Zigawo za Dongosolo la Magalimoto Oyendetsera Magalimoto: Kupanga Molondola kwa Magalimoto Oyendetsa Magalimoto Othamanga Kwambiri

Mu mpikisano wa magalimoto oyenda panja, monga FIA European Autocross Championship, galimoto yoyendetsa galimotoyo imakumana ndi mphamvu yamphamvu komanso yothamanga nthawi yomweyo. Pamene galimoto yodutsa galimoto kapena 2WD autocross ikuthamanga kuchokera pamene dongo lagwedezeka kapena kulumpha kwakukulu, mphamvu yonse yotumizira mphamvu imagwera pa zida zamakina oyendetsa galimoto. Ma flange a axle oyendetsa galimoto, ma differential housings, ma intermediate shafts, ndi ma sprocket carriers ayenera kutumiza mahatchi ambirimbiri kumagudumu pansi pa mikhalidwe yogwira ntchito kwambiri popanda kulephera.

Kwa magulu othamanga akatswiri omwe amayendetsa ma drivetrain apamwamba kapena kukonza makina apamwamba monga ma gearbox a Sadev racing, kulephera kwa gawo limodzi kumatanthauza DNF (Did Not Finish) nthawi yomweyo. Kupanga zida za drivetrain zomwe zimatha kupirira ma dumps ambirimbiri a clutch okwera kwambiri panjira zadothi zogwira kwambiri kumafuna kusankha bwino zinthu, kusintha kapangidwe ka makina mosamala, kukonza makina molondola, komanso kukonza bwino zinthu.

Pogwiritsa ntchito malo apamwamba a CNC turn-mill center, precision Wire Electrical Discharge Machining (Wire EDM), thermal hardening controlled, ndi closed-loop Coordinate Measuring Machine (CMM) inspections, CREATINGTEC imapereka zida zoyendetsera zolimba kwambiri zomwe zimapangidwa kuti zisunge umphumphu wathunthu pansi pa kupsinjika kwakukulu kwa torsional.

Ngakhale kuti zitsulo zopepuka za aluminiyamu ndizoyenera kwambiri pazinthu monga zoyimitsidwa kapena zomangira zamagetsi, zida zoyendetsera mwamphamvu zimafuna zipangizo zomwe zimakhala ndi mphamvu yodula bwino, nthawi yayitali yotopa, komanso kuuma kwambiri pamwamba kuti zisawonongeke kwambiri chifukwa cha kugwedezeka kwa katundu wozungulira. Ku CREATINGTEC, timasankha zitsulo zapamwamba kwambiri zomwe zimagwirizana ndi zofunikira zamakina zomwe zimagwiritsidwa ntchito poyendetsa galimoto:

• Makhalidwe a Makina: Yodziwika bwino chifukwa cha kulimba kwake kwakukulu, kulimba kwake kofanana, komanso mphamvu zake zotopa kwambiri.
• Ntchito: Iyi ndi njira yathu yokhazikika yopangira ma flange oyendetsera, ma shaft apakati, ndi ma adapter a wheel axle. Imapirira kugwedezeka kwadzidzidzi komanso kusweka kwa chassis mwamphamvu popanda kudulidwa kapena kupotozedwa ndi elastic.

• Makhalidwe a Makina: Ili ndi pakati pake popindika kwambiri, pogwira mphamvu yokoka, yokhala ndi pamwamba pakunja komwe kumatha kupangidwa ndi carburized kwambiri kuti isawonongeke.
• Ntchito: Yabwino kwambiri pa magiya amkati osiyana, zonyamulira zonyamula zinthu zambiri, ndi majekete akunja a spline komwe kukangana kwa dzino ndi dzino kuli kwakukulu, koma pakati pake payenera kukhalabe kolimba mokwanira kuti muyamwitse kukwera kwadzidzidzi kwa drivetrain.

Kuti titsimikizire kuti zinthu zonse zili bwino kwambiri musanayambe kupanga makina, gulu lililonse la chitsulo chosaphika chomwe chimalowa mufakitale yathu yopangira zinthu zolondola ya 2,568 square metres chimadutsa mu gawo lofunikira la Incoming Quality Control (IQC). Kapangidwe ka zinthu kamatsimikiziridwa pogwiritsa ntchito Spektromita Yotulutsa Magazi kutsimikizira kuti chromium, molybdenum, nickel, ndi carbon zomwe zili mkati mwake zikugwirizana bwino ndi miyezo yapadziko lonse ya ASTM. Chitsulo chilichonse chosaphika chomwe chikuwonetsa kusiyana kwa mankhwala kapena kusagwirizana kwa kapangidwe kake chimakanidwa nthawi yomweyo.

Tisanapange G-code ya makina athu a CNC turn-mill, gulu lathu la uinjiniya—komwe membala aliyense amakhala ndi zaka zosachepera 5 zaukadaulo wopanga makina komanso luso lopanga zinthu m'maofesi—limachita ndemanga yayikulu ya Design for Manufacturing (DFM). Sitimangoyika fayilo yokhazikika ya STEP; timakonzanso mawonekedwe amkati mwa gawolo kudzera mu lens ya torsional physics ndi magwiridwe antchito a makina.

Pogwiritsa ntchito njira yoyeserera ya pakompyuta, mainjiniya athu amagwiritsa ntchito mikhalidwe ya malire omwe amatsanzira mphamvu yozungulira yomwe imafanana ndi mphamvu yozungulira yomwe imakumana nayo panthawi yothamanga kwambiri kuchokera pakona. Von Mises akugogomezera, timazindikira madera omwe anthu amakumana ndi nkhawa kwambiri.

Kuti tikonze bwino gawoli, timawonjezera makulidwe a njira zofunika kwambiri zolemetsa, monga malo olumikizirana pakati pa flange shaft ndi nkhope yake yokwezera. Nthawi yomweyo, timayika matumba ochepetsera kulemera m'malo ocheperako kupsinjika panja pa zonyamulira za sprocket, ndikumeta mpaka 18% ya kulemera kozungulira. Izi zimachepetsa kusinthasintha kwa gawo, zomwe zimathandiza kuti nthawi yoyankha ya injini ifulumire popanda kuchepetsa chitetezo.

Masitepe akuthwa amkati kapena kusintha mwadzidzidzi kwa dayamita pa shaft yozungulira ndizomwe zimayambitsa kulephera kutopa kwa torsional mu mpikisano wa off-road. Pamene torque ikupotoza shaft, kupsinjika kumasonkhana pamalo opingasa awa, zomwe zimapangitsa kuti ming'alu yaying'ono ya tsitsi ikule mpaka italephera kudulidwa bwino.

• Kutsuka Fillet Mokulira: Timasintha masitepe akuthwa a madigiri 90 ndi ma sweep otambalala, otambalala (R2.5 mm).
• Mbiri Zosalala Zofewa: Masitepe pang'onopang'ono amatsimikizira kuti mizere yovutikira ya torsional imakhalabe yofanana kutalika konse kwa gawolo, kuletsa kusonkhanitsa kwa nkhawa komwe kumachitika pamalopo.
• Kufananiza Njira Yogwiritsira Ntchito: Ma sweep onse osinthika okhala ndi zingwe adapangidwa kuti agwirizane ndi ma inserte okhazikika okhazikika, kuchotsa zizindikiro za phokoso la zida (Ra 0.8 um surface finish target) zomwe zingagwiritsidwe ntchito ngati malo oyambira kusweka kwa kutopa.

Zigawo za Drivetrain zimazungulira pa liwiro lalikulu lozungulira, nthawi zambiri kupitirira 6,000 RPM. Kugawa kulikonse kwa kulemera kosiyana, kusinthasintha kwakunja, kapena kusagwirizana kwa mphindi imodzi kudzapanga ma harmonics amphamvu kwambiri komanso kugwedezeka kwa parasitic. Mphamvu izi zimawononga mwachangu ma bearing othandizira, kung'amba zomangira za rabara, ndikuyambitsa kutuluka kwa madzi otumizira. Kuti zitsimikizire kuti zimakhala zozungulira komanso zolunjika, CREATINGTEC imagwiritsa ntchito malo apamwamba opangira ma CNC ozungulira ambiri.

Kupanga zinthu mwachizolowezi kumafuna kuti zida zigwiritsidwe ntchito molimba pa lathe, kusunthidwa ku makina opera kuti zibowole mabowo, kenako n’kubwezeretsedwa ku chopukusira. Nthawi iliyonse katswiri wa makina akachotsa gawolo kuchokera mu chuck ndikuliyikanso mu makina ena, zolakwika za anthu ndi kulekerera ntchito zimawonjezeka.

• Kusamutsa Kosalekeza kwa Spindle: Chida chachitsulo chimamangiriridwa kamodzi mu chuck yayikulu. Makinawo amatembenuza ma profiles akunja oyambira ndikuboola dayamita yolondola yamkati motsatira mzere umodzi wapakati wa coaxial.
• Kugwira Ntchito Pakugwiritsa Ntchito Zida Pamoyo: Popanda kutulutsa gawolo, makinawo amagwiritsa ntchito zida zolimba kwambiri kuti aphwanyire matumba akunja ochepetsera kulemera ndikuboola mapatani a mabowo a flange.
• Mipata Yokhazikika: Kayendedwe ka ntchito kogwirizana kumeneku kamatsimikizira kuti Pitch Circle Diameter (PCD) ya mabowo oikira imakhalabe yozungulira bwino kwambiri ku central drive spline axis mkati mwa kulekerera kochepa kwa zosakwana 0.01 mm.

Mbali yofunika kwambiri ya flange yoyendetsa galimoto, shaft yapakati pa axle, kapena adaputala ya sprocket ndi mawonekedwe amkati a spline omwe amatsekereza pa shaft yotulutsa ya gearbox. Ma spline awa ayenera kukhala olimba kwambiri kuti apewe kugwedezeka kozungulira.

Ngakhale 0.05 mm ya kusewera kozungulira mkati mwa cholumikizira cha spline imapanga mphamvu yogundana ndi nyundo nthawi iliyonse dalaivala wothamanga akasintha kuchoka pa hard braking kupita ku throttle yotseguka kwambiri. Kugundana kobwerezabwereza kumeneku kumawononga mano mwachangu, zomwe zimapangitsa kuti ma spline achotsedwe komanso kutayika kwathunthu kwa mphamvu yoyendetsera.

Kuti apange ma profiles a spline opanda cholakwika komanso opanda backlash, CREATINGTEC imadutsa njira yopangira makina yachikhalidwe ndipo imagwiritsa ntchito njira zamakono. Makina Otulutsa Mawaya Amagetsi (Waya EDM):

• Kulondola kwa Mizere ya Micron: Waya wa EDM umagwiritsa ntchito waya woonda wamkuwa wowongoka wowongoleredwa ndi kompyuta (wamtali wa 0.20 mm mpaka 0.25 mm) wokhala ndi ma pulse amagetsi amphamvu kwambiri kuti uwononge chitsulo cholimba kudzera mu kukokoloka kwa spark.
• Kuchepetsa Kupsinjika Maganizo: Popeza palibe mphamvu yodulira yamakina yomwe imagwiritsidwa ntchito pa ntchitoyo panthawi ya kukokoloka kwa waya, zinthuzo sizimakumana ndi kupsinjika kwa makina komwe kumachitika chifukwa cha kukokoloka kwa zida, kapena kusweka pang'ono.

Chigawo choyendetsera bwino kwambiri sichikhala chokonzeka kugwiritsidwa ntchito m'malo otsetsereka mpaka chitasinthidwa kutentha kuti chisinthe matrix yake ya kristalo. Kutengera ndi zinthu zomwe zasankhidwa panthawi ya uinjiniya, timachita njira zapadera zochizira kutentha mkati mwa uvuni wathu wa digito:

Chigawo chopangidwa ndi makina chimatenthedwa mofanana mpaka kutentha kwake kokhazikika (840 C mpaka 870 C), chimasungidwa mpaka kapangidwe kake katakhazikika, kenako chimazimitsidwa mu bafa la mafuta lolamulidwa. Kenako gawolo limatenthedwa nthawi yomweyo (540 C mpaka 650 C) kuti lichepetse kufooka kwa mkati, zomwe zimapangitsa kuti kuuma komaliza kwa pakati pa chinthucho kukhale koyenera pakati pa 32 HRC ndi 38 HRC.

Pazigawo zomwe zimafuna khungu lakunja lolimba kwambiri komanso lolimba kwambiri, zigawozo zimayikidwa mumlengalenga wa mpweya wa kaboni pa 900 C, zomwe zimapangitsa kuti maatomu a kaboni alowe m'zigawo zakunja za chitsulocho. Chigawocho chimapanga malo ozama a pamwamba pa 0.8 mm mpaka 1.2 mm ndi kuuma kwa pamwamba kufika pa 58 HRC mpaka 62 HRC.

Kuti titsimikizire kuti palibe zinthu zolakwika zomwe zatuluka m'malo mwathu, timagwiritsa ntchito njira yowongolera khalidwe la zinthu zosiyanasiyana. Gawo lililonse la drivetrain limatsatiridwa kudzera mu deta yolembedwa motsatizana kuyambira pa mawonekedwe ake osaphika mpaka kulongedza komaliza.

Pa nthawi yogwiritsira ntchito makina, akatswiri amagwiritsa ntchito njira yopangira Ma probe a Renishaw omwe ali mumakina a infrared kuti muwonetsetse malo omwe gawo lilipo ndikuwunika momwe zida zimagwirira ntchito nthawi yeniyeni. Pambuyo pa gawo lozungulira, zizindikiro zoyimbira zimawunika momwe zinthu zimayendera.

Pambuyo pokonza kutsuka ndi ultrasound kuti muchotse zitsulo zonse zazing'onoting'ono, zida zoyendetsera zimalowa m'chipinda chathu chowunikira choyera cha 20 C cholamulidwa ndi nyengo. Timagwiritsa ntchito 3D yolondola kwambiri. Makina Oyezera Ogwirizana (CMM) kuti mujambule chigawocho. Zigawo zokha zomwe zikutsimikizira kuti zatsimikizika mokwanira ndi 100% ndizo zomwe zimapita patsogolo mpaka kuphimba ndi kulongedza komaliza pamwamba.

Mwa kuphatikiza zitsulo zapamwamba kwambiri, kukonza makina a CNC osinthira makina kamodzi, kulumikiza kwa ma waya a EDM mosalumikizana bwino, komanso kuwongolera kokhwima kwa metrology mkati mwa malo athu okwana 2,568m2, CREATINGTEC imasintha malingaliro aukadaulo wosaphika kukhala zida zoyendetsera zolimba kwambiri komanso zopepuka zopangidwa kuti zipirire mayendedwe ovuta kwambiri amasewera amoto padziko lonse lapansi.