Lab Log: Zaɓin Karfe Mai Alloy da Maganin Zafi don Adaftar Bucket Mai Tsabta

A Adaftar haƙoran Komatsu bokitishine haɗin tsarin da ke tsakanin gefen bokitin haƙa rami da kuma ƙarshen haƙorin da za a iya maye gurbinsa. Yana shan cikakken ƙarfin haƙa - wanda akan na'urar haƙa ramin PC200 zai iya kaiwa 140 kN a gefen haƙorin bokiti - kuma yana aika shi daga haƙorin ta hanyar adaftar zuwa cikin leben bokiti. Idan adaftar ta fashe ko ta yi laushi a wurin da aka huda ramin, ƙarshen haƙorin ya ɓace kuma mai aiki dole ne ya daina haƙa ramin, ya dawo da haƙorin, sannan ya maye gurbin adaftar - aiki na minti 25 akan $2-3 a minti ɗaya na rashin aiki na injin.

A cikin masana'antarmu ta JM China, muna yin adaftar Komatsu daga ƙarfe mai ƙarancin ƙarfe - yawanci 30CrMnSi ko 35CrMo - saboda waɗannan ƙarfe suna samun taurin da ake buƙata na HRC 45–52 bayan an kashe mai da kuma an daidaita shi yayin da ake kiyaye isasshen taurin tasiri don ɗaukar nauyin aikin haƙa rami. Tsarin simintin yana amfani da tsarin kumfa da ya ɓace tare da mold na yashi na silica. Bayan simintin, ana sanya kowane adaftar a cikin ruwan zafi a 920°C na tsawon awanni 2, a kashe mai zuwa zafin ɗaki, sannan a rage shi a 250°C na tsawon awanni 3 don cimma taurin da aka nufa. Matakin simintin yana da mahimmanci: a tsallake shi kuma adaftar yana da rauni a HRC 58–60, yana iya karyewa a farkon tasirin dutse. Yana da zafi fiye da kima a 350°C kuma taurin yana raguwa zuwa HRC 38–42, yana rage tsawon lokacin lalacewa da kashi 40%.

Muna kiyaye ƙayyadadden tauri na HRC 48 ± 3 don adaftar Komatsu na yau da kullun da HRC 52 ± 2 don nau'in nauyi da masu kwangilar rushewa suka ƙayyade. Ana tabbatar da tauri ta hanyar ma'aunin Rockwell C mai maki uku a kowace adaftar: ɗaya a ƙarshen hanci (yankin da ke riƙe haƙorin), ɗaya a wurin da ke riƙe fil ɗin (yankin da ke ɗaukar fil ɗin riƙewa), da ɗaya a tushen hawa (yankin da ke haɗawa ko kuma ya manne a kan leben bokiti). Tauri na gefen hanci dole ne ya kasance cikin maki 2 na HRC na babban fil ɗin - in ba haka ba bambancin lalacewa tsakanin saman biyu yana hanzarta sassauta haƙori. Idan ƙarshen hanci yana da laushi (HRC 42) yayin da babban fil ɗin yake da tauri (HRC 50), ƙarshen hanci yana sawa da sauri 30% kuma haƙorin yana haɓaka wasan gefe bayan awanni 120. Mai aiki ba zai iya jin wannan wasa a cikin motar ba - amma fil ɗin riƙewa yanzu yana ɗauke da kayan gefe da ba a tsara shi ba, kuma yanke fil ɗin da wuri yana iya zama mai yiwuwa.

A watan Janairun 2025, mun gwada adaftar guda 50 daga sabon rukunin jefawa da aka yi da 50 daga samarwarmu ta yanzu. Sabon rukunin — wanda aka yi da ɗan zafi daban-daban na 35CrMo — ya nuna taurin hanci zuwa fil na maki 3.8 na HRC a matsakaici, idan aka kwatanta da 1.6 na rukunin da ake yi yanzu. Babban dalilin shine zafin man quench mai zafi na 15°C mafi girma a ranar farko ta samarwa ta sabon rukunin, wanda ya rage tsananin quench a ƙarshen hanci mai siriri amma ba a kan babban fil mai kauri ba. Mun mayar da man quench zuwa 45°C kuma mun tabbatar da cewa yaduwar taurin ta koma matsakaicin maki 1.6 a cikin kwanaki huɗu masu zuwa na samarwa. An rage adaftar guda 50 daga rukunin da ba su dace ba zuwa "tsarin yau da kullun" kuma an sayar da su akan farashi mai rahusa don aikace-aikacen da ba su da wahala.

Rikodin Samarwa: Siminti, Maganin Zafi, da Tabbatar da Girman Adaftar Komatsu K-Series

Bayanin fil ɗin Komatsu K - wanda aka yi amfani da shi a kan samfuran haƙa PC30 zuwa PC800 - ya ƙayyade ramin fil mai tauri tare da kusurwar da aka haɗa da 2° a kan ramukan sama da ƙasa, takamaiman diamita na fil (12 mm don PC50 har zuwa 30 mm don PC650), da kuma nisan tsakiya zuwa ƙarshen fil wanda ya bambanta dangane da girman adaftar. Bambancin fiye da 0.3 mm a cikin matsayin ramin fil yana nufin ba za a iya saka fil ɗin riƙewa ta cikin haƙori da ramukan adaftar ba - kuma dukkan adaftar ɗin ya zama tarkace. Wannan daidaiton girma ana cimma shi ta hanyar haɗa injin CNC bayan siminti da kayan aiki na musamman wanda ke nuna matakin tushe na adaftar.

Muna amfani da injin kowace adaftar a cikin saiti ɗaya a kan cibiyar injina mai tsayi mai kusurwa huɗu. Tsarin aiki shine: (1) fuskantar tushen hawa - yana nufin wuraren gano simintin daga tsarin kumfa da ya ɓace; (2) haƙa ramin fil kuma a sake haɗa shi zuwa haƙurin H8 (misali, 20.0 +0.033/0.000 mm don adaftar PC200); (3) niƙa ramin riƙe haƙori a kan bakin hanci; da kuma (4) haƙa ramin giciye ta cikin fil don maƙallin riƙewa. Bayan yin injin, ana duba kowane adaftar akan injin aunawa (CMM) tare da ƙudurin 0.005 mm. Mahimman girman - diamita na ramin fil, nisan fuska daga tsakiya zuwa sama, da faɗin bakin hanci - ana auna su kuma an rubuta su a cikin rahoton rukuni wanda ke tare da kowane jigilar kaya zuwa ga masu rarrabawa na Japan.

A shekarar 2024, mun samar da adaftar da ta dace da Komatsu guda 38,000 a cikin nau'ikan girma 20. Matsakaicin ƙin yarda shine 1.1%, ma'ana adaftar 418 sun gaza duba CMM kuma an goge su ko kuma an sake yin aiki da su. Rashin nasarar da aka fi samu - kashi 62% na jimlar ƙin yarda - shine matsayin ƙwanƙwasa: nisan da ke tsakanin fuska zuwa tsakiya yana wajen taga haƙurin ±0.3 mm. Mun gano wannan da bambancin faɗaɗa zafi a cikin ƙwanƙwasa: ƙwanƙwasa da suka sanyaya a hankali a cikin ƙwanƙwasa (saboda yawan danshi na yashi) sun nuna ƙarin ƙwanƙwasa 0.15–0.2 mm a ƙarshen hanci, suna canza matsayin ƙwanƙwasa ƙwanƙwasa dangane da matakin tunani. Maganin foundry shine aiwatar da sanyaya ƙwanƙwasa mai sarrafawa na mintuna 180 ± 10 kafin girgiza - a da, lokacin sanyi ya dogara ne akan ikon mai aiki kuma ya kasance daga mintuna 120 zuwa 240. Bayan aiwatar da sanyaya mai sarrafawa, ƙimar ƙin amincewa da matsayin ƙwanƙwasa ƙwanƙwasa ya ragu daga 0.68% zuwa 0.19%.

Ga masu rarrabawa na Japan - waɗanda galibi ke da kayan haɗin 200-500 a kowane girma - tsarin bin diddigin rukuni da muke bayarwa yana ba su damar gano kowane adaftar ta lambar rukuni da kuma dawo da rikodin jefawa, jadawalin maganin zafi, da rahoton girman CMM. Wannan bin diddigin yana ƙara zama dole ta hanyar tsarin kula da inganci na kamfanonin gine-gine na Japan, wanda ke buƙatar a samar da duk kayan sawa ga duk wanda ke da kayan sawa.Ƙungiyar Kayan Aikin Gine-gine ta Japankamfanonin membobi suna ɗauke da cikakkun takaddun tarihin masana'antu.

Bayanan Fili: Aikin Tsarin Rike Filo a ƙarƙashin Lodawa Mai Zagaye

Tsarin riƙe fil - maƙallin maɓuɓɓugar ƙarfe ko maƙallin riƙe polyurethane wanda ke kulle fil ɗin riƙewa a wurinsa - shine ƙaramin ɓangaren haɗa adaftar amma tushen gazawar filin da aka fi sani. Lokacin da maƙallin riƙewa ya karye ko ya rasa ƙarfi, maƙallin riƙewa yana aiki a kwance a ƙarƙashin girgizar haƙori, kuma ƙarshen haƙorin ya faɗi daga adaftar a cikin zagayowar aiki 10-20. Bakin haƙori da ya ɓace a wurin rushewa a tsakiyar Tokyo - inda mai haƙa PC350 yana karya harsashin siminti mai ƙarfi - yana nufin injin dole ne ya tsaya, mai aiki dole ne ya sauko, ya gano haƙorin a cikin tarin tarkace (wanda zai iya ɗaukar mintuna 10 a wurin da cunkoso ya faru), ya dawo da shi, sannan ya sake sanya shi da sabon maƙallin riƙewa. A farashin injin $80 a kowace awa na aiki da kuma mintuna 30 na tsayawa ba tare da an tsara ba, kowace asarar haƙori tana kashe $40 a lokacin aiki na injin - tare da kuɗin aiki na mai aiki da mai kula da tsaron wurin.

Mun gwada kayan riƙewa guda uku a kan injin ɗaukar kaya mai zagaye a cibiyarmu ta Zhengzhou a shekarar 2024: (1) ƙarfe mai kauri 65Mn, wanda aka yi masa zafi zuwa HRC 44–48; (2) ƙarfe mai kauri 60Si2Mn, wanda aka yi masa zafi zuwa HRC 46–50; da kuma (3) taurin kai na polyurethane 95A. Gwajin ya zagaya kowace ƙugiya ta hanyar zagaya cire haƙori 50,000 a mita na 0.5 Hz - wanda ya yi kwaikwayon mafi munin yanayin canjin haƙori gaba ɗaya a kowane motsi a cikin shekaru 2. Faifan 65Mn sun nuna lalacewar ƙarfin faifan 22% bayan zagayowar 50,000 - daga ƙarfin riƙewa na farko na N 280 zuwa 218 N. Faifan 60Si2Mn sun nuna raguwar kashi 15% - daga 300 N zuwa 255 N. Faifan polyurethane sun nuna raguwar kashi 35% - daga 200 N zuwa 130 N - kuma uku daga cikin faifan polyurethane guda 20 sun fashe a wurin hulɗar faifan 30,000 zuwa 38,000.

Dangane da waɗannan sakamakon, yanzu muna amfani da maƙullan ƙarfe na bazara na 60Si2Mn a matsayin mizani akan duk girman adaftar Komatsu sama da PC200, kuma muna ba da maƙullan 65Mn akan ƙananan girman PC70 da PC130 inda ƙaramin matsin lamba na maƙullan har yanzu ya isa ga matsakaicin nauyin haƙori na 20 kN. Maƙullan polyurethane suna nan don aikace-aikacen da ba su da mahimmanci kamar duba haƙoran bokiti amma ba a ba da shawarar su don rushewa ko haƙa duwatsu ba. Mun haɗa da ƙarin maƙullan riƙewa guda goma tare da kowane pallet na adaftar 50 da aka aika zuwa ga masu rarrabawa na Japan - aikin da aka karɓe shi da kyau saboda maƙullan sune ƙaramin ɓangaren da aka fi rasawa a ayyukan gyaran filin.

Sakamakon Gwaji: Kwatanta Juriyar Abrasion a Tsakanin Maki Mai Tauri

Mun gudanar da gwajin gogewa mai sarrafawa wanda ya kwatanta ƙarfen adaftar a matakai huɗu na tauri: HRC 38, HRC 45, HRC 50, da HRC 55. Kowane samfurin farantin 50 mm × 50 mm × 12 mm ne da aka yanke daga adaftar samarwa a sashin hanci. Gwajin ya yi amfani da na'urar busasshiyar tayoyin roba da yashi bisa ga ASTM G65 - tsari na D, nauyin kilogiram 5, juyin juya hali 1,000 - kuma mun auna asarar girma a cikin milimita mai siffar cubic.

Sakamakon: HRC 38 ya rasa 85 mm³. HRC 45 ya rasa 62 mm³ - ci gaba da kashi 27% akan samfurin mafi laushi. HRC 50 ya rasa 48 mm³ - ci gaba da kashi 23% akan HRC 45 da kuma 44% akan mafi laushi. HRC 55 ya rasa 41 mm³ - ci gaba da kashi 15% akan HRC 50 amma ci gaba da kashi 7 mm³ kawai. Dokar rage riba a bayyane take: ribar juriyar sawa daga HRC 50 zuwa HRC 55 kaɗan ne, yayin da asarar taurin tasiri take da mahimmanci. Gwajin Charpy V-notch akan samfuran iri ɗaya ya nuna cewa kuzarin tasiri ya ragu daga 24 J a HRC 50 zuwa 14 J a HRC 55 - raguwa da kashi 42%. A cikin aikace-aikacen rushewa inda adaftar dole ne ya jure bugun dutse kai tsaye, ƙaruwar haɗarin karyewa a HRC 55 ya fi ƙaruwar lalacewa ta 15% na rayuwa.

Wannan bayanan gwaji suna jagorantar shawarwarin samfuranmu. Don motsi a cikin ƙasa mai yashi ko ƙasa mai laushi - inda gogewa ita ce hanyar lalacewa mafi rinjaye - muna ba da shawarar HRC 50–52 don tsawon lokacin lalacewa ba tare da karyewa ba. Don rushewa ko haƙa duwatsu - inda nauyin tasiri ya yi tsanani - muna ba da shawarar HRC 46–48 don riƙe ƙarfin tasiri yayin da har yanzu suna samun juriya mai karyewa. 'Yan kwangilar rushe kasuwar Japan da muke samarwa a Tokyo da Osaka sun daidaita akan matakin HRC 46–48 tare da madaidaitan madaidaitan 60Si2Mn, kuma yawan amfani da adaftar su na shekara-shekara a kowace na'urar haƙa PC350 yana da matsakaicin adafta 36 - maye gurbin ɗaya a kowace sa'o'i 10 na aiki - idan aka kwatanta da adafta 48 a kowace shekara a HRC 38–42 daga tushen mai fafatawa.

Ra'ayin Abokin Ciniki: Dabarun Raba Hannun Jari da Binciken Dawowar Garanti

Wani mai rarraba haƙoran Komatsu na ƙasar Japan da ke Yokohama yana da girman adaftar haƙoran Komatsu guda 18 daga masana'antarmu. Suna samar da kimanin abokan ciniki 350 na jiragen haƙoran haƙora a yankin Kanto, waɗanda suka haɗa da ƙananan injin haƙora (PC30–PC70) don gyaran gidaje har zuwa manyan injin haƙoran haƙora masu rushewa (PC490–PC800) don rushe gine-gine masu tsayi. Mai rarrabawa yana yin odar a cikin rukuni na kwata-kwata na adaftar 5,000–8,000. A cikin 2024, sun ba da rahoton adadin dawowar garanti na 1.2% akan adaftar mu - raka'a 96 cikin 8,200 da aka aika - idan aka kwatanta da adadin dawowar 3.8% na mai samar da su na baya.

Mun yi nazarin adaftar da aka dawo da su guda 96. Rushewar: adaftar guda 42 sun lalace fiye da yadda ake amfani da su a matsakaicin farashi - an gano su ne ga abokan ciniki da ke amfani da su a haƙa duwatsu ba tare da nauyin nauyi ba. Adaftar guda 31 sun sami fashewar ramin fil - an gano su ne ga masu aiki da ke amfani da ƙarfin bokiti don cire dutse daga rami mai iyaka, wanda ya haifar da lokacin lanƙwasawa a kan sandar fil wanda ya wuce ƙarfin lanƙwasa 180 kN na adaftar PC200. Adaftar guda 12 sun rasa haƙori saboda gazawar kilif ɗin riƙewa - akan rukuni da aka aika kafin mu canza zuwa kilif ɗin 60Si2Mn. Adaftar guda 11 ba samfurinmu ba ne - su adaftar masu fafatawa ne waɗanda aka haɗa su da kuskure a cikin rumbun ajiyar mai rarrabawa a cikin rukunin dawowa. Bayan gyara don dawowar da ba ta samfurinmu ba, ainihin ƙimar dawowar garanti shine 1.04%. Manajan siyan mai rarrabawa ya gaya mini: "Mun saba kasafin kuɗi na 5% na farashin siyan adaftar don maye gurbin garanti. Tare da samfurin ku, muna kan 1.2%. Wannan shine ainihin tanadin kayan layi."

Ga kasuwar Japan, tsarin oda na adaftar daidaitacce yana bin tsarin yanayi. Buƙatu yana ƙaruwa a watan Afrilu (farkon shekarar kuɗi, lokacin da kasafin kuɗin gini ya kasance sabo) da Oktoba (a farkon lokacin rushewar lokacin rani). Dokar tsaron hannun jarin mai rarrabawa ita ce: mafi ƙarancin raka'a 3,000 ga girma shida masu sauri (PC78, PC128, PC138, PC200, PC228, PC400), raka'a 1,500 don girman matsakaici, da raka'a 500 don manyan girman injin haƙa. Muna kiyaye lokacin jagora na kwanaki 45 akan girma na yau da kullun da kuma kwanaki 60 akan nau'ikan aiki masu nauyi. Wannan yana bawa mai rarrabawa damar aiki tare da juyawar hannun jari na 4.5 a kowace shekara - sama da matsakaicin masana'antar juyawa 3 - ta hanyar dogaro da hasashen jadawalin samarwarmu.

Nazarin Lamarin: Rundunar Sojojin Ruwa Ta Tokyo Ta Rage Faduwar Hakora Da Kashi 75%

Wani kamfanin rushewa a Tokyo wanda ke aiki da injinan haƙa rami na PC350 guda takwas da injinan haƙa rami na PC490 guda uku sun rushe matsakaicin gine-ginen siminti 14 a kowace shekara - gine-ginen ofisoshi, garejin ajiye motoci, da kuma tubalan gidaje har zuwa hawa bakwai. Kafin shekarar 2024, sun samo na'urorin adaftar haƙoran bokiti daga wani mai samar da kaya a Osaka. Yawan asarar haƙoran jiragen ya kasance 0.14 a kowace na'ura a kowace rana - ma'ana rundunar ta fuskanci asarar haƙori a kowace rana 4.2 a cikin injinan 11. Kowane taron yana buƙatar tsayawa na minti 35-45 (don nemo da kuma dawo da ƙarshen haƙorin da ya ɓace, duba na'urar adaftar, da kuma shigar da wanda zai maye gurbinsa), wanda ke cinye sa'o'i 3.2 a kowace rana a cikin rundunar.

A watan Janairun 2024, manajan rundunar ya tuntube mu bayan ya ji labarin takamaiman aikinmu a wani baje kolin kasuwanci na JCEA. Mun samar da adaftar nauyi guda 500 (matakin HRC 50 tare da madannin bidiyo na 60Si2Mn) don rundunar PC350 da kuma 200 don rundunar PC490 - duk an ba su takardar shaidar CMM tare da bin diddigin tsari. Mun kuma bayar da horo na kwana biyu na shigarwa a wurin da ya shafi: (1) madaidaicin karfin juyi don fil da madannin riƙewa - 45 Nm don PC350 da 75 Nm don PC490, wanda aka auna da makunnin karfin juyi, ba "ji" ba; (2) ka'idojin duba gani don lalacewar adaftar - maye gurbin lokacin da faɗin bakin hanci ya lalace da mm 5 daga girman asali; da kuma (3) jadawalin maye gurbin madannin bidiyo - duk bayan sa'o'i 200 na aiki ba tare da la'akari da yanayin gani ba.

A cikin watanni 12 bayan canjin, yawan asarar haƙoran jiragen ya ragu daga aukuwa 0.14 a kowace rana ta injina zuwa aukuwa 0.035 - raguwar kashi 75%. Jimlar tsayawa ba tare da tsara ba don asarar haƙora ya ragu daga aukuwa 511 a cikin rundunar a cikin 2023 zuwa aukuwa 128 a cikin 2024. Asarar sa'o'in ma'aikatan jirgin ya ragu daga awanni 3.2 a kowace rana zuwa awanni 0.8 a kowace rana - yana dawo da kuɗin aiki na $46,000 a kowace shekara. Manajan rundunar ya ba da rahoton cewa biyu daga cikin PC350s sun yi aikin rushewa gaba ɗaya - watanni huɗu na kwanaki na awanni 14 - ba tare da asarar haƙori ɗaya ba. "Hakan bai taɓa faruwa da adaftar da ta gabata ba," in ji shi a cikin kiranmu na gaba.Jagororin gina OSHAga kayan aiki masu nauyi da kuma kayan aiki masu nauyi, suna jaddada muhimmancin kula da kayan aikin haɗin ƙasa yadda ya kamata, kuma rage asarar haƙori da ba a zata ba yana taimakawa kai tsaye wajen inganta ayyukan rushewa ta hanyar kawar da tsayawar injin da ba a shirya ba kusa da fuskokin rushewa masu aiki.

Ga masu rarrabawa na Japan da abokan cinikin jiragensu, saƙon da ke cikin wannan binciken shine: farashin adaftar - ¥3,500–¥8,000 a kowace naúra dangane da girma - ba shine ma'aunin da ya dace ba. Ma'aunin da ya dace shine farashi a kowace awa ta aiki. Adaftar PC350 wacce ke kashe ¥6,000 kuma tana ɗaukar awanni 250 kafin maye gurbin ta kashe ¥24 a kowace awa. Adaftar mai gasa a ¥4,500 wacce ke ɗaukar awanni 150 tana kashe ¥30 a kowace awa. Adaftar mai inganci tana adana ¥6 a kowace awa - kuma akan injin da ke aiki awanni 2,500 a kowace shekara, wato ¥15,000 a kowace na'ura a kowace shekara. Lokacin da manajan rundunar jiragen ruwa ya ninka hakan da injinan haƙa ƙasa 350 a cikin tushen abokan cinikin mai rarrabawa, yuwuwar tanadi na shekara-shekara shine ¥5.25 miliyan - kuma hakan yana kafin lissafin tanadin lokacin rashin aiki daga ƙarancin abubuwan da suka faru na asarar haƙori.

Tambayoyin da ake yawan yi akai-akai