm karfe da 6 % yarda kowane gefe, da rata ne 0.12 mm a kowane gefe. Tsarin tsari shine: Tsare-tsare kowane gefe = Kauri na abu × (Clearance% / 100). Mahimman ƙima suna daga 3-12 % dangane da buƙatun kayan aiki da inganci.
Menene kyakkyawan blanking da ake amfani dashi?
Ana amfani da ɓata mai kyau lokacin da wani sashi yana buƙatar cikakken shear, kusan gefen mara ƙoshi ba tare da injinan sakandare ba. Aikace-aikace na gama gari sun haɗa da ɓangarorin gear, faranti na sprocket, abubuwan gyara wurin zama na mota, da madaidaitan sassa masu faɗi inda ingancin gefen ke shafar aiki ko taro kai tsaye. Kyakkyawar ɓarna yana haifar da gefuna tare da 90-100 % kuna da tsayi mai tsayi a ƙarƙashin 0.05 mm.
Ta yaya zan rage tsayin burr a blanking?
Don rage burr tsawo: (1) kaifafa ko maye gurbin sawa naushi da mutu gefuna, (2) inganta yarda zuwa 5-7 % kowane gefe ga mafi yawan karafa, (3) amfani mai rufi ko carbide kayan aiki don kula da gefen kaifi tsawon, (4) tabbatar da dace kayan rike-ƙasa a lokacin da aikace-aikace mai kyau takardar da dagawa, (3). kusa-sifili burr.
Wane tonnen latsa nake buƙata don blanking?
Yi lissafin tonnage ta amfani da dabara: Ƙarfi = (Ƙarfin Ƙarfin Ƙarfafa × Ƙarfin Shear) / 1000 (a cikin kN, metric) ko / 2000 (a cikin ton, sarki). Koyaushe ƙara 20-30 % aminci factor. Misali, barin wani sashi na 100mm × 50 mm daga karfe 2 mm mai laushi yana buƙatar kusan 225 kN (ton 23). Dole ne latsa kuma ya sami isasshen tsayin bugun jini, girman gado, da saurin buƙatun samarwa.
Kuna buƙatar ingantattun sassan da ba su da tushe zuwa ƙayyadaddun ku? Tuntuɓi Karfe bugawa Sassan don tattaunawa game da buƙatunku mara kyau - daga samfuri zuwa samarwa mai girma, tare da kayan aiki na cikin gida da ingantaccen masana'anta.