Magance matsalolin ingantattun matsaloli na babban matsi na jefa harsashi biyu kama harsashi

Zaɓi zuwa: Kayan kayan kwalliyar dual-clutch gearbox suna rigar akwatin gear dual-clutch, harsashi mai goyan baya ya ƙunshi kama da harsashi na gearbox, harsashi biyu da aka samar ta hanyar simintin matsi mai ƙarfi, a cikin aiwatar da haɓaka samfura da samarwa sun sami matsala mai wahala mai haɓaka ingancin haɓaka, ƙarancin ƙimar cancantar kusan kusan 60% 95% ta ƙarshen matakan haɓakawa na yau da kullun zuwa 2.

Wet dual-clutch watsa, wanda ke amfani da sabbin kayan aikin kascade, tsarin motsi na injin lantarki da sabon mai kunna wutan lantarki-hydraulic.Bakin harsashi an yi shi da babban simintin simintin ƙarfe na aluminum, wanda ke da halaye na nauyi mai nauyi da ƙarfin ƙarfi.Akwai famfo na hydraulic, ruwan mai mai mai, bututu mai sanyaya da tsarin sanyaya waje a cikin akwatin gear, wanda ya gabatar da buƙatu mafi girma akan ingantaccen aikin injina da aikin rufewar harsashi.Wannan takarda ta yi bayanin yadda ake magance matsalolin inganci kamar nakasar harsashi, ramin raguwar iska da ƙimar wucewar ɗigo wanda ke shafar ƙimar wucewa sosai.

1,Maganin matsalar nakasa

Hoto 1 (a) da ke ƙasa, Akwatin gear ya ƙunshi babban matsi na simintin simintin gyaran gyare-gyare na aluminum gami da mahalli mai kama.Kayan da aka yi amfani da shi shine ADC12, kuma kaurin bangon sa na asali shine kusan 3.5mm.Ana nuna harsashin akwatin gear a hoto na 1 (b).Matsakaicin girman shine 485mm (tsawo) × 370mm (nisa) × 212mm (tsawo), ƙarar shine 2481.5mm3, yanki mai tsinkaya shine 134903mm2, kuma nauyin net yana kusan 6.7kg.Bangaren rami ne mai zurfi mai bakin ciki.Idan akai la'akari da masana'antu da fasaha na fasaha na mold, da amincin samfurin gyare-gyare da kuma samar da tsari, da mold da aka shirya kamar yadda aka nuna a cikin Figure 1 (c), wanda ya hada da uku kungiyoyin na sliders, motsi mold (a cikin shugabanci na m rami) da kafaffen mold (a cikin shugabanci na ciki rami), da thermal shrinkage kudi na 51.0 da aka tsara zuwa 5.0.

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A haƙiƙa, a cikin aiwatar da gwajin simintin gyare-gyare na farko, an gano cewa girman matsayin samfurin da aka samar ta hanyar simintin mutuwa ya sha bamban da buƙatun ƙira (wasu mukamai sun haura kashi 30%), amma girman ƙirar ya cancanta kuma ƙimar raguwar idan aka kwatanta da ainihin girman shima yana cikin layi tare da dokar ragewa.Domin gano musabbabin matsalar, an yi amfani da 3D scanning na harsashi na zahiri da kuma ka'idar 3D don kwatantawa da bincike, kamar yadda aka nuna a hoto na 1 (d).An gano cewa tushen sakawa yanki na blank ya lalace, kuma adadin nakasawa ya kasance 2.39mm a cikin yanki B da 0.74mm a cikin yanki C. Domin samfurin yana dogara ne akan madaidaicin ma'anar blank A, B, C don madaidaicin matsayi na gaba da ma'aunin ma'auni, wannan nakasar yana kaiwa ga ma'auni, sauran nau'ikan tsinkaya, girman girman jirgin sama zuwa A.

Binciken musabbabin wannan matsala:

Themighter matsa lamba casting mita tsari shine ɗayan samfuran da aka tsara a kan ƙayyadadden ƙayyadadden kayan aikin da ke motsawa a kan ƙayyadaddun ƙayyadadden kayan aikin yau da kullun yayin da babu makawa furannin;

②Akwai silidu a gefen hagu, ƙananan da dama na mold, waɗanda ke taka rawa wajen matsewa kafin rushewa.Ƙarfin tallafi mafi ƙanƙanta yana a babba B, kuma gabaɗayan halin da ake ciki shi ne haɗuwa a cikin rami yayin raguwar thermal.Babban dalilai guda biyu na sama suna haifar da nakasa mafi girma a B, sannan C.

Tsarin haɓakawa don magance wannan matsalar shine ƙara ƙayyadadden tsarin fitar da mutuwa Hoto na 1 (e) akan kafaffen shimfidar mutuwar.A B ƙara 6 kafa mold plunger, ƙara biyu kafaffen mold plunger a cikin C, kafaffen fil sanda ne dogara ga sake saiti ganiya, a lokacin da motsi mold clamping jirgin sama saita sake saiti lila danna shi a cikin wani mold, mold atomatik mutu matsa lamba bace, da baya na farantin spring sa'an nan tura saman ganiya, dauki himma don inganta samfurori fitowa daga kafaffen kashe mold, don haka kamar yadda za a gane det.

Bayan gyaran gyare-gyare, an rage nakasar lalacewa cikin nasara.Kamar yadda aka nuna a FIG.1 (f), nakasassu a B da C ana sarrafa su yadda ya kamata.Point B shine + 0.22mm kuma maki C shine + 0.12, wanda ya dace da buƙatun kwane-kwane na 0.7mm kuma ya sami samar da taro.

2. Maganin shrinkage rami da zubewar harsashi

Kamar yadda kowa ya sani, babban simintin simintin gyare-gyare wata hanya ce ta kafa wanda ake cika ƙarfen ruwa da sauri a cikin rami na ƙera ƙarfe ta hanyar amfani da wasu matsa lamba kuma yana ƙarfafawa cikin sauri a ƙarƙashin matsin lamba don samun simintin.Koyaya, dangane da halaye na ƙirar samfuri da aiwatar da simintin simintin gyare-gyare, har yanzu akwai wasu wuraren haɗin gwiwa masu zafi ko ramukan raguwar iska mai haɗari a cikin samfurin, wanda ya faru ne saboda:

(1) Yin simintin matsi yana amfani da babban matsa lamba don danna karfen ruwa a cikin rami mai saurin gaske.Ba za a iya fitar da iskar gas a cikin ɗakin matsa lamba ko kogon ƙura ba gaba ɗaya.Wadannan iskar gas suna shiga cikin ƙarfe na ruwa kuma a ƙarshe suna wanzuwa a cikin simintin gyare-gyare a cikin nau'i na pores.

(2) The solubility na gas a cikin ruwa aluminum da m aluminum gami ne daban-daban.A cikin tsarin ƙarfafawa, ba makawa gas yana haɗewa.

(3) Ƙarfe na ruwa yana ƙarfafawa da sauri a cikin rami, kuma idan babu ingantaccen ciyarwa, wasu sassan simintin za su haifar da raguwa ko raguwar porosity.

Ɗauki samfurori na DPT waɗanda suka shiga cikin samfurin kayan aiki da ƙananan matakan samar da kayan aiki a matsayin misali (duba Hoto 2): An ƙididdige ƙimar ƙarancin ramin haɓakar iska na farko na samfurin, kuma mafi girma shine 12.17%, daga cikin abin da ramin shrinkage na iska ya fi girma fiye da 3.5mm ya lissafta 15.71% na jimlar 4.5 mm. 3%.Waɗannan ramukan ƙaƙƙarfan iska sun fi mayar da hankali ne a cikin wasu ramukan zaren zare da saman rufewa.Waɗannan lahani za su yi tasiri ga ƙarfin haɗin gwiwa, matsananciyar ƙasa da sauran buƙatun aikin tarkace.

Don magance waɗannan matsalolin, manyan hanyoyin sune kamar haka:

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2.1TSARIN SANYA KWALLIYA

Ya dace da sassan rami mai zurfi guda ɗaya da manyan sassa masu mahimmanci.The forming part na wadannan Tsarin yana da kawai 'yan zurfin cavities ko zurfin rami part na core ja, da dai sauransu, da kuma 'yan molds aka nannade da wani babban adadin ruwa aluminum, wanda shi ne mai sauki sa overheating na mold, haddasa m mold iri, zafi fashe da sauran lahani.Sabili da haka, wajibi ne a tilasta sanyaya ruwan sanyi a wurin wucewa na ƙirar rami mai zurfi.Sashin ciki na tsakiya tare da diamita mafi girma fiye da 4mm ana sanyaya shi da ruwa mai girma na 1.0-1.5mpa, don tabbatar da cewa ruwan sanyi yana da sanyi da zafi, kuma sassan da ke kewaye da su na iya fara ƙarfafawa kuma su samar da wani Layer mai yawa, don rage raguwa da halayen porosity.

Kamar yadda aka nuna a cikin Hoto 3, haɗe tare da bayanan ƙididdiga na simulation da samfurori na ainihi, an inganta shimfidar wuri na ƙarshe na sanyaya, kuma an saita babban matsi mai matsa lamba kamar yadda aka nuna a cikin Hoto 3 (d) a kan mold, wanda ya dace da sarrafa yawan zafin jiki na samfurin a cikin yankin haɗin gwiwa mai zafi, ya gane daidaitattun samfurori na samfurori, yadda ya kamata ya rage yawan tsararrun ramukan da aka tsara da kuma tabbatar da ƙimar ramukan.

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2.2Extrusion na gida

Idan kaurin bangon ƙirar ƙirar samfurin bai yi daidai ba ko kuma akwai manyan nodes masu zafi a wasu sassa, ramukan raguwa suna da yuwuwar bayyana a cikin ingantaccen ɓangaren ƙarshe, kamar yadda aka nuna a FIG.4 (C) kasa.Ba za a iya hana ramukan raguwa a cikin waɗannan samfuran ta hanyar aiwatar da simintin mutuwa da haɓaka hanyar sanyaya ba.A wannan lokacin, ana iya amfani da extrusion na gida don magance matsalar.Partial matsa lamba tsarin zane kamar yadda aka nuna a cikin adadi 4 (a), wato shigar kai tsaye a cikin mold Silinda, bayan narkakkar karfe cika a cikin mold da kuma solidified kafin, ba gaba daya a cikin Semi-m karfe ruwa a cikin kogo, da a karshe solidification lokacin farin ciki bango ta extrusion sanda matsa lamba tilasta ciyar don rage ko kawar da shrinkage kogo lahani, domin ya mutu ingancin high quality.

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2.3Extrusion na sakandare

Mataki na biyu na extrusion shine saita silinda bugun jini sau biyu.Na farko bugun jini ya kammala wani bangare na gyare-gyaren rami na farko na farko, kuma lokacin da ruwa na aluminum da ke kewaye da shi ya karu a hankali, aikin extrusion na biyu ya fara, kuma an sami sakamako biyu na pre-simintin da extrusion a ƙarshe.Ɗauki gidan gearbox a matsayin misali, ƙimar da ta dace na gwajin gas na gidan gearbox a farkon matakin aikin bai wuce 70%.Rarraba sassan yoyon fitsari galibi shine mahadar hanyar mai 1# da kuma hanyar mai 4# (ja a hoto na 5) kamar yadda aka nuna a kasa.

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2.4TSARIN CIN GUDU

Tsarin simintin gyare-gyaren simintin gyare-gyaren ƙarfe shine tashar da ke cika rami na ƙirar simintin simintin gyare-gyare tare da narkakken ruwa na ƙarfe a cikin ɗakin latsawa na inji mai mutuƙar zafi a ƙarƙashin yanayin zafi mai zafi, matsa lamba da sauri.Ya haɗa da madaidaicin mai gudu, mai tseren giciye, mai gudu na ciki da tsarin shaye-shaye.An shiryar da su a cikin aiwatar da ruwa mai cika rami mai cike da ruwa, yanayin kwararar ruwa, saurin gudu da matsa lamba na canja wurin ƙarfe na ruwa, tasirin shayewa da mutuƙar ƙima suna taka muhimmiyar rawa a cikin nau'ikan yanayin yanayin yanayin zafi na sarrafawa da ƙa'ida, sabili da haka, tsarin gating an yanke shawarar mutu simintin ingancin ƙasa kamar yadda mahimmancin yanayin yanayin microstructure na ciki.Zane da kuma kammala tsarin zubewa dole ne su dogara ne akan haɗin ka'idar da aiki.

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2.5ProceOingantawa

Die simintin tsari tsari ne mai zafi wanda ke haɗawa da amfani da na'ura mai mutuƙar mutu, mutu simintin simintin da ƙarfe na ruwa bisa ga tsarin da aka riga aka zaɓa da sigogin tsari, kuma yana samun mutun simintin tare da taimakon wutar lantarki.Yana ɗaukar kowane nau'i na la'akari, Irin su matsa lamba (ciki har da ƙarfin allura, takamaiman matsa lamba, ƙarfin haɓakawa, ƙarfin kulle mold), saurin allura (ciki har da saurin naushi, saurin ƙofar ciki, da sauransu), saurin ciko, da sauransu), yanayin zafi daban-daban (narkewar zafin jiki na ƙarfe na ruwa, mutu simintin gyare-gyare, zafin jiki, da dai sauransu), lokuta daban-daban (lokacin cikawa, lokacin riƙewar matsa lamba, ƙimar zafin jiki, matsakaicin matsakaicin lokaci, matsakaicin adadin zafin jiki, da dai sauransu). Dient, da dai sauransu), kaddarorin simintin gyare-gyare da kaddarorin thermal na ƙarfe na ruwa, da dai sauransu. Wannan yana taka muhimmiyar rawa a cikin matsi na simintin mutuwa, saurin ciko, halaye masu cikawa da kaddarorin thermal na mold.

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2.6Amfani da sababbin hanyoyin

Don magance matsalar yoyon sassa na sassan da ke cikin takamaiman sassan harsashi na gearbox, an yi amfani da maganin katangar aluminium mai sanyi a matsayin majagaba bayan tabbatar da bangarorin samarwa da buƙatu.Wato, ana ɗora shingen aluminium a cikin samfurin kafin cikawa, kamar yadda aka nuna a hoto na 9. Bayan cikawa da ƙarfafawa, wannan abin sakawa ya kasance a cikin ɓangaren ɓangaren don magance matsalar raguwar gida da porosity.

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Lokacin aikawa: Satumba-08-2022