Ukuthi yini indlela yokufaka isikhundla sesithili esihlukileyo esebenzisa i-wire EDM ukuze ubuyise ukuthi kwenziwa ngokupheleleyo kwe-micron

Ukuqonda Imithwalo Yokuvavanya Kwinkulungwane Yokuqinisa I-Wire EDM Ngokwezinyathelo Zokuphakama

Ukuchaza Umkhakha Wokuphakama Ngamikroni: Imithwalo Yokuvavanya Kwinkulungwane Yokuqinisa (±0.0002 in / ~5 µm)

Ukufumana ukuphakama ngamikroni kwindawo yokuqinisa yomthwalo wemithwalo yokuqinisa ngomthwalo wokugcina (wire EDM) kuthetha ukuthi kufanele kubhekwe ngokuphelele imithwalo yokuqinisa yase-±5 µm (±0.0002 in)—lokhu kuyinto engeyona kuhlanu kwezinye zokuphakama kwesihlangothi sesandla. Lokhu kukhona kubhekwa njengomkhakha owahlukile umsebenzi wokwenza amathooli okuphakama kanye nesikhundla sokwenza izinto ngokujwayelekile. Itable elandelayo ishika izigaba zokuphakama zokujwayelekile.

Ukufika kwezilinganiso ze-±5 µm kubangela ukuthi kufuneka kwenziwe ukulungiswa kakhulu kuzonke izinhlangano zokusebenza. Kungafanele kubhekwe nje ukuguqula kwesikhathi, ukudlula kwamaphetha, noma ukuphakanyiswa kwemithandazo ekhona kungahleli kusuka kwezilinganiso ezivumelekile. Ukulinganisa ngolaser nokulinganisa ngokuchaza izinkinga zokuhamba kuyasiza ukuthi sibone izinkinga ezingaphansi zokuhamba—kubiza idatha esidingekayo ukuze sibuye sifunde izitabhu zokulungisa izinhlangano zokusebenza. Ukuthi iziphumo zokuhamba zibe yizilinganiso ezinkulu kanye nezincane kubangela ukuthi kufuneka kwenziwe ukuthintana kwezindawo zokusebenza ukuze kubekhe isikhathi sokuhlala kwe-±1 °C, ngoba ukuphakanyiswa kwesikhathi kuphakanyisa ubunzima bezinhlangano zokusebenza kuphakanyisa umgudu wamaphetha ngamazinga amancane.

Indlela yokugcina imithandazo yenzela ukuthi izinkinga zokuhamba ziyaphakanyiswa futhi ukuthi kufuneka kwenziwe ukulungiswa

Ukuphatha kwe-Wire EDM kwenza ukususa umfanekiso ngamashilaphu amahle amahle angakhiqiza kwindawo eyodwa, okungakhiqiza kanye nokuvula umfanekiso. Lokhu kubhekise kumfanekiso wokugcina isimo sokufana: umbala wokugcina kwemashilaphu, imvelo yemishilaphu, nokusebenza kokufusha kubhekise kumfanekiso wokugcina, ukuphakama, ukuphakama kwezinye izindawo, nokubhala kwesikhumba sokubhala—konke lokho kubhekise kumfanekiso wokugcina. Ukugcina isimo sokufana kwenza ukuthi kubhalelwe imishilaphu yegeneratho nokujabulisa uvoltage wokugcina ukuze kugcinwe isimo sokufana esisodwa. Umvuzo wokufusha kufanele kube yindlela eyodwa—ukungafushi kakhulu kungavumela amasimbi ukuthi abe yizindlela zokushilapha ezibiza isimo sokufana sokugcina. Ngokuhambisana nokushilapha kwezinye izinhlobo zomfanekiso nokubhala, i-CNC control ibuye ibuye isikhathi sokufuna nokubhala kwezinye izindawo ngokushesha. Lokhu kubhekise kumfanekiso wokugcina wokugcina isimo sokufana kanye nokusebenza kwezinhlobo zokugcina—akakhi kusuka kumfanekiso wokugcina wokugcina.

Ukugcina isimo sokufana sezinhlobo zokugcina zesi-EDM se-Wire

Ukuqiniseka kwemithambo yomkhakha wokusebenza kwe-wire EDM akuyiyo kuphela umphumela wokubalwa kwakho kwe-geometric kodwa kubhekene ngokuphelele nokuqiniseka okuhle kwemikhahla yakho eyinkulu. Ukulungisa okuncane kwezinto zokugcina imithambo nezindlela zokuphatha izinkampani zokusebenza kuzokwenzela ukuthi ispark gap ibe yisiqu—lokhu kusiza kubona amaphuzu okukhula ngokufanayo.

Ukulungisa Ukugcina Imithambo Ukufuna Ukuthola Ukulinganisa Kwemiphumela

Ukulinganisa kwesixhobo sokubeka imithwalo kuyasebenza ngokuvikela ukuphatha kwezixhobo ngokuthi isetshenziswa kwi-kerf. Imithwalo yezixhobo—okunjalo kubhalwa ngokusebenzisa i-digital tensiometer—kufanele ibe phakathi kwezilinganiso ezincinci, okunjalo phakathi kwe-800 g kunye ne-2,500 g kuma-wire wesi-0.25 mm esihlukile. Ukuchaphazela kancane njengoko kubonakala ku-±0.2 gf kungahlela ukuchaphazela kwesixhobo, okunika izinkulungwane zokugqibela nokugqibela kokugqibela okungafanele kakhulu kwe-Ra 0.4 µm. Ukulinganisa kusetyenziswa ukulandela kwezixhobo zokubeka imithwalo ukuze kubhekwe imithwalo yezixhobo ezingenakho kwi-braking system. Uma akukho ukuvikela oku, isixhobo sikhohlwa noma sifika ngaphezulu kumaphakade emaqhinga amancinci—noma kuphi umsebenzi wokuhamba kwe-axis uyisayini ngokupheleleyo—kuzoba kususa indawo yokusebenza futhi kuzoba kusindisela izindlela zokusebenza ezibalulekile. Ukubhalwa kwezikhathi zokulinganisa kusiza ukuthi isixhobo esihamba ngokupheleleyo sibe nomkhawulo wokungabili kancane kune-4 µm kumgqa wokubeka kwayo. Ukubeka imithwalo engavikeli kakhulu kusiza ukuthi isixhobo asihlale kusuka kumaphakade, kusiza ukuthi izindlela zokusebenza ziyisayini zibe yizindlela zokusebenza zokubaluleka kwe-micron.

Ukulinganisa Kwesistimu Yemithi Yokuqondisa: Umkhondo Wokugcina, Ukuthinteka Kwezinkambo, Nokuphatha Kokufa Ngemithi

Umfundo wokuphakama kwezinto ziyinkimbinkimbi ezenzekayo—akayi kuphela umsitha wokuchitha izinto—futhi ukubalwa kwayo ngokucophelela kuyidinga ukuthi kwenziwe ngokuphelele. Indima yalo eyokuphakama kuyokuba yinkimbinkimbi yokuvimbela kuze kube nesikhathi sokuvimbela kwezinto zokuphakama, okwenzeka ngokuvimbela kwezinto zokuphakama, okwenzeka ukuthi kwenziwe isikhathi sokuvimbela kwezinto zokuphakama. Kuma-EDM wokufaka imithambo eminye, ukuthi kwenziwe ngokuphelele kufanele kubekwe phakathi kwe-10 ne-20 µS/cm. Ukuchitha kwezinto zokuphakama kufanele kwenziwe ngokuphelele kwe-1 µm noma kungenzeka kancane: izinto zokuphakama ezincane kakhulu njengokwe-10 µm zingabamba isikhathi sokuvimbela futhi zibangene emisebenzini yezindlela eziningi zokuvimbela. Ukubalwa kwegcino kuyakubiza amanqaku okuchitha okungaphakathi nokungaphakathi ukuze kwenziwe umsitha wokuchitha owodwa, ongenakho amabhobhobo, okuyakubiza imithambo yonke—ukunqoba izinguquko zokuchitha nezinhlobo zokuzihlukanisa. Ukuphela kwesikhathi sokuchitha—kubalwa ngokuhambisana nesayizi yomsebenzi—kuyakususa izinto zokuphakama kumkhumbi, okuyakuvumela ukuthi kwenziwe izindawo ezinkulu zokuvimbela okuyakubiza imithambo. Ekugcineni, isistimu yemithambo yezinto zokuphakama esibalwe ngokuphelele iyakuvumela ukuthi kwenziwe isikhathi sokuvimbela esifanayo—okuyisiphelo esingapheliyo sokuthola isikhathi sokuvimbela esifanayo nezindawo zokuvimbela ngokuphelele kwe-±2 µm.

Ukulinganisa Kwemithambo Yomkhombisi Wokugcina Iwiri Ngokwezomthambo

Ukulinganisa kwemithambo kwenza indlela yokubhekana nokuthi umkhombisi wokugcina iwiri unakha ukugcina izinkinga ezinkulu. Nakuba iziphakamiso zokugcina zokugcina izindleko ziyabhekana nesikhathi, isithuthi sokugcina sibhekana naphi esikhathini sesihlakazini. Umkhombisi ongahlanzwa ngokupheleleyo noma ubonakala ngokuphambili kungagcina isikhathi esihlakazini, nakuba yiziphi izindleko zokugcina. Ukulinganisa kwemithambo kusukela kusukela kuyabonakalisa ukuthi imithambo yomkhombisi iyahlakaza nezidingo zokubhekana.

Ukulinganisa Kwemithambo Ngokusebenzisa Ukulinganisa Kwelaser Nokulinganisa Kwelballbar

Ukubhekwa kwe-laser kusinika umlando wokubhekwa wokugcina okuphambili kwezinkulungwane zokugcina, ngokusebenzisa ubude bokusha kwezilayesa njengesikhundla sokubhekwa esitholakala. Kuyabhekisa amaphutha okuhlela, amaphutha okuguqula, nokuguqula kwezinkulungwane kusukela ekuphansi kwemikroni—kukhomba abasebenzi ukuthatha izitabhu zokubhekwa kwezinkulungwane kwe-CNC. Nakuba ukugcina kwezinkulungwane kuyisisekelo esibalulekile, amaphutha okubhekwa kwezinkulungwane zokuguqula kubonisa izinkinga zokudlula okulayesa akakwazi ukubhekwa. Lokho kukuphela ukubhekwa kwe-ballbar kuyisisekelo: i-ballbar engezansi iyabhekisa ukungafani kweziservomechanism, ukungafani kwezinkulungwane, nokuhlukana kokuhlukana kwezinkulungwane ngokudlula kwezinkulungwane zokuguqula. Isibonelo, isithombe se-ballbar esishiyayo isibonelo sokungafani kwezinkulungwane zika-X neka-Y. Ukusebenzisa lezi zixhobo ngokulandela—ilayesa kuqala ukubhekwa kwezinkulungwane, emva koko i-ballbar ukubhekwa kweziservomechanism zokudlula—kukhombisa ukuthi ukuhlela kwezinkulungwane kuyisisekelo esibalulekile kanye nokudlula.

Ukubhekwa kwezinkulungwane zokugcina, ukubhekwa kwezinkulungwane zokuhlela, nokubhekwa kwezinkulungwane zokugcina

Ukuphambana kwezinyathelo ezilungileyo, isimo sezinsizakalo phakathi kwezinyathelo ziyachaza ububanzi bezinto. Amaphutha okuhamba ngokuzulazula kuyenza indlela yokuhamba iyahamba ngokuzulazula noma iyahamba ngokuphepha, futhi kuyenza ukuthi kubhekwe njengokuthi kubhekwe ngokuzulazula kusukela emva kwezinyathelo zokuhamba. Idata yomkhombi wokuhlola ukuthi lezi ziphutha zingakhomba ukuthi kunezimpikiswano zezingu-4 µm ngasemva kwesikhundla sesingu-100 mm sokuhamba. Lezi zimpikiswano zihlanganiswa ngolaser ngokujabula ukuthi kubhekwe ukuthi kunezimpikiswano zokuhamba ngokuzulazula kusukela emva kwezinyathelo zokuhamba. Ukuthi izinyathelo ezimbili zihlukaniswe ngokuzulazula—okuthi kuyizinyathelo ezimbili zokuhamba ngokuzulazula—kuchazwa ngokusebenzisa isikwere sesenkulu noma isikwere sokuhlola ngolaser. Ukuthi izinyathelo ze-X ne-Y azihlukanisi ngokuzulazula kuyenzela ukuthi kubhekwe njengokuthi kubhekwe ngokuzulazula kusukela emva kwezinyathelo zokuhamba. Izinhlelo zokusebenza zezindawo zezinkampani zasezinsizakalo zisebenzisa lezi zimpikiswano zezindawo zokuhamba ukuze zifunde ukuthi kufanele kwenziwe ukuthi kubhekwe ngokuzulazula kusukela emva kwezinyathelo zokuhamba, futhi kubhekwe ngokuzulazula kusukela emva kwezinyathelo zokuhamba ukuze kubhekwe ngokuzulazula kusukela emva kwezinyathelo zokuhamba—kubhekwe ngokuzulazula kusukela emva kwezinyathelo zokuhamba.

Ukuvuselela ukuthi kubhekwe ngokuzulazula kusukela emva kwezinyathelo zokuhamba ngokuzulazula kusukela emva kwezinyathelo zokuhamba ukuthi kubhekwe ngokuzulazula kusukela emva kwezinyathelo zokuhamba

Ukubhala kwe-Adaptive Skim Pass ngokuphathelene nokuthinteka kwemithambo futhi ukuthinteka kwezinto zokubhala

Ukubhala kwe-Adaptive skim kusindisa ukuthinteka kwemithambo okungakwazi ukuguqula izinsizakalo ngemikhumbu eminingi kakhulu kusukela emiphakathini yezinsizakalo ezingaphezu kwe-1–2°F. Emva kokubhala kwezinye izinkambu, ngalokho lokubhala okulandelayo kusebenzisa amandla angaphansi kakhulu—kufika emlandweni wokuqala we-25 A kuya emlandweni wokugcina we-4 A—futhi ukunciphisa ukuthinteka kwezihlathi ukuze kubhale kahle ilayiya yezinto zokubhala futhi ukuzibophelela isikhumba. Ukuguqula kwezinsizakalo zokuguqula ngokudlula—kungenani 6 µm ngalokho lokubhala—kunakeza ukuguqula kwezinsizakalo kungaphezulu kwe-0.003 mm ngaphansi kwesikhombisa se-200 mm. Ukubhala kwezinkambu ezi-4 zisindisa ubuhle bokubhala kusukela ku-Ra 3.2 µm kuya ku-Ra 0.4 µm, kushintsha ukubhala kwezinkambu kusukela ku-8–12 mm²/min kuya ku-1–2 mm²/min yokugcina. Ukuchaza ukuthi umphakathi wokubhala uyabekwa ngaphakathi kwe-±1°F—futhi ukubhala amadhibhayisi, ububanzi bezihlathi, nezinhlobo zokubhala—kunakeza amasipho ukuthola ukuthinteka kwe-micron ngokuphathelene ngezinsizakalo ngaphandle kokubhala kabusha.

Isikhombisi Sokuqala

Iyini i-Wire EDM?

Ukusebenza kwe-Wire EDM (Ukusebenza kwe-Discharge Yokubhala) kukuphatha okusebenzisa isihlangu esincane sokubhala ukukhupha izinto ngokuphelele, kusetyenziswa amasparki welektriki ukukhupha izinto.

Kungani ukubalwa kubalulekile ukufinyelela kwe-micron?

Ukubalwa kuhlinzekile ukuthi zonke izisifunda, njengoko kuyisihlangu sokubhala, ukulanda kwesifunda sokubhala, nokubalwa kwesifunda sokubhala, kuzobalwa ngokuphelele ukuqhubeka kokubalwa okunokuthintela ukuthi kwenziwe amaphutha okuvela kwezindlela zokugcina, ukungafanele kwezinhlobo zokubhala, noma ukuguqula kwesifunda sokubhala.

Ukugcina kufaka kanjani kwezinhlobo zokubhala?

Ukugcina kuvumela ukuthi izinto zizwe noma zilahle, okunokuthintela ukuthi isihlangu sokubhala sishintsha ngemikhulu emibili futhi sibhekise ukuphelele kwezinhlobo zokubhala.

Izithombe ziphi zasebenziswa ukubalwa kwezinhlobo zokubhala?

Ukubalwa kwe-laser, ukubalwa kwe-ballbar, izikwere zesi-granite, nezilayesa zesi-optical ziyizithombe ezinkulu zokubalwa nokuhlela ukubalwa kwezinhlobo zokubhala.

Ukubalwa kwe-dielectric fluid kufaka kanjani kwezinhlobo zokubhala?

Umfumbi wokuphatha ukuthi yilokhu okungakwazi ukuthi kubhekise umsindo ngokuphathwa; ukulinganisa kahle kwakho kusinika ukuthi kubhekise kahle, ukuthinteka, nokulanda ukuze kufikelele emisindweni yomsindo esifanayo.