Yakha isayensi ethandwayo

Ukwakha ibhekisela ekusetshenzisweni kwemishini yokuthunga ukufaka ingcindezi ku-billet yensimbi ukukhuthaza ukuguqulwa kwepulasitiki, ukuze kutholakale izakhiwo ezithile zemishini, ukuma nobukhulu obuthile bokuthunga, kungenye yezingxenye ezimbili ezinkulu zokuthunga (kufaka phakathi ukuthunga kanye nokunyathela). Ngokuthungela, kungasusa amaphutha njengokuncibilikisa insimbi, futhi kwenze ngcono isakhiwo esincane. Ngesikhathi esifanayo, ngoba ukugeleza kwensimbi okuphelele kuyagcinwa, izakhiwo zemishini zokuthunga zivame ukuba ngcono kunokuthungwa kwezinto ezifanayo. Emishinini efanele, ezingxenyeni ezibalulekile ezinomthwalo omkhulu nezimo zokusebenza eziqinile, ngaphandle kwesimo esilula esingasebenzisa ipuleti eligoqiwe, iphrofayili noma izingxenye zokushisela, iningi lama-forging lizosetshenziswa.

1. Izinga lokushisa lokuguqulwa

Izinga lokushisa lokuqala lokuvuselela insimbi licishe libe ngu-727℃, kodwa i-800℃ ivame ukusetshenziswa njengomugqa wokuhlukanisa, okungaphezu kuka-800℃ kuyi-hot forging; phakathi kuka-300 no-800℃ kubizwa ngokuthi i-warm forging noma i-semi-hot forging, i-forge ekamelweni lokushisa ibizwa ngokuthi i-cold forging. I-Forgings esetshenziswa ezimbonini eziningi i-hot forging, kanti i-warm forging kanye ne-cold forging zisetshenziswa kakhulu ekubumbeni izimoto, imishini ejwayelekile kanye nezinye izingxenye. I-Warm forging kanye ne-cold forging kungasindisa ngempumelelo izinto.

2. Isigaba se-Forge

Njengoba kushiwo ngenhla, ngokwezinga lokushisa lokufaka, lingahlukaniswa libe yi-hot forging, i-warm forging kanye ne-cold forging. Ngokwendlela yokwakha, ukufaka kungahlukaniswa kube yi-free forging, i-die forging, i-grinding ring kanye ne-special forging.

1) Ukwakha kwamahhala

Kubhekisele endleleni yokucubungula yokusebenzisa amathuluzi alula ajwayelekile noma ukusebenzisa amandla angaphandle ngqo ku-billet phakathi kwe-anvil ephezulu nephansi yemishini yokugaya ukuze kuguqulwe indawo engenalutho futhi kutholakale i-geometry edingekayo kanye nekhwalithi yangaphakathi yemishini yokugaya. Imishini yokugaya ekhiqizwa yindlela yokugaya yamahhala ibizwa ngokuthi i-free forgings. Imishini yokugaya yamahhala isekelwe kakhulu ekukhiqizweni kwemishini yokugaya ene-batch encane, kusetshenziswa isando sokugaya, umshini wokucindezela we-hydraulic kanye neminye imishini yokugaya ukwakha nokucubungula i-billet, nokuthola imishini yokugaya efanelekile. Inqubo eyisisekelo yokugaya mahhala ifaka phakathi ukucasula, ukwelula, ukushaya, ukusika, ukugoba, ukusonta, ukudiliza kanye nokugaya. Imishini yokugaya yamahhala yonke isetshenziswa kwimodi yokugaya eshisayo.

2) Ukwakha isikhunta

I-mold forging ihlukaniswe ibe yi-open die forging kanye ne-closed die forging. I-billet yensimbi iyacindezelwa futhi iguquguquke ekamelweni le-folding die elinesimo esithile ukuze kutholakale izingxenye ze-forging. I-die forging ngokuvamile isetshenziselwa ukukhiqiza izingxenye ezincane nezinkulu. I-mold forging ingahlukaniswa ibe yi-hot die forging, i-warm forging kanye ne-cold forging. I-warm forging kanye ne-cold forging kuyisiqondiso sentuthuko yesikhathi esizayo se-die forging, futhi imelela nezinga lobuchwepheshe be-forging.

Ngokusho kwamaphuzu ezinto ezibonakalayo, i-die forging ingahlukaniswa futhi ibe yi-black metal die forging, i-nonferrous metal die forging kanye nemikhiqizo yempuphu. Njengoba igama lisikisela, izinto ziyinsimbi yensimbi efana ne- I-Carbon Steerl, izinsimbi ezingezona i-ferrous njengethusi ne-aluminium, kanye nezinto zokusansimbi eziyimpuphu.

Ukukhipha kufanele kuhlotshaniswe nokwakha insimbi, futhi kungahlukaniswa kube ukukhishwa kwensimbi esindayo kanye nokukhishwa kwensimbi elula.

I-Closed die forging kanye ne-closed heading forging ziyingxenye yezinqubo ezimbili ezithuthukisiwe ze-die forging. Ngenxa yokuthi akukho mphetho ondizayo, izinga lokusetshenziswa kwezinto liphezulu. Ukuqedwa kwe-complex forgings kungafezwa ngenqubo eyodwa noma eziningana. Njengoba kungekho mphetho ondizayo, indawo yokucindezeleka ye-fogging iyancipha, futhi umthwalo odingekayo nawo uyancipha. Kodwa-ke, kufanele kuqashelwe ukuthi i-billet akufanele ivinjelwe ngokuphelele, ngakho-ke ivolumu ye-billet kufanele ilawulwe ngokuqinile, indawo ehlobene ye-forging die kanye nokulinganiswa kwe-forging, futhi kulwelwe ukunciphisa ukuguguleka kwe-forging die.

3) Finyelela indandatho

Ukugaya indandatho kubhekisela ekukhiqizweni kwezingxenye zendandatho ezinobubanzi obuhlukene ngemishini ekhethekile yokugaya indandatho, ephinde isetshenziswe ukukhiqiza izingxenye zamasondo ezifana namasondo emoto namasondo esitimela.

4) Ukwakhiwa okukhethekile

Ukwakha okukhethekile kufaka phakathi ukwakheka kwe-roll forging, ukugoqa okuphambeneyo kwe-wedge, ukwakheka kwe-radial, ukwakheka kwe-liquid die kanye nezinye izindlela zokwakheka, lezi zindlela zifaneleka kakhulu ekukhiqizweni kwezingxenye ezithile ezibunjwe ngendlela ekhethekile. Isibonelo, ukwakheka kwe-roll forging kungasetshenziswa njengenqubo ephumelelayo yokwakheka kwangaphambili ukuze kuncishiswe kakhulu ingcindezi yokwakha elandelayo; ukugoqa okuphambeneyo kwe-wedge kungakhiqiza ibhola lensimbi, umgodi wokushayela kanye nokwakheka kwe-radial kungakhiqiza ukwakheka okukhulu njengebharele lesibhamu kanye nomgodi wesinyathelo.

5) Isikhunta sokwakha

Ngokwendlela yokunyakaza ye-forging die, i-forging ingahlukaniswa ngokuthi i-swing rolling, i-swing rotary forging, i-roll forging, i-wedge transverse rolling, i-rolling ring kanye ne-intended rolling. I-Roll-rolling, i-swing-rotary forging kanye ne-rolling ring nazo zingacutshungulwa nge-fine forging. Ukuze kuthuthukiswe izinga lokusetshenziswa kwezinto, i-rolling forging kanye ne-transverse rolling ingasetshenziswa njengenqubo yokuqala yokucubungula izinto ezincane. I-Rotary forging, njenge-free forging, nayo inenzuzo yokuthi uma iqhathaniswa nosayizi we-forging, ingakhiwa esimweni samandla amancane okwakha. Indlela yokufaka, kufaka phakathi i-free forging, izinto zokucubungula kusukela ebusweni besikhunta kuya endaweni ekhululekile, ngakho-ke, kunzima ukuqinisekisa ukunemba, ngakho-ke, isiqondiso sokunyakaza kwesikhunta sokwakha kanye nenqubo yokufaka ejikelezayo ngokulawulwa kwekhompyutha, ingasetshenziswa amandla aphansi okwakha ngesimo esiyinkimbinkimbi, imikhiqizo enembile kakhulu, njengezinhlobo zokukhiqiza, ubukhulu obukhulu be-steam turbine blade forgings.

Ukunyakaza kwesikhunta semishini yokubopha akuhambisani nezinga lenkululeko. Ngokwezimpawu zomkhawulo wokuguquguquka kwendawo efile, imishini yokubopha ingahlukaniswa ngezindlela ezine ezilandelayo:

Ukunciphisa ifomu lamandla okwakha: ukucindezela kukawoyela kushayela ngqo umshini wokunyathelisa uwoyela oshelelayo.

Imodi yomkhawulo we-quasi-stroke: umshini wokucindezela uwoyela ushayela umshini wokucindezela uwoyela wendlela yokuxhumanisa i-crank.

Umkhawulo wokushaya: ukucindezela ngomshini okushayela isilayidi nge-crank, induku yokuxhuma kanye nendlela yokuxhuma.

Imodi yokukhawulela amandla: kusetshenziswa indlela yesikulufu yokucindezela okujikelezayo nokungqubuzana.

Ukuze kufezwe ukunemba okuphezulu, kufanele kuqashelwe ukuvimbela ukugcwala ngokweqile endaweni ephansi efile futhi kulawulwe isivinini kanye nendawo yokufa. Ngoba lokhu kuzoba nomthelela ekubekezeleleni kokubumba, ukunemba kwesimo kanye nokuphila kwefa lokubumba. Ngaphezu kwalokho, ukuze kugcinwe ukunemba, kufanele kuqashelwe futhi ukulungisa ukuvuleka kwesitimela se-slider guide, ukuqinisekisa ukuqina, ukulungisa indawo efile kanye nokusebenzisa idivayisi yokudlulisela uxhaso kanye nezinye izindlela.

Kukhona futhi ukunyakaza okuqondile nokuvundlile kwamaslayidi (ukuze kufakwe izingxenye ezincane, ukupholisa ukugcoba, kanye nokukhiqizwa okusheshayo kwezingxenye ezifakwayo), ukusebenzisa idivayisi yesinxephezelo kungandisa ukunyakaza kwezinye izindlela. Izindlela ezingenhla zihlukile, amandla okubopha adingekayo, inqubo, ukusetshenziswa kwezinto, isivuno, ukubekezelela usayizi kanye nezindlela zokupholisa ukugcoba zihlukile, lezi zici nazo ziyizici ezithinta izinga lokuzenzakalela.

3. Izinto zokwakha

Izinto zokwakha ikakhulukazi ziyinsimbi yekhabhoni kanye nensimbi ye-alloy yezingxenye ezahlukahlukene, kulandele i-aluminium, i-magnesium, ithusi, i-titanium kanye ne-alloys yazo. Isimo sokuqala sezinto zokwakha yizinto zenduku, i-ingot, i-metal powder kanye nensimbi ewuketshezi. Isilinganiso sendawo ye-cross-section yensimbi ngaphambi kokuguqulwa kwendawo ye-cross-section ngemva kokuguqulwa sibizwa ngokuthi i-forging ratio. Ukukhetha okulungile kwesilinganiso sokwakha, izinga lokushisa lokushisa elifanele kanye nesikhathi sokushisa, izinga lokushisa lokuqala lokwakha elifanele kanye nezinga lokushisa lokugcina lokwakha, ukuguquguquka okufanelekile kanye nesivinini sokuguqulwa kunobuhlobo obuhle bokuthuthukisa ikhwalithi yomkhiqizo nokunciphisa izindleko.

Ngokuvamile ama-forging amancane naphakathi ayinduku eyindilinga noma eyisikwele njenge-billet. Ukuhleleka kokusanhlamvu kanye nezakhiwo zemishini zezinto zenduku ziyafana, zinhle, zinembile ngesimo kanye nosayizi, ikhwalithi ephezulu, kulula ukuhlela ukukhiqizwa ngobuningi. Uma nje izinga lokushisa lokushisa kanye nezimo zokuguquguquka zilawulwa ngokufanele, ama-forging anokusebenza okuhle kakhulu angakhiwa ngaphandle kokuguqulwa okukhulu kwe-forging.

I-Iningot yenzelwe kuphela izinto ezinkulu zokufakelwa. I-ingot iyisicubu esikhishwe ngaphandle esinamakristalu amakhulu ekholomu kanye nesikhungo esikhululekile. Ngakho-ke, kuyadingeka ukuphula amakristalu asilinda abe yizinhlamvu ezinhle futhi wenze ukuhlanganiswa okukhululekile ukuze uthole ukuhlelwa kwensimbi enhle kanye nezakhiwo zemishini.

I-billet eyenziwe ngensimbi yempuphu ecindezelwe neshisiwe ingakhiwa ngaphandle kwe-fly side die esimweni esishisayo. Impuphu yokufaka iseduze nobuningi be-general die forging, inezakhiwo ezinhle zemishini kanye nokunemba okuphezulu, okunganciphisa ukusebenza okulandelayo. I-powder forgings ihlelwe kahle ngaphandle kokuhlukanisa futhi ingasetshenziswa ukukhiqiza izinto zokusebenza ezifana negiya elincane. Kodwa intengo yempuphu iphakeme kakhulu kunentengo ye-general bar, futhi ukusetshenziswa ekukhiqizeni kunqunyelwe ngezinga elithile.

Ingcindezi engaguquki isetshenziswa ensimbini ewuketshezi ethelwe ekamelweni lokubumba ukuze iqine, icwebezele, igeleze, iguqulwe ibe yipulasitiki futhi yakheke ngaphansi kwengcindezi, ngaleyo ndlela kutholakale ukuma nokusebenza okufiselekayo. I-liquid metal die forging iyindlela yokwakha phakathi kwe-die casting kanye ne-die forging. Ifaneleka kakhulu ezingxenyeni eziyinkimbinkimbi zodonga oluncane okunzima ukuzakha ekubumbeni okujwayelekile.

Izinto zokwakha ngaphezu kwezinto ezivamile, njengezingxenye ezahlukahlukene zensimbi yekhabhoni nensimbi ye-alloy, kulandelwe yi-aluminium, i-magnesium, ithusi, i-titanium kanye ne-alloy yayo, i-alloy yokushisa okuphezulu esekelwe ensimbini, i-alloy yokushisa okuphezulu esekelwe e-nickel, i-alloy yokuguqulwa kwe-alloy yokushisa okuphezulu esekelwe e-cobalt ngendlela yokwakha noma yokugoqa, kodwa lezi zinsimbi ngenxa yendawo yazo yepulasitiki zincane kakhulu, ngakho-ke ubunzima bokwakha bukhulu kakhulu, izinto ezahlukene zokushisa okushisa, izinga lokushisa lokwakha kanye nokushisa kokugcina kokwakha zinezidingo eziqinile.

4. Ukugeleza kwenqubo

Izindlela ezahlukene zokugaya zinezinqubo ezahlukene, phakathi kwazo inqubo yezobuchwepheshe yokugaya okushisayo iyona ende kunazo zonke, ukuhleleka okuvamile yilokhu: ukuphakelwa kwe-billet; ukufudumeza ngokugaya; ukulungiselela ukugaya nge-roller; ukugaya nge-die; ukusika; ukubhoboza; ukulungiswa; ukuhlolwa okuphakathi, ukuhlola usayizi kanye namaphutha ebusweni bokugaya; ukwelashwa kokushisa kokugaya ukuze kuqedwe ukucindezeleka kokugaya nokuthuthukisa ukusebenza kokusika kwensimbi; ukuhlanza, ikakhulukazi ukususa isikhumba se-oxidation ebusweni; ukulungiswa; ukuhlolwa, ukugaya okujwayelekile kufanele kudlule ekuhlolweni kokubukeka nokuqina, futhi ukugaya okubalulekile kufanele kuhlolwe ngokuhlaziywa kokwakheka kwamakhemikhali, izakhiwo zemishini, ukucindezeleka okusele kanye nokuhlolwa okungonakalisi.

5. Izici zokufakelwa

Uma kuqhathaniswa nokuthungwa, insimbi ingathuthukisa isakhiwo sayo kanye nezakhiwo zayo zemishini. Ukuguqulwa kokucubungula ukushisa kwezicubu ngemuva kokubumba, ngenxa yokuguqulwa kwensimbi kanye nokusetshenziswa kabusha, kwenza i-dendrite yokuqala ejiyile kanye nokusanhlamvu kwekholomu kube yinhlamvu encane, usayizi ofanayo wenhlangano yokwenziwa kabusha kwe-axial, yenza ukuhlukaniswa kokuqala, ukukhululeka, ama-pores, i-slag kuya ekuqineni nasekushiseni, inhlangano iba seduze kakhulu, ithuthukise i-plasticity kanye nezakhiwo zemishini zensimbi.
Izakhiwo zemishini zokubumba ziphansi kunezo zokubumba zezinto ezifanayo. Ngaphezu kwalokho, ukucubungula ukubumba kungaqinisekisa ukuqhubeka kwenhlangano yefayibha yensimbi, ukuze inhlangano yefayibha yokubumba kanye nesimo sokubumba, ukuhleleka kwensimbi kuqediwe, kuqinisekise ukuthi izingxenye zinezakhiwo ezinhle zemishini kanye nokuphila isikhathi eside. Izakhiwo ezikhiqizwa ngokubumba okuqondile, ukubumba okubandayo, ukubumba kwezinga lokushisa kanye nezinye izinqubo azinakuqhathaniswa nokubumba.
Ukwakha kuyinto lapho insimbi icindezelwa khona ukuze kudalwe isimo esifiselekayo noma kwakhiwe amandla okucindezela afanele. La mandla avame ukufezwa ngokusebenzisa isando noma ingcindezi. Inqubo yokwakha yakha isakhiwo sezinhlayiya ezincane futhi ithuthukisa izakhiwo zomzimba zensimbi. Ekusetshenzisweni kwangempela kwezingxenye, umklamo ofanele wenza izinhlayiya zigeleze ziye ohlangothini lokucindezela okuyinhloko. Ukwakha kuyinto eyakha insimbi etholakala ngezindlela ezahlukene zokukhipha, okungukuthi ukuncibilikisa insimbi ewuketshezi, ngokuthulula, ukucindezela, ukumunca noma ezinye izindlela zokukhipha ekubunjweni okulungiselelwe, ukupholisa ngemva kwesihlabathi, ukuhlanza kanye nokwelashwa ngemva kokwelashwa, into enesimo esithile, usayizi kanye nokusebenza okuthile.