Platform walda yana buƙatar fiye da zafi da ƙarfe kawai. Yana da inda mutuncin tsarin ke saduwa da hanyoyin kaya na ainihi-inda madaidaicin madaidaicin walda zai iya shiga cikin sake yin aiki mai tsada, jinkirin ƙaddamarwa, ko mafi muni, gazawar filin a ƙarƙashin damuwa na cyclic. A Botou Haijun Metal Products Co., Ltd., mun aiwatar da jerin walda sama da 12,000 a kan tsarin aikin noma, firam ɗin kayan aikin gini, da tsarin tallafin isar da saƙo mai sarrafa kansa. Abin da muka koya ba bisa ka'ida ba ne: an haɗa shi cikin rahotannin DFM, ƙonawa ta hanyar katako, da ma'aunin murdiya bayan walda.
Pre-Weld Preparation Ba Ne Tattaunawa-Ba Na Zabi Ba
Yawancin gazawar walda na dandamali suna farawa kafin baka ya fado. Muna ganin ta akai-akai: ƙungiyoyi sun tsallake tabbatar da dacewa da haɗin gwiwa, ɗaukan ƙayyadaddun abu, ko yin watsi da sauye-sauyen girman niƙa a cikin batches na bakin karfe. A wurin aikinmu na Botou, kowane taron dandamali yana farawa da cak guda uku waɗanda ba za a iya sasantawa ba:
Haƙuri tazarar ≤ 0.5 mm fadin cikakken tsayin haɗin gwiwa - auna tare da ma'auni * kafin * manne, ba bayan ba Base karfe zafin jiki ≥ 10 ° C a cikin yanayin sanyi; kasa da haka, preheat zuwa 50 ° C don carbon karfe, 100 ° C don 304 bakin - an tabbatar da ma'aunin zafi da sanyio a maki uku a kowace mita. An tabbatar da tsaftar saman ta hanyar goge-goge + gwajin farar fata: babu ragi a bayyane, babu man sawun yatsa, babu ƙurar niƙa da ta makale a cikin ramuka Mun taɓa kawar da manyan majalisu guda 17 saboda ƙarfe ɗaya na ƙarfe mai sanyi ya zo tare da kauri marar daidaituwa. Layin oxide ya karye ba daidai ba yayin GMAW, yana haifar da micro-porosity a tushen wucewar tushe. Yanzu, duk coils masu shigowa suna yin nazari na bayyani don daidaiton oxide na saman-kuma muna daidaita kwararar iskar gas (daga 18 L/min zuwa 22 L/min) lokacin da bambancin sikelin ya wuce ± 0.3 µm.
Zaɓin Tsari Yana Ƙarfafa Ayyukan Tsari
Zaɓi tsakanin FCAW, GMAW, da SAW ba game da saurin gudu ba ne - game da daidaita shigarwar zafin jiki ne zuwa lissafi, kaurin abu, da lodin sabis. Don tsarin dandamali tare da kauri na bango na ≥6 mm da ci gaba da haɗin gwiwar fillet, muna tsoho zuwa waldawar baka ta amfani da waya E71T-1. Me yasa? Tsarin slag ɗin sa yana jure wa ɗan ƙaramin bambance-bambancen dacewa fiye da ƙaƙƙarfan waya, kuma ƙimar ajiyarsa mafi girma yana yanke faɗin yankin da ke fama da zafi (HAZ) da 22% da GMAW a daidai amperage.
Amma don dandamali na ma'auni na bakin ciki-kamar benayen tallafi na aluminum don tsarin hawan hasken rana-muna canzawa zuwa GMAW mai juzu'i tare da waya 1.2 mm ER5356. Mitar bugun jini yana tsayawa a 120 Hz; Ana kulle kololuwar halin yanzu a 145 A. Wannan yana hana ƙonawa akan zanen 2.5 mm yayin kiyaye zurfin shigar ciki ≥1.8 mm. Wasu na iya jayayya cewa MIG ya fi "sauki" don aluminum. Koyaya, ba tare da sarrafa bugun jini ba, mun auna ƙimar 37% mafi girma na murdiya da 4 × ƙarin porosity a cikin yanayin ɗanɗano - an tabbatar ta hanyar gwajin hoto akan samfuran welds 120.
Dabarun Maƙarƙashiya Yana Ƙayyade Kwanciyar Hankali
Matsala ba sa riƙe sassa-suna sarrafa saura damuwa. Mummunan lamarin dandali na yakinmu ya faru ne a kan tsarin noma na mita 3.2: madaidaitan C-clamps guda shida sun haifar da takura na gida, yana tilasta murdiya waje a tsakiyar tazara. Yanzu muna amfani da clamping jere: na farko gyara gefuna datum, sannan a yi amfani da ƙugiya masu iyo a tazara na 300-mm tare da flanges waɗanda ba na datum ba, suna sakin kowane matsi *bayan* waldi na kusa yana sanyaya zuwa 60°C. Kyamarorin zafi sun tabbatar da wannan yana rage murɗawar kusurwa da kashi 65% tare da matsawa a tsaye.
Mun kuma shigar da ramummuka-mai faɗi-0.8 mm, yanke tare da Laser-tare da wuraren canjin matsananciyar damuwa. Waɗannan suna aiki azaman hanyoyin magance damuwa a lokacin sanyaya. A cikin dandali ɗaya na kayan aikin gini, ƙara ramukan 12-mm guda uku sun rage karkatar bayan walda madaidaiciya daga 2.1 mm/m zuwa 0.4 mm/m — ba tare da injin walƙiya ba.
Dubawa Dole ne Ya Wuce Kayayyakin gani
Binciken gani yana kama kashi 41 cikin 100 na munanan lahani a cikin welds, bisa ga bayanan NDT na cikin gida daga 2022-2023. Muna buƙatar tabbatarwa mataki uku:
Sa ido na ainihi: Duk ƙwayoyin walda na mutum-mutumi suna rikodin ƙarfin lantarki, halin yanzu, saurin tafiya, da ƙimar ciyarwar waya a kowane yanki na 50 mm. Maɓalli > 3% yana haifar da dakatarwar atomatik Tabbatar da girman bayan walda: Kowane dandali yana jujjuya binciken CMM akan ƙirar CAD - mai da hankali kan ƙirar rami mai mahimmanci, kwanciyar hankali (≤0.08 mm), da daidaiton ƙafar walda (± 0.3 mm) Gwajin lodi mai aiki: Bazuwar 5% na batches samarwa suna jure nauyin nauyin 1.5 × don 120 seconds. Muna auna juzu'i a maki takwas-ba kawai matsakaicin ba, amma gradient a fadin tsarin Wannan horon ya sami matsala mai maimaitawa a cikin ginshiƙan shinge mai zurfi: karɓaɓɓen bayyanar gani da ke cike da rashin haɗuwa a mahaɗin radius da flange da aka zana. Gwajin Ultrasonic ya nuna kashi 92 cikin 100 na irin wannan welds suna da katsewar ƙasa. Mun sake tsara ginshiƙan haɗin gwiwa - ƙara 0.5 mm tushen fuskar fuska da rage haɗakar kusurwa daga 75 ° zuwa 65 ° - kuma mun kawar da aibi.
Welding Platform Tsari Ne—Ba Mataki Ba
Waldawar dandamali yana samun nasara ne kawai lokacin da ƙira, zaɓin kayan aiki, injiniyan kayan aiki, sarrafa tsari, da dubawa suna aiki azaman tsari ɗaya. A Botou Haijun, muna ɗaukar kowane dandamali azaman halitta mai ɗaukar nauyi-ba tarin sassa na walda ba. Gudun aikin mu mai yarda da ISO yana haɗa ra'ayoyin DFM * kafin * ambato, cancantar tsarin walda * kafin * sakin kayan aiki, da takaddun shaida na kayan aiki * tare da kowane jigilar kaya*. Ba mu sayar da walda. Muna ba da ingantaccen ci gaba na tsari.
Ga injiniyoyi masu ƙayyadaddun walda na dandamali, fara nan: ayyana hanyar ɗaukar nauyi da farko, sannan zaɓi tsarin lissafi na haɗin gwiwa, sannan tsarin daidaitawa zuwa ƙarfe-ba wai baya ba. Wannan canjin shine kawai ya yanke sake yin aiki da kashi 38%, dangane da bayanan 2023 daga ayyukan abokin ciniki 47. Waldawar dandamali ba game da haɗa karfe ba ne. Yana da game da ba da garantin watsa ƙarfi—a cikin yanayi, cikin canje-canje, a cikin shekarun da suka gabata.
