Ukukhulu kweqinekileyo ye-Machine yokuDlala i-Wire EDM kwiindlela zokwenza zamanje

Ukuprecisiweyo kunye nokucinanelelo kakhulu kwiindlela zokudlala ezinezitya eziphambeneyo

Isicelo se-Tolerances seSub-Micron kwiindlela zokwenza zamanje

Ukudluliselwa kwezindiza kanye nezinhlelo yokwenza izinhlelo zokubambisa zomoya kudinga kwezinkimbinkimbi ezikhulu kakhulu noma ngokungenaphandle kwezinkimbinkimbi zokulinganisa ezingu-0.0001 inches noma ngaphezulu ukwenza izispekhi zokusebenza kanye nezimalayezo zokuphepha. Izinhlelo ze-CNC zilandela izinkinga ezikhona njengokuhlobana kwezindlela nezikhumba zokubendela xa kusebenzwa ematerialeni elula noma emakhiweni amathathu. Fula imigqamane yesitireni, kudinga ukulula kwamazantsi aphansi kuka-Ra 0.4 microns ukungena ngokuhluka kwezinkinga ngokweqile. Kufana nazo izinto ezijikelezayo njengokubusa izibhuti zokugcina apho noma izinkinga encane kakhulu zokulula kungaholela kuzinkinga ehlathini ngemuva kokufakwa kwazo.

Yini i-Wire EDM Ingayilapha Ukunciphisa Okuningi Nokucophelela Okuningi

Ukukhutshwa kwe-Wire EDM kumelela lezi zixhobo eziphathwayo zokukhupha ngokusebenzisa ukukhawuleza okugcinwe, okuvumela ukuba kuhlanganise amatheshiwo amabiweyo ngokungenako kwezikhala ezingama-±0.0001 inci noma xa kusebenzelwa nezinto ezinzima njengesilindile esikhathmahlawuleyo okuyi-titanium. Izicathami ze-CNC ezinezinkqubo eziphambene nezinye izinto eziphambene nezinye kuxhuma kakhulu kuzo zonke izinto ezingama-8 ukuya kuma-12 Newtons, ukugcinwa kwezixhobo zokulula kwe-dielectric ukuya kuma-0.5 MPa ukuya kuma-1.2 MPa, futhi ukulawulwa kwezibhakabhaka zokuvamisa ukuya kuma-5 ukuya kuma-15 micrometers. Lezi zilungiselelo kuzokuvumela konke ukuba kube ngokulandelana xa kusebenzwa kakhulu kwezindlela eziningi. Ngoba le ndlela ayiphikiswa, akukho daba lokuthi kumele kuhlale kakhulu njengokusebenzisa izindlela ezijwayelekileyo. Abasebenzisi besicathami babeka ukuthi kumele kube ngokuphelele kakhulu, noma kube ngama-99.9% kwezinye izikhala eziningi. Le ndlela yokusebenza kumele kube yilapho kakhulu kwezindawo ezisebenzela kakhulu kwezindleko ezinkulu lapho ukucinzelwa kumele kube yilapho.

Isicatjwana: Ukunyuselwa kwezinhlobo zokudla ngokusebenzisa i-Wire EDM

Umdlali omkhulu wezinhlobo zokudla wabangela ukuncipiswa kwezirejekthi zemipelo ngama-72% emva kokushintsha i-wire EDM yezinhlobo zika-Inconel 718. Ngokulungisa umehluko wokuphumelela (120-150 µJ) futhi usebenzisa i-brass wire enkulu ka-0.006", bakwafumene ukunciphisa kwezinhlobo kwe-0.0002" esetshenziswa kuzo zonke izimpelokati ezingama-316 ezimpelweni. Le ndlela yabangela ukuphela kwezinyukelo ezingcono futhi zilindele kahle ukuziphileni kwe-AS9100 kwezinhlobo eziphambene nezinto zokudla.

Ukulungisa Izindlela Ngokwokwenza Ukunciphisa Okuningi Nokubuyiselwa

Imachini ephambene yo edinga lekhiwe nezici ezifana neqembu lokugcina ipilisi kanye neyinhloso yokuthiwa yilapho phakathi kwekhawodhi nekhasi. Lapho izinto akuyona ngokuphelele kuyavumelekile, lezi zinhlelo zokuthiwa zihlinza ngokuzenzekela. Izilonda zepilisi ezisetshenziswe kule machini kungena ukuthiwa kuthathe isikhathi sokuphuma kusukela kumasekondi amabili kuya kumasekondi amabili kulingana noluhlobo oluthathwa kuzona ngokushesha. Lokhu kusiza ukuba ububanzi besikweletu kuyaphela kakhulu ngemva kokuqala kwezikhathi ezide, kudala kungaphansi kumashumi amathathu amathathu kweyoni ngemva kwekhorona ehlile. Ngokuba yileli nqobile yokuphelela, abasebenzisa le machini bangakhiwa ukuba lapha lapho kuzokudla ngezinye izinto ezifana nezicelo zokwenza izinto ezincane zezokudla noma izicelo ezinhle zokwenza izinto ezinezindlela ezinhle lapho kakhulu ukuthayeka kwezici ezincane kuyadinga kakhulu.

Ukwenza Izingxenye Ezinhle Ngekakhulukazi Yokuphatha Ukulingana

Ukuhamba Phezulu Kwezindlela Ezinhle Zokwenza Izicelo Zokudla Nezicelo Zokuhamba

Ukusebenziswa kwezithuthi kuleli xesha kufuna iindlela ezinemigqa esingayi kungabonakali xa kona kuphela iminyaka engama-2 yaqala. Thatha iindleke zokubona ngokwesibonelo, iindleke zokubola ziyacacwa ukuba nezicelo eziphambene nezicelo zokubola. Kwaye ke ngikwazi ukuba ngikuchaza ngokusebenzisa iindleke zokunyanga zokubola, kufuneka zinezindleke ezithile eziphezulu ngokweemikroni kwaye zilungele kule ndlela. Ngokusebenjiswe kwiNkambo yeManufacturing Research Institute enyaka ya-2023, malunga neethatu kweziyodwa zezithuthi ziyakwenza iindlela eneemigqa engaphantsi kwe-50 mikroni ngoku. Loko ke kuthathwa ngokuphindwe kabili kwale ndlela xa kona kuphela 2018 xa le ndlela ayikho ngokwenene.

Ukusebenzisa iindleke ngaphandle kwekho ukwenza iindlela ezithandwayo

Ukukhupha kwe-Wire EDM kususa ngaphandle kokubeka inqanawa kwiintsimbi, ukwenza kube lula ukusebenzisa izinto eziphapha njengokwezi lwe-titanium kunye nezihlanca zokubhokhwe ngaphandle kokuvuleka. I-CNC milling ekuhlaleni kuya ukuba yindlela yobude bezinga lezixhobo zokusebenza. Kodwa nge-Wire EDM, sithetha ngokubhala kwezikhowudi eziphumeleyo eza kuyila into esele kuyo. Iimpetho? Iindlela eziphezulu kumacala, ngokuthile kufika kwi-0.05 mm ijadiyasi, kunye nezibini eziphambene nezibini eziphezulu kakhulu. Sicacile ukuba kufike kwi-50 ku-1 kumacala amacala esibhakabhaka esincinci sangaphandle kwezinye iindlela.

Isicathami: Ukwenza I-Turbine Blade Usebenzisa i-Wire EDM

Umdlali wokwenza izinhlobo zokuxhumana nezwe yasekhanda ukunciphisa isikhathi sokwenza i-blade ngo-40% nasekuphumelela ekuneni kwezilungo ezingama ±2 µm. Umbindle wabo wokuchinja izingxenye zokucubika kwe-1,200 kuzinye ngayinye kwehlukaniswa kwe-Inconel 718, okwengeke kuthole ukulingana kwezilungo ezingama 0.1 mm. Ukulandwa ngemva kokuxinwa kwakubonisa ukuthi ikhono le-99.8% litholwe ngokomthetho wezinhlobo zasekhanda ze-AS9100, lokungena kwekuhlela futhi ngendlela yokwenza futhi.

Ukusebenzisa i-CNC ne-Path Planning ebukelwe kwe-AI ukwenza okufanayo okucinga ukucacile

Iteknoloji yesokudonsa yamathwire ethile ekugcineni inqanawa yokuhlela ngokwe-CNC namasipho esilungiselelo esemkhathini engenakubonakala ngokuthi kuhlangene nokugcinwa kwezindlela zokugcina. Inqanawa ethile yakhula amathiphu okugcina ngama-60% xa isebenza kuzindlela zokwenza izindlela ezithile zokwenza i-die ezinezinto eziningi ngokwesicatshulwa esiphathelene nokuqala kwemifanekiso yesivumo esikhulu kuleli xesha elledlule. Le masipho asilungiselelo ayizokuhlela ngokuphelele kugcinwa kwezindlela phakathi kwe-8 kuya kuma-20 Newtons futhi ayizokuhlela ukugcinwa kwezindlela zokugcina. Okuthakazelisa ngaso kungaba yisimo esifanayo esingaba yisikhathi eside sokuqinisekisa ukucinca kwezindlela zokwenza ngama-0.005 mm ngokungena kwe-kilogram-force esikhathini eside sokuqala kwezindlela zokwenza okungaba ngama-500 futhi kungaba ngaphezulu kwezinyathelo ngaphandle kokungena kwezindlela zokwenza.

Ukudonsa Okuhlelwa Kwamathewula Athile Noma Amathewula Athile

Ukuthuthukiswa Kwamathewula Amakhulu Noma Amasteele Athile Kwezinye Iindawo Zokwenza Noma Iindlela Zokwenza

Imipini yasekosini nezinhlelo zokwenza izindlela manje isebenza kakhulu kwezinhlanzi ezinhle ngokwe Inconel 718 ku-63% kwamaphathi aphakeme (Izinhloso Zasekelo 2023), futhi kuthuthukiswa ngokudinga ukungena kwezindlethu kanye nokunyanzelwa. Istele ezinhlukahlukene kakhulu ezingaphezu kwe-60 HRC idlala indawo ephakeme kwe-45% yezinhlelo zokugaya, kodwa izinhlelo zokugaya zasekuhlaleni zinezinkinga zokusebenza nezinhlanzi ngokuba yizindlela zokugaya okuphakeme kanye nokuguqwa kwezindlethu.

Ukugaywa kwezindlethu Kuthula Imiphumela Yekhanda Lomkhiqizo

Ukusebenza kwe-Wire EDM kukusebenza ngokuthumela izimboni zokuvuleka zokuvuleka phakathi kwekhabhamanzi yekhabhamanzi nekhanda encane, kancane kancane ukuthula kwezinto esikhundleni sokulayisha ngendlela yokwenza okwenziwa yimethods eziqinile. Umoya owakhiwe ngamaqondo athi amabi kakhulu, ngemibilinga engama-12,000 Celsius kaphakathi kwenqanawa. Lo moya amandla ukumelana ngokuthula kwezinto ezikhulu njengamakhemikhali akhulu nezinhlayiya zokubhola. Ngokuvumela izinhlayiya zokubhola, zikhona isimo sobukhona bazo kakhulu xa usebenzisa into engenakukhonzeka njengi-Inconel, zidinga ukubuyiselwa ngendaweni yemizuzwana engama-15 yokusebenza ngqo. Kungakhathaliseki leli mibono le-Wire EDM. Kuhla kakhulu kusebenza ngendlela ethembekile kahle kumaqondo amaningi, okwenza kusebenzela kahle kumaqondo ezingenakubukhona kakhulu.

Isicatshulwa: Ukusebenzisa Izinhlayiya Zokubhola nge-Wire EDM

Isicelo sezinga lelimali sasemaphakathi sabonise indlela yokulungisa iturbine disk ye-Inconel 718:

I-Wire EDM isikhulumi esikhulu sokwenza inkambo emlandweni ngemiphumo ngama-70% ngenkathi isebenza nezimathiswano zase-AS9100 zokwenza izimoto ezinhlobo zasezulwini.

Izinkqubo zokulawula iphethelo kwezindlela zokugaya ngokushesha kanye nokuhlukile kumatheleli aphakeme

Izinhlayiya ezinhle ziyashintsha iphethelo le-impulse ngaphansi kwe-2 nanoseconds, zokulungisa ukulethwa kwamandla ngokwemithwalandwe yemathiswano. Le nkqubo yasekisa amathuba okugaya kwe-tungsten carbide ngama-40% ngenkathi ikhumbula ukuthi kungenani ama-sub-5 µm. Izindlela zokugaya ngokuphindwe kabili nge-technique ye-i-Groove ziyenhlela amathiswano okugaya kuma-Ra 0.25 µm, ukwesekela izimathiswano zokwenza izinto ezisematheni ngaphandle kokulungiswa ngokwezifiso.

Inkambo emhlophe kakhulu kanye nokudinga okuncane kwezinyathelo emlandweni

Ukudinga kwezinto eziphumelelayo kwezinyathelo emlandweni kusula ukudinga kwezinyathelo ezilandelayo

Iindlela njenge-utshicelo lwemidindlela yemidindlela nezokwelapha kakhulu iqhobela izinto ezingavumelekanga kwaye zidinga ukusebenziswa ngokubanzi emva kokudlulwa. I-Wire EDM iyakhiwa amanqanaba okuqhekepheke aya kwi-Ra 0.16 kuya kwi-0.4 micrometers, okuvelayo kwiingxelo njenge-implants kunye neturbine parts ngaphandle kokudinga ukulayela ngokukhawuleza. Ngokwe ingxelo yendlela yoqobo le-2025, oko kwi-42 per senti yezinkampani zibe yindlela zabo zokugqibela okuphindwe kabini xa ziqala ukusebenzisa i-Wire EDM kumatyeni amakhulu njenge-Inconel okanye ititanjani. Le nto ithetha ukuba ukunceda kwezimali kunceda kakhulu emathethweni aphathwayo apho wonke intla iyagqitha.

Ukusebenza Kwemvelo Yokuqhekepha Kuphuma Ngokweqileyo

I-Wire EDM isenzo ngendlela eyahlukileyo kumaqondo aqhubekayo. Esikhundleni sokugcina imvelo ngokuchithwa, ikhuphuka kizikhathu ezingqamlezileyo ngokusebenzisa intshumayelo ebonakalayo, okungathi akukho ukugcinwa komoya kwenziwe kumoya osebenzayo ongavunyelwe ukuthi kudale amagwebu amancane emuva. Xa abasebenzisa ikhwezi yamathikha kakhulu phakathi kwe-0.02 kanye no-0.05 milimita, bahlale bavusele ngamanzi angasunguliwe, baphumelela ngama-90% angaphezulu kwezikhala ezifanayo ekusebenzeni nezindlela ezijwayelekileyo zokwenza izindleke ezikhuphakileyo. Kumaqondana enza amagiyela esithuba, lokhu kuthiwa ukunciphisa izindleko. Abaningi baletha ukuthi izikhathi zokwenza ziyanda kabusho nge-30%, futhi futhi kuzindikwa ukuthi kuzo zonke izikhathi zilandela ukwamiswa okuphezulu kwe-ISO 2768-mK ngokuthi kukhona isikhathi esincane sokuphatha amagwebu asidlayo nezindlela zokugcina.

Isicathami: Ukwenza Umphumela Wemaliweyo Ngezikhala Ezifewekileyo

Ikhampeni elikhulu ye-equipment yemiphumela yemibala yakatholwa yakamuva ukusebenzisa izindlela zokwenza i-wire EDM ngokuvamile kakhulu ngokushoqileyo kwebhantsha lombane lomphefumulo lwekobalti-nekholomiyum. Oku kubonwe ngokuthi kunesivinini esikhulu kakhulu esikhundleni kakhulu ngokugcwele, sithi kwa-0.2 microns ngaphandle kokudinga kwenye inkqubo. Ngokwesicatshulwa esipapashwe kwi-Journal of Medical Manufacturing ngo-2023, le nqwaleni yakhula ukugcina ukugcina kwezindlela zokwenza ngokwezifiso kanye nokunciphisa kwezinkinga kakhulu - kusuka kuma-12% isikhundla kuma-0.5%. Kubekezela abasebenzisa oku kuzo izindlela zokulawulwa zaseFDA, lezi zinto ziyindlela ebaluleke kakhulu. Izindlela zokulawulwa kwezikhundla ezinkulu kuma-5 microns zingavimba izigaba zokuvunyelwa, ngakho-ke ukwenza i-step yokuqala ngokucacile kuyindlela ebaluleke kakhulu ekufundeni izindlela zokulawulwa.

Izindlela zokudlulisa ngokuphindwe futhi i-technique ye-i-Groove ngokwenza ngokucacile

Izinhini zokugcina umgca ngokwamanje zilandela izindlela eziningi zokugcina futhi nezinhlobo zokugcina i-Groove ezingcono ezingavikela ukuncipha okungathanda futhi kwezindlela eziphakathi kahle kithi. Xa usebenza nezimbadeli zokubhala izindlela ezimbili kungase kuthuthukisa phakathi kwezinye izindlela. Iphasi ngokuphelelwe kungase ikhulu kakhulu, ibuyekeza kusuka kuma-1.6 microns Ra kuya kuma-0.4 microns Ra, ngelokho kuyakhula ukuncane kwezibalo kungaba kwi-2 microns. Kubasebenzisi bezinhini abasebenzisa izinhini ngokuphelelwe, le ndlela yokusebenza iyahlukisa konke. Izindawo eziningi zihlala zisebenzisa lezi zinhini ukuhamba ngokungagciwanga, ngakho ukuthola iziphumo ezinhle kusukela kokuqala kuyakhi kakhulu ukuthola iziphumo ezinhle.

Ukuzimela kanye nokusebenza ngokungagciwe kwezinhini zokugcina umgca

Ukuhambisa kwezokusebenza ngokungagciwe kwezindlela zokubhara nezinhloso zokuhamba

Imicaba ye-automotive ne-aerospace ngokuwaqamba kakhulu uhlelo lwabo lwezimali ezisebenza ngemva kwemva. Ngokwesicatshulwa soMFG Tech Report wa-2024, amathiliwa amabili angaphandle kwezinye zingoba yindlela egcwele yezindleko zokusebenzisa izindawo ezingenabantu. Izinhini zokugaya izingceke kakhulu xa kufanele zisebenze ngemini noma ngemva kwemva. Le zinhini zingagaya amaphuzu wokunyela komkhiyamali nezinhlobo zokugaya izimpukane ngokucacile kakhulu, wonke ngenkathi awukho onto engonakala phansi kwabo. Oku kusebenza ngokuthi, izinhlanu zikhula amaphesenti angama-40 kwezindleko zokusebenzisa bantu ngaphandle kokuthilela kakhulu kwezinkimbinkimbi. Noma ngemva kwemva eziningi eziyisicaba, zikhumbula futhi kuzindleko zokuthola kwe- plus noma minus engu-1 micrometer.

Ukuxhuma kwe-CNC ne-Robotic Integration Iyenza ukuthi ukuzothutha kusemaphini kube lula futhi kungena ngokwehlisa

Imicabha ye-wire EDM yasekuhlukeni inquma ukuxhumana nezicaba zokubhala ngokusebenzisa izicaba zokwenza izinto, okwenza ukuba kube ngama-98.5% wokusebenza xa kwenziwa amadoti kwezinhloso zokubhola. Le zicaba ezine-roboti zonke ukwenza amaphindwa amakhulu - bathuma amagugu kumathilini bese baya nabalinganiwe ngaphandle kokuthandwa kwekudide. Ngokwesibonelo, izicaba zokukhishwa kwezindleko zokukhishwa kuhulumeni ukushintsha izinketho zokukhishwa njengoba zihamba, zokuphendula ngokushesha kanjani okuhamba nezindleko ezahlukahlukene ngale ndlela. Kumaqondana owamise amaphethini kwezinhloso zokubhola, lezi ziphumo zibangela ukuthi kuthathwe amathuba okulandela kakhulu. Oku kuthatha ngisho neyure yokuqala kuthathwa ngaphansi koku-minithi ezimbili, okwenza uhlu olukhulu lapho izikhathi zokuphela ziyathambekile futhi izimo zokh quality ziyahlala phezulu ngokuhlanganisa.

Ukuhlela Imisebenzi ye-Workflow Ukusebenza Ngokuphelele, Ngaphandle Kwesicelo

Ukusebenza okungamntu kwe-EDM kudinga:

• Ukuhlelele kwezinhlobo zokukhishwa ukwenza ukuthi izindleko zokukhishwa zibe yidinganayo
• Imithwadi yokuvikela ukugcwala kwezimali ngokusebenzisa izinhloso zokuvuma
• Ukuhlanjwa okwenziwe ngokuzenzekelayo kwekanga esikhundleni kanye <5 µm izindlela zokugcina

Ababhuyeke kakhulu abasebenzisa le ndlela babhalwe 300+ amahora wokusebenza ngqo phakathi kwezithuba zokulungiswa. Izindlela zokusebenza zasekhanda ezintsha zasekhanda zivumela ukulungiswa okwenziwe nge-IoT, ukuvavanya amapharamitha angama-50 wokusebenza ukuze kuvikele ukungasebenzi.

Imibuzo Evame Ukubuzwa

Yeyiphi i-Wire EDM futhu iyiphi nto engaphambene nezindlela zasekhanda?

I-Wire EDM (Electrical Discharge Machining) iyindlela yokusebenza engenazo izinto ezingaphakathi esebenzisa izimboni zokuxa zokuxa ukususa amagugu, ekuvumela ukucinca okuphezulu nokwenza amaphawula amakhulu ngaphandle kwekanga yezinto, ngokuhlukelela nezindlela zasekhanda ezisebenzisa amandla wezinhloso.

Kungani i-Wire EDM ikhona ngokubaluleke kwezinhlangano zasekhanda nezomohlaba?

I-Wire EDM ikhona ngokubaluleke kwezinhlangano zasekhanda nezomohlaba ngokuthi kuvumela ukucinca okuncane kune-micron, okudingekayo ukwenza amaphawula amakhulu futhu amathiphu okuphezulu kanye nezinto ezingcono esebenza ngokuphezulu njengoba amagugu wokupheka kanye nezinto zokubulisa izintaba.

Ukungcola Wire EDM ukuchithwa kwezinhlobo ezikhulu njenge-Inconel ne-titanium?

Yebo, i-Wire EDM ingavumela ukuchithwa kwezinhlobo ezikhulu njenge-Inconel ne-titanium ngokusebenzisa umphimbo omkhulu ovela kwezindlela zokuchithwa, ukuthula kwezindlela zokuchithwa eziphumelelayo ngokuthi kwehlise ukuchithwa kwezinhlobo nezindlela zokuchithwa.