Yini EDM Spark Erosion Machine Iyenza Ukulondoloza Okuphephile Kwemali

Indlela Yasebenza Kwamagqanti a-EDM Spark Erosion

Yintoni i-Electrical Discharge Machining (EDM)?

I-EDM ibhala amagama esi- Electrical Discharge Machining, okusebenza njengendlela yokuthola kwezinye izindlela zokuthola amagca kwezinto ezithayisa kwezokusebenzisa izicathami. Esikhundleni sokusebenzisa izicathami zokuthayisa eziqinile, izinhini zase-EDM zisebenzisa izi-electrodes ezakhiwe kuma-metals afana ne-copper, isiliva, noma i-graphite. Lezi electrodes zenza ama-sparks amancane esikhundleni sokuthi kwenza kwezinto ngaphakathi. Okwenza i-EDM ikhethekile kukho ukuthola kwezinto eziphambene nazo zokuthayisa njengesi-hardened steel ne-tungsten carbide, izinto okungcola ukuthayisa ngendlela eziqinile. Izindawo zokusebenzisa lezi zinto ezifanelekileyo ziyasebenzisa i-EDM xa izindlela eziqinile azisebenzi.

Umthwalo wokuthola kwezisparks: Yini i-EDM iyenza ukuthola kwezinto ngokuphephile

Izimakhina zokulula izindlela zase EDM zisebenza ngokudala umehluko wevholthiji phakathi kwelektroda nekhiye esele kumgangatho wefluid engcono. Xa ishedyo phakathi kwebili iphakathi kwe-0.01 kuye kwe-0.05 milimita, kukhona izindlela zokucoca izinhla. Lezi zindlela zidla amaphoyinti amabiwe, ngemibiko engaphezulu kwe-10,000 degree Celsius, okwanda kuncipha kwalokho amabiwe. Okuthandwa ngokuthi le fluid engcono iyasebenza ngokushesha ngemuva kwalokho. Iyakhuphela ubudlelwane bokucoca futhi ithola konke okuncane okuphansi, ngakho ke ikhiye ayayilwa. Izimakhina ezintsha kungenzeka ukuthi zithumele kanye nezinkulungwane ezingu-500,000 ngemizuzwana ngayinye! Le moya wekulula kuvumela abasebenzisi ukuthola amadatha kusukela kuma-10 kuya kuma-20 kubic milimita ngemizuzu ngayinye xa bekusebenzisa isiteleni, ngemuva kwalokho kuvumela ukuthola kakhulu kusukela kuma-5 micrometers.

Ukulwa ngaphandle kwezixhobo: Kungakanani i-EDM isebenza ngokungahleli ishushu nokulwa

I-EDM isebenza ngendlela eyahlukileyo ngokuba akukhoqhuma ngeyodwa phakathi kwezixhobo nezinto ezisebenziweyo. Loku kuthiwa yizindlela zokusebenza ngokungahleli ishushu okanye ukulwa kwamandla aphakathi okunokuthiwa kuhlengwa kwezinkawu ezingaphantsi noma ukusebenzisa izinto ezikhanyisiweyo. Kuzo zinto njengezixhobo zezimoto, ngqo kube zezinye izilonda, le nto iyinkulu. Kuneempendulo ezifumanekayo ngokugqithile eziphethe ukusebenzisa i-EDM esikhundleni sokusebenza ngendlela ye-milling yokuqala, kuthatha ukutshintsha kweqondo emva kokusebenza ngokugqithile kwezingu-9 kwezingu-10. Ummandla wokwenza izinto zasekhankatha uyasebenzisa le nto ngokunye xa kwenziwa izinto ezikhanyisiweyo zasekhankatha. Zinokwenziwa ngokuchanekileyo le qondo ngaphandle kokulwa kwezibalo ngaphezulu okanye ngaphantsi kwe-3 microns, okuyindlela encinane xa kucinga ngokuncinane kwezinto ezidingekayo.

Ukuncinane kwezibalo kwe-EDM

Izinhini zokulayisha kwe-EDM zifinyelela ukucinzelwe kwe-micron ngokuthi zihlinza izindlela zokukhupha izinhloso, nezinhini eziphambene nazo zihlinza ukuthi zibe yilapho kuhlanganisa ±2µm (±0.002mm). Lokhu kuyindlela yamaphakathi amathathu okuhlanganisa: ukususwa komkhiqizo ngaphandle kokuthintana, ukulondoloza kwelektrodi kuhlanganisa nokulayishwa kwezinhlambo zokulayisha.

Ukufinyelela kwezindlela Ezifinyelela kuhlanganisa ±2µm

Izinhini zase-EDM zokuthunyelwa zilandela izinhloso ezingu-50nm noma ngaphezulu ukulondoloza kwezindlela zokukhupha ukwenza izinto njengezinhloso zokukhupha injini yokunyatha nezinhloso zokulayishwa kwemali. Ngokuhluhlana nezindlela zokukhupha eziphambene nazo, izinhloso zase-EDM zingahlinzi ±2µm kuhle kuma-60HRC tool steels.

Izinhloso Ezingavumelana Nezinhloso Ezifinyelela kwe-EDM

1. Ukulungisa Kwelektrodi Okulayikayo - Izinhloso zomqondo zilungisa kwe-0.2-0.5% yokulayikwa kwelektrodi yamathela ngalinye icala
2. Ukulinda intampura - Izinhloso zomqondo zihlinza ±0.1°C ngokusebenzisa ukulula ukungcola ukungcolisa ukuthi kungene kwezinto
3. Ukulayishwa Kwezinhlambo - Ukuhlukahluka okuningi kwezifiltrasi kuyakaphela ukukhanya okungaphezulu kwe-5–10 MΩ·cm ukuze kube nephu kwe-spark

Isicathamiyo: I-±3µm kumehluko kwezinhlobo zokwenza kwezindiza zokushisa

Isicathamiyo se-2023 kwezinhlobo zokushisa yasebenzisa i-sinker EDM ukwenza amakhulu aphumayo kuma-aloyi amaningi anezinhlobo zokushisa nezinhlobo zokulingiswa zangaphandle kwe-±3µm. Le ndlela yaphumela amakhulu angu-0.08mm ngesikhala esingcono kanti kuyakaphela izindawo ezingene ezingu-0.3mm ngemathuba encane futhi ayishe ngokushesha okungu-48% kunoma yiliphi indlela elandelwayo yokulayisha.

Indima yomoya wesilinda nezinhlelo zokukhombisa ukulingiswa

Ukuhlola okuphezulu kwezimoya zokulingiswa (12–15 bar) ukususa izinketho ezingu-0.3ms ngasinye ispark, ukuvikela ukuthi kungaphindwe ukulayishwa okongeza ikrefu ngamandla angu-5–8µm. Ngokufanayo, izimotolo ezingcono zokuxhumana (0.05µm) ziyashintsha ukugcinwa kwezimvu (±0.01N) nezindlela zokulayisha (0.05–6mm/min) ukulungisa ukuthi kungaphindwe ukukhula ngokwengxenye yemfutha kwezindlela ezingu-80+ izinsuku.

Umbo lapha kakhulu ngaphandle kwezinye izenzo

Izindawo zokulingiswa zombo lapha: Kusuka ku-Ra 0.1µm kuya kwezombili eziningi

Amashini we-erosion e-Electric Discharge Machining (EDM) engenza imishini yokwenza amandla kanye nezinye izinhlelo zokulula kwe-Ra 0.1 microns kuye kumaqondo owodwa owokubona izibhamu. Okukhawuleza le nto kumaqondo amanye wokwenza izinhlelo kukuthi izinhlelo eziqinile ziselwe imishini yokwenza izinyathelo, futhi i-EDM isebenza ngendlela enye engenza amacathududu amancane ngokushisa. Ngaseminyakeni yesibili, ngokwesicathami esishicilelwe yisigcawu se-Advanced Manufacturing, kuhleli amapherecenti angama-40 wabanye nezinhlelo zokwenza izinhlelo zokulula zimelwe ukwenza amashadi amanye kakhulu ngenxa yokuthi i-EDM inikeza kahle ukudinga kwezinhlelo ezibaluleke kakhulu ezidinga ukwenza izinhlelo zokulula ezincane kune microns amathathu. Ngokuthi kunezimo ezi, abakhelwe izinhlelo zokwenza izinhlelo ziyethemba kakhulu i-EDM xa bakhelwa izinhlelo zokulula njengezinhlelo zokulula zokugcina noma izimbadada zezibhamu lapho kancane kakhulu ukungcola kwezinyathelo kungaholela kakhulu ekuphileni kwezinhlelo.

Ukucima ukudinga kwezinyathelo emuva kokwenza nezinyathelo yokulula

Ngokuba uyifinyelela kakhulu kwezinye zokuphuma ngemva kwalokhu kwekala yokuqala, i-EDM isusa imicabho yesewerisi nezindleko zematerial. Isibonelo:

• Akukho ukulayisha ngendlela yokubona kudingeka kwezinye ezingu-95% zemoldi yematerial ephelile (ngokwembono yempi yempi)
• Ukungabi ngekho kwekulayisha ngaphezulu izinto ezingcono ngokusheshayo njengezindleko ezingcono noma izindleko eziphezulu
  Le ngxenye yokuthuthukiswa iyisibonelo esikhulu kumaterial enobungo obuphakeme njengokwehlukaniswa kwe-tungsten, lapho imicabho engenakwa yokuvelisa izindleko ngokuphindwa kwe $240 ngasinye (Isihloko seJournal of Manufacturing Systems, 2022).

Ukuthuthukiswa kwekala nekakhulu kwezinye zokuphuma kwezokwenziwa

Abasebenzisa amapharamitha we-EDM ukuze abeke amathambwe kanye nezidingo zokuphila:

Le nesu le kuvumela abasebenzi ukuthi bahlale ukukhula phakathi kwezindawo eziphansi futhi zilale ukuba zihlale zimhlophe, zimvu zokwenziwa okuphambene nokuthula—le thekani ebonile ukuthi kunciphise amathemu kanye nezinsuku ngokuphindaphindwa ngama 18–22% kumaphakathi wokwenziwa.

Ukwehliseka kwe-Burr ne-Stress-Free Machining: Izinsu esikhundleni se-EDM

Imashini ye-EDM spark erosion iyindlela yokwenza izindleke ngokuphelele ngaphandle kokugcinwa ngokusebenza ngokuhlakana kwezinhloko. Le ndlela engenayo yokuthintana kwezinhloko kuvikela ukuthunyelwa futhi kuhlele isimo semoto, okuyindlela ebaluleke kakhulu kumakhasimende afanele.

Ukuthi EDM Kunciphisa noma Ikhansela Imvume Yokuprosesa Emuva

Le ndlela ya-EDM yokususa amagugu engenayo yokuthintana kwezinhloko kuvikela ukuthi kwehlise ngokuthi kuyilisa futhi kungakhulumi izinhloko. Imali edoliwe ngokuthi kuyilisa amagugu ayilisiwe, kwenza ukuthi amathemu athole ukuphathelene okuphelele njengo Ra 0.4µm—futhi kahle kahle kuyindlela yokuvumela ukuthi kungakhulumi ukuphathisa nekwehlisa izindawo ezifinyelelwa ngokuthula. Lokhu kuvimba izindawo zokugcina nekwehlisa izindawo ezifinyelelwa ngokuthula okunemathemu kanye nezinsuku eziphindaphindwa ngama 15–30% kumasebenzi aphindaphindwa.

Ayikho Amabhula, Ayikho Ukungcola, Ayikho Ukulahleka Kwamathiza - Isikhululeko se-EDM

Ngaphandle kokuxhunyaniswa kwamathiza-nemonti, i-EDM iyahluka:

• Ukulahleka kwamathiza : I-Electrodes ikhona kunesikhathi esingu-10 ngaphandle kwezicathami zokukhula ematereni embalwa
• Ukungcola okwenzeka ngokunye nokushisa : Amavulelo okushisa angaphansi kwe-0.1J ayahluka izindawo eziphathelene nekushisa
• Ukugcina okwenzeka ngokunye nokushisa : Izinto eziphansi kakhulu ezingu-0.2mm zikhona zingavunyelwa

Lokhu kwenza i-EDM kuyisiko esifanele dlaminiyeli zokushisa kwezinhloso zaseNhliziyo nezinto zokubelisa ezintweni ezincane ezidinga ukuthintwa

Ukusebenza okuhle kanye nokuba yimali engcinyayo yokususa amaphoyinti

Noma ukuthi i-EDM isusa amaphakethe ngokusheshwa kune ukugaya (2-8mm³/min vs 30-100mm³/min), inikeza uhlelo olungile ngokwesibonelo ngokwenza:

Lezi zinhle zilungisa ukusheshwa okuncane kokuwasha, ngakho-ke kwamanye amagaya esilisa esililodwa nezinhlelo zokwenza amathuluzi.

I-EDM yamagaya esililodwa nezinhlelo ezinhlelo

Ukugaya amagaya esililodwa, i-Tungsten, nezinhlelo zokwenza amathuluzi ngokulula

Amashini we-erosion e-Electric Discharge Machining (EDM) usele ukusebenzisa kahle kumasebenzi olunye nezindleke ezikhona ngaphezulu kweveli ye-HRC70. Ayisebenzi kahle nezindleke ezikhona ezithuthile, izilishwa nezindleke ezikhona ezi-carbide ezithuthile okusebenzisa kahle ngezindleke ezingcono. Iindleke zokusebenza ngendlela enkulu ziyasebenza ngokuthi zikhulelwa ngokukhawuleza noma isebentile ikhulelwe kakhulu ngenxa yokusebenzisa amashini. Ukuze kusebenzisa i-EDM kuyindlela esebenza ngokuthi kuthatha amandla okushisa ngendlela yokuthi kuthathe ukuthi kuthathe ukuthi kuthathe isebentile ngokuthinta. Ngenxa yokuthi akukho uhlobo lweqhoboka, abasebenzisi kudinga ukuthi bakhe amaphethini amakhulu nezindlela ezithuthile ngokuthi kuthathe ukuthi kuthathe isebentile ngokuthinta. Lokhu kuyindlela esebenza ngokuthi kuthatha amandla okushisa ngendlela yokuthi kuthathe ukuthi kuthathe ukuthi kuthathe isebentile ngokuthinta. Lokhu kusebenzisa kakhulu kumasebenzi apho ukucacile kuyindlela yokuthi kuthathe ukuthi kuthathe ukuthi kuthathe isebentile ngokuthinta.

Ukwenza amaphethini amakhulu nezindlela ezithuthile okungakwaziwa ngendlela yokusebenza ngendlela enkulu

Lo technology ithola amageometri asengiwo nge milling noma turning, njenge 50:1 depth-to-width ratios kumacathode channels noma ±3㎛-tight radii kumatshintsho emanzini. Isifundo se 2023 sika Advanced Manufacturing Institute sabona ukuthi i-EDM ybheka amagenge esikhwephu nge 18% xa yenza amanozzles we fuel injector enematholi e 0.05mm. Imindleke yemikhethe yayo iyakuvumela:

• Amacavity amathathu e spiral kumatolwana wokungenisa iphlasitiki
• Amagqabi amaphansi nezindzima eziphakathi kumatolwana wesicelo
• Amaphawu amakhulu kudonga 50㎛ kwezinto zokuvakashela izinkanga

Ukusebenziswa okuphandayo kumatholi we mold ne die manufacturing industries

Kabanzi labantu abasebenza kuqhuba izimbo zokwenza izimbo ezinhlelweyo ziyasebenzisa teknolojia ye-EDM xa bezohlela nezimpawu ezinhlelweyo nezinhlelo zokukhupha lelihlanu. Lo msebenzi ubungisa impumelelo kakhulu kumqamatha wokubhola ngoba i-EDM iyakwazi ukusebenzela izimbo eziphathwe ngokuxhumana nezinhlamvu ezilandelweyo. Lokhu kancipha konke ukusebenza okubekwe kakhulu okwenzelwe kwehlukahlukene okwetebelwe kwezinye izinyanga. Noma kunjalo, ngekuba abasebenzisi bethanda ukuthi izinto zibe ngamakhulu nezilindele futhi zibekwe kuzilwane ezintsha, i-EDM ishona kakhulu. Sibona futhi ukusebenzwa kwayo ekwenzeni izindlela zokulula esikhathini kuzimbo zokubhola futhi nezimpawu ezinhlelweyo ezidingekayo kuzimbo zokubona kwezinye izigaba.

Imibuzo Evame Ukubuzwa

• Yiziphi izinhlobo zezilwane eziyiswe kakhulu kusebenzwa kwe-EDM?
  I-EDM isebenza kahle kuzilwane ezikhulu njengesilwane esiphathwe, isilwane se-tungsten carbide, nezilwane zonke ezinamandla elekthriku.
• I-EDM iyajikela ukuphepha okuphezulu kanjani?
  I-EDM ikwazi ukuba nezinkinga ezingu- micron ngokuthi asikhohlise ukukhupha kwematerial, ukulawula kwezikhawulo zokubeka kwezikhawulo, nokwenza ngokuhle indawo yemfuku yemfukwane.
• I-EDM iyahlula izidingo zokuprosesa ngemuva kwekhi?
  Yebo, i-EDM ikwazi ukuba yisicathami esiphelile kwiindlela zokusebenza, okwenza ukunciphisa noma ukubuya kabusho ukunqamula, ukugaya, noma ukupholisa.
• Yiziphi izintelo zokusebenza kwe-EDM kunokusebenza okuqinisiwe?
  I-EDM inikeza amacut eziphelele ngaphandle kokugcinwa kwezinhlelo, iyahlula amagaya, kanye nokwenza ukuba kube nendawo encane kwezindlela zokuprosesa ngemuva kwekhi, okwenza yona indlela engcono kwezinto eziphambene kanye nezinhlelo eziphambili.
• I-EDM iyinkambu kunoqinisekiso lwokudla?
  Njengoba i-EDM ingaba inekhene emcane kakhulu yokukhupha umaterial, ubungo bokugcina kwezikhawulo, ukunciphisa izindleko zokudlulwa, futhi ukuphela kwezicathami kungenxa yokuqinile kwezinkinga kungenxa yokuqinile kwezinkinga okuphambili.