A halin yanzu, akwai matakai da yawa na masana'antu don tsarin kayan abu mai haɗaka, wanda za'a iya amfani da shi don samarwa da masana'antu daban-daban.Duk da haka, idan aka yi la'akari da ingancin samar da masana'antu da farashin samar da masana'antun jiragen sama, musamman ma jiragen sama, yana da gaggawa don inganta tsarin magani don rage lokaci da farashi.Prototyping da sauri sabuwar hanyar masana'anta ce bisa ka'idodin ƙira mai hankali da tarkace, wanda fasaha ce mai sauri mai rahusa.Fasalolin gama gari sun haɗa da gyare-gyaren matsawa, ƙirƙirar ruwa, da ƙirƙirar kayan haɗe-haɗe na thermoplastic.
1. Mold latsa m samfurin fasaha
The m samfur fasahar gyare-gyaren tsari ne da ke sanya prebed prepreg blanks a cikin gyare-gyaren mold, kuma bayan mold aka rufe, da blanks suna compacted da kuma karfafa ta dumama da matsa lamba.Gudun gyare-gyaren yana da sauri, girman samfurin daidai ne, kuma ingancin gyare-gyaren yana da kwanciyar hankali da daidaituwa.Haɗe da fasaha ta atomatik, zai iya cimma yawan samarwa, aiki da kai, da ƙananan farashi na abubuwan haɗin fiber carbon fiber composite structural ginshiƙai a fagen zirga-zirgar jiragen sama.
Matakan gyare-gyare:
① Sami nau'in ƙarfe mai ƙarfi wanda ya dace da ma'auni na sassan da ake buƙata don samarwa, sa'an nan kuma shigar da ƙirar a cikin latsawa kuma zafi shi.
② Gabatar da abubuwan haɗin da ake buƙata a cikin siffa ta mold.Preforming mataki ne mai mahimmanci wanda ke taimakawa inganta aikin sassan da aka gama.
③ Saka sassan da aka riga aka tsara a cikin injin zafi.Sa'an nan kuma damfara da mold a wani babban matsa lamba, yawanci jere daga 800psi zuwa 2000psi (dangane da kauri daga cikin part da kuma irin kayan amfani).
④ Bayan sakin matsa lamba, cire ɓangaren daga ƙirar kuma cire kowane burrs.
Amfanin gyare-gyare:
Don dalilai daban-daban, yin gyare-gyaren fasaha ce ta shahara.Wani ɓangare na dalilin da ya sa ya shahara shi ne saboda yana amfani da kayan haɓaka na zamani.Idan aka kwatanta da sassa na ƙarfe, waɗannan kayan galibi suna da ƙarfi, masu sauƙi, kuma sun fi jurewa lalata, yana haifar da abubuwa masu ingantattun kayan inji.
Wani fa'idar yin gyare-gyare shine ikonsa na kera sassa masu sarkakiya.Ko da yake wannan fasaha ba za ta iya cika saurin samar da allurar filastik ba, tana ba da ƙarin siffofi na geometric idan aka kwatanta da kayan da aka haɗa da lanƙwasa.Idan aka kwatanta da gyare-gyaren allura na filastik, yana kuma ba da izini don dogon zaruruwa, yana sa kayan ya fi karfi.Saboda haka, ana iya ganin gyare-gyare a matsayin tsaka-tsaki tsakanin gyare-gyaren alluran filastik da kuma masana'antar kayan da aka haɗa.
1.1 Tsarin Samar da SMC
SMC shine taƙaitaccen bayanin ƙarfe na ƙarfe na samar da kayan haɗin gwiwa, wato, ƙarfe na ƙarfe na samar da kayan haɗin gwiwa.Babban kayan albarkatun ƙasa sun ƙunshi yarn na musamman na SMC, resin da ba a cika ba, ƙananan abubuwan ƙarawa, masu filaye, da ƙari daban-daban.A farkon shekarun 1960, ya fara bayyana a Turai.A cikin 1965, Amurka da Japan sun ci gaba da haɓaka wannan fasaha.A karshen shekarun 1980, kasar Sin ta gabatar da manyan layukan samar da kayayyaki na SMC da matakai daga kasashen waje.SMC yana da fa'idodi kamar ingantaccen aikin lantarki, juriya na lalata, nauyi mai sauƙi, da ƙirar injiniya mai sauƙi da sassauƙa.Kayayyakin injinsa na iya kamanta da wasu kayan ƙarfe, don haka ana amfani da shi sosai a masana'antu kamar sufuri, gini, lantarki, da injiniyan lantarki.
1.2 Tsarin Samar da BMC
A cikin 1961, an ƙaddamar da fili mai gyare-gyaren resin ɗin da ba shi da tushe (SMC) wanda Bayer AG ya haɓaka a Jamus.A cikin 1960s, an fara haɓaka Ƙararren Ƙwararren Ƙwararren Ƙwararren Ƙwararren Ƙwararren Ƙwararren Ƙwararren Ƙwararren Ƙwararren Ƙwararren Ƙwararren Ƙwararren Ƙwararren Ƙwararren Ƙwararren Ƙwararren Ƙwallon Ƙwallon Ƙasa (BMC) wanda aka sani da DMC (Dough Molding Compound) a Turai, wanda ba a yi girma ba a farkon matakansa (1950s);Bisa ga ma'anar Amurkawa, BMC BMC ce mai kauri.Bayan amincewa da fasahar Turai, Japan ta samu gagarumar nasara a aikace-aikace da haɓaka BMC, kuma a cikin shekarun 1980, fasahar ta girma sosai.Ya zuwa yanzu, matrix ɗin da aka yi amfani da shi a cikin BMC ya kasance resin polyester mara kyau.
BMC na cikin robobi na thermosetting.Dangane da halayen kayan aiki, zazzabi na kayan ganga na injin gyare-gyaren allura bai kamata ya yi girma ba don sauƙaƙe kwararar kayan.Don haka, a cikin tsarin yin gyare-gyaren allura na BMC, sarrafa zafin jiki na ganga kayan yana da matukar mahimmanci, kuma dole ne a samar da tsarin sarrafawa don tabbatar da dacewa da zafin jiki, don cimma madaidaicin zafin jiki daga sashin ciyarwa zuwa abinci. bututun ƙarfe.
1.3 Polycyclopentadiene (PDCPD) gyare-gyare
Polycyclopentadiene (PDCPD) gyare-gyaren galibin matrix ne mai tsafta maimakon filastik da aka ƙarfafa.Ka'idar aiwatar da gyare-gyaren PDCPD, wacce ta fito a cikin 1984, tana cikin nau'i ɗaya da gyare-gyaren polyurethane (PU), kuma Amurka da Japan suka fara haɓaka.
Telene, wani reshen kamfanin Zeon Corporation na Japan (wanda ke cikin Bondues, Faransa), ya sami babban nasara a cikin bincike da ci gaban PDCPD da ayyukan kasuwanci.
Tsarin gyare-gyaren RIM da kansa yana da sauƙin sarrafa kansa kuma yana da ƙananan farashin aiki idan aka kwatanta da matakai kamar feshin FRP, RTM, ko SMC.Farashin mold ɗin da PDCPD RIM ke amfani da shi ya yi ƙasa da na SMC.Misali, injin kaho na Kenworth W900L yana amfani da harsashi na nickel kuma ya jefa core aluminum, tare da ƙaramin guduro mai ƙarancin ƙarfi tare da takamaiman nauyi na 1.03 kawai, wanda ba kawai yana rage farashi ba har ma yana rage nauyi.
1.4 Kai tsaye Ƙirƙirar Kan layi na Fiber Reinforced Thermoplastic Composite Materials (LFT-D)
Kusan 1990, LFT (Long Fiber Reinforced Thermoplastics Direct) an gabatar da shi zuwa kasuwa a Turai da Amurka.Kamfanin CPI a Amurka shine kamfani na farko na duniya don haɓaka kai tsaye a cikin layi wanda aka haɗa dogon fiber ƙarfafa kayan gyare-gyaren thermoplastic da fasaha mai dacewa (LFT-D, Direct In Line Mixing).Ya shiga kasuwancin kasuwanci a cikin 1991 kuma shine jagora na duniya a wannan fannin.Diffenbarcher, wani kamfani na Jamus, yana binciken fasahar LFT-D tun 1989. A halin yanzu, akwai galibi LFT D, LFT ɗin da aka keɓance (wanda zai iya samun ƙarfafawar gida dangane da matsalolin tsarin), da Advanced Surface LFT-D (bayyanar gani, babban fili). inganci) fasaha.Daga hangen nesa na samar da layin, matakin diffenbarcher's press yana da girma sosai.Tsarin extrusion na D-LFT na Kamfanin Haɗin gwiwar Jamus yana cikin matsayi na gaba a duniya.
1.5 Fasahar Samar da Simintin Ɗaukaka (PCM)
PCM (Tsarin ƙarancin simintin gyare-gyaren simintin gyare-gyare) an haɓaka ta Cibiyar Laser Rapid Prototyping Center na Jami'ar Tsinghua.Ya kamata a yi amfani da fasahar ƙira mai sauri ga tsarin simintin yashi na gargajiya.Da fari dai, sami simintin CAD na simintin gyare-gyare daga sashin CAD samfurin.Fayil ɗin STL na simintin simintin CAD an jera shi don samun bayanan martaba na ɓangaren ɓangaren, wanda sannan ake amfani da shi don samar da bayanin sarrafawa.A lokacin aikin gyare-gyaren, bututun ƙarfe na farko yana fesa manne daidai gwargwado a kan kowane yashi ta hanyar sarrafa kwamfuta, yayin da bututun ƙarfe na biyu yana fesa mai ƙara kuzari a hanya ɗaya.Su biyun suna jujjuya halayen haɗin kai, yana ƙarfafa yashi ta Layer da kafa tari.Yashin da ke yankin da manne da mai kara kuzari ke aiki tare yana ƙarfafa tare, yayin da yashi a wasu wurare ya kasance a cikin yanayin granular.Bayan warkewar Layer ɗaya, Layer na gaba yana ɗaure, kuma bayan duk yadudduka sun haɗa, an sami mahallin sararin samaniya.Yashi na asali har yanzu busassun yashi ne a wuraren da ba a fesa manne ba, wanda ya sa ya fi sauƙi cirewa.Ta hanyar tsaftace busassun yashi a tsakiya, za'a iya samun simintin simintin gyare-gyare tare da ƙayyadadden kaurin bango.Bayan shafa ko sanya fenti a saman saman yashi na ciki, ana iya amfani da shi don zubar da ƙarfe.
A curing zafin jiki batu na PCM tsari ne yawanci a kusa da 170 ℃.Ainihin kwanciya da sanyin sanyi da ake amfani da su a cikin tsarin PCM ya bambanta da gyare-gyare.Kwanciyar sanyi da cirewar sanyi ya haɗa da sanya prepreg a hankali a kan ƙirar gwargwadon buƙatun tsarin samfur lokacin da ƙirar ta kasance a ƙarshen sanyi, sa'an nan kuma rufe ƙirar tare da latsa kafa bayan an gama shimfidawa don samar da takamaiman matsa lamba.A wannan lokaci, da mold ne mai tsanani ta yin amfani da mold zafin jiki inji, The saba tsari shi ne tada zazzabi daga dakin da zazzabi zuwa 170 ℃, da dumama kudi bukatar a gyara bisa ga daban-daban kayayyakin.Yawancin su ana yin su da wannan filastik.Lokacin da zazzabin ƙirjin ya kai yanayin zafin da aka saita, ana yin rufi da adana matsa lamba don warkar da samfur a babban zafin jiki.Bayan an gama warkewa, ya zama dole a yi amfani da injin zafin jiki don kwantar da mold zafin jiki zuwa zafin jiki na yau da kullun, kuma ana saita ƙimar dumama a 3-5 ℃ / min, Sa'an nan kuma ci gaba da buɗewar mold da cirewar sashi.
2. Fasahar samar da ruwa
Fasahar samar da ruwa (LCM) tana nufin jerin abubuwan da ke samar da fasahohi waɗanda ke fara sanya busasshiyar fiber preforms a cikin rufaffiyar ƙura, sa'an nan kuma allura ruwa guduro a cikin kogon mold bayan ƙulli.A ƙarƙashin matsin lamba, guduro yana gudana kuma yana jiƙa zaruruwa.Idan aka kwatanta da matsi mai zafi na iya samar da tsari, LCM yana da fa'idodi da yawa, kamar dacewa da sassan masana'anta tare da daidaiton girman girma da kuma hadaddun bayyanar;Ƙananan farashin masana'antu da aiki mai sauƙi.
Musamman tsarin RTM mai matsananciyar matsin lamba wanda aka haɓaka a cikin 'yan shekarun nan, HP-RTM (High Pressure Resin Transfer Molding), wanda aka rage shi azaman tsarin gyare-gyaren HP-RTM.Yana nufin tsarin gyare-gyaren yin amfani da matsa lamba mai ƙarfi don haɗawa da allurar guduro a cikin injin da aka kulle da aka riga aka ɗora tare da kayan ƙarfafa fiber da abubuwan da aka riga aka haɗa, sannan samun samfuran kayan abu ta hanyar cikowar guduro, impregnation, curing, da rushewa. .Ta hanyar rage lokacin allura, ana sa ran sarrafa lokacin masana'anta na kayan aikin jirgin sama a cikin dubun mintuna, samun babban abun ciki na fiber da masana'antar sassa masu inganci.
Tsarin tsari na HP-RTM yana ɗaya daga cikin hanyoyin samar da kayan haɗin gwiwa da ake amfani da su sosai a masana'antu da yawa.Fa'idodinsa sun ta'allaka ne ga yuwuwar cimma ƙarancin farashi, gajeriyar zagayowar, samarwa jama'a, da samar da inganci mai inganci (tare da ingantaccen ingancin ƙasa) idan aka kwatanta da hanyoyin RTM na gargajiya.Ana amfani da shi sosai a masana'antu daban-daban kamar masana'antar kera motoci, ginin jirgi, masana'antar jirgin sama, injinan noma, sufurin jirgin ƙasa, samar da wutar lantarki, kayan wasanni, da sauransu.
3. Thermoplastic composite abu kafa fasaha
A cikin 'yan shekarun nan, kayan haɗin gwiwar thermoplastic sun zama wurin bincike a fagen samar da kayan haɗin gwiwar gida da na duniya, saboda fa'idodinsu na juriya mai ƙarfi, ƙarfin ƙarfi, haɓakar lalacewa, da kyakkyawan juriya na zafi.Welding tare da thermoplastic composite kayan iya muhimmanci rage yawan rivet da kuma guntun haɗin gwiwa a cikin jirgin sama tsarin, ƙwarai inganta samar da inganci da rage samar da farashin.A cewar Airframe Collins Aerospace, mai siyar da sifofi na farko na tsarin jirgin sama, wanda ba a matsa zafi ba zai iya samar da tsarin thermoplastic mai weldable yana da yuwuwar rage zagayowar masana'anta da kashi 80% idan aka kwatanta da ƙarfe da kayan aikin thermosetting.
Yin amfani da mafi yawan adadin kayan da ya dace, zaɓin tsarin tattalin arziki, yin amfani da samfurori a cikin sassan da suka dace, cin nasarar manufofin ƙira da aka riga aka ƙaddara, da cin nasarar ƙimar ƙimar farashin samfurori na samfurori sun kasance jagora koyaushe. na ƙoƙarce-ƙoƙarce ga ƙwararrun kayan aiki.Na yi imanin cewa za a haɓaka ƙarin hanyoyin gyare-gyare a nan gaba don saduwa da bukatun ƙirar samarwa.
Lokacin aikawa: Nuwamba-21-2023
