Ilimi- Kintai

Wannan takarda a taƙaice ta bayyana fasalin tsarin, buƙatun fasaha da matsalolin masana'anta na simintin ƙarfe mai nauyi. Yana bayani dalla-dalla kan hanyoyin simintin gyare-gyare, hanyoyin ƙirar tsarin gating da hanyoyin kera irin wannan simintin. The tsari halaye, samar abũbuwan amfãni da aikace-aikace ikon yinsa, guduro yashi m mold simintin an gabatar. Ta hanyar sarrafa tsari mai tsauri, zaɓin albarkatun ƙasa masu dacewa, ingantattun hanyoyin maganin spheroidizing da inoculation, da dabarun pretreatment na musamman yayin aikin samarwa, ana iya samar da manyan simintin ƙarfe na ductile masu inganci. Wannan na iya samar da nassoshi na fasaha don ingantaccen tsarin simintin gyare-gyare na simintin gyare-gyare masu kama da haka.

Mahimman kalmomi: Simintin ƙarfe mai nauyi mai nauyi; Simintin gyare-gyare; Tsarin simintin gyare-gyare

Fasahar simintin gyare-gyare na zamani za ta ƙara haɓaka haɓakarta da haɓakawa ta fannoni da dama, kamar makamashi da adana kayan abu, rage gurɓataccen gurɓataccen abu, haɓaka daidaiton girman simintin, rage lahani na simintin, da daidaitawa ga haɓaka sabbin kayan haɗin gwal [1]. Kamfaninmu yana da ƙarfin samarwa na shekara-shekara na ton 20,000 na sassan ƙarfe na simintin ƙarfe (ban da bututun ƙarfe na centrifugal). Mun ci gaba da tafiya tare da ci gaban da simintin masana'antu da kuma samu nasara ɓullo da (furan guduro yashi + kumfa juna m mold) simintin tsari da kuma injin kumfa juna simintin tsari, maye gurbin na gargajiya (itace juna + katako core akwatin) gyare-gyare da core taro tsari tare da kumfa juna m mold.

Bangaren ƙarfe na ductile (QT500-7) da muka ɗauka yana da babban nauyin 18,350 kg, tare da babban girman jiki na (tsawon × nisa × tsawo) 3,650 mm × 1,480 mm × 1,230 mm × 100 mm, babban kaurin bangon jiki na 450 mm, kuma mafi kauri ya kai 100 mm. Siffar farfajiyar taro ba ta dace ba kuma tana da ƙayyadaddun buƙatun inganci. Akwai ramukan makafi guda biyar masu diamita 170 mm da zurfin 70 mm, da kuma ramuka shida masu diamita 540 mm da zurfin 1 mm. Adadin oda guda biyu ne, kuma gabaɗayan wahalar simintin ya yi girma. The part tsarin da aka nuna a Figure XNUMX. Our kamfanin yana da samar iya aiki na injin kumfa juna, guduro yashi da kumfa juna m mold simintin tafiyar matakai. Bayan aiwatar da bincike da kimantawa, an yanke shawarar yin amfani da yashin guduro na furan + tsarin kumfa mai ƙarfi don samarwa, daga baya ana magana da shi azaman simintin gyare-gyare. Wannan zai iya tabbatar da lokacin bayarwa da kuma rage farashin samarwa.

Hoto 1 Tsarin tsari mai girma uku

-------------------------------------------------- ---------------         

1. Tsare-tsaren aiwatar da simintin gyaran kafa

Ƙaƙƙarfan simintin gyare-gyare ya bambanta da na yau da kullum da yashi. Babban mahimmancin simintin simintin gyare-gyare shine yana amfani da tsarin kumfa maimakon ƙirar katako. A lokacin tsarin ƙira, masu fasaha ba sa buƙatar yin la'akari da rarrabuwar lambobi mara kyau, manyan kawunan, matsayi, da daftarin kusurwoyi don rushewa. Suna buƙatar ƙara alawus ɗin injina ne kawai da rage ƙimar simintin gyare-gyare. Tsarin tsari yana da sauƙi. Da farko, an raba samfurin zuwa sassa da yawa, sa'an nan kuma an haɗa sassan tare. Tsarin da aka haɗa yana da daidaito mai girma, yana amfani da ƙarancin albarkatun ƙasa a cikin tsarin yin tsari, kuma yana da ɗan gajeren zagayen samarwa fiye da ƙirar katako. A lokaci guda, yana sauƙaƙa aikin gyare-gyare, yana kawar da gyare-gyaren daban-daban, gyare-gyaren mahimmanci, da kuma haɗuwa da mold da core. An inganta ingantaccen samarwa sosai. Koyaya, idan ba'a yi la'akari da tsarin simintin da kyau ba, yana iya haifar da takamaiman lahani na simintin kamar wrinkling, haɗa slag, da porosity.

         

1.1 Tsari Tsari

1.1.1 Tsarin Kumfa

Tsarin kumfa daidai yake a cikin sifa da tsari kamar simintin gyaran kafa. Dangane da zanen ɓangaren, ana ƙirƙiri ƙirar ƙira mai girma uku bayan ƙara izinin injina da ƙimar raguwar simintin gyaran kafa. Sannan an raba tsarin zuwa na'urori da yawa don tabbatar da cewa yana da sauƙi ga ma'aikata su yanke da ajiye allunan kumfa, da kuma sauƙaƙe haɗuwa da tabbatar da daidaiton girman tsarin da aka haɗa. Ana yanke allunan kumfa da aka yi amfani da su ta hanyar zane-zanen CNC da yankan waya na lantarki, sannan a haɗa su ta hanyar haɗin gwiwa don samar da tsari. Don tabbatar da cewa tsarin yana da isasshen ƙarfin matsawa da juriya na lalacewa, an zaɓi allunan kumfa polystyrene tare da yawa na 20-22g/L. An sanya tsarin da aka haɗa a cikin tukunyar bushewa na musamman don 10-12 hours. Ana sarrafa yawan zafin jiki na bushewa a 45-55 ℃. Bayan bushewa, ana lulluɓe ƙirar tare da yadudduka biyu na simintin simintin ƙarfe na tushen ruwa ya ɓace murfin kumfa da Layer ɗaya na murfin graphite na tushen barasa. Hanyar sutura tana tsomawa, kuma ana sarrafa kauri mai rufi a 3-3.5mm.

                 

1.1.2 Na Musamman Kumfa Core Mold

Sashin tsakiya na simintin gyare-gyare babban rami ne. Saboda babban kwane-kwane na ƙirar, don tabbatar da isasshen ƙarfi a wannan ɓangaren yayin yin gyare-gyare, an yi wani ƙwanƙwasa na kumfa na musamman tare da ainihin siffar rami. A lokacin gyare-gyaren, wannan ƙwararren ƙwanƙwasa na kumfa yana aiki a matsayin goyon baya na ƙasa don haɓaka tsattsauran ra'ayi na gaba ɗaya, tabbatar da cewa tsarin ba ya lalacewa yayin aikin ramming. Bayan an yi gyare-gyaren, an juya akwatin kuma an cire kullun kumfa. Ana iya sake amfani da wannan kumfa core mold.

      

1.2 Tsarin Tsari

Yin simintin gyare-gyare yana da girma, kauri da kuma bayanan martaba. An karɓi tsarin gating ɗin buɗe ƙasa-rukuni biyu na ƙasa. Wurare masu mahimmanci na gida an sanye su da ƙarfe na sanyi na waje don hana ƙurawar ƙurawar ciki. An yi la'akari da ka'idar daidaitawar ƙarfafawa a cikin ƙirar tsari. An saita masu tashi da ramukan huɗa don tabbatar da ciyarwa, kawar da slag da hura iska.

 

1.2.1 Tsarin Tsarin Gating

Lokacin samar da kauri da manyan simintin ƙarfe na ductile, yana da fa'ida don rage lokacin zuƙowa gwargwadon yuwuwar don rage iyo na graphite da tarin abubuwan da aka haɗa [3]. Ta hanyar nazarin siffa da tsarin ciki na simintin gyare-gyare, an ɗauki tsarin gating mai buɗewa na rukuni biyu, wanda aka raba zuwa sama da ƙasa. Ana amfani da tsarin gating na ƙasan ƙasa don cikawa, yayin da tsarin gating na saman na sama ana amfani da shi don kawar da slag, iskar gas da ciyarwa. Ana rarraba tsarin gating guda biyu a bangarorin biyu na tsarin kumfa. An gabatar da tsarin gating na saman Layer a kasan babban hawan sama, wanda ke da isassun iskar gas kuma yana ba da damar ƙwanƙwasa mai iyo a cikin narkakken ƙarfe da slag ɗin da gasification na filastik kumfa ya samar don yin iyo sosai, yana tabbatar da tasirin ciyarwar mai tashi da kawar da lahani na haɗar simintin.

Wannan simintin simintin simintin ƙarfe ne mai nauyi, kuma ana iya ƙididdige lokacin zuƙowa bisa simintin ƙarfe mai launin toka:

t = S2L (1)

A cikin dabarar, L yana wakiltar jimillar nauyin narkakken ƙarfe a cikin ƙirar, tare da ƙididdige yawan amfanin ƙasa na 92%, kuma ana ɗaukar L azaman 19,945 kg; S2 shine madaidaicin kauri na bango, wanda aka ɗauka azaman 2.2; don haka, lokacin zubar da ruwa t = 310 seconds, kuma don tsarin zubar da ruwa guda biyu, ana ɗaukar lokacin zubar kamar 155 seconds. Za'a iya ƙayyade lokacin zubowar simintin ƙarfe na ductile ta hanyar lissafin hanyar yin simintin ƙarfe na launin toka, sannan a rage shi da 1/3 zuwa 1/2 [1], ɗaukar lokacin zubar t = 90 seconds. Dangane da ginshiƙi na lokacin zubar da manyan simintin ƙarfe na ductile, an tabbatar da lokacin zubar da ruwa, kuma ana iya ganin lokacin da aka zaɓa ya dace.

Dangane da dabara don ƙididdige yanki mai toshe kwarara:

∑A_block = L / (0.31μPt) (2)

A cikin dabara: ana ɗaukar madaidaicin μ a matsayin 0.5, ana ɗaukar Hp azaman 40 cm, L = 19945/2 = 9972.5 kg.

Sannan, A_block = 9972.5 / (0.31 × 0.5 × 90) ≈ 113 cm². Ganin cewa mafi ƙarancin ɓangaren da ke hana kwararar ruwa na tsarin buɗe ƙofar shine sprue, an zaɓi bututun yumbu mai diamita na Φ120mm don sprue ta hanyar lissafi. An saita rabon yanki na giciye na kowane ɓangare na tsarin ƙofar azaman A_sprue: A_transverse: A_inlet = 1: (1.2 - 2.0): (1.5 - 2.0). Saboda haka, an zaɓi ɓangaren giciye na mai wucewa ta hanyar wucewa azaman 150mm × 120mm; an zaɓi ɓangaren giciye na mai shiga ta hanyar wucewa azaman siffar trapezoidal tare da ƙungiyoyi guda biyu, tare da tushen sama na trapezoid shine 110mm, ƙasan tushe shine 140mm, kuma tsayi shine 80mm. Ainihin rabon yanki na giciye na tsarin gate yana da kusan A_sprue: A_transverse: A_inlet ≈ 1: 1.6: 1.8. An nuna zane-zanen tsarin gate a Hoto na 2.

Hoto na 2 Zane-zanen Tsarin Zubar da Ruwa

 

1.2.2 Zane na Chills na waje

Don yin simintin gyare-gyare tare da bango mai kauri, ana amfani da sanyin waje a cikin wurare masu mahimmanci da kauri don hana lahani mara kyau da samun daidaiton ƙarfi. Lokacin samarwa, yawan amfani da sanyi yakamata a sarrafa shi sosai. Dole ne saman sanyi ya zama santsi ba tare da tsatsa ko ramuka ba [4]. Kafin kowane amfani, ya kamata a harbe su da fashewa kuma a lulluɓe su da wani abin rufe fuska na barasa. Ya kamata su dace sosai tare da filin wasan ba tare da wani gibi ba.

1.2.3 Zane na Risers da Venting

Ƙa'idar ƙira: Tabbatar cewa an biya diyya ga wuraren da kauri don raguwa. Kamar yadda simintin ya kasance mai kauri kuma babba, ana amfani da masu hawan diyya don ramuwa don samun ƙwararrun simintin gyaran kafa [5]. Ana sanya masu hawan diyya goma masu diamita na 280mm da tsayin 400mm a bangarorin biyu na saman saman simintin. Mai gudu a kwance na sama da mai gudu na ciki yana wucewa ta cikin masu hawan, yana ba da damar daɗaɗɗen ƙarfe mai zafi a cikin masu hawan da kuma tabbatar da cewa slag na iya shawagi kuma a fitar da shi, don haka samun sakamako mai haɗuwa na ramuwa, cire slag, da iska.

Tashoshi na ciki na ciki na ƙirar kumfa da tashoshi na waje na waje na mold sune matakan tsari guda biyu don inganta yanayin gasification na ƙirar da kuma haɓaka cikakkiyar tseren iskar gas daga mold. Don yin kauri da manyan simintin gyare-gyare, ban da sanya masu tashi sama a saman saman simintin, ana iya saita tashoshi masu yawa na fitar da iska a cikin ƙirar kuma tare da wajen ƙirar kumfa. Kafin a rufe babban akwatin, ana buɗe tashoshi na iska a cikin ƙirar a cikin wuraren da ke cikin kauri na saman simintin don tabbatar da cewa iskar gas ɗin da ke cikin kogon ƙura za a iya fitar da su cikin lokaci yayin matakin farko na zubowa.

2 Ikon Tsari Tsari

Ana sarrafa ƙari na resin a 0.9% zuwa 1.2%, tare da iyakar babba don manyan simintin gyare-gyare da murhu. Da farko, an kafa tushen kumfa na musamman a kan dandalin gyare-gyare, kuma an sanya tsarin kumfa a kan kumfa na musamman don yin ƙananan ƙira. Bayan an gama warkewa, an juya akwatin, kuma an cire kumfa na musamman kafin yin gyare-gyare na sama.

Don ramukan makafi da tsayin ramuka a ƙarshen gaban simintin, an riga an shigar da sandunan ramuka na musamman waɗanda ke yin ramuka a kowane rami. Ana yin sandunan da ke yin ramuka ta hanyar haɗa bututun yumbu mai girman daidai da ramukan makafi da tsayin ramuka, a cika su da yashi na guduro, a saka sandunan ƙarfe a tsakiya, a haɗa su, da kuma rufe waje tare da murfin graphite na tushen barasa. Bayan an gama warkewa, ana sanya su a cikin kowane rami na ƙirar filastik kumfa. Don hana bututun yumbu daga canzawa yayin aikin gasification na ƙaƙƙarfan tsari, an saka sandunan ƙarfe na Φ16mm a tsakiyar don gyara su zuwa ƙirar yashi, kuma an ƙara wani tsari mai siffar T zuwa ƙarshen ƙarshen ƙwanƙwasa mai zaren don tabbatar da tsayayyen sanduna tare da yashi guduro a waje. Bayan da aka yi ƙananan ƙira, an juya akwatin, kuma ana amfani da sandunan ƙarfe na zagaye na Φ10mm don buga tashoshi na iska a cikin wurare masu kauri na ƙirar kumfa. Ana saita tashoshi na waje da yawa na Φ30mm nesa da 40mm daga waje na tsarin kumfa, kuma zurfin tashoshi na iska daidai yake da tsayin ƙirar kumfa.

        

3 Maganin Spheroidizing da inoculation

Maganin Spheroidizing yana ɗaya daga cikin mahimman hanyoyin samar da sassan ƙarfe na ductile, kuma fasahar sarrafa shi kai tsaye yana shafar aikin ƙarfe na ductile [6]. A cikin jaka spheroidizing da inoculation magani an karɓa, tare da ZFCR-7 spheroidizing wakili da aka yi amfani da kashi na 1.2% da YFY-150 inoculant a kashi na 0.6%. Ana tabbatar da tasirin spheroidizing da inoculation ta hanyar ƙara yawan adadin inoculant da inoculation da yawa.

Saboda girman nauyin simintin gyare-gyare, don saduwa da buƙatun alamomin ayyuka daban-daban da haɓaka ikon hana lalata narkakken ƙarfe, dangane da ƙwarewar masana'antun da yawa, ana aiwatar da riga-kafi na ƙarfe na ƙarfe. Wato, kafin jiyya na spheroidizing, ana ƙara magungunan riga-kafi a cikin narkakkar ƙarfe, yawanci 0.8% SiC wakili na riga-kafi, tare da manufar haɓaka ƙwayoyin nucleation da haɓaka ingancin ciki da ruwa na narkakken ƙarfe.  

4 Gudanar da Tsarin Zuba

Ana ɗaukar fakiti sau biyu a lokaci guda. A lokacin aikin zubar da ruwa, ana buƙatar babban adadin ruwa da ci gaba da zubewa ba tare da katsewa ba. Matsakaicin zafin da aka rasa don ƙirar kumfa ya ɓace gabaɗaya digiri 30 zuwa 50 na ma'aunin celcius sama da na yau da kullun na yashi. Don ingantattun sassa masu kauri da nauyi, ana zaɓar zafin da ake zubarwa don zama 1410 zuwa 1420 digiri Celsius. Kafin spheroidization, abun da ke ciki na zubin baƙin ƙarfe shine 3.5% zuwa 3.7% C, 1.2% zuwa 1.4% Si, Mn ≤ 0.5%, P ≤ 0.06%, S ≤ 0.04%, da 0.5% Cu. Bayan spheroidization, ana sarrafa abun da ke ciki don zama 3.4% zuwa 3.6% C, 2.3% zuwa 2.5% Si, Mn ≤ 0.5%, P ≤ 0.06%, S ≤ 0.012%, 0.5% Cu, da 0.04% zuwa 0.06% saura. A duk lokacin da ake zubar da ruwa, ana aiwatar da ciyarwar cikin tsari ta hanyar ƙoƙon zuba, tare da sarrafa adadin ciyarwa a 0.08% zuwa 0.1%.

5 Sanyaya Halitta

Bayan an gama zubowa, ana amfani da insulation mai kyau na zafi mai zafi da rugujewar yashin guduro don ba da damar simintin ya yi sanyi a hankali kuma cikin yardar rai a cikin gyare-gyare, cimma manufar rage damuwa da tsufa [7]. Dangane da gogewar da ta gabata tare da manyan simintin gyare-gyare, ana cire tsarin rufewa awanni 8 bayan zubawa, ana cire baƙin ƙarfe mai danna akwatin sa'o'i 24 bayan haka, kuma an buɗe ƙirar kuma an cire yashi sa'o'i 96 bayan haka, tare da cire saman gating da tsarin riser.

6 Microstructure da Kaddarorin Fim ɗin

An gudanar da gwaje-gwajen aiki a kan sandunan gwaji. Sakamakon ƙarfe na jikin simintin an nuna shi a Hoto na 3 .

Siffa ta 3 Tsarin Ƙananan Gine-gine

 

Kammalallen 7

Ta hanyar samar da yanki na farko na simintin ƙarfe mai nauyi mai nauyi, an tabbatar da tasiri da ma'ana na tsarin gating da riser yayin aikin samarwa. An ƙara haɓaka ƙirar tsarin gating, wanda ke haɗa cikawa, shayewa, cire slag da ciyarwa. Matsalolin haɗaɗɗun slag, wrinkling da shrinkage porosity waɗanda ke da yuwuwar faruwa a cikin tsarin gyare-gyaren harsashi an warware su. Saboda kauri bango na simintin gyare-gyare, da dogon ƙarfafa lokaci da kuma high yi bukatun, akwai babban matsaloli a cikin samar da tsari. Ta hanyar kula da tsari mai tsauri, zaɓin albarkatun da suka dace, matakan da suka dace da spheroidizing da inoculation, da dabarun pretreatment na musamman, yana yiwuwa gabaɗaya don samar da manyan simintin ƙarfe na ductile mai inganci.

 

Vigor tana da ƙwarewa sama da shekaru 20 kuma ƙwararrun ma'aikata ne a fannin yin siminti da ƙera kayayyaki. Idan akwai wani abu da za mu iya taimaka muku ko kuma kuna da kayayyaki da kuke buƙatar haɓaka, da fatan za ku iya tuntuɓar mu a info@castings-forging.com