I-EDM Die Sinking Machine: Ukuhlungwa Kuzo Zingcindezi Ezihlelekileyo Kuzindlela Zokudela

Indlela Iinkinobho Ze-EDM Zendlula Zenzela Ukwenza Iimold Ezikhulu

Izimboni ze-EDM zokufaka izindlela zihlakaniphile kakhulu ekwenzeni iingcambu ezinxulumene ngemithwalo ephuthumayo njengeguba eliqine, titanium, kunye ne-tungsten carbide ukusebenzisa indlela yokuhlakulwa kwezibhamu. Kutheni oku kubonakala ngaphezulu kunemifuyo engqonge noma ukugcwalisa? Kulungile, zinokwenza iindlela ezihlala ezipheleleyo ezifika ku-0.1 mm radius, ngokunxulumene nokuphakama kwezigaba ezincinci ezidingekayo kizinto ezjikelezayo njengezixhobo zomntwana kunye nezigaba ezincinci zezinyawo zegalelo lezinyawo. Amabhangi aninzi ayisebenzisa graphite noma amathambo oCopper ukukopa le minyango embalimbali phantsi kwizigaba zabo zokuzalisa, zibophelela ubuncike bokulinganiso bokungekho mncinane osi-5 microns phakathi komnyango wokuqala nomnyango wesibini.

Umdlalo Oqhubekayo Wokugcwalisa Ngokushisa Kwamathuba

Umsebenzi wenza ukuthi i-electrode ne-workpiece zingqamuluzwe kumzimba wesivaphazempilo, wenza iziviviso ezingu-10,000–50,000 ngosuku olunye kusengwa okuqukethwe kwi-8,000–12,000°C. I-voltage (50–300V) nesikhathi sokungena (2–200 µs) sihlehliswa ngokucophelela ukuze kususwa imitha engu-0.02–0.5 mm³ ngasinye isiviviso, njalo kuyakhangelwa ubunjwala besandla (Ra) phakathi kwe-0.1–0.4 µm.

Isibonelo: Isisekelo kuThuliwo lwe-Automotive

Ukwaziswa kukaCAM Resources ngo-2023 kwakubonisa indlela abaningi aba-sinker EDM bayaqhubeka ngalokhu kubekelwa emuva izindleko zokwakha izimodi zokudonsa kwe-aluminum eziphambiliyo esetshenziswa emkhumbini we-battery ye-vehicle yaselekthrikhi. Umsebenzi waba nobunzima obuqukethwe kwi-15 µm phakathi kwezixhumanisi ezingu-8, wabesebenza ukupholisha ngendlela eyayisodwa futhi wabusa ukuchithwa kusuka kuma-12% usuke ku-0.8%.

Kungani Ubuncinane Kumele Kuqondakale Emthinteleni Namuhla Ngezinhlelo Zokungenela EDM

Izimali eziphakeme kunge-±0.01 mm zivikela ukwakha kwe-flash kumagqabi atholakala ngokufakwa kovinini futhi zihlinza izimoto ezimfuzane kumathulwa amakhulu. Ngaphandle kuka-CNC machining, i-EDM ayikhathaze izimali ezingezansi ezingakwamukelwa ukuthi ziyophuze izimodi ezingenziwa ngokuphelele ngemuva kokucopheleka—lo yisahluko esibalulekile ekwakhiweni kwezinhlaka zokubuka ezidinga <0.005 mm yokungahambeki kwewavu.

Ubunzima obubi besayizi kuNtsindelo ya EDM: Izizathu nezinyathelo zokulungisa

Ubunzima besayizi obungaphezu kuka-0.5 µRa emashinini asebenzisa izindlela ze-EDM zihlaziywa ngokungafani kwebala lezinhlekele futhi ngezinhliziyo zokucopheleka. Nakuba i-EDM ihlanganisa ubunzima phakathi kuka-0.15–0.2 µRa ngemizimba engcono, izinguquko kumathuba wokusebenza kungakhetha ukuphindaphindwa kwezilingo ezinebunzima. Masibuke izindawo ezithile zokuhlukunyezwa kanye nezinqumo ezibonakalayo ngodadewethu.

Izinhliziyo zokucopheleka kanye nokuhlukunyezwa njengamaphimbo amakhulu okubunzima besayizi

Ukukhanya nokusabela kusheshako okutholakala ng during discharge erosion kungaholela emakhelwini angaphezu kwe-12,000 degrees Celsius, okubangela ukuthi kwebalekele izikhathi ezincane nezinhlayiya eziyashiselwe. Ngokwemfundo ethile eyandululayo ngoLwesihlanu, uma umshudumulo wodlame we-dielectric awufunyanwa ngendlela efanelekileyo, kuyakwenzeka ukuthi kube lula ngokuphakamisa ukuhlinzekeka kwesithamo. Lokhu kuyakwenzeka ukuthi izikhathi zibe yini ngezinkulungwane ezimbili ngaphakathi kwezinto ezivuthiweyo. Uma ifunyanwa ngendlela embi, i-sludge enezingqimba iyagcina ngexesha futhi ibangela izindlela ezingavumelekileyo ezifuna ukuthi zibophephe amaxesha. Idatha yesivikelo ibonisa ukuthi malunga nezintathu ziphansi zazo zonke izinkinga zokuhlinzekeka ebonakalayo emasundwini asebandleni ayasebenza ngokomthwalo kutheniwa ngokungabi khona ukungeniswa kwe-dielectric flow rate ngendlela efanayo.

Ukuziphatha Kwezimali Ezilungileyo Nezimali Zokuhlengahlenga Kwesilinganiso

Ukudlula kulezi ziphumo kunciphisa indawo yomthombo wokuthinta, ukudala izinkomba ezihambisana ezibangelwa ngokuphelelwa kwesivimvo.

Indima yokuseta izindlela zokuthintana ekugcineni isivimvo

Ukulungiselela kakhulu kizindlela zokuthintana kubaluleke kakhulu. Ukongenisa i-off-time nge-25% kunciphisa ubunzima besivimvo nge-0.12 µRa ngokuvumela ukuthi umshwelo wodlame udlale ngempela. Umanyalo ka-2024 olwenziwe emasimbini ethungsten carbide wabonisa ukuthi ukulungiselela kwezindlela ngemithathu kunciphisa inqanawa yezinqunga nge-37% kunazo ezinye izinhlayiya ezenziwe ngendlela eyodwa.

Izinqumo zokulungisa ukuthintana ngemikhondo engcono

Phakamisa ukusebenzisa izinyathelo ezimbili zokugaya:

1. Isikhathi seGaya : Susa imodi 95% ngosimilo 10 A
2. Ukugaya Okuncane : Lapha kususwa ku-6 A, Ra 0.8 µ
3. Ukuqeda : Usimilo 2 A ngesilinganiso sesimo 0.5 mm/s, ukufinyelela kuma-Ra ≠ 0.2 µ

Lendlela, ngokunambalala nokubamba isiphazamiso sangempela semithuthi yokwahlukanisa, kusungula ixesha lokuphahla ngama-60% ekwenzeni izinto zezemfundo yesizwe.

Imithwalo Yokwahlukanisa Nezinkinga Zokuhlusha Kuzinyathelo Zomshini Wokuhleka Kwemithuthi YEDM

Ukuhlusha Okulula Kukhona Ukulaywa Kwesilulu Ngexesha Lokuhleka Kwimithuthi

Ukudluliswa okubi kweziqu esoqondiso kungumuthi omusha kuphela okuthi igumbu ikhula ngexesha le-EDM die sinking. Uma ukuquka kwegumbu kunciphisa ngapha koko kudingayo (ngokuvamile phakathi kwe-0.5 ne-2.0 bar, kulingana nendlela yokusebenzisa), le mikhumbi engcinezayo yezinto ezithintwayo zihlala phantsi ezigapini zengcinezelo esizange ziqunywe. Kutheni kusenzekile emva koko? Ngokuqinisekileyo, imininingwane yesixhobo ibonisa iindaba ezintathu ekusenzekileni koko. Okokuqala, kuzenzeka ukuba kukhangelelwe kwasekuhlaleni okubangela ubuchule bokwenza umfanekiso. Okwesibini, iivuli zikwaziswa ngokungahle kuba amaqadi aqhubeka aphakamisa phantsi kwazo. Kwesithathu, i-elektrodi zihluka kakhulu kunokuba kufuneka. Ngokomzekelo, emsheneshweni wevuli - ngoko ke kwiindaba zeminyaka yengu-2023 ngobuchule bomsheneshwano, makungu-thithi yazo zonke iindlela zokukhupha izivuno zikwenzekayo ngokungahle kwezivuno. Indlela eqhelekileyo kukuba iixhamla ezintsha zixhomekeke kolu daba ngokulungisa ukuquka ngendlela eyaziwayo nokuhamba kweelektrodi ephulaphula amagunya apho aya kuthi athembekile.

Ukusebenzisa KweNye Indlela Noma iDielectric Fluid Engaphoqwayi Ethatayipha Isebenzo

Xa isimo esingahambelani nesilinganiso seviscosity noma izici zeconductivity kusetyenziswa, umsebenzi wokuphulwa kwegceke kubukeka kuhlukahluka. Amabhasa anje angama-hydrocarbon ashishicilelwa ukusebenziswa kumisebenzi yeEDM yedie sinking ngoba aqhubeka akunciphisa izikhamu futhi achithe amaqhasha ngaphakathi kwendlela. Kodwa kukhona indaba enkulu lapho izinto ezithile njengezibuko zikhaboni noma i-tramp oil zafaka kumongo ngemisebenzi engaphoqwayi. Ngokwesiqephu esaphendukile ku-Machining Dynamics Journal ngo-2022, lezi ziphumo zingasebenza ngokuchitha ubunzima be-dielectric kabusha phakathi kwe-18 kuya ku-22 iphesenti. Lokhu kusho yini ngokwemfundvo? Izikhala zezikhamu zizobaluleka kakhulu futhi sizobona ububi bokwenzeka ngenxa yokushisa kuzo zonke izinto ezenziwa kanjalo nezinqamlezelo.

Ukucisha iNdlala kanye Neqiniso Lendlela Yokusebenza Ukufana Nezimphakathi Ezifanayo

Ukuhlanjulula ubunzima be-dielectric kudinga:

• Ukulungiswa kweqembu lokulahla : I-1.5x indiza yokukhupha kwamagugu emehluko yezililo
• Ukucaphuna okuneminyaka : Ukubamba kwezinto eziphakeme kusuka ku-5–10 µm ukuze kube nesimilo esigcwele
• Ukunyuziswa kwemperipheni : Isilinganiso se-25–35°C sokusebenza ukuze kugweshwe ukushintsha kwebomvu

Ukunyanga Okwesibili Kukhishwa Ngokungafanelekile Kokuqhasha Nezimpawu Zalo

Izinto ezizungezile zokudlulisela zingasebenzise igapu yesparka futhi zenza izinyukezi ezingavumelekile ezifika ezindaweni engazange zifuni. Lokhu kuyashintshana kakhulu futhi kwenza izinkinga zokulingana ngaphezu kuka-0.05 kusuka ku-0.15 mm ekuhlengalengeni lwemoto. Okukhangelwa ngakamnyama kukuthi le nyukezi ezingavumelekile zenza amathuba athintekayo athintekayo angaba phansi kuka-12,000 degrees Celsius, okwenzeka ngempela kakhulu kumthwalo wamandla wamagugu alilili. Ukuhlanjelwa okuqukethwe kwezimali ngema-250 kusuka ku-300 ihora zokusebenza kwemikhumbi kunciphisa lezinkinga ukuthi kuzale. Futhi, ukugcina izimali ezihlanjwayo kunciphisa isikhathi izinekede kuzolahlwa kabusha, ngokuvamile kunciphisa ngamanye amahora angu-40% ngokuxoxwa kwisiphiwo.

Ukungahlelekwa Kwezihlabathi Ngokungahlelekile Kwesiphaqamiso Nokungahlelekile Kweminyaka

Ukuhluza Kabusha, Ukugayayo Kwegolide, Nezinhlayiya Zokususa Isithombe Ezifakelana Nokulinganisa

Izimboni ze-EDM zisebenza ngokuhluka kweziphaqamiso ezigcwele ukulungiselela lezi zilinganiso ezinconywayo, nokho kube khona inkinga yokuqhuma apho iziphaqamiso ziye ngaphandle koko kufanele, zibangela konke okuhlelekile kwezihlabathi. Xa lezi zigolide ziguqukile emva kwezindleko ezinde, isiphaqamiso sikhula phakathi kwe-0.03 kuya ku-0.08 mm ngokwembono yezimali eziningi, okunakekela amabhubhu ahlanjulwa kangcono kunjalo. Kukhona ukubaluleka kwakhona ekulungiseni ubungakanani bokususa isithombe. Uma kuzama ukukhuphukela isivinini sezindiza, kusinda umsebenzi, kepha futhi kuguqukile igolide ngokushesha futhi kwenza intonga enkulu yokuchithwa kwintonga. Lokhu kungashiyelwa ukucopheleka, kanti kungaba ngu-12 iphesenti uma kusebenzela nezihlobo nezinto ezinhlelekile.

Ukuguquka Kweminyaka Nokuchithwa Kwesiqhamo Esiphazanyiswa Ekuxhumene

Ukubheka izinyathelo zokulungisa ngonyaka we-2024 kwakubonisa into ethile eyahlekisa - umbalo omutholwa kwezintambo ezingu-3 wemiphindo yonke yezimiselo eziphazanyayo ihluka ngemvula noma ukuvibrata okwenzela ukuthi umshinelwane wahlule. Inkinga ivuthiwe kangcono ngokuhlukunywa kwezinqunyatha, ikakhulu xa kusebenzi nezimpawu ezibangisa njengegciwane elihlanzekile noma amacarbite. Xa lezi zixhobo ziqaqaziswa, zenza amagap eziphambili ngaphandle kokusho, kuyakwenza konke kube luncane kakhulu. Ukulondoloza okuthile malunga nokugcina ubuncane kusho ukuthi ukugcina ubumnzana besifundazwe kusungulwe kungabeka phansi imiba yokulungisa ngama-22% kuzo zonke izisebenzo ezihlelekileyo ze-EDM. Amabhange ayodwa abasebenzayo nezidingo eziphucukileyo aqala ukubona lokhu kufundwa.

Izindlela zokulungisa Ubunjani bokuhweba Kusuka kuZimpawu Zonke

Ukuze ungavimise amagap angafani:

• Sebenzisa izinhlelo zokulungisa ukuhweba okulandelana ngokusheshayo ukuhlela ivholthiye ngokulandela isigaba esithile sokuhlukunywa kwezixhobo
• Sebenzisa izikhangelo ezithile zomthelela (umzekelo, +0.015 mm kwi-electrodes ze-graphite ngaphandle kuka +0.008 mm kwe-copper)
• Landela ukulinganisa phakathi kwemisebenzi ngalinye i-15–20 ucingo olwenziwa ngohlelo lokugcina ngezinqamuzi

Ukulungiselela uhlelo phakathi kwezilinganiso eziphambili kakhulu nezidinga zezihlalo

Nakuba izimboni ze-EDM die sinking zibhujiswa ukulingana kuka ±0.005 mm, iziphumo ezihlukanayo zazinzima ngokuhlanganisa ukulahlekelwa kwezixhobo nokulahlekwa kwegesiyo ye-dielectric. Abayengi bafinyelela ukulingana okungenani kuka 0.01 mm ngokusebenzisa:

1. Ukubuyisela kuqala ukusakazeka kwe-Z-axis ngalolilanga
2. Ukuthi uhliphe izixhobo emva kwezikhathi ezingu-15–20 zokusetshenziswa ngokuphindaphindiwe
3. Ukunikezela inkinobho yokulandela uhlelo ngokuzenzekalelayo ngezinhleli ze-infrared

Izikhathi zokuhlenga okuqukethwe zikhubaza izinkinga zomkhawulo ngo-60%, zihlanganisa uhlelo phakathi kwezilinganiso eziphambili kakhulu nezihlalo zokwakha.

Ukungaqondakali kwezimali: Ukukhokha kwezicathulo kanye nokudonsa kwe-arc kwi-EDM Processing

Ukudonsa kwe-EDM kanye ne-DC Arcing kusuka kuzindlela ezingavumelekileyo kwiqembu le-mold

Xa izinhini zokufaka i-EDM zihlukana kakhulu, zizothatha ukuthi zilahlekelwe ngemiphumela njenge-pitting yezinhlangothi noma i-DC arcing, ikakhulukazi xa zisebenza kuzo zimodi ezihlelekileyo zezithuthi ezingcono abayengqiya bathanda ukuzihlukuma. Okuqondileyo kuyakho konke – uma isistimi sokuphatha i-servo ayikwazi ukugcina lezi ziphazha ngendlela efanele, ke manje konke okunye kuhlanganisa kusuke kuhlala kudla amanye amaphakheji angalidingeki. Ngokubeka kwesiviko esishicilelwe ngo-2022 yi-International Journal of Advanced Manufacturing Technology, umbala ozithathile wezimphumela zomthuthi (mold defects) zisuka kule ndlela yokuthinta okungavumelekile xa kusebenziwa emsebenzini onjalo. Lona ungama omkhulu kakhulu kubasalela abathintana nokuba kuzinzuzela ubumnandi ngaphandle kokuthatha imali enkulu ekwenzeni kabusha.

Izindlela Ezifundiswa Ukulungisa Ukuqina Kwe-Arcing Ngexwayiso Le-EDM

Abasebenzisi bacophelela iziphumo ezivela ku-arc ngokusetshenzisa izindlela ezintathu ezibalulekile:

1. Ukugcina ubunjwaba be-dielectric fluid ngezansi kwe-5 µS/cm ukuze mukhuthaze izikhuthazo ezivese
2. Ukusebenzisa izinzo eziphumla neziqukethelezile ezingaphansi kwe-5% yokuqashiselana kwegunya
3. Ukusebenzisa izimanga ezivuthiwe phakathi kwemigwa yekhuthazo

Ukulungiswa okuhlanjwayo kwezinhlelo zolawulo kwegunya kunciphisa izigapu ezithembekile, ngemuva koko amanzi abilawa abilawa ake akhuthazwe ayizinsuku ezingu-72% zezinkinga zomshini wokuthinta (Precision Engineering Society, 2023).

Izinkinga ekulungeni iziqinisekiso zesayensi ngokubambisana nemithombo ebhaliwe

Ukuthola izimiselo zokuphuma ezifanele ekulinganeni nokuba ziphi izinto eziphathelene ngokubambekayo kuyindlela esihlukileyo kumele kube yinkinga engaphezu kwemithombo engaphezu kakhulu. Izinhlelo zokugcina zezinkuni zabelana nge-0.8 kuze kube ngu-1.2 microns emigodini yezinkuni, kodwa xa kusebenziswa izixhumanisi ze-graphite kumaloyi we-titanium, abasebenzisi kumele bakhuthaze ivholthi nge-15 kuze kube ngama-20 phesenti ukuze bafakale njalo. Ngoba le miphikiswano ingaba yinkulu kangaka, ikakhulukazi xa kunezinguquko ezintathithwe ngamaphesenti angaphezu kuka-40 ngokulinganiselwa kwi-National Annealed Copper Standard, abasebenzi abaningi basebazi ukuthi kumele bahlawule imviko yokungabambeki ngexesha elishaya lapho behlala kusinye isimo esinye. Kungenjalo, wonke umsebenzi awusebenzi njengoko kucacile.

Izixhobo Zokulawula Ezilandelana Ngenkathi Iqinisekisa Ukuphela Kwamandla

Imithombo ye-EDM yamanje inemithwalo ye-machine learning eyazinga izikhathi zokuphuma ezahlukahlukene eziyisampuliwa ngamathuba angu-10 MHz. Uma le minthombo engqondene bakhona izimpawu zokuthi kuzoshiba isiphazimandla, bangashintsha izikhathi ze-pulse ngemizuzwana engu-50 kuphela. Lokhu kususa ubuncinane besiphazimandla nge-90 iphasenthi kunazo ezidala ezasebenzisa kuphela ukulinganisa kwevholthaji ngokusho kwesiviko sika-Advanced Manufacturing Review ngo-2022. Kungaba nobunye obubi: amakholo ethirmali. Lezi ziphakamiso azisebenza kuzinkinga zokunyakaza kwezihlangothi, zibophelela kakhulu ngaphakathi kuka-phasi-nayi 2 mikromita nokuba kukhona imisebenzi emide yokuhlaga engavaleki kakhulu ubuncane.

Isikhombisi Sokuqala

Ngubani i-EDM die sinking machine?

Umdlalo we-EDM we-die sinking usebenzisa umdlalo wokwenza isiphazimandla ukuze wenze izahluko ezinhle nezikhulu kumagugu amadala njenge-sitheeli namatitanjhamu ngendlela yokuqhakazwa kwezivuno, lokhu kuyakho kakhulu ekwenzeni izinto ezinebuncane.

Kungani izimboni ezinkulu zokusebenzisa izinhlayiya zomdlalo we-EDM?

Izinhliziyo zomdlalo we-EDM zinikeza amandla ekwakha izigaba ezinhle ngemiphakethi engaphezu, njengezigaba ezide nezigugu ezihlakaniphile kusidlo, ngaphandle kokuthi kwenzeke ubuchwepheshe obukhazimula umlondolozi.

Kungani umlondolozi wodlalelo kubalulekile ekushintsheni kwemithombo ye-EDM?

Umlondolozi wodlalelo unquma izimboni futhi ususa izibonakaliso ngexesha lokushintsha kwemithombo ye-EDM. Ukunqamuzana kwayo okuhle nokuphila kunciphisa ukushintshelwa okucacile kanye nokunweka kwisikhathi sezinhlayiya.

Siyakwenzani ngezinkinga zokugulayo kwiziganeko eziphazanyayo kwe-EDM?

Izinkinga zokugulayo kwiziganeko ziphazanyayo zingakwazwa ngokulungiselela iziqinisekiso ze-electrical, thetha inqobo yomlondolozi wodlalelo, kanye nokusebenzisa izikhathi ezahlukene zokushintsha ukuze kube luhlaza.

Izinhliziyo ze-EDM zizilungiselela kanjani ukucacile kokuqhathaniswa okucacile?

Izinhliziyo ze-EDM zizilungiselela ukucacile ngokulungiselela futhi ziqinisekise ukulinganiselana kwetool, zisebenzise izinhlelo zokulungiselela, kanye nokwenza imvume yokuphila kwizinhlayiya ngokuyisikhathi.