Igqanti le-EDM Wire Cutting: Imithombo yokulungisa ukuze Usebenze ngeminyaka engaphezulu

Ukucaciswa Kwinkqubo Yomoya We-EDM Wire Cutting Machine

Isikhwama se-dielectric esetshenziswa kumashini edlula amawhele kwe-EDM sifake izinto ezimbili ngokufanayo: isebenza njengesikhwama sokugcina kwezimali kanye nokulula izinto ngenkathi kusebenza. Ngaphandle kalesi sikhwama, kungaba kukhona ukungcola okukhulu ngisho ngokungathi amashini ayikwazi ukulondoloza le gap discharge esibalweni phakathi kwelethe kanye nekhowudi. Ngokwengezwe, lesi sikhwama silahlaba konke le mibhalo yemali etholakala ngenkathi edlulwa, okusiza ukungavimbeli izicathami ukuba nezindleke noma zivimbelwe. Ngokwesicelo lasekupheleni kuleli njengo Manufacturing Technology Journal, amashini apho abasebenzisa bakhululela kakhulu lezi zinhlelo zesi-dielectric besebenza ngokuningi ngenkathi ethole 18% kahle ngokujwayelekile. Ngokwemva, lapho isikhwama sikhuphwe, iziqhelo tenda ukuba yisithupha kakhulu. Sibeke kakhulu lapho ubude bokugcina kweyimpela kweyimpela kwehlukana ngokuningi ngenkathi etholakala kwehlukana ngenkathi esetshenziswa isikhwama esishintshiwe noma esikhuphwe.

Ukubheka kanye nokuvimbelwa kwekhumla kwisikhwama se-Dielectric

Xa uyenza imi-check engamagqibo ngokwesekelwe kwezilayi, buyise kumaqondo wesilayi okuqala ukuba yilanga (emulsification), ukungqinelwa kwezilayi zokwehliswa, noma xa ipH iphansi kuka-6.5 okanye iphezulu kuka-8.5. Le minto iyacoca ngoba izinto ezijikeleze ngokweqile njengama-oksidi ajikeleze kwaye amaqhekeza amancane angaphambiliyo ayenza ukuba amaqhube apholile. Ngokwesicatshulwa soMnyango weIndustriyo 2022, le ndawo zilayi ezingaphumelelanga ziyanciphisa amandla kakhulu (47%) kwezinye zokusebenza kwezimvume zaseDM. Ukuba ufuna ukulandelela ngokulungileyo, faka uhlobo lwenani lwezinto ezincinci ukuze ulibone into enkulu kune-15 microns. Kwaye ungalibali izilayi zokwehliswa zokuxhuma nendlela zazo, zisebenza ngokulungileyo xa zilanda amaqhube aphakathi kwezinye izinto eziphathwa ngokusebenzisa imiciko yamacala.

Ukulandelela Ingqwalaselo neffiseyensi yomthuthi wokulungisa amanzi

Fusha 5% ye tank ye-dielectric ngokoweke ukususa izimpawu ezithathwe. Faka kabusha i-cartidges yefiltri lapho kune ukuhluka kwamandla angaphandle kwe-1.5 bar noma ngamagama okusebenza 600 amahora.

Ukubuya kwe-Dielectric Fluid Ngokwesiko nezibonelo zomkhiqizi

Abamkhiqizi abaningi be-EDM bathanda ukubuya ngokuphelele kwe-dielectric fluid ema-1,200-1,500 amahora okusebenza noma lapho ikhondo eliyiza ngaphezulu kwe-30 μS/cm. Okuhlelwa okuphakathi kwezindlela zokugcina (ngaphezulu kwe-3 amabhrekhi/ngohora) kuyindlela yokuthola ukuthi ifluyidi isebenza kanje. Qhuma ukuthi ifluyidi ephelile ithunyelwe ngokusebenzisa izinkampani eziqinisekisiweyo yokuzilungisa ukuze uqinisekise ukuthi kuhlanganwe nezimo ze-EPA ne-ISO 14001.

Ukukhetha, Ukusebenzisa, nokubuya kwe-EDM Wire ngendlela Ehlukile

Ukusebenzisa i-EDM Wire Ephambene Nokweqile Ukuthola Ukunciphisa Okuhle

Ukukhetha wehile EDM enkulu kumele kubangela wonke umehluko xa kufika kuzo ukuphinda amacuts akhona futhi ukulondoloza izindleko. Amakhampeni anje-ane ayithemba kakhulu kuwile le brass kumakhiwa kancane-kaningi kwezimali ezingu-8 kuma-10 ngoba iyasebenza ngokuhambisa umoya futhi ayikhansi izindleko. Ababhili beshayela ukuthi bafunda ukuthi bafaka izinkanyezi ezine zinc, ngoba lezi zimele ukukhupha kancane kancane ngama-15 kuya kuma-20% xa kusebenza ngokucacileyo. Wehile ezinciyileyo kumele kuziwashwa ngokuhle. Xa zibhurwa phakathi kwenqubo, iziphathimandla zakhona ziyafika kakhulu. Ayikho kuphela ukuthi imishini iyophakathi ithambile ukulanda ukubuyiswa, kodwa izinto ezithulwe kufanele zibuyiselwe futhi. Abakhawulezeli besikoleni bavuma ukuthi ngamunye umehluko wewile ubizwa ukuthi ubangela izindleko kusukela ku-200 kuya kuma-500 dholola ngokuthi yiziphi izinto ezithulwe.

Imithwadi Eningiyo Yohlelo Lwehile Nokulinda Ukuhlukahluka

• Gcina amapholi wehile endaweni enekhalelo leklima (40–60% wehumi, <25°C) ukuvikela ukuthi ayithathwe ngokushisa
• Sebenzisa izigqoko ezingenayo le ntung'omane ngokuphindaphinda ukubamba ukuze kuvikeleke ukulaywa okanye ukungena kwezindlela
• Hlola umoya ukuze kubonakale ukuphuzwa okanye ukungcola ngaphambi kokulayela—izindlela eziphansi ezingaphansi zenza ukontrola isparka

Ukufanisa Uhlobo Lomoya Nendawo Yalo kwiinkcukacha zomshini

Izimoya ezingaphansi (0.0008–0.004") zivumela ukulaywa okuphambene kodwa kudinga ukutshintshwa kwezilayisho zomshini ukuze kuthwalwe ukuphula. Qaphela ukuba kucacisa incwadi yakho yomshini—ukusebenzisa umoya we-0.010" kwiintsuku ezilayweyo kwi-0.008" zindlela zenza ukusebenzela kwe-12% kwaye yenze isiqingatha sokugqibela siphambene.

Ukulinganisa ngokohamba nomsebenzi wokulondoloza

Ukucacisa ukulingana nokulinganisa ukuze ubukele kakhulu

Ukulayisha ngempela kuzo zindlela zokugaya ngemoto zokugaya kwenziwa yindlela ngokuphindwe kabili ukunciphisa ukungaphezulu kwezinhawu. Isicatolemo esisha lesihlanu lesihlanu (2024) sithole ukuthi kungeziwa isixishu kwezikhetho eziphumelelayo ziyasebenza ngokungathulayo. Amakhampeni anake ukuba nendawo yabo yokuqondisa ngama-2 microns ngezinye izikhathi ngokulandelana ngezinye izikhathi ngezindlela zokulandelana noma izigaba zokulondoloza. Futhi, sikhumbuzwe ukuthatha iindlela zokulungisa ukushintshwa kwesikali esikhumayo ukuthi kuthole ukuthi kutheni ukushintshwa kwesikali okungathulayo kungafika kumaqeba amaningi. Imithi yokusebenza ikusho ukuthi kufanele ukulandelana kwemoto kugcwelwe ngokuphindwe kabili ngokungafani nezinyathelo ezimbili. Le ndlela encane ikusiza ukuba kungenzeka ukulayisha ngokuphezulu, ngakho kubaluleke kakhulu kumaqeba amaningi aphumelele apho noma ukushintshwa okuncane kungaba nokungcono.

Ukugcina ulinganiso lwemoto, Isivinini, nezinketho zokusebenza

Ukugcina ubuchule bekhwekhwe kuzo kuziphakathi kwe-8 kuya kwe-12 Newtons kwenza ubuntukela kakhulu xa kuvuma ukuthi kuthathwe amacat ekuhlolweni ngekhwekhwe. Uma izigaba zokulayela ziyephepha kancane kwezingu-10 milimitha ngemizuzu, izinto ziyekela ukuthi kuthathe isiphandla esiphakathi kwezinsparki. Xa kusebenzwa nezinhlobo ezahlukene zamakhlangu, abasebenzisa kufanele bacheke ukuthi ziyakhonkela kanjani ngaphambi kokusetha izilayela zokumisa. Xa kusebenzwa nezinhlobo ezikhulu zamakhlangu efuthumeleni, ukunciphisa isikhathi sokuthumela kancane kwezingu-50 microseconds sikhona kakhulu kwenza ukuhlelela okungenani ngama-30% njengoba sibonile kusebenzweni. Futhu kungase uthinte nazo izinhlelo zokulandela ngokushesha. Zilindela ukuthi izingu-5% zokuvula ziyephepha, lokhu kuvumela abasebenzisi ukuthola izinkinga ngaphambi kokuthi izimo zokuthola amakhweyana ziyekela futhi ziruwe yindlela yabo yokuqala.

Ukuthuthukisa Ubunzima Bokusheshela nezinhloso Zokugcinwa

Izikhathazelo ngeminyaka kwezimali zokusebenza nezinhlobo zokulungelela zivike amaphutha okungcola. Shintshe izigu lwebrass ezibonileyo ukuthi kungaphansi kwe 0,1 mm, ngokuba kuneqenqeno lobudlelwane obungatholakali kuzindlela ezithile kakhulu kakhulu. Imvunankelo ye-dielectric fluid kufanele ibe ngaphansi kwe 20 µS/cm ukuvikela amandla okungcola aphakathi kakhulu kakhulu.

Ukulubika nokuphepha kwezinhlobo zemikhina

Ukulubika kwezinhlobo eziyashintsha ukuthi kungcinwe ukushintshwa kwezimali zokusebenza

Ukulubika kahle kunciphisa ukungcolana nge 40% kuzindlela eziphezulu kakhulu njengokwehliswa nezinyathelo zemball (Industrial Maintenance Journal 2023). Isifundo esitholileyo kubasebenzisi bokwenjinieri betholileyo ukuthi 68% yedleke lapho kungasebenzi kakhulu kusobala ngokungabi ngegreysi. Landele leli qhinga lokuphepha:

Sebenzisa kuphela izilubrikethi ezivunyiwe yiMfaneli—izilungiselelo ezitholakalayo zingavivinya amaseyu fakuthi kakhulu kwekhipha ngama-22% (Tribology Today 2024).

Ukuhlula nokusebenzisa izifilti ukuze kusebenze ngaphansi komphela

Izifilti ezimbuywe zingxilima ama-34% wokuphulwa kwezinhlayiya zemali edolobheni le-EDM (Inkcazo yeMachining eqile 2024). Sebenzisa ukulandelela kwezinye zokulandelela ngemva kwesibonelo:

• Izifilti zokungenela eziprincipale : Shintshela uma isihlukelo sempilo siphumelela kancane kune-0.8 bar
• Izifonti zemali edolobheni : Kulula ngokusebenzisa imisikakhe yemifanekiso yokusula konke okungabikho
• Imigqa yokubuyisa yohlolwane : Bheka ukuthi kungaba kukhona ukuthuthwa kwezithuthi kuzo zindawo zemigqa

Imifilithri engavunyelwanga iyavumela amachini okugcina amawhele EDM ukulandelana ngama-15–20% okunyusa ukusebenza kwamandla, ukuthutha ukugcina kwezimotolo zokulawula nezimodi yokulawula.

Ukulawula Imizimba Yemhlahlandlela nezinkokhelo Zokulungiswa Ngokuzenzekelayo

Ukulawula Umbiko, Umgcipheko, Nokuqhafane Ngokomdlanga

Ukugcina ubudlelwane obulandelene nezinhloso ezingu-20 kanye nezingu-24 zedigri Celsius ukusekela ukulawulwa kwezinto eziphakeme ngaphakathi kwemashini yokugcuka uthwini. Kungase kube phansi kakhulu - okungcono kungaphansi kwe-60% umlinganiselo wemali ukuze amandla angasekela amandla. Kumaqine apho emashinini aphakathi kwezinye iindlela ezininzi, ukubeka amapadi amathandwayo okuyikhuthazela noma ukubeka kuzo i-base zokuxhasa kuyakunceda kakhulu. Iindlela ezincane ezivumelana nezinye izindawo kungase zingachithwa njengento engxakekile kodwa zenza amandla kakhulu kumindleko yokulinganisa ngeminyaka engama-6. Kunezindawo ezithiwa ngokuthile ukuthola amandla angu-15% kuphela ngokuthuthukiswa okuphelele kungase kungabonakali kudala ukuba ukusebenza kusemula.

Ukugcina indawo yokusebenza iyaclean ukwenzela ukuthi amandla athinte ukusebenza

Imisebenzi yokuhlula ngekuphela kufanele ibe yinkcazo engavulindle kanye nezinhlayiya zokuvacuna ezifakwe ngokusebenzisa i-HEPA ukuhilwa kwezinhlanu zokuxuba zokuxuba eziphathelene nezinhlanu zokuxuba. Kuyafanele futhi ukuthi uvule amandla okuphela emachining zones ukuze izinhlanu zokuxuba zingalandi kuzindawo eziphathelene njengokwehlukaniswa kwezinhlanu noma yisayithi yezinhlanu zokuxuba. Imibhalo yabekwe ngenyanga yesikolo ebe namuhla - izifekelo ezilandelayo i-ISO Class 7 ezilandelayo sawubona ukuthi izinkinga zokuxuba zaziphansi ngenkathi yezingu-3/4. Lo mphumela wokuthi konke okunye kudinga ukuthi kuthuthukwe umehluko.

Ukusebenzisa Isikhowudi Sokuphila Ngemva Yokuphila

Dala inqakamba yokuphila ephoqelela kwezibalo elilandelayo:

Bala izindleko zokugcina ngokusebenza kwezinhlayiya ngokushintshana kwezinhlayiya fakwe kuzindleko zokulungiswa okungu-manufacturer. Izifekeli ezisebenzisa izinhlelo zokulungisa izindleko eziphethe kwe-AI zilayela ukuthi izikhathi eziphakanyiswe phakathi kwezindleko zilungiswa ziyinkimbuka ehlukene nezindleko ezilungiswa ngokweminyaka zingaphezulu kuka-41%.

Imibuzo Evame Ukubuzwa

Iindleko zokwenza nge-edm ziyini?

I-edm ifuna ukungena kwezimali futhi ukulula kwezinhlayiya, kubeka phakathi kwezinhlayiya futhi ukungena kwezinhlelo.

Kutheni kufanele kubekwe futhi i-edm?

Kufanele kubeke futhi ema-1,200-1,500 ezinhlayiya zemoto noma lapho ikhondo lihamba ngaphezulu kuka-30 μS/cm.

Kutheni ukukhetha i-edm ikhono elikhulu?

I-edm enobuhle bekwa okuphezulu bese kubekwa phakathi kwezindleko zokusebenza, kungena kwezindleko futhi kungena kwezinhlayiya.

Iziphiqo eziphambeneyo kakhulu zokugoverna uhlobo ngokwendawo emashini ezi EDM?

Vumelana nempumelelo phakathi kwama-20-24°C kanye nemveliso engeza kumathe 60% ukungena kwehlukahluka kanye nokwehla kwamagqunywe.