Ukusebenzisa kweGqalelo le-EDM yeDie Sinking ekwakhiweni kweVulavula lokuphelele

Indlela i-EDM Die Sinking Machines Ishenxiseka Ngayo: Izahluko Ezimangalisayo zeSpark Erosion ekwakhiweni kweVulavula

Izifundo zeNkqubo yeSinker EDM: Ukudweba Kugcine kwi-Spark kwiMachining Engenanto

Ukusebenza kwe-EDM kwenziwa ngokususa izinto nge spark erosion esetshenziswa kahle. Xa sikhuluma nge EDM, okwenzekayo kuyinhloso enjalo. Le ndlela ikhuluma ukuthi kufakwa i-shaped electrode ezundini nezinto zemetal ezenziwa, zombili zizodwa ku yindlela ekhulwa ngazo, ngokuvamile yisimo se-hydrocarbon oil. Le ndlela inendlela eyatholakala - ikhondla izinto, isiza ekukholiseni indawo, nokusula izinto ezincane ezingcwelewa ngexesha lokuzenzela. Okuqondileyo kulendlela kukuba kwenza izixuku ezincane phakathi kwe-electrode no-workpiece, ngoko ke-0.01 kuya ku 0.5 mm. Le ziphazinyo zifinyelela amathepherethura aphezu kuka 8,000 degrees Celsius, zomphethe izinto ngaphandle kokuthinta ngokuphatha. Ngoba akukho thinta ngokudonsa phakathi kwezivivinyo nezinto ezihlalihlwayo, siyesebenza le miphumela embi yokugaya kwezivivinyo noma ukungekwa okungcono kumalayizi. Lokhu kusiza abasebenzi bakhule umfanekiso omuhle ngokukhulu emetal yenhlangothi eyodwa njenge H13 noma D2 steel engaphezu kwezilingo zokungenisa. Kanti simemeza futhi yindlela eyakhulwa ngayo - ichaza indlela enye ethembekile ekunikela izixuku azikwazi ukuthutha futhi ayamele isikhala esigcwele phakathi kwe-electrode no-workpiece. Konke lokhu kudibanisa ukuqinisekiswa okuncane kangaka okuphakathi kwe-plus noma minus 2 micrometers, okubalulekile kakhulu xa kuxoxwa ngezimvume zezinto ezifana ne-lenses lapho konke okuchazwe kudinga.

Izinto ze-Electrode kanye Nezinqubo Zokukhetha: I-Graphite vs. Copper vs. Copper-Tungsten Yezidingo Eziqondene Nesikhunta

Ukukhethwa kwama-electrode kulinganisa ijubane lokucubungula, ukumelana nokugqoka, ukuqedela indawo, kanye nobunzima bezici. Izinto ezibonakalayo ngamunye ukhonza izindima ezihlukile e-EDM tiered isu:

I-graphite electrode imishini ~ 30% ngokushesha kunethusi kodwa ibonisa ukugqoka okukhulu okuyenza ilungele ukususwa kokuqala okukhulu. Ithusi linikeza ukuqina okuphezulu komhlaba kanye nokubekezelelana okuqinile ekuqedeni. I-copper-tungsten iyakufanelekela lapho ubulukhuni obukhulu (isb., ukufakwa kwe-tungsten carbide) noma imininingwane emihle kakhulu idinga ukugqoka okuncane kwe-electrode nokuzinza okushisayo okuhlukile.

Kungani i-EDM Die Sinking iphakeme lapho ukugaya okuvamile kwehluleka khona: I-Physics of Hard Material Machining (Tungsten Carbide, Harded Tool Steels)

Amathuluzi ajwayelekile okusika avame ukugqwala ngokushesha lapho kusetshenziswa izinto ezinzima kune-50 HRC ngenxa yokuqhekeka, ukushisa okwenziwa ngesikhathi sokusebenza, nokulimala kwesakhiwo sensimbi uqobo. Ukucwiliswa kwe-EDM kuvimbela zonke lezi zinkinga ngokuphelele ngoba kusebenza ngendlela ehlukile kunezindlela ezivamile. Kunokuba ithembele emandleni angokwenyama, i-EDM isebenzisa ukushisa ukuze isuse izinto kancane kancane. Le nqubo idala izinhlansi ezincane ezicibilikisa izindawo ezincane ngaphandle kokucindezela izinto ezizungezile noma ukudala lezo zindawo ezicasulayo ezishiswa ukushisa ezingase zibuthakathaka izingxenye. Yini eyenza le ndlela ibe yigugu kangaka? Ivumela abakhiqizi ukuba benze izikhala ezihlanzekile ngendlela emangalisayo ezincane njengo-0.1 mm ezintweni ezinzima njengensimbi yamathuluzi engu-D2, kanye nezimo eziyinkimbinkimbi ngaphakathi kwezingxenye ze-tungsten carbide ezihlanganisiwe ezingenakwenzeka ukuzenza ngokusebenzisa izindlela ezivamile zokugaya noma zokugaya. Lapho kusetshenziselwa izinsimbi eziqinile, izitolo eziningi zibika ukuthi imishini yazo ye-EDM igcwalisa imisebenzi cishe ngokuphindwe kabili kunokusebenza kokugaya ngokunemba, kodwa nokho igcina ukubekezelelana okuqinile kakhulu kuze kufike ezingeni le-micron.

Ukuziphatha Kwesikhashana Nokucophelela: Ukulwa KwiGeometri Eziningi Zomlilo Ngokusebenzisa i-Die Sinking EDM

Ukufinyelela Emakhathini Ephambili, I-Slots Enguqu, NeRibs Eziphakeme Ngaphandle Kokugayaya Kwesixhobo Noma Izone Zokunyathela Kwamandla

I-EDM engcinezelayo eyancibilika ikhuthaza ukukhetha kwemodi ngokunqula izidingo ezimbili eziphambili zokwenza ixhobo ngendlela yokumiswa: ukugayaya kwesixhobo nokungahleli kwamandla. Ngoba ukuchithwa kuhlala kukhona ngaphandle kokuthintana:

• Amakhathi aphambili afumaneka ngokuphatha okupheleleyo kwe-radius ye ±2 µm—akukho mda wokugayaya kwesixhobo;
• I-slots engeyiyo ne-ribs eziphakeme (up to 20:1 aspect ratio) zilinda ubume bokulinganisa ngoba i-dielectric flushing ichitha izinto ezikhathazekayo kumindleko ethile;
• Akukho yona indawo ekunyathelwa kuyo amandla isenza ukuthi isteeli eqinileyo njengeH13 isebenze yimikhiwo yazo kunene nentsebenzo yokunqula.
  Le ngxelo ibonisa impendulo yeRa 0.1–0.4 µm ngqo kumalishi we-tungsten carbide, ihlanjulula noma ichitha ixesha lokupolisha okwesibini kwaye ilahle isikhathi sokuprosesa emva koko ngama-40–60% kunye neendlela eziphuculeyo.

I-Electrode EDM yamathuba amakhulu ayezindiza: Kusukela kuMondlo weCAD kuNtonga loMgca wokuhlola i-Electrode

Ukuguqulwa kwezenzo elisha kwenza ukuthi izakhiwo zodidi zibe ngamandla ephrodhikhi ngezindlela ezihlanganiswe, ezigcinezelayo ngokuvavanywa:

1. Ukuguquka kweCAD : Amamodeli ayezindiza aziphambili aguqukisiwa kwi-jometry ye-electrode ngesevisi yeCAM;
2. Ukuplaniswa kwemigca ekugcineni : Amabhuloko okulungisa igap yespark ayamukela ukunciphisa kanye nokunakekela ukususwa kwegesi ngokulinganayo;
3. Indlela yokudonsa ehlanganiswe : Amaphawuva aphelile (ayisikhathi sonke isigaba) asuswa izingxenye ezinkulu ngokushesha, emlandelani nezophindo (icopper noma icopper-tungsten) ezonikeza umlando ophendula kanye nomthelela wokuphela.
   Kumasebenzi e-automotive—njengezimvume zelense zakhiwanga ezenziwa kwi-nitrided P20 steel—le ndlela ichaza igqiwe ngokulinganayo ±2 µm lemandla, ihlinzeka ubuciko bokubona kanye nokulinganiseka phakathi kweenkonzo ngaphandle kokusebenzisa ukulungisa ngendlela ethile.

Ubungakanani obuhle kakhulu kanye nokuncipha kokuprosesa emva kokwenza kumasebenzi aphathekayo

Ukufinyelela Kwesayensi Epheleleyo yeRa 0.1–0.4 µm Nokuncipha Kwegciwane Esebenzisweni Ekugcineni Isteeli Egqithile

Ukugcina kwe-EDM kuthola lezi zikhwama ezihlukileyo ezingcono kakhulu ezingaphantsi kukaRa 0.1 ukuya ku 0.4 microns kumakholo esithwale ekhanyisiwe. Lokhu kuyaphantseka kakhulu kunaleyo eyenzeka ngokuphindaphindayo ngaphandle kokubangela izinkinga. Kunye, akazange kube nenkinga yezikhashana eziphelele eziphazanyekayo ephazanyekayo ngezindlela zelasekhiwa noma iplasma. Ngoba i-EDM isebenza ngendlela yokucindezelwa engaphandle kwalokho iyisicwangciso emaqashini amathile, akunalo ubuchule bomechanical lapha. Kanti futhi, okulungile konke, akakho izikhala ezizenzakalelayo zokwanda kwiprothesi ngempindiselo ethinta imali ngokuthi ibe yimodi. Uma abayikezi bezothola izinto njengezilawuli zepolatholi zeelektroda, shintshana ubude bepaluse ngalinye, kanye nobunikazi benkqubo yokuratha kwamandla, bangasusa izidingo zibaleni ngama-80 iphasenthi ngokwesiqiniseko sase-ASM International eshushuwe ngo-2023 kwi-journal ya Advanced Materials & Processes. Konke lokhu kusizo kuthuthuka kakhulu kohora oludala emacaleni emva koko. Amabhandla aphelele ahlale athi asusa umsebenzi wokuphatha phansi ukuya kumpela kuya kuthathu kwezinkulungwane. Lokhu kuthatha ukuthi izinxenye zibuyelela izikhathi zazo ngokuphindaphinda lapho zisetshenziselwa ngokuphindaphinda kakhulu kanye nezikhalo eziphindaphindayo emisebenzini yokufaka.

Ukusebenzisa Kwasebhakheni: Ukugcina Kwe-EDM Kuqobo Lokuqina Kwamaphoyintu Okunika Isimo Kwemoto

Kusukela Ekudizayeni I-Electrode Debelela Ukunciphisa Okugciniwe: Ukulawula Kwe-Tolerance Ngaphakathi ±2 µm e-P20 + Issteel Efanekiswe Ngenhla

Umongo wemoldi wezithuthi kufuneka uphumelele kakhulu kumahluko, ikakhulu xa kwenziwa izinto ezihlobene nesimilo sezithuthi njengezemba lezinzo kanye nezivimba zezilonda zepaneli yamandla. Kusebenza kahle ukusebenzisa i-EDM die sinking kuP20 engeyona inkokheli ephindekayo (nitrided) ekuquketheni kwe-HRC phakathi kuka-45-52 ngoba izindlela ezifundisa ngokushesha ziqeda ukuguqulwa kwentliziyo futhi zibangela ukuba kube nenhlangothi engavamekanga. Ngokudala iziqinisekiso ngokucophelelayo, ukulawula izilungiso ze-spark ngendlela efanelekile, kanye nokulandela izigaba ngelinye elizama, abasebenzisi bangafika kuma-tolerances ezenziwa ngaphandle okuqukethwe kwi-2 microns noma kuzo zonke izimo ezinkulu. Okukhomba kule ndlela kukuthi iyaphatha ubumnandi bokuphansi ukuze kube khona ukugcina okuncane emva kokuprosesa, okusondlela ukukhula kwezinto ku-tholela ngelishwa ngelishwa kodwa kuyaphila izinto eziphila kakhulu ezingcono zonke izinkinga zombono.

Izophumo le-EDM ekwakhiweni kwe-Mold: Izinhlelo zomsebenzi ezinezimali kanye nezinhlelo zokwakha izinto ezimbili

Ukuthunyelana kwe-Sinker EDM ngezinqamleli ezakhiwa ngokwesibonelo futhi nezinkinga zokulinganisa ngaphakathi kwemfaziswano

Okulandelayo kulesinkingi kuyizindlela ezihlangene ezigcwele ezingavimba umugqa phakathi kwezinhlelo zokwakha. Ngokwenza okudluliswa, manje singakhiya iziqhamo ze-graphite ne-copper-tungsten ezenziwe ngamathuba amashisa angcono angaphandle futhi nezinqumatha ebona njengomlando. Lokhu kususa ixesha lokwakha iziqhamo ngendlela ebalulekile kunalezo zindlela zeqhina ne-grinding, ngaproximately ama-two thirds ukuya ku-four fifths ngokusho kwebhulogi yosayensi. Isici esihle kangaka? Lezi ziqhamo ezintsha zisebenza kahle nezinhlelo ze-sinker EDM eziphakeme kuzo izixhobo zokulinganisa ezingabeka izinto ezithile njengebini labo baphakade, ubude bomgca obuphakeme, futhi uma izinsiza zilinda kwi-specs ngenkathi kuzwaqalwa. Uma izilinganiso ziyekela ema-limit etholakala, isibonelo plus or minus ama-2 microns, imishine iyazi ukuguquguquka kwezinkinga, ukulungisa ixesha le-pulse, amandla, noma ukuqinisekisa kwamanzi ngaphandle kokudinga komuntu othinta konke ngendlela yokuphatha. Xa kudweliswa ne-AI eyilungisa izinkinga zokusebenza ngokushweshwe kudatha walesikhathi, lokhu kukuchazwa kwezinkinga ze-sinker EDM, i-3D printing, nezinkinga zokubuyisela ngexesha elijulile kuyiyenzela into entsha kumakhi we-mold abadinga both speed and rock solid precision kuzo zonke izinkampani zakho zakhiwo.

Imibuzo Evame Ukubuzwa

Ukuthini ukugcwalisa kwe-Die EDM?

Ukugcwalisa kwe-die EDM yindlela yokwakha eyisebenzisa ukucodwa kwegciwo ngamashishi ngaphandle kokuxhunyaniswa ngqo phakathi kowejine neyigciwo.

Kungani ukukhetha iziqhamo ze-graphite kunazo eziyintshaba-tungsten?

Iziqhamo ze-graphite ziyafudumeza kakhulu ekumeleni kwegciwo ezinkulu kodwa zihlukana kakhulu, ngelixa i-silika zenkohlwa-zitunjsten zinika ukucopheleka okuncane kakhulu nokucopheleka okumnandi kumanyathelo amahle.

Ingaba i-EDM ingagcwalisa igciwo eliqinile?

Yebo, i-EDM ingasebenza kugegi likaqinile njenge-tungsten carbide nase-tool steels ngaphandle kokuchithwa kwesimo noma izindawo ezingavunyelwa ngokushisa.

Kanjani i-EDM iyafinyelela ukucopheleka ekwakheni kwebango?

Ngokusebenzisa ukucodwa kwegciwo, i-EDM ibeka amandla ekubekeni ubude bempawu nokuphepha kwesayizi nakaphi naqeda okuvamile, ekulungiseni ukuguquka kwesimo nokuqina kwegciwo.

Kanjani ukugcwaliswa kwe-die EDM kususelwa kuzinto zokwenza zamanje?

Ukufaka kwe-EDM kuxhunyaniswa nezakhiwo zokudala futhi nezinyathelo ezinhle, ekuvumela ukwakha kwezinqawatha ngokushesha kanye nokucophelela okuphephile kanye nokubuyisana ngezimali kwexakisha njengoba kusebenza.