Isimilo se-EDM: Uqobo Lwesimo Ekudluliseni Amathambo Amancane

Ukufundwa kwemithi ye-EDM nokuthi kuthatha yini indima yalo ekuxhumene nokuqhamuka kabusha

Ngubani umthi we-EDM? Izahluko ezimbili zokusebenzisa izindlela zokugcwalisa ngezinhlayiya

Izimakhini ze-EDM, enguqukazi ye-Electrical Discharge Machining, zisebenza ngokuthumela iziqhamo zesilonda esihlelekile phakathi kwelektroda nemongo yomlando. Lezi ziqhamo zibulala umlando ngokuphindaphindiwa okuphazinyayo kuze kube yimali enkulu. Okukhanya kwe-EDM ngaphandle kohlelo olunjalo phakathi kwegunya nomsebenzi. Esikhathini smanje, i-EDM ingaba nobuhleli obuphezulu—sithetha nge-0.001 milimita ngaphezu nangaphansi kokubalwa xa kusebenziswa izinto ezinzulu njenge-titanium noma isitshayi esibekwe. Lo buhleli kubaluleke kakhulu embangweni apho ukuphula okuncane kakhulu kungaba yinkinga enkulu, njengoba kwenza izicelo zezihlwelegama noma izihlwelegama zokugcina.

Ukulandela Kwezobuchwepheshe ze-EDM Emphakathini Wokwenza Ngobuhleli

Ukwenzo kwe-EDM kade kwaqala ukuba kutholakala ekhishini ngalesikhathi se-1960s, kodwa akawunalo into okwavela njengoba sibona manje. Ngaleso sikhathi, abasebenzisi basefuna ukulungisa iziqhamo ngendlela eyayisobala, lokhu kwaba kunciphisa ubuncane obukhona—ngokuphelele kungenzeka kuphela ngaphezulu noma phansi kakhulu 0.1 mm. Hhayi ke ngomculo, izinto zashintshelwa kakhulu. Izinhlelo zokubophezela ezingcono zisebenza ngokuhambisana nezithuthi zempethulo ye-nano-second ukuze zilungise izindlela zomshini njengoko kudingeka. Lokhu kusho ukuthi iziphoso zokhokha zihlehlile kakhulu manje, ngokulinganiselwa kungekho kungalapha 85% ngaphansi kwezifinyezo ezazenzela ngayo ngo-2005. Lezi zibopho zavula amathuba amasha ekwakha izinhlaka ezinkulu ezingu-3D emshenjini, apho izinye izinxenye zingafinyelela umthelela wobude kuye kangakanani 20 ku-1. Iyimpela le nto uma ucabanga ngayo.

Kungani Izimotolo ze-EDM Ziyehlisa Ekwenzeni Kusosilingo Esincane

I-EDM ingcono kunemithodi yomshini ekwenzeni kusosilingo esincane ngamathuba amathathu:

• Akukho nyukelo yomshini : Icima ukuguquka kweqeda lapho kushintshwa
• Ukuphumelela Kwamathetha : Ihlenza izilonda eziphakeme (>60 HRC) ezingafinyelelwa ngomshini wokugaya
• Ubuncane bokwenzeka kwezulu : Izindlela zokuphuma kwesiseko sizungulisa i-zone ezithintekile yisiseko ngezansi kwe-5 μm

Leli qhaza linakekela ukuthi i-EDM ibe yinto engalutholiweka yokugaya amakhanda emizuzwana kumagunya okunyusa izinzo, nokudala amathambo amancane kumadivayisi enezimoto-ngaphandle-kwethenkhasi.

Izinhloso Ezibhekene Ne-Micro-EDM: Ukufinyelela Kukuba Kuncane Kunesikhathi

Ukusebenza Kwemali Micro-EDM: Ubusika Bekususa Imali Emancane

Umethode we-Micro-EDM usebenza ngokwakha izivivane ezincane phakathi kwelectrode enkulu kakhulu neyiphi na into eqhelekileyo ekudinga ukushintshwa. Xa izinkinga ze-enerji zilinda ngezantsi kuka-10^-6 joules, lezi zivivane zikha iindlela eziphakade kwi-0.1 ukuya ku-5 micrometers, zonke njalo zibuyisela ububi bokugcina kwicala. Okuqondileyo kule ndlela kukuba akayi kuthintana ncaleni eyaziwayo. Nakuba isebenza ngomlando othandothando njenge-tungsten carbide okanye i-ceramic composites, abasebenzisi bangafumana ubume bomda obuphakade kwi-plus or minus 1 micrometer. Lo myalelo wokubulawa uyekisela kuthini abafumaphi baya kumethode ye-Micro-EDM xa kufuneka bahlawule izikhululo ezihlala kakhulu ezisetshenziswa kumathuba-entaba-ngamathuba (lab-on-a-chip) noma amaqiniso amancane afunekayo kumcala opakade obuphezulu.

Izikhumbuzo Ezibalulekileyo Zemfundo: Isilinganiso SeNhlawulo Yomlando (MRR) Nenhlalakahle Yecalala (Ra)

Ukuthola okukhulu kusuka ku-micro EDM kusho ukuthola indawo eqinile phakathi kwezindleko zokukhupha umehluko nokahle kweyisebe. Iziphakamiso ezilungile kangaka zingasebenza ngama-0.05 milimita yekhube njengeminiyu phezu kwe-stainless steel ngaphandle kokulahla izihlalo eziqinile kakhulu ezingu-0.1 micrometer Ra ezidingekayo izinto njengezimpilo zezimpilo apho isivinini sesivinini nesimilo sezibonakaliso sibaluleke. Imboniso yokuzilondoloza eyayisemlonyeni ubudlelane bethu bathi ukuthi ukuxhumanisa izikhathi ezingaphansi kwezintathu micoseconds nezindlela ezinhle zokusula kwedielectric kuyakhuthaza uhlelo lwesimo ngaproximately 23% ngokwemboniso etholakele ngoPonemon Institute ngolwesandule. Lokhu konke kuyenzelisa ukuhlakanipha ekwenzeni izinto ezinezici ezithile apho konke okuchazwe kuyabangela.

Ukukhuthaza Kwesikhathi: Ukuvikela Isimo Sokugcina Esingaphansi Kwe-Nanosecond Ekugcineni Izimakhine

Izimakhine ze-EDM zamanje zisebenzisa iziguqukazi ezavikilwe ngamatransistor ukuze zithumele izikhathi zokugcina eziyizingu-2–5 ns, 50× ngokusheshayo kunazo zomdla we-RC. Lokhu okucacile kangaka kusenzo kube yimali:

Lokhu kumele ukwenza izimboni zokunquma kwezithwala ngezinkinga ezinezingxenye ezingu-8:1 ngamathulini atholakala, kuhlukanisa indima yokwehla yomsebenzi ka-micro-EDM ekwenzeni okuphephile.

Ukuthuthukisa Izikhathi Ezibalulekileyo Zomsebenzi ku-Micro-EDM

Ivoltaji, Isikhathi Sefowula, ne-Capacitance: Ukulungisa Ukuhleleka

Emisebenzini yesikhathi esizeni EDM, ukufinyelela kunciphisa kune-10 microns yokwabiwa kudinga ukulungiswa okuhle kwemiparamitha eyisisekelo. I-voltage yokuqala ishiya phakathi kwe-50 kuya ku-120 volts, izinxenye zepuluse zihlala phakathi kwe-2 kuya ku-100 microseconds, kanti amandla wokugcina ayahlala phakathi kwe-0.1 kuya ku-10 nanofarads. Xa kusebenziwa ngeHastelloy C 276 emakheleni amancane, abasebenzisi bafunene ukusetha ixesha le-pulse ngaphezu kwe-115 microseconds lithintele iziphazamiso ze-taper ngaproximately 28% ngaphandle kokuchitha okukhulu kumathila ekususweni, efika kuyidlula ngokuthi kuhlale kuyidlala ngaproximately 0.12 milimitara yekhube ngomzuzu. Kumaqine we-tungsten carbide, ukugcina amandla wokugcina phansi kwe-5 nanofarads akhetheke konke. Oku kusiza ekukhathazeni ukuthi lezixhobo ezivuthiwe zingakhangele ngaphansi kwe-2 microns, into etholakele kwiimvavanyo ezahlukeneyo zezibalo zokuphendula ezenziwa ezingatshani zomthombo.

Ukubeka inyaniso Ngexesha Leliwela Nokulawula Ngokulinganiselana Emashinini EDM Esiyisodwa

Imithombo ye-EDM engcono manje ibambisana ukubamba isipungu esincane sokugcina ngeembono zokwenza ngokwayo. Lo mthombo unesensori eyili-12 ezisebenzisa ngokubangela ukuqwalasela izikalo zephasimende ngokukhawuleza kakhulu, okwenzela ukuba itshintshise iindlela zokunika amandla ngaphambi kokugcina kwisiphumo. Kutheni lokhu kuthetha ngempeleni? Le miqathango inokulondoloza ubuncane obungaphezu kuka-1.5 micrometers phakathi kweentsuku ezimbini eziyishumi elishiyagalombili xa ikhulula lezi ziphazamiso ezincane zokulima kwizibhambo ze-turbine zenqwelo. Ngokulinganiselwa kwisityhini, izigulukazi zibiza ngelixa likanye elingu-40% ngokuphindaphindwa kwezikhokho xa le miqathango yokudibanisa yasebenzisa kunokuba kusebenzise iindlela eziphucileyo. Lo hlelo lalungiswa ngokujikelezelayo ngaphakathi kweengxenye zokuzalisa.

Ukulungiselela i-High MRR Ngesidingo se-Surface: Ukuphulaphula Iziphazamiso Ezibalulekileyo

Kukhona into ethile ye-catch-22 ekhanda le-micro EDM xa kufanele kube nemiphumela emihle. Ingcinga yikuthi kufuneka uthole izindlela zokuthuthana kakhulu kwi-rates yokususa umongo ngaphezu kweminithi engu-0.15 mm ngaphansi kwe-0.2 microns yemipumela yobude bempahla. Abasebenzi basebenzisa i-algorithms ezinhlobonhlobo eziphathelene nokuthatha izinyathelo ezimbili, bazijulile izikhathi ezivamile zomlando phakathi kwe-1:3 ne-1:6. Xa kugcwaliswe kuqobo oluhle lwetitanjhamu, le mithetho iphumelela njengoba iphumula impahla ngenkathi imiswa yomlando ihluka ngama-15%. Into eqondileyo. Futhi xa sibuka ukuthuthukwano kusasa, abagcotshi bayaqhubeka ngezikhathi ezincane eziquka ngamashumi amakhulu angamashumi athupha ngosuku. Lezizwezo zisha impahla yekhanda ngamahlule amabili ngamathupha futhi kancane kakhulu kuzindlela zokugayaza ezintweni eziphakade ngaphezu kwe-200 microns ngosuku, okwenzela ukuthi zibe yimfashini eyinkimbinkimbi kumsebenzi wasekuhlaleni apho ubumnandi bukhona.

Ukusebenzisa Kwezimali Ze-EDM Ezinkulu Ekwenzeni Izixhobo Ngokufutshane

Izimali ze-EDM zinika amandla okwenza izixhobo ngokufutshane eziphucukileyo kuzo zonke iindustri ngokufakelwa kwezinto ezingaphezu kwe-50 μm ezintathini ezibuthi, ezikhabhoni, nezinzi ezilungileyo. Indlela yabo yokubhinta engaqondani nokuba ihlala ibhinte ngaphandle kwezinkinga eziphucukileyo kwizindleko eziphumelelayo, zenza ukuba zibe yimfuneko yokwenza izinto ezine mitha enkulu ofunakelekayo.

Ukugcwalisa Iihole Eziphucukileyo: Ukubhinta Okuphucukileyo Kwizinto Ezidibanisa Ukubhinta

Izimboni ze-EDM namuhla zingahlweba amathambo okulahla ukushisa emashinini kumthombo omncane kakhulu njenge-0.1 mm ngelishwa iqhakazelo liphakade elingaphezu kwe-micrometer eziyi-2. Umphakathi wemithambo yezulu usebenzisa kakhulu le teknoloji ngoba izilonda ezibekene ne-nickel zidinga amathambo amnyama angama-400 ngalunye ulwahlaza ukuze aqondise ukushisa okuphakeme kakhulu kwezindawo zokushisa okuphakade kungekho mibili 1,500. Noma kunjalo kuyisikhundla esihlelekileyo ekusebenziseni lezo zilinganiso ezinzima, umgodi wesayizi ungasebenzi kancane kakhulu ngaphansi kwe-micrometer e-0.4 Ra, lokhu kuyinto eyinkimbinkimbi ekubeni isivinini sibe neminyaka engaphezulu nokusebenza kakhulu emehlweni ephuthilekayo.

Isifundo seNkonzo: Ukwenza Izivuno Zokunquma Kombusi Ngokusebenzisa i-Micro-EDM

Umphakathi omunye ophathelene nombala wokuxhumana wabeka usindiswa kwesithathu-5% kombuso ngokusebenzisa izivuno ezizenziwe ngu-EDM ezingenazo amathambo angama-72 ehlukile kakhulu ane-80 μm. Lokhu kukhangelela ekubekekeni kwezinhlobo zokushisa ngama-12% futhi ukulungiswa kwezivumelwano zezimali eziphakeme kanye ne-Euro 7. Indlela yayiqhamuka <1% ukuguquka kwe-diameter phakathi kwezinhlanu zokuphatha ezingu-10,000.

Ukwenza Kwamandla We-Micro-Channel kwiLab-on-a-Chip kanye Nezixhobo Zomjikelezo Omcinezane

I-EDM machines ikha izindlela zomlilo ezibinazo 200 μm nge 5 μm yomgca wesilwandle emacaleni akunye nemithombo yokulinghloliso. Lokhu kuvumela amathuba okuhlola angcono ngaphakathi kwesilinganiso ±0.5 μl/min—okubalulekile kumanyathelo yokugcina ingcinwa enobulungiswa be-99.9%. Izahluko ezisha ezenzekelayo zivumela ukusebenza okwodwa kwezindlela eziphambili ezi-64 emagqumeni asekhundleni esebenzisa isitshanti se-316L.

ukugcina Kwe-3D Micro: Ukuthutha Izingxenye Ezinxulumene Ngeengxenye Ezide

Lo teknoloji ikha i-MEMS components enobungakanani be-15:1 kanye ne-2 μm yobuchwepheshe bomfanekiso. Ngaphandle kokugcina ngendlela eyaziwayo, i-EDM ibekepha <0.1% yobuchwepheshe komshini xa ikha i-3D micro-cavities emagqumeni ase tungsten carbide atholakala ngokukhulu kumazinyo olawulo.

Ukugcina Ubunzima Kwaye Izezimali Zokuphela Kwiteknoloji Ye-EDM Machine

Ukuzivocaba Kwinkqubo: Ukuqwalasela, Ubunzima, Kunye Nokugcinwa Kwizibalo

Izimakhini ze-EDM zimanje zingasebenza ngokwesilinganiso sika-micron ngokuzithemba kweziviko eziphambili zokwenza imodi. Abazalisi abaningi basebenzisa i-Cp values ezingu-1.67 futhi i-CpK ngaphezu kwama-1.33 ukuqinisekisa ukuthi izinto zilunge ngaphakathi kwezidingo eziphansi ezidingekayo, njengezinhlayiya zezimoto zezomoya noma izimpande zezokulima. Indlela eyinhloso yalesi sidzingo kukusebenzisa izinhlelo ze-SPC ezibheka phansi inani lebude bokugaya okungenamnye ama-micron ngelishwa lizide kakhulu eliphindwe kabusha amacubic millimeters angaphezu kwe-3 ngeminithi, ngokungahliki kokuphakeme kwezinhliziyo ezihlakaniphile. Lezi zimakhini zanelwa nezinhlelo ezinzulula ezikwazi ukulungisa ubukhuni bezixhobo njengoko kusenziwa, zilungisa izindlela zezinekilede ngokuzenzakalelayo. Lokhu kudala ukunciphisa okungu-80% kwezimposiso ezinezilinganiso ngokulinganisa nokulungiswa okuthekwini ngokwemibhalo yesandla yesandla egxilwayo ngo-2022.

Indoda Yezimakhini ze-EDM: I-AI, I-IoT, Nokulungiswa Okuphiqephele

Ukukhula kwe-teknoloji ye-EDM kuthuthuka phambili ngokuhlanganisa ubunzima bokwenza izilungiselelo nangenxa yobuchwepheshe obugcwele, ngaphandle kokulawula ukusebenza ngendlela ekhokelwe kwi-internet. Izimiso zomfundo wasekhona zibuka izinto ezingu-120 nangezinye eziphakathi kwazo njengezindleko zokumisa izikhathi phakathi kweziviko futhi amandla wokuhlaza kumthwalo wodlame. Ngokwale data lonke, le ndlela ingezwa kusinika izizathu ezidelelayo ngamathuba angu-94%. Lokhu kusho ukuthi abakhethi bakhala ngendlela ethile xa bekhipha izilungiselelo zabo. Isosayensi esiyinhloso ngaphezu koko kukususa izinkinga ngaphambi kokuqhubeka, okubukeka iziqhamo ezibalulekile njengezinqolobane zespindle nezithuthi zokunika amandla. Ngokwemfundo emvelayo kumcabango wokwakha okunjalo ophumelele ngoPitsholo olwendulo, lezi zinhlelo zisusa izahluko ezingalindelekile zezixhobo ngama-37%. Xa izinkampani zifaka lezi zitekithi ezintsha, sibona izinguquko ezihlakaniphile ebusuku buqhawe.

• amawaka okugcina kakhulu ngaphanda kwe-60% ngokulawula umgodi wempika ngendlela eyakhiwe
• ukubuyela kakhulu kwisikhundla se-0.5 μm ngemithombo eqinisekisiwe ngexhumanisi le-neural network
• ukuncipha kwezimali ngama-45% usebenzisa izinhlayiya ezintuthukile

Izinhlelo zihlukanisa ephindelana ukwenza okudala nokuthatha imicimbi emincane, zibonakala, zivikela indima yokwenza ngqo iimoldi zokunxibhela eziphucuphucu ngeezibuko zokuchazela izililo ezinezilinganiso ze-5:1—impumelelo engaphezulu kuka-3X kunee ndlela ezisiseko.

Imibuzo Evame Ukubuzwa

Yintoni into enconywayo yokusebenzisa i-EDM machines kunee ndlela zokugcina eziphambili?

I-EDM machines inikeza indlela yokugcina engaphandle kokuthinta kumoto, efaka ukungahleli kwalomoto nokutshintsha kwisampula, yenzela ukuba ibe yisixhobo esihle kakhulu ekwenzeni iingcinga ezilandelayo ngamathuba amazimu.

Ithini indlela ethile i-EDM technology iphucuke ngonyaka?

Ukukhula kwe-teknoloji ye-EDM kuyeza kususela kumehluko wohlelo lwesandla kuze kube yisistemu yokulawula okuthuthukisa nokhiya kwamazulu ngemizuzwana engu-1/1000000000, ekhathaza ubumnandi nokuncipha kwemiphikiswano yesikhungo.

Kungani i-Micro-EDM enziwe ngokusha ukudala izinhlanzi ze-micro-fluidic?

I-Micro-EDM inika ubumnandi nobuhle, ikhomba ukudala izinhlanzi ezihle zezinhlanzi ze-micro-fluidic ezingcono kakhulu ezidingekayo kumashini we-lab-on-a-chip ngoba ingakheka kakhulu umthwalo wokunqula.

Izitekithi zezosuku ziziphi eziphatha kumashini we-EDM?

Izitekithi zezosuku kumashini we-EDM zifaka i-AI yokulungisa uhlelo ne-IoT eyothelwe ukubeka iminikane ukuze kugcinwe ubume nokulunga; izici zokulungiswa okuphathekayo zibangela ukuncipha kakhulu kwezigaba zomshini.