Izinkinga zokuprosesa eziphi kungakhulula ngokushesha i-machine yokubhala ngokusebenzisa i-EDM enobunzima obukhulu

Ukukhupha Ukuguqula Kwesithunzi Sasezindaweni Zokudlula Okwanele Kwezindawo Eziningi, Ezinamandla Okungaphezu Kwemilinganiselo Yezindawo

Kungani Ukudlula Okwanele Akufanele Ngaphezu Kwemilinganiselo Yezindawo 6:1 Emazini Emanzi

Ukudlula kwezinkqubo zokudlula ngokuzenzakalelayo kubalulekile ukuthi kubhekwe ubukhulu bekuphakanyiswa kwezinkqubo zokudlula ngokuzenzakalelayo uma ubude kusilinganisi sabandla kubhala kune-6:1 emaziphi ezinkqubo eziyisisekelo—njengokuthi kuziphi zokusebenza eziningi kune-55 HRC noma amasuperalloy ayesilwane senikeli. Ingxenye eyodwa yendlela yokuqonda kukuba izindawo zokudlula ngokuzenzakalelayo zihamba ngokushisa kakhulu njengoba indlula iyaphambana. Indlula engeziwe ayinakho ukuthi ibe yisibonelo sokuthi isebenze ngokuzenzakalelayo, futhi lokhu kubeka isibonelo sokuthi isebenze ngokuzenzakalelayo, futhi kubeka isibonelo sokuthi isebenze ngokuzenzakalelayo—kunquma kune-0.2 mm ngemboni yezinkqubo ezingaphezu kwe-50 mm. Amathuba okudlula ngokuzenzakalelayo ayaphakama ngokushisa kakhulu njengoba ubude kusilinganisi sabandla kubhala kakhulu, futhi lokhu kubeka isibonelo sokuthi kungabonakala ukuthi indlula iyaphakama kakhulu; amaphoyisa wezinsizakalo zokuhlanganisa zazibonisa ukuthi kune-40%+ yezinkqubo zokudlula ngokuzenzakalelayo ziyaphakama kakhulu kunezinkqubo ezingaphezu kwe-8× kubandla kwezinkqubo zokudlula ngokuzenzakalelayo kwe-Inconel 718 (isibonelo sezinsizakalo zokuhlanganisa zokuvakasha kwe-2023). Ukudlula kwezinkqubo zokudlula ngokuzenzakalelayo kubhekwa ngokuzenzakalelayo: izinkqubo zokudlula ngokuzenzakalelayo zingaphezu kwezinkqubo zokudlula ngokuzenzakalelayo zingadlula ngokuzenzakalelayo, futhi lokhu kubeka isibonelo sokuthi kungabonakala ukuthi kungadlula ngokuzenzakalelayo, futhi kubeka isibonelo sokuthi kungadlula ngokuzenzakalelayo kune-800 °C—kubeka indlula yisibonelo sokuthi kungadlula ngokuzenzakalelayo, futhi kubeka isibonelo sokuthi kungadlula ngokuzenzakalelayo. Nangona izinkqubo zokudlula ngokuzenzakalelayo zinconywa ukuthi zidhlula ngokuzenzakalelayo, zidhlula ngokuzenzakalelayo futhi zidhlula ngokuzenzakalelayo kakhulu, futhi zidhlula ngokuzenzakalelayo kakhulu kwezinkqubo zokudlula ngokuzenzakalelayo. Isiphumo sokugcina sikhona ukuthi kungabonakala ukuthi kungadlula ngokuzenzakalelayo, ukuthi kungadlula ngokuzenzakalelayo kakhulu, futhi ukuthi kungadlula ngokuzenzakalelayo kakhulu kwezinkqubo zokudlula ngokuzenzakalelayo zokuhlanganisa nezinkqubo zokudlula ngokuzenzakalelayo.

Ukuthi indawo yokudrilliya yase-EDM iyafika kwezinkambu eziqinile, ezingenaburri, ezingu-12:1 (isibonelo, izihlangu sezinye zezihlangu)

Imishini yokuqondisa kwe-EDM iyabulawa amandla okugcina okubonakala kanye nokuphuma. Ngaphandle kokuchitha, iyasebenzisa indawo yokuchitha eyahlukileyo eyahambisana ukuze yenze izimithi zokugcina ezihle kakhulu zokuthintela isikhundla sokusebenza ngendlela esingathinti kona. Ngaphandle kokuthintela ngokugcina isikhundla, indawo yokuchitha ibe yisibonelo sokuhlelwa kahle kuzo zonke izindawo zakhe—kubangela ukuthi izinkamba zibe nezinhlobo zezindawo zokuhluka zokwesibili zokwesibhotho zokwesibili (10:1 kuya kuye 12:1) kanye nezinhlobo zokuhluka kwezindawo zokwesibili zokwesibhotho zokwesibili (0.03 mm). Isistimu yeservo yomkhondo omkhulu sibonakalisa umkhondo wokugcina ngokuvula ngokushesha indawo yokuchitha uma kubonakala ukuthintela okungafanele noma izinto ezingavuliwe zokuthintela. Umfula wokugcina ophakeme uyathakelwa ngaphakathi kwendawo yokuchitha, uyathintela izinto ezithintele kusukela kumkhondo futhi uyabulawa ukuthintela kwezinto ezithintele kabanzi—kubangela ukuthi izinkamba zibe nemiphakathi engenaburra ngaphandle kokwenza izinye izinqumo. Umsebenzi wokuchitha kwe-turbine blade oyedwa kuyenza izinkamba zokuhlaka zokufuna zokwesibili zokwesibhotho zokwesibili (0.25 mm diameter × 3.0 mm deep (12:1)) kwe-nickel alloys ngokuthintela kwezindawo zokwesibili zokwesibhotho zokwesibili (±0.015 mm) kanye nokuthintela kwezindawo zokwesibili zokwesibhotho zokwesibili (Ra < 1.0 µm). Lokhu kombinethi yokuthintela ngaphandle kokuthintela, ukuthintela kwezindawo zokwesibili zokwesibhotho zokwesibili, kanye nokuthintela kwezindawo zokwesibili zokwesibhotho zokwesibili kubangela ukuthintela okuhle kwezinkamba ezide kwezinto ezihle kakhulu zokuthintela—lokhu okungakwaziwa ukwenza ngokuthintela kwezinto.

Ukuvumela Ukuproducwa Kwemicro-hole ephakeme kwezinto ezihlukene zokusebenza eziqinile

Ukuhlinzeka kwemiphumela yemicro-drill yezinhlobo zokusebenza nezinhlobo zokusebenza zokugcina izinkampani nezinhlobo zokusebenza zokugcina izinkampani

Amadriyeli amahlezi emikhala ayaphela kusho kakhulu xa abhulayi izinkampani zokusebenza ezinomthwalo wokusebenza nezinkampani zokusebenza zezinkolelo zokusebenza (HRC 58–65). Amandla okubhulayi aphakathi kakhulu ayenza ukuthi amadriyeli athwele, aqhiphe noma ashiye ngokuphambuka—ikakhulu ekuseni kwezinkampani zokusebenza. Ukuthi izinkampani zokusebenza ziyathwele kakhulu kuyenza ukuthi umsebenzi uyaphendula kakhulu, ukuthi ubude lwesibhakabhaka lisilinganiswe futhi ukuthi isibhakabhaka sisebenza kahle. Ngaphandle kwalokho, ukubhulayi kwe-EDM kususa konke ukuthi amadriyeli asenzi isebenziso esihlukene: isibhakabhaka sisusa ngokusebenzisa ukuthi izinkampani zokusebenza ziyabhalwa ngokuvumelana, kususa ukuthi kune-torque, thrust, nokuthi kunezindawo zokuxhumana ngokuphambuka. Lokhu kusiza ukubhulayi kwezibhakabhaka ezincane kakhulu ezinomkhala we-0.1 mm ngokuthi ubude bawo buyingaphezu kwe-20:1—kanye nasezinkampani zokusebenza ezingaphansi kakhulu. Isibhakabhaka sokubhulayi esisuka ngaphandle, esihlanganiswe nezinkampani zokusebenza zokubhulayi ezinomthelela phakathi kwezinkampani zokusebenza, kusiza ukuthi izinkampani zokusebenza ziyasusa izinto ezinomthelela kwezinkampani zokusebenza, kusiza ukuthi izinkampani zokusebenza ziyasiza ukuthi isibhakabhaka siyasebenza kahle lapho amadriyeli amahlezi emikhala ayashiywa ngokushesha.

Ukufikisa ukuphakanyiswa kwe-±1.5 µm kwezindawo ne-Ra <0.4 µm yekuphakanyiswa kwesurfasi ngomshini wokubhala ngokuphelele wesifunda

Imishini yokuqondisa i-EDM eziyisisekelo ziyathumela ukuthi izikhundla zibe nesivinini esiphakathi se-±1.5 µm futhi isibonelo sezinye ziyaphansi kwe-Ra 0.4 µm—ukusebenza okungakwaziwa ngokusebenzisa ukuthatha izinkampani ezincane ngokuphelele emazinkampani ephakeme. Lokhu kubhekwa kusukela ekulawuleni kweservomotori esiphakathi, okuyisikhangeli sokugcina isikhundla sokushaya esifanayo esingaphezu kwezimicrometre eziningi, okunqamuka ukuthi kuzamekwe nokushaya okungafanele. Ukuboniswa kwezikhundla ezincane kuvumela ukuthi i-elecrode ibhale isikhundla esisikhiphayo ngokungafanele kakhulu, futhi iziphakamiso zokufusha ezingaqondiswanga ziyagcina indawo yokusebenza isihlanu futhi isivinini. Imishini eyisizukulwane iyasebenzisa izikhundla zokubhala ezinkulu kuzo zonke izihlangothi futhi izihlangothi zokuhamba ezinezivinini ezingavuthi ukuze ziyisikhangeli sokuthi izinkampani zizobhalwa ngokuphakathi kwezinhlobo zokusebenza. Kuyisisekelo sokuthi akukho mvelo wokuthatha okwenza ukuthi umsebenzi uzamekwe, futhi ukushaya okuphelele kuvumela ukuthi isibonelo sibe nesikhundla esifanayo—kungabi nesikhundla esisodwa noma esithothwe. Kumaqondo amaningi njengezinkampani zokuthatha amanzi noma izinto zokusebenza kwezintlungo, lokhu kuvumela ukuthi izinkampani zibe nesivinini esihle futhi esihle kakhulu ngokuphelele emva kokuthatha, futhi kuyasiza ukuthi akukho inkinga yokusebenza emva kwalokho.

Ukuvikela Ukusebenza Kwemithambo Yokudrill Ngokwezinye Zokuphatha Ngokwemithambo Yokuphatha Okunye

Amasistimu Okukhupha Okuphelele: ijet yomnotho wokukhupha okuphindekile + ubukhulu obuyintloko ukususa amasimbi ngokushesha

Ukukhupha izinkunkuma kuyindlela eyodwa yokubhekana nezinkinga eziphakeme kwe-EDM drilling esebenzisa indlela yokuthi isibonelo sikhulu kunezinye, apho isibonelo sokusebenza sisekhona kahle kusenza ukuthi izinkunkuma zihlale kahle kumgqa futhi zithintele ukuthi kwenzeke ukuthi kubhekene ngokuphambuka kwamandla. Isibonelo sokusebenza esisemthethweni sokugcina amandla (pulsed electrolyte jet) sivumela lokhu ngokuthi sithumela amandla okusebenza okuthi ayisibonelo esisemthethweni, okuthi asiphathelise izinkunkuma ezincinci kusendaweni yokusebenza ngalokho ngalokho kokuthi kubhekene ngokuphambuka kwamandla—kuvuma ukuthi kungena kakhulu ukuthi kubhekene ngokuphambuka kwamandla ngokuphambuka kwe-30% kulokho okuthi kubhekene ngokuphambuka kwamandla ngokuphambuka kwe-continuous flow, ngaphandle kokuthi kwenzeke ukuthi kubhekene ngokuphambuka kwamandla kwe-electrode. Ukuthi kubhekene ngokuphambuka kwamandla ngokuthi kubhekene ngokuphambuka kwamandla kuyavumela lokhu kabanzi: izinhlobo zokubhekana ngokuphambuka kwamandla zibheka ukuthi kubhekene ngokuphambuka kwamandla kumgqa ngokuphambuka kwamandla kwe-microseconds ukuze zibone ukuthi kubhekene ngokuphambuka kwamandla kwezinkunkuma ezincinci, futhi zithintele ukuthi kubhekene ngokuphambuka kwamandla kwe-pressure ku-800 kPa ngaphambi kokuthi kubhekene ngokuphambuka kwamandla kwe-baseline. Lokhu okuthi kubhekene ngokuphambuka kwamandla kuyavumela ukuthi kubhekene ngokuphambuka kwamandla kumgqa kubhekene ngokuphambuka kwamandla kahle, kuvuma ukuthi kubhekene ngokuphambuka kwamandla kubhekene ngokuphambuka kwamandla kahle ngokuphambuka kwamandla kwe-3,000 sparks per second. Ngokwaleso simo, izihlangothi ziyabhekana ngokuphambuka kwamandla kahle kwe-diameter tolerance nangokuphambuka kwamandla kwe-depths kwe-300 mm—ngaphandle kokuthi kubhekene ngokuphambuka kwamandla kwe-re-cast layer thickness futhi ngaphandle kokuthi kubhekene ngokuphambuka kwamandla kwe-electrode failure ngokuphambuka kwamandla kwe-full-shift production runs.

Ukukhupha izindlela zokugqibela zokushisa nokugqibela kwezindlela zokushisa ngokusebenzisa ukulungiselela kwesikhundla ngokusebenzisa iservomotor

Ukuphazamisa kwesibili—izikhathi zokuphazamisa ezingavamile ekuseni kokuphazamisa okukhulu—kuyisibonelo esiphakeme sokuphazamisa kanye nokwethula kwesandla, okuncedisa ukuthi izinkambu zizwe ngaphezulu kwe-15 µm kusuka kwezinhloko. Ukulawula kwe-gap okufanayo nge-servo kususa leliyisibonelo ngokuhlola ukuthi kune-gap eyodwa yezinkambu ezi-20–50 µm phakathi kwe-electrode nezinto ezihlola. Izindlela zokubhalwa kwe-voltage zokubona ngokushesha zibona izinkinga zokuphazamisa ngemicroseconds, futhi zibiza ngokushesha ukuthi i-electrode ibuyekeze noma ukuthi isivinini sesifunda sithintwe ukuze isula izikhathi zokuphazamisa ezingavamile kabefore ziyaphakama. Le ndlela yokugcina imithombo yokuqondisa iyagcina ukuthi ukususa kwesandla kuyasebenza kuphela ku-zone yekuphazamisa okuchazwe, futhi iyathola izinkambu eziphakeme, eziphakeme, nezinhloko zezinkambu eziphakeme ngokulinganisa ±2 µm—kodwa nangoba yil-Inconel 718. Ukuphazamisa kucwabela ku-0.5% kwe-diameter yeelectrode, futhi kususa inkinga yokusebenzisa i-reaming yezinye izikhathi. Ukulawula okugcinwe kuvumela ukuthi izindlela zokuhlanza zihlanganise nezindlela zokuhamba kwe-electrode, futhi ziyagcina ukuthi kunezimo zokugcina izinkambu zonke ngokuphelele—futhi ziyathola ukuthi izinkambu ziyatholakala ngokuphakeme kwe-sub-micrometer.

Imibuzo Evame Ukubuzwa

Ukuthi ngubani umph advantage omkhulu we-EDM drilling ngaphezulu kwe-mechanical drilling?

I-EDM drilling isikhuba amandla emechanical njenge-torque ne-thrust okuzosika ukuguqula kwesithuthu kanye nokuphela kwakho. Ngendlela eyodwa, iyisebenzisa ukugqibela kwespark ekukhethekileyo ukuze kufikelele ku-ma-hole ohleli kakhulu kanye ne-burr-free ematerials ethile ezingcono kakhulu.

Izidingo zokugcina kwezidingo zokugcina (depth-to-diameter aspect ratios) eziyisikwenzekayo ngu-EDM drilling ziyini?

I-EDM drilling inakwenzeka izihole ezinokugcina kakhulu kanye nezidingo zokugcina ezifika ku-20:1, okuphakeme kakhulu kunezidingo zokugcina zokuqondwa zemachining ezingcono kakhulu ezifika ku-6:1.

Kumaterials muni i-EDM drilling ibalulekile kakhulu?

I-EDM drilling ibalulekile kakhulu ematerials ethile ezingcono kakhulu njenge-tool steels ezingcono kakhulu (HRC 58–65), amasuperalloys enickel (isibonelo, Inconel 718), kanye nemithombo engcono kakhulu.

Ngaba i-EDM drilling inakwenzeka ukuthi ifikelele ku-surface finish ephelele kanye ne-dimensional accuracy ephelele?

Yebo, imishini ye-EDM drilling inakwenzeka ukuthi ifikelele ku-surface roughness engaphansi kuka-Ra 0.4 µm kanye ne-positional accuracy engaphakathi kwe-±1.5 µm, futhi ithola izidingo ezikhulu zezindlela zokusebenza kwezimpilo kanye nezinhlayiya zamafuel.

Yini okungakhuthaza ukugcina kakhulu nokugcina kabusha kwe-EDM drilling?

Ukubhekisana kokugcina kweservo kanye nokubhekisana kwezikhathi zonke kungakhuthaza ukugcina kakhulu nokugcina kabusha, kubeka ukuthi indawo yokuqondisa iyabhekisana ngokuphelele futhi iyabhekisana ukususa umfanekiso kwezindawo zokugcina ezithile.