Vibratory aging is a high-efficiency, energy-saving and environmentally-friendly technology promoted in China. It is a time-effect high-tech that applies the resonance principle to eliminate residual stress and prevent deformation of metal workpieces within half an hour. It improves product quality and reduces time-cost for enterprises. It is of great significance to improve production efficiency and solve the environmental pollution problem of coal-fired heat aging.
China has applied vibration aging technology since the 1970s, and it has been nearly forty years. Enterprises have experienced different historical development stages for vibration aging technology, from understanding to understanding, from doubt to belief, from trial to application. At present, China has entered a large number of application stages of vibration aging technology. How to successfully apply vibration aging technology is an important issue for the application of vibration aging technology in China. Nanning Shenhua Vibration and Ageing Technology Research Institute has been committed to the promotion and application of vibration aging technology for many years. Combining our practical experience, we have put forward some opinions on how to successfully apply vibration aging technology, in order to improve The application level of vibration aging technology in China has helped.
To successfully apply vibration aging technology, enterprises must use fully automatic vibration aging equipment, and must develop correct vibration aging technology. There must be serious and responsible operators, and there must be strict quality management system. The four are indispensable!
Vibration aging equipment is the basic condition for applying vibration aging technology. China's vibration aging equipment has been independently produced from foreign countries' vibration aging equipment since the 1970s. In the following twenty years, only manual vibration aging equipment can be produced. This equipment can only be operated by operators. Based on the feeling and experience of vibration aging treatment, the main problem is that the vibration aging quality is difficult to guarantee and the operation is complicated. After many companies purchase this equipment, although it is known that vibration aging technology is a good technology, it is afraid to produce a large amount of production. The application is only used when it is not used. With the use of computer technology in vibration aging equipment, in the late 1990s, China developed a fully automatic vibration aging equipment, which can automatically select the key vibration and aging process parameters of vibration aging by computer. The vibration aging quality is guaranteed and the operation is simple. The birth of automatic vibration aging equipment has laid an advanced and reliable equipment foundation for the successful application of vibration aging technology, which has been widely welcomed by the majority of enterprises! Metaphorically speaking, the manual vibration aging equipment is like a heat treatment aging furnace without furnace temperature control, and the automatic vibration aging equipment is like a heat treatment aging furnace capable of automatically and accurately controlling the furnace temperature. Therefore, the use of fully automatic vibration aging equipment is a prerequisite for the successful application of vibration aging technology.
Although the fully automatic vibration aging equipment solves the hardware problem of the vibration aging technology application, it is also necessary to formulate a correct vibration aging process to solve the software problem of the vibration aging technology application. Here we give two examples to demonstrate.
Our company participated in an international mechanical exhibition in Guangzhou in 1999. Our equipment was on site with a workpiece for vibration and aging demonstration. At that time, an engineer from Guangdong Foshan Pump Factory came to see our workpiece vibration aging sound. Very small, I was surprised. He said that their factory applied vibration aging technology as early as 1993, but the vibration and aging of the workpiece is very loud, the whole factory can hear it, the operators must wear earplugs, the whole factory is troubled by this, even Because it is possible to cancel the vibration aging process because of noise and environmental protection problems, we will ask for a post-mortem to see if we can solve the sound problem. After the meeting we went to the factory. Their pump housings are treated with a vibration aging platform. The vibration aging sound is louder than the aircraft sound. Not only the operator, but other people in the workshop, can't stand it. After careful understanding, we found that the vibration aging process is not correct. They chose the high-frequency formant for vibration aging treatment. The vibration aging sound is inevitably great. We use the low-frequency formant for processing, and the vibration aging sound becomes very small. ,almost none! So many years of problems have been solved in one day.
Our company participated in a casting conference in Shanghai in 2000. At the meeting, the deputy chief engineer of Jiangsu Crankshaft General Factory told us that they bought a set of vibration aging equipment for the vibration aging treatment of the flywheel shell in 1995. I didn't dare to use it afterwards, mainly because the vibration was uneven, and some of the flywheel shells vibrated well, and some of them were weak. We asked us to see if we could solve this problem. After the meeting we went to the factory. The flywheel shell is subjected to vibration aging treatment in batches using a vibration platform, and the vibration is not uniform. After careful understanding, we found that there is a problem with the vibration aging process. The eccentric angle of the exciter is not adjusted enough, so the vibration is not uniform. When we increase the eccentric angle of the exciter, the vibration is even. In this way, the vibration aging technology that has been in use for several years has been re-used!
This shows how important it is to develop a correct vibration aging process. Our Shenhua Research Institute attaches great importance to the vibration aging process. For each of our users, we must conduct vibration aging technology training, so that the technical and operational personnel can independently master and formulate the correct vibration aging process. As for how to formulate the correct vibration aging process, China has promulgated and implemented the national standard for vibration aging process in 1991. This is the crystallization of years of experience in vibration aging technology, and enterprises must learn and master.
Operators are people who use vibration aging equipment for many years, and they play a decisive role in the quality effect of vibration aging. The workpiece is subjected to vibration aging treatment, which is different from the heat treatment. The surface of the workpiece with thermal aging has an oxide layer, and the effect can be roughly judged from the appearance, but the appearance of the workpiece with vibration aging does not change, and the effect cannot be judged from the appearance. In addition, the vibration aging time is very short, that is, about 15 minutes, can effectively eliminate the residual stress in such a short time, depending on whether the operator is responsible for the vibration aging process requirements. Only the responsible operators can effectively guarantee the vibration aging process. A mechanical factory in Shunde, Guangdong Province has a deep understanding of this. Originally, an operator, after the vibration aging treatment of the workpiece, the machining can fully meet the technical requirements, and later changed an operator, through the workpiece he processed, and some Yes, some can't. Later, we went to the scene to find out that the operator was not responsible for the vibration and aging treatment. After the education, the operator changed the working attitude, and the vibration aging quality was stabilized. As an emerging science and technology, vibration aging will inevitably have higher requirements for operators, and science and technology are not to be hypocritical and proud!
Strict quality management system is necessary for the production of any industrial enterprise, and vibration aging production is no exception. At present, a prominent problem in the application of vibration aging technology in China is that quite a number of enterprises have not established a strict quality management system for vibration aging production. The quality inspection department does not include vibration aging in the inspection scope, and the operators themselves check it. It is harmful. The reason for this is that on the one hand, the quality inspection department did not send someone to learn to master the vibration aging technology, and did not know how to test the vibration aging effect quality. On the other hand, the leader believed that the vibration aging treatment could not judge the quality effect from the appearance, Need to be tested. In fact, China has promulgated and implemented the national standard for vibration aging process as early as 1992, which provides a scientific test basis for vibration aging inspection work. On the other hand, automatic vibration aging equipment can process one workpiece per vibration aging treatment. The vibration aging process curve and parameters, as long as the process curve is compared with the national standard, the vibration aging quality effect can be directly tested, so the vibration aging quality test is completely ok. Guangxi Yuchai Group uses many sets of vibration aging equipment. They have strict quality management system for vibration aging. Every time a operator processes a workpiece, the vibration aging process curve must be recorded and checked by the quality inspector. During the working hours, the processed workpieces are transferred to the next process, so their vibration aging quality effects have been very stable and reliable. I hope that every enterprise that applies vibration aging technology can learn from Yuchai and shut down the quality from the system!
In summary, as long as the company uses fully automatic vibration aging equipment, develops the correct vibration aging process, has serious and responsible operators, has a strict quality management system, can successfully apply vibration aging technology!
Nanning Shenhua Vibration and Ageing Technology Research Institute can successfully apply vibration aging technology to Chinese enterprises, provide advanced and reliable Shenhua series automatic vibration aging instrument, and develop correct vibration aging technology. (Author: Institute of Nanning Shenhua VSR technical director Yang Shengfeng phone)
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