I-EDM Die Sinking Machine: Okungcolisa Ukwenza Amakhanda Angcono

Ukuthi Izimakhina Zokufaka I-Die Ze-EDM Zenza Yini: Izinhlelo Zokulahleka Kwezivivinyo Ezihle

Indlela YokuFaka i-Die (Die-Sink EDM) Nokusebenza Kwizinhlelo

Izimakhina ze-EDM zifaka i-die ngokusebenzisa izivivinyo ezihle eziphumelelayo ukuze zikwathise amagugu atholakala. Lokhu kusuke kwenzeke uma isilondolo esithunywa ngendlela ethile sisebenzisana nesiqhamo esikhona emthanjeni wesilonda. Sisodwa silikonjini noma silwandle, futhi le silondolo yenza umgudu ocacile ngokuthi iyishisa izivivinyo ezingu-1000 ngosuku. Ngamavolti angama-300, lezi zivivinyo zihlupha amagugu ngaphandle kokuthi ziphakamise iqhamo. Okukhomba kalesi ndlela kukhona kwenzeka ukuthola izici ezincane kakhulu. Fakazela lezi zinkinga ezibhekene ngezansi ezingaphezu kuka-0.1 mm, noma izinhlangothi ezingenanto njengo-Ra 0.4 microns. Amasenzo akhethekile engasebenzi ngaleso myalelo ngaphandle kokuhlupha iseqhamo.

Indima Yomthanjana We-Dielectric Nezivivinyo Ezihle Eziphumelelayo Ekususweni Kwamagugu

Amadula ebhilethriki etholakala kumakhemikali akhiwe ngamakhomishini ayisiseko asebenza njengendawo yokuhlambulukela phakathi kwegcine emva neqeda lesebenzi, ekulungiseleleni ukuthi kungabi khona ukugcwalisa okungafuneki, ngelishia elibiza izinto ezincane ezingatholakala ngexesha lenkohlaka. Xa iduli iyekeka ngempumelelo kusayithi, ingaba ngaphansi kwamagugu angama-40 ngokulinganisa nemithodi engaphantsi yekhono. Izimbi zase-EED zasa zisingeki kuphela ukusetha nokulahla. Ziyenzela ngokubheka ixesha lesparki, okuqukethwa kusuku esinye kuze kube sikhombisa esilishumi amashumi amabili, kwaye zihlanze indawo phakathi kwezinto, okuqukethwa kuma-5 kuze kube ma-50 micrometers. Lokhu kuguquguquka kunceda ukufinyelela isivinini somfanekiso ohleli ngexesha, ngamaxesha afika kuma-500 milimitara yobungakanani ngohora, ngelishia ihlinzele ukuphila kwesiqu esingathintwa sisiqu esingathintwa esingathintwa.

Umbiko wocingo olungileyo nesiphumo sakho kumgogodla wocingo nomqondo wephesenti

Isimo nemigomo yamatholakalo kumelela kakhulu ekwenzekeni kwemitholakala engeziwe. Uma kukhona phutha encane engaphezu kuka-±5 micrometers esikweni sengxenye, oku kuyashiswa ngokubanzi ku-±15 micrometers xa kusebenziswa izimboni ezikhokhelayo njenge-tungsten carbide. Izitholakalo zegrafithi ezakhiwe ngemizuzwana futhi zinezandla ezintotile kangakanani njengo-0.01 millimeters zingakha izinhlangothi ezilula kakhulu zibonakale njengomkhondo (amagugu wobude baphansi kuka-0.1 ukuya ku-0.2 micrometers). Iziphetholo ezisekelwe ku-copper zange zilinde kabanzi emva kwalapho ziqhubeka ziqina ngempilo ephila. Izinhlelo zase-CNC ezisha ngokuzenzakalelayo ukuqina kwegunya kusiza ukuthi lezi zitholakalo zilinde kabili ngama-30%. Lokhu kusho ukuthi abakhi uzothinta amagugu afakiwe ngaphakathi kuka-±2 micrometers emva kwezinkululeko ezingu-10,000 noma ngaphezulu ngaphandle kokudinga ukuthi zishintshelwe.

Ukugcina Imigomo Yemitholakala Emingiwe Ne-Akhrithi Ngendlela Ye-EDM

Ukudala izindlu ezihlukahlukene, izigaba ezimbi, nezinto eziningi

Amashini akhuphakela kwe-EDM ayakwazi ukwenza izinxenye ezinhlelekileyo zomlondolozi engakwenzeka ngendlela yokugaya. Indlela iyathatha iqhina elisemthethweni noma i-electrodes ezenziwe ngendlela ethile ukuze ikhuphe umongo. Abakhi amathambo bangafinyelela emagxineni angaphansi kwe-0.1 mm futhi bakhuphe izigubhu ezinde kune-50 mm emathambini athintekayo. Kuzindustri ezifana nezimali noma yezondlo apho ubunzima kubalulekile, le ndlela ibalulekile kakhulu. Cabanga ngamathambo okunquma kudinga izinhlanga ezincane zokulahla, noma izixhumanisi zezempilo apho konke okuncane kumelwe kube yimali xa kufika ekuphathekiseni nomuntu wesiphilofile nokuhlonishwa.

Ukufinyelela kwi-tolerances ezingu-micron emathambeni athintekayo namandla

Indlela engaphakathi kuyo thekile iphressa yomshayeli, ihlengelela ukuba ibe khona amatholakala angama-±3 μm nangenxa yezinto ezikhanyisiwe (HRC 60+) nezinto eziphaphaziyane njenge-tungsten carbide. Izithuba ezilandelayo zokugcwalisa nokugcina zilondoloza ubunzima bempilo emaphephandabeni embalwa (≈1 mm ubude), apho izindlela zomshayeli zingahlukile ekuthinteni noma kuhlukaniswa.

Ukulungiselela ubunjwaba bephansi (Ra) nobuchanakazi bekuqhubeka ukuze kube lula

Izigeni zase-EDM zihlanjelana ngexabiso lepuluse nangokungenayo komviko ukuze kufinyelelwe kuziphansi okujwayele kakhulu ku-Ra 0.1 μm ngemuva kokulondoloza ubuchanakazi be-±5 μm. Istrathaji eziningi zihlanganisa izinkinga ezinobukhulu (up to 400 mm³/min) ngexesha lokugcwalisa negunya eliphambili elilandelayo—olibaluleke kakhulu kumaphepha wamabhizinisi abonakalayo namakomponi akhanya kakhulu endaweni yesithuthi.

Ubunzima obungcono kakhulu nobuchanakazi bukaqhubekayo kumsebenzi wokugcina umphethe

Ukulungiselela i-EDM imigomo yezimali ezikhanya kakhulu nezimali ezingumgibeli

Ukubophezela kahle kwesivinini (2–32A), ubude bepulse (2–500μs), nokugapana kwezibhamu (0.01–0.2mm) kuthuthukisa ubunzima besayizi (Ra) ngama-40% kungeza kwezinyo. Ukubamba izibhamu ngokuzithembeka kusihlwanjiswa imigomo ngexesha elishintjisayo ukuze siphinde sihlele Ra ≈ 0.4μm—okuyiyo into ebalulekileyo kumakholamu okufakwa komlando ofuna ukuncitshiselana okuncinci kwegloss.

Iindlela Zokuthuthukisa Ubunzima Besayizi (Ra) Ngokusebenzisa Icandelo Lokugcina Ekugcineni

Icandelo elilodwa lokugcina elinobude obancinane bawadikili (0.1–0.5mm angaphantsi kwesilinganiso) lithuthukisa ubunzima besayizi ngama-60–80% ngokusebenza:

• Ukuncipha kwamandla wophazanyo (≈5μJ) ukuze kuncipiseke ubude bezibhamu
• Iimpulsi ezinezikhathi eziningi (≥250kHz) ukuze zimncitshise amandla ethirmali
• Ukusungulwa kwegesi ekhuphayo kuhlelwe kahle (isixhobo se-0.3–0.6MPa)

Le ndlela ibeka amakholamu ukuguqula kusayizi yokuqala ye-Ra 0.8μm kuze kube yasekugcineni Ra 0.2μm yesayizi enye yemilo ngemigca engu-3–5 yokugcina.

Isifundo Sombuso: Ukugcina KweMold Yomthwalo Ophucukileyo Ngendlela Ye-EDM Die Sinking Machine

Umbuso wokugcina osebenzisa izimu ze-LED zezimoto zibonisa ukuthi izinhlelo zomshayeli we-EDM zimanje ziyakwaziha kangakanani. Lezi zinhlelo zingenzela amaxeshe ngexesha le-Ra ebaleni ngaphezu kuka-0.15 microns futhi zilondolozo ubukhona bokufakwa ngaphakathi kwemizwa yazo zonke ezingu-120 ngaphezu kwezinkinga ezingu-2 microns. Uma abasebenzisi basebenzela i-copper tungsten electrodes noma iziqu le-dielectric ezisuselwe ku-hydrocarbon, basebona into eqinisileyo ekhona. Isikhathi esisodwa sokuphahla okwenziwa ngendlela eyayisebenzi siphansi ngama-40 phesenti ngaphandle kokulahleka kwebhola elihle ebuhleni be-amaxeshe akhe emsintu. Okunempela kakhulu kukuthi, ngithi njalo iprothesi, ukwahlukana kweqondo kwasula phansi kwe-0.005mm emthwini othuthayo obalwe ngama-HRC 62. Lo msebenzi ka-EDM ubonisa ngempela ukuthi kungani kubalulekile kakhulu ukwenza izimu ezinezimali ephakeme emnyakeni wamanje.

I-EDM Yezinto Ezikudingeka Ukuzivikela: I-Carbide, I-Tungsten, Nezinhlangothi Ezithuthayo

Ukuzivikela Kuhle I-Tungsten, I-Carbide, Nezinhlangothi Ezithuthayo

Amashini akwehla e-EDM asebenzela izinto ezihlukene kune-HRC 65, kufana nalezo ezinzulu njenge-tungsten carbide nezinkulungwane zezixhamla ezithintekileyo ku-60-62 HRC. Ngoba akukho uhlangano oludonsiwa ngendlela yokuhlisa ispark, izixhamla azizuzeki, lokhu kusho ukuthi singakha iindawo ezihlelekileyo nangona ku-cobalt bonded tungsten carbide. Ukuxhamla okutheku kungasebenzi ngalolu daba ngoba kuyakhula ukuthi kuhlehlise kabonke izixhamla zokuxhamla. Kwiindawo zokusebenza ezenza lezi zinto ezibophephileyo, i-EDM ihlala ihlasela izindleko zokuxhamla phakathi kwe-30% ne-40% ngokuqhathaniswa nezinye izindlela njengekhiya yelase. Le ndlela yohlaselo ihlala ibangela ubunzima obukhulu kumthetho wokwakha.

I-Grafith vs. I-Copper Electrodes: Ukusebenza, Ukuchithwa, Nenkokheli Yemisebenzi

Izilonda ze-Graphite ziyathandwa kakhulu kuma-tungsten carbide ngokuthi zinezimo ezihle zokwesabala kwizivivinyo eziphakeme. I-copper iyafanelekile kakhulu kumagqoko we-hardened steel edinga izimboni ezi-Ra ≈ 0.8 μm, nokho isilinganiso esiphansi sokushaywa kwayo kakhulu kuyakhula ukuba kubuyiselwe ngaphezu kwe-22%.

Ukuvuselelwa Kwemva Kukugcina Okuphucileyo Kuzilonda Zokwenza Ukwenza Ukudonsa

Izilonda ezihlanjwe ze-copper-tungsten zifika kuzindleko ezingaphezu kwe-18% kumagqolo eziphucileyo enezimali eziphakeme ngelishwa zibambelela ubuncike bokulinganisa (≈ 0.05 mm) kumagqolo. Iziqu ezinamathambo angaphandle ezifakwe kumameko ethixo ayidlulisela i-arc gaps ngama-27%, zinikela amandla okulingana ngokufutshane (±5 μm) kumagqolo e-hardened D2 steel. Le mithombo ivuselela indima eyasemva phakathi kokuhambo nokulondoloza kwezinto ezinamandla ekunye nezimali.

Imisebenzi Yasekuhlaleni Nenxaxheba YeEDM Die Sinking Machines

Imisebenzi emibalwa kumoto, umoya, nendalo yokugcina izigqibo

I-EDM die sinking machine yayisenzakalela kakhulu yonke indalo lapho kudingeka ukwenza iimoldi eziphambileyo kakhulu. Ngokomzekelo, ngomzansi wemoto, lezi zixhobo zenza iimoldi ezinhle ngokunxulumene ezisetshenziswa kumathini okulayiza nokuthutha komphumela. Ekhaya kwesivuno, abasebenzi basebenzisa zazo ukugcwalisa izinto ezilungile ngokukhanya njenge-titanium yezibhamu zeturbine ezenza izindlela zokulahla phakathi ezihlukileyo. Umzansi wemedical akawekelwanga, ngoba abayikreba basondla kule thekhenoloji xa benza iimoldi zezixhobo zokuphatha nokuthutha kanye nokuthutha kwezinhlelo-mgudu zeengcinga ezinokubalwa. Ngokwesondlo sezindalo esenzelwe ngo-2023, malunga nezingane ezine kuzinguhlalo ezihlanu zezimali ezithembekile ziyabhekana na-sinker EDM xa zisebenzisa nezinyo eziphambile kangaka ezintathu kunye nge-60 HRC. Kuyakwenzeka ngempela ngoba izindlela eziphucukelayo azikwazi ukufanana nalezo zixhobo zizifakazela kule ndima eziphucukileyo.

Imiphbenefiti yokugcwalisa engaqhubi: ukususa ubuchopho kumakomponenti atholakala

U-EDM usebenza kahle kakhulu kumagunya amahle ngoba akukho uhlangano lwasebenziswe phakathi kohlelo nokuthi kusebenziswa kulo. Cabanga ngale mikhumbi enzululwane yesayensi yesihlalo engaphansi kwemilimitha engu-1 noma le moldi ehle ngokushesha esetshenziswa emicrofluidics yezempilo. Kulinganiselwe nezindlela zokugaya ezingaba nemandla angama-740 kN ngamunye we-square millimeter, u-EDM uyekwa izinkinga zokuhambisa ngokushintsha ngokuthi usebenzisa izivivane ezohlwayo. Abazotha abaningi bafuna into ethile eyahlukene futhi. Xa basebenzisa nezinhlayiya zesiyaluminiumi eziphuhlile kumagunya wobuchwepheshe, baphumana nokuba kube namathuba angu-40 iphasenthi angaphansi kokungabi khethiwe kabonke. Ayenzelwa konke lokhu ngoba umthelesi uphendula kahle kusindiso olunjengoba sihlupheka u-EDM kunokuthatha ngokubamba.

Kungani izinkampani zohlelo & zodidi zisebenzisa i-sinker EDM ukuthuthela nokubuyela kabusha

Abakhi besithuthi bafinyelela ukulingana kwezilinganiso ±2μm phakathi kwezikhathi zokwakha ezingu-10,000 futhi kangaka ngokusebenzisa iziqhamo ze-copper-tungsten. Umnikeli omkhulu wemibili yezimali wakhuphula izikhathi zokuhlengahlenga kwesithuthi ngo-300% emva kokushintsha kuze kube nge-graphite electrodes kumalayizi wehot-stamping. Ngokuzivikela kwezimilo eziphathelene nokugcinwa kwezixhobo ezihlengalanga, i-EDM iyisusa isimo sevidi ngo-25–30%.

Izibonelo ezintsha: ukuzinikela kanye nezinhlelo zomphakathi kumagunya e-EDM

Izinhlelo zokulungiselela izikhathi zokugcina okuhleliwe ziyishintsha izimpawu ngexesha elithile, zilapha ixesha lokugcina umgodi wamandla ngama-18%. Izimbi ezihlukaniswe nge-cloud manje zihlela ngokuzenzekala ukulungiswa kwezinqunyane zeziqhamo kanye nokuhlengalanga kwe-dielectric fluid, zivumela imisebenzi engaphandle kwezibalo kwi-95% yezinkokhelo zokugcina amalayizi emigangeni yokwakha kwezimali eziningi.

Imibuzo Evame Ukubuzwa

Yiziphi izindlela ezigcinwa ngu-EDM die sinking machines?

I-EDM die sinking machines ihlanjwa ngendlela yokuqeda ngokugcina, isebenza ngokushaya kwezixhobo zokwelashwa ukuze ikale isimo somfanekiso wamandla ngaphandle kokuthintana.

Kungani umshwelo wokwehla kusiza inkululeko ye-EDM?

Umshwelo wokwehla usebenza njengomqondo, ukukhokha ukugcwaliseka okungafuneki nokususa izinxalenye ezithintekileyo, ngakho kuthuthukisa ubushushu nokunciphisa izinhlayiya eziyashintjiswa ngejika 40%.

Yiziphi izinhlobo zezilwane eziyiswe kakhulu kusebenzwa kwe-EDM?

I-EDM ihlelekile kumzimba ozinzulu ukuzivikela njenge-tungsten carbide ne-steele ethintekile, ngoba ikuvumela ukuzivikela ngokucacile kangangoko ungakhohlwa izixhenxe zokugcina.

Kungani iziqhamo ze-copper ziyathandwa kumsebenzi wokugcina?

Iziqhamo ze-copper zihlinza ukugcina ngokuchaza kancane nembangela yokukhathala, ekhuthaza ubunikeni ngemva kokuphatha kakhulu.

Yiziphi izibonakude zasemandulo ezikusiza ekuthuthukiseni ubushushu be-EDM?

Iziphiqaphi njengeziqhamo ezihlanjiwe ze-copper-ne-tungsten nezimbi ezenziwe ngamaphazini aphantsi anezimbi ezifakiwe emshwelweni wokwehla zakhuthaza izilinganiso zokususa izimbi futhi zivumele amahluko amancane, ekhuthaza ubushushu be-EDM ngendlela ephakeme.