Lalacewar Tambarin Karfe: Tushen Tushen, Rigakafi & Gyara matsala

Kowane aiki tambarin karfe yana fuskantar lahani - burrs, fasa, wrinkles, springback, da scratches surface suna cikin tsari. Bambance-bambancen da ke tsakanin gudanar da samar da riba mai fa'ida da tarkace shine yadda kuke saurin gano tushen dalilin da aiwatar da aikin gyara. A Ƙarfe Tambarin Ƙarfe, ƙungiyar mu masu inganci ta rubuta sama da lahani 200 a cikin shekaru 20+ na ci gaba da mutuwa, mutuwar canja wuri, da zane mai zurfi. Wannan jagorar yana raba mafi yawan lahani, tushen su, da ingantattun ayyukan gyara.

Lalacewar tambari shi ne duk wani sabani daga ƙayyadadden girma, saman, ko buƙatun aikin wani yanki mai hatimi, wanda ya haifar da kaddarorin kayan aiki, yanayin mutu, sigogin latsawa, ko al'amurran da suka shafi ƙirƙira.

Ƙarfe na Ƙarfe gama-gari

Lalacewar tambari ya kasu kashi biyar dangane da inda suka samo asali. Fahimtar nau'in yana ƙunsar iyakokin warware matsalar:

• Lalacewar kayan aiki - rashin daidaituwa taurin, bambancin kauri, haɗawa, al'amuran shugabanci
• Mutuwar lahani - sawa gefuna, guntu abubuwan da aka saka, tashoshi mara kyau, ba daidai ba
• Lalacewar latsa - bambancin tonnage, kuskuren faifai, rashin daidaituwa na sauri, matsa lamba
• Lubrication lahani - rashin isasshen mai, danko mara kyau, gurɓataccen aikace-aikace, uneven
• Lalacewar ƙira - m radii, kasa Draw rabo, matalauta blank ci gaba, bace reliefs

Ƙirƙirar Burr da Abubuwan Ingantaccen Edge

Burrs sune mafi yawan lahani na hatimi - kusan kowane aikin huda da huda yana haifar da wani matakin burr. Tambayar ita ce ko tsayin burr ya wuce ƙayyadaddun bayanai.

Tushen Tushen Burrs da yawa

• Ƙunƙarar naushi ko kashe gefuna - dalilin #1. Buga gefuna suna dira a hankali tare da kowane bugun jini. Carbon karfe kayan aiki ya rasa kaifi bayan 500,000-1,000,000 hits; carbide yana kula da ingancin gefen 5,000,000+ hits.
• Rashin kuskure - Tsaftacewa mai matsewa ko faɗi da yawa yana haifar da nau'ikan bursu daban-daban. Mafi kyawun sharewa shine 5-8% na kauri na abu a kowane gefe don ɓarna gabaɗaya, 3-5% don daidaitaccen aiki.
• Bambancin taurin abu - abu mai shigowa mai ƙarfi fiye da ƙayyadaddun yana buƙatar ƙarin ƙarfi, samar da rollover da burr. Tabbatar da taurin coil mai shigowa akan ƙayyadaddun ƙirar mutu.
• Load daga tsakiya - sassan asymmetric ko ɓangarorin da ba su da kyau suna haifar da haɗin kai marar daidaituwa-to-mutu, mai da hankali ga lalacewa a gefe ɗaya.

Ayyukan Gyara

Fatsawa da Karya Lokacin Samarwa

Cracks suna faruwa lokacin da nau'in da aka yi amfani da shi ya wuce ƙarfin haɓaka kayan. Wannan shine nau'in lahani mafi tsada - sassa masu fashe sune 100% juzu'i.

Nau'in Crack gama gari

• Edge cracking - fasa da ke farawa a gefen da aka yanke na blank, yadawa cikin yankin da aka kafa. Sakamakon burr-induced danniya taro, gefen gefe daga gaban shearing, ko abu tare da low gefen stretchability (AHSS maki).
• Radius cracking - fasa a saman saman lanƙwasa ko zana radius. Ya haifar da radius mai matsewa don mafi ƙarancin lanƙwasawa na kayan, ko lankwasawa daidai da alkiblar mirgina.
• Canjin Wrinkle-to-crack - a cikin zane mai zurfi, matsananciyar mariƙin mara nauyi yana hana wrinkling amma ya wuce bango, yana haifar da karaya a radius mai mutuwa.
• Corner cracking - fashe a sasanninta na zane na rectangular inda abu ke shimfidawa ta hanyoyi biyu lokaci guda. Yana buƙatar zana beads ko ƙarin lissafi don sarrafa kwararar ƙarfe.

Dabarun Rigakafi

• Tabbatar da elongation na kayan - abu mai shigowa dole ne ya dace da ƙayyadaddun ƙayyadaddun ƙayyadaddun ƙayyadaddun ƙayyadaddun (misali, ≥37% na SPCC, ≥41% don SPCE). Nemi rahoton gwajin niƙa tare da kowane coil.
• Girmama mafi ƙarancin lanƙwasa radii - annealed 304 bakin: 1.0T; 6061-T6 aluminum: 3.0T; DP780 karfe: 1.5T. Zane radii ≥ mafi ƙanƙanta don gami da fushinku.
• Gabas yana lanƙwasa daidai gwargwado ga jagoran hatsi - lankwasawa a layi daya zuwa mirgina shugabanci yana rage yawan elongation da 20-40%.
• Yi amfani da simintin FEA - Samar da software na simulation (AutoForm, PAM-STAMP, LS-DYNA) yana annabta bakin ciki, fatattaka, da wrinkling kafin gina ginin. Kwaikwayo $5,000 na iya hana sake yin aikin $50,000.

Wrinkling a cikin Zurfafa Zane Sassan

Wrinkling a cikin zane mai zurfi yana faruwa lokacin da damuwa mai ƙarfi a cikin flange ya wuce juriya na kayan abu, yana haifar da flange zuwa ninka cikin radial wrinkles yayin bugun bugun jini.

Wrinkling shine takwaransa ga fatattaka - dan kadan matsi mara nauyi yana ba da damar wrinkles; da yawa yana haifar da tsagewa. Gano mafi kyawun taga shine babban ƙalubalen ci gaban zurfafa zana mutu.

Tushen Sanadin

• Rashin isassun ƙarfin mariƙin komai - mafi yawan sanadi. Ƙara matsa lamba akan matashin kai har sai wrinkles ya ɓace ba tare da haifar da ɓacin rai ba.
• Matsakaicin girman zane - iyakataccen zane shine ~ 2.0 don karfe, ~ 1.8 don bakin karfe da aluminum. Wucewa wannan yana buƙatar zane mai matakai da yawa tare da anneal na matsakaici.
• Lubrication mara daidaituwa - wuce haddi mai mai a gefe ɗaya yana rage juzu'i a cikin gida, yana barin yankin don ciyar da sauri da kuma ɗaurewa.
• Siffa mara kyau - zagaye blanks don zagaye kofuna; Wuraren da ba madauwari ba suna buƙatar ingantattun siffofi (wanda aka haɓaka daga FEA ko gwaji) don daidaita kwararar ƙarfe.

Ayyukan Gyara

• Increase blank holder force in 5–10% increments until wrinkles are eliminated
• Ƙara beads ɗin zana don sarrafa kwararar ƙarfe a takamaiman yankuna
• Canjawa daga madaidaicin madaidaicin madaidaicin zuwa bayanin martabar mai ɗaukar hoto mai taku ko mai kwankwasa
• Idan rabon zane ya wuce iyakar mataki ɗaya, ƙara tashar ja
• Rage danko mai mai ko canzawa zuwa mai jujjuyawa mafi girma a gefen mai amfani mara kyau

Kurakurai Dimensional Springback

Springback shine farfadowa na roba wanda ke faruwa bayan an cire kayan da aka yi, yana sa sashin ya koma juzu'i zuwa siffarsa ta asali. Ita ce mafi girma tushen kuskure guda ɗaya a cikin lanƙwasa hatimi.

Springback yana rinjayar kowane ɓangaren lanƙwasa ko kafa. Girman ya dogara da ƙarfin samar da kayan abu, lanƙwasa radius-zuwa kauri rabo (R/T), da kusurwar lanƙwasa. Ƙarfe mai ƙarfi (AHSS) da aluminium alloys suna nuna mahimmancin dawowa fiye da ƙaramin ƙarfe.

Quantifying Springback

• Karfe mara nauyi (SPCC): 0.5-1.5° springback a 90° lankwasa, R/T = 1
• Bakin 304: 2–4° springback a daidai yanayi
• DP780 AHSS: 4-8 ° springback - yana buƙatar ramuwa mai tsanani
• 6061-T6 aluminum: 3–5° springback

Hanyoyin Ramuwa

• Overbending - ƙirƙira kusurwar mutuƙar don wuce gona da iri ta adadin da aka annabta. Mafi inganci don lanƙwasawa mai sauƙi.
• Bottoming/coining - yi amfani da matsananciyar ƙarfi don saita lanƙwasa kusa da sifili. Yana buƙatar 5-10 × ton na karkatar da iska.
• Canjin R/T - radius mai ƙarfi yana rage springback amma yana ƙara haɗarin fashewa. Nemo mafi ƙarancin radius wanda baya fashe.
• samarwa cikin zafi - na AHSS maki sama da 980 MPa, dumi forming a 200-300 ° C da cika fuska rage springback yayin da rike ƙarfi bayan quenching.

Lalacewar Sama: Scratches, Galling, and Pickup

Lalacewar saman yayin yin tambari ta fito ne daga hulɗar mutu-workpiece. Canja wurin ƙarfe (galling), ɓarna mai ɓarna, da ɗaukar hoto suna haifar da alamun bayyane waɗanda ba za a yarda da su ba don kayan kwalliya ko kayan aiki.

Galling da Metal Canja wurin

Galling yana faruwa ne lokacin da walƙiya mai ɗanɗano tsakanin kayan aiki da mutuƙar shimfidar wuri yana canja wurin abu zuwa ga mutu, yana haifar da ci gaba da ɓarna a sassa na gaba. Austenitic bakin karfe (304, 301) shine mafi munin mai laifi saboda yanayin ƙarfin aiki da yanayin mannewa.

• Rigakafin: Yi amfani da Rubutun kayan aiki≥0 TiN HRC, yi amfani da man shafawa mai ƙarfi tare da EP (matsananciyar matsa lamba) ƙari, rage saurin haɓakawa.
• Mutuwar kulawa: goge mutu saman kowane 10,000-50,000 bugun jini; sake sutura lokacin da rufi ya nuna lalacewa.

Die Marks and bugawa Lines

• Die Lines - layukan da aka ɗaga a kan ɓangaren ɓangaren da ya dace da canjin radius. Yaren mutanen Poland mutu radii zuwa Ra ≤ 0.2 µm don sassa na kwaskwarima.
• Layin Tsare (Ƙungiyoyin Lüders) - layukan gani a kan ƙananan ƙarfen ƙarfe na ƙarfe daga ƙarancin samar da albarkatu. Cire ta hanyar ƙididdige ƙarfe da fata (mai birgima) ko ta hanyar riga-kafin 2-3%.
• Karba - aluminum da jan karfe gami da jan karfe na iya ajiye abu akan filaye masu mutuwa. Yi amfani da chrome-plated ko goge carbide mutu tare da mai mai dacewa.

Dimensional Non-Conformance

Bayan bazara, wasu dalilai da yawa suna haifar da gazawar girma a sassa masu hatimi:

• Bambancin kauri na abu - ± 10% bambancin kauri a cikin coil mai shigowa yana fassara kai tsaye zuwa ± 10% bambanci a cikin nau'ikan sassan da aka kafa. Ƙayyade jurewar kauri mai ƙarfi (± 0.05 mm don daidaitattun sassa) kuma tabbatar da abu mai shigowa.
• Die wear - tashoshin mutuwa masu ci gaba suna lalacewa akan farashi daban-daban. Tashoshin farko da ba su da komai suna sawa da sauri fiye da kafa tashoshi. Bibiyar yanayin girma don tsinkaya lokacin da ake buƙatar sake yin ƙira.
• Ƙaddamar da thermal - high-gudun bugawa (600+ SPM) yana haifar da zafi a cikin mutuwa, yana haifar da haɓakar thermal. A cikin daidaitaccen aiki, yi amfani da sanyaya mai sarrafa zafin jiki da ƙira ta mutu tare da ramuwar zafi.
• Tsari daidaitaccen ciyarwa - daidaitaccen filin mutuƙar ci gaba ya dogara da yanayin jujjuyawar abinci da haɗin gwiwar matuƙin jirgi. Rubutun ciyarwar da aka sawa yana haifar da kuskuren farar ± 0.1-0.3 mm, yana taruwa a fadin tashoshi.

Material-Defections

Haɗawa da Laminations

Abubuwan da ba na ƙarfe ba (oxides, sulfides) a cikin ƙananan ƙarfe na ƙarfe suna aiki azaman abubuwan damuwa, haifar da fasa yayin kafawa ko gazawar gajiya a cikin sabis. Haɗin da ke sama da ƙimar ASTM E45 Nau'in A 2.0 ko Nau'in B 1.5 yakamata ya haifar da ƙin yarda da abubuwa masu mahimmanci.

Edge Cracking in AHSS

Advanced high- ƙarfi karfe (DP, TRIP, CP maki) da muhimmanci ƙananan gefen stretchability fiye da m karfe. Yanke gefen da ya tsira a cikin SPCC na iya fashe a DP780. Ragewa: yi amfani da Laser-yanke ko niƙa gefuna maimakon sheared gefuna don shimfidawa-flange aikace-aikace; ƙayyade ingancin gefen a kan zane (tsawon burr, zurfin rollover).

Ruwan Bawon Orange

Girman hatsi mai yawa (daga cirewa a zafin jiki mai yawa ko kuma na dogon lokaci) yana samar da rubutun "bawon lemu" a bayyane akan filaye da aka kafa. Sarrafa zazzabi annealing ± 10 ° C kuma ƙayyade matsakaicin girman hatsi (ASTM E112 lambar girman hatsi ≥ 6 don sassan kayan kwalliya).

Matsalar Saurin Magana

Kulawa da Rigakafi don Rigakafin Lalacewar

Mafi kyawun tsarin da ake amfani da shi don sarrafa lahani na bugawa shine rigakafi ta hanyar kiyaye mutuwa ta tsari:

• Kowane motsi: duban gani na sassa na farko da na ƙarshe; bincika burrs, fasa, da alamun saman
• Kowane bugun jini 10,000-25,000: auna ma'auni mai mahimmanci akan sassan samfurin; duba ingancin gefen
• Kowane bugun jini 50,000-100,000: cikakken binciken mutuwa; auna izinin naushi-zuwa-mutu; Duba jagorar fil da bushings
• Kowane bugun jini 200,000: Cikakkun mutuwar teardown, tsaftacewa, regrinding baki, da maye gurbin bangaren
• Bibiyar bayanan SPC - yanayin yanayin girma yana bayyana matsalolin tasowa kafin su samar da guntu. Saukowar Cpk daga sigina 1.5 zuwa 1.2 cewa ana buƙatar kiyayewa.

Tambayoyin da ake yawan yi

Menene mafi yawan sanadin burrs a bugawa karfe?

Cire naushi da gefuna masu mutuwa sune tushen dalilin 70-80% na gunaguni. Ƙunƙarar gefuna tana raguwa a hankali tare da kowane bugun jini - kayan aikin ƙarfe na carbon yana buƙatar sake yin jujjuyawar kowane hits 500,000 zuwa 1,000,000, yayin da kayan aikin carbide ke kiyaye ingancin gefuna don 5,000,000+ hits. Ƙirƙirar jadawalin regriding na kariya dangane da ingancin bayanan sashi yana kawar da mafi yawan al'amuran burr kafin su isa ga abokin ciniki.

Ta yaya zan hana fashe lokacin da ake buga ƙarfe mai ƙarfi (AHSS)?

AHSS maki (DP590, DP780, DP980, MS1200) da ƙananan elongation da gefen stretchability fiye da m karfe. Mahimmin matakan rigakafin: (1) ƙirar radius na lanƙwasa ≥ 1.0T don DP590, ≥ 1.5T don DP780, ≥ 2.5T don DP980; (2) lankwasa gabas daidai gwargwado zuwa mirgina shugabanci; (3) amfani da Laser-yanke ko niƙa gefuna maimakon sheared gefuna don shimfidawa-flange fasali; (4) ƙididdige lubricants mai ƙarfi tare da abubuwan EP; (5) yi la'akari da samar da dumi (200-300 ° C) don mafi yawan nau'ikan geometric.

Menene ke haifar da bazara kuma ta yaya zan biya shi?

Springback yana farfadowa ne na roba bayan kafa - wani bangare yana komawa zuwa ainihin siffarsa. Yana ƙaruwa tare da ƙarfin yawan amfanin ƙasa, mafi girman rabon R/T, da ƙaramin kusurwar lanƙwasa. Hanyoyin ramawa sun haɗa da overbending (ƙira mutun kusurwa 2-8 ° da ya gabata manufa dangane da abu), kasawa / coining (5-10 × iska lankwasawa tonnage), da kuma yin amfani da matsa lamba radii. Don AHSS a sama da 980 MPa, zafi mai zafi a 200-300 ° C yana ba da ingantaccen kulawar bazara.

Ta yaya zan magance wrinkling a cikin zurfin zane?

Sakamako na wrink daga rashin isassun matsi mara nauyi, girman zane mai wuce kima, ko lubrication mara daidaituwa. Fara da ƙara ƙarfin mariƙin da ba komai a cikin ƙarin 5-10%. Idan wrinkles ya ci gaba a matsakaicin matsa lamba, ƙara zana beads don taƙaita kwararar ƙarfe a takamaiman yankuna. Idan ma'aunin zane ya wuce 2.0 (karfe) ko 1.8 (aluminum), ƙara tashar ja. Aikace-aikacen mai ba daidai ba kuma yana iya haifar da wrinkling asymmetric - tabbatar da daidaitaccen ɗaukar mai a cikin sarari.

Menene lahani na saman da bugawa ya mutu kanta?

Lalacewar saman uku na yau da kullun sun haɗa da: (1) galling — walda mai ƙyalli yana canza ƙarfe daga kayan aiki zuwa mutu, yana haifar da ci gaba. Mafi na kowa tare da bakin karfe da aluminum. Hana tare da kayan aiki mai rufin TiN/DLC da man shafawa na EP. (2) Alamar mutuwa - layukan da aka ɗaga su a raye-rayen mutuwa. Yaren mutanen Poland mutu radii zuwa Ra ≤ 0.2 µm. (3) Layukan miƙewa (Ƙungiyoyin Lüders) - alamomin da ba su dawwama a bayyane akan ƙananan ƙarfe na carbon. Ƙayyade kayan da aka wuce da fata (mai birgima) don kawar da su.

Sau nawa ya kamata a bincika da kiyaye mutuwar tambari?

Mafi ƙarancin lokacin dubawa: kowane motsi (duba gani na sassa na farko / na ƙarshe), kowane bugun jini na 10,000-25,000 (ma'auni mai girma), kowane 50,000-100,000 bugun jini (binciken ɓangarori na grid), da kuma kowane 20000arwar bugun jini. Don hatimi mai sauri (> 600 SPM) ko kayan abrasive (bakin ƙarfe, babban carbon carbon), raba waɗannan tazarar. SPC saka idanu na ma'auni masu mahimmanci yana ba da mafi kyawun abin dogara don kiyayewa - raguwar Cpk ƙasa da sigina 1.33 wanda ya mutu ana buƙatar kulawa.

Kammalawa

Lalacewar tambari babu makawa - amma ana iya sarrafa su. Makullin shine ganewar asali na tsari: gano nau'in lahani (kayan abu, mutu, latsa, lubrication, ƙira), yi amfani da jerin abubuwan bincike na tushen tushen, da aiwatar da aikin gyara kafin tarkace ya taru.

At Ƙarfe Tambarin Ƙarfe, ƙungiyar mu masu inganci tana amfani da saka idanu na SPC da kiyaye lafiyar mutuwa don kiyaye ƙimar lahani a ƙasa 500 PPM akan shirye-shiryen samarwa. Kowane sabon mutu yana fuskantar gwaji tare da rubutaccen binciken labarin farko kafin sakin samarwa.

Kuna buƙatar taimako tare da batun ingancin hatimi? Tuntuɓi ƙungiyar injiniyarmu don goyan bayan matsala ko koyi game da ingantattun tsarin mu.