ya raba sakamakon cikakken binciken da kamfanin ya yi inda aka kwatanta Inconel 625 daskararrun sanduna da sabbin sandunan Sanicro 60.
Inconel 625 mai gasa (UNS lambar N06625) wani superalloy ne na tushen nickel (superalloy mai jure zafi) wanda aka yi amfani da shi a cikin marine, nukiliya da sauran masana'antu tun farkon haɓakar sa a cikin 1960s saboda ƙarfin ƙarfinsa da juriya ga yanayin zafi. . yanayin zafi. Ya kara kariya daga lalata da iskar shaka.
Sabuwar ƙalubalen shine bambance-bambancen sanda mai zurfi na Sanicro 60 (wanda kuma aka sani da Alloy 625). An ƙera Sabuwar Sandvik mai rami mai zurfi don samar da kyakkyawan aiki a wasu wuraren da Inconel 625 ke mamaye, wanda aka yi daga babban ƙarfi na nickel-chromium gami wanda zai iya jure matsanancin yanayin zafi a cikin mahalli mai ɗauke da chlorine. Mai jure wa lalatawar intergranular da lalata damuwa, yana da daidaitattun juriya na Pitting (PRE) fiye da 48.
Makasudin binciken shine don kimantawa tare da kwatanta aikin injin Sanicro 60 (diamita = 72 mm) tare da Inconel 625 (diamita = 77 mm). Ma'auni na kimantawa shine rayuwar kayan aiki, ingancin saman da sarrafa guntu. Menene zai fito fili: sabon girke-girke na mashaya mara kyau ko duka mashaya na gargajiya?
Shirin kimantawa a Sandvik Coromant da ke Milan, Italiya ya ƙunshi sassa uku: juyawa, hakowa da bugun.
Ana amfani da MCM Horizontal Machining Center (HMC) don hakowa da gwaje-gwajen bugawa. Za a gudanar da ayyukan jujjuyawa akan Mazak Integrex Mach 2 ta amfani da masu riƙe Capto tare da sanyaya na ciki.
An kimanta rayuwar kayan aiki ta hanyar kimanta lalacewa na kayan aiki a yankan saurin gudu daga 60 zuwa 125 m/min ta amfani da ma'aunin alloy na S05F wanda ya dace da ƙarshen ƙarewa da roughing. Don auna aikin kowane gwaji, an auna cire kayan kowane saurin yanke ta manyan ma'auni guda uku:
A matsayin wani ma'auni na injina, ana ƙididdige samuwar guntu da kulawa. Masu gwadawa sun kimanta tsara guntu don abubuwan da aka saka na geometries daban-daban (Mazak Integrex 2 da aka yi amfani da shi tare da mariƙin PCLNL da CNMG120412SM S05F mai juyawa) a saurin yanke na 65 m/min.
Ana yin la'akari da ingancin saman bisa ga tsauraran sharuɗɗa: ƙarancin yanayin aikin bai kamata ya wuce Ra = 3.2 µm, Rz = 20 µm ba. Har ila yau, ya kamata su kasance masu 'yanci daga girgizawa, lalacewa, ko ginannun gefuna (BUE - kayan gini akan kayan aikin yanke).
An gudanar da gwaje-gwajen hakowa ta hanyar yanke fayafai da yawa daga sandar 60 mm guda ɗaya da aka yi amfani da su don jujjuya gwaje-gwajen. An haƙa rami da injin ɗin ya yi daidai da kullin sandar na tsawon mintuna 5 kuma ana yin rikodin lalacewa na baya na kayan aiki lokaci-lokaci.
Gwajin zaren yana kimanta dacewawar Sanicro 60 mara kyau da inconel 625 mai ƙarfi don wannan muhimmin tsari. An yi amfani da duk ramukan da aka ƙirƙira a cikin gwaje-gwajen hakowa da suka gabata kuma an yanke su tare da fam ɗin zaren Coromant M6x1. An loda shida a cikin cibiyar injinan kwance ta MCM don gwaji tare da zaɓuɓɓukan zaren daban-daban da kuma tabbatar da cewa sun tsaya tsayin daka a duk lokacin zaren. Bayan zaren, auna diamita na ramin da aka samu tare da caliper.
Sakamakon gwajin ya kasance babu shakka: Sanicro 60 m sanduna sun fi ƙarfin Inconel 625 tare da tsawon rai da ingantaccen yanayin ƙasa. Hakanan ya dace da sanduna masu ƙarfi a cikin ƙirar guntu, hakowa, taɓawa da bugun kuma an yi daidai da kyau a cikin waɗannan gwaje-gwajen.
Rayuwar sabis na sanduna mara kyau a cikin mafi girma gudu yana da tsayi fiye da sanduna masu ƙarfi kuma fiye da sau uku fiye da sanduna masu ƙarfi a saurin yanke na 140 m/min. A wannan babban gudun, ƙaƙƙarfan sandar ya ɗauki mintuna 5 kawai, yayin da mashaya mara kyau yana da rayuwar kayan aiki na mintuna 16.
Sanicro 60 rayuwar kayan aiki ya kasance mafi kwanciyar hankali yayin da saurin yanke ya karu, kuma yayin da saurin ya karu daga sau 70 zuwa 140 m / min, rayuwar kayan aiki ta ragu da kashi 39% kawai. Wannan shine 86% gajeriyar rayuwar kayan aiki fiye da Inconel 625 don canji iri ɗaya cikin sauri.
Fuskar sanduna mara kyau ta Sanicro 60 ta fi santsi fiye da na inconel 625 mai ƙarfi. Wannan duka biyun haƙiƙa ne (ƙananan saman bai wuce Ra = 3.2 µm, Rz = 20 µm), kuma ana auna shi ta gefen gani, alamun girgiza ko lalacewa a saman saboda samuwar kwakwalwan kwamfuta.
Sanicro 60 hollow shank yayi daidai da tsohon Inconel 625 solid shank a cikin gwajin zaren kuma ya nuna irin wannan sakamako ta fuskar lalacewa da ƙarancin samuwar guntu bayan hakowa.
Sakamakon binciken ya goyi bayan cewa ramukan sanduna ingantaccen madadin sanduna ne. Rayuwar kayan aiki sau uku ya fi tsayi fiye da gasar a babban saurin yankewa. Sanicro 60 ba kawai yana daɗe ba, yana da inganci, yana aiki tuƙuru da sauri tare da kiyaye aminci.
Tare da zuwan kasuwar duniya mai gasa wacce ke ingiza masu sarrafa injin don yin hangen nesa na dogon lokaci game da jarin kayansu, ikon Sanicro 60's na rage lalacewa akan kayan aikin injin ya zama dole ga waɗanda ke neman haɓaka tazara da ƙarin farashin samfuran gasa. . yana nufin da yawa.
Ba wai kawai na'urar zata dade ba kuma za'a rage sauye-sauyen, amma yin amfani da ginshiƙi maras kyau na iya ƙetare duk tsarin aikin injin, kawar da buƙatar rami na tsakiya, mai yuwuwar ceton lokaci da kuɗi mai yawa.