I-Machine Eziyiswe ngokwezilwane: Umshini Wokugcina Ubudlelwane Bokukhuphuka Kwematerialo Ebuhlungu

Yini Imachini Ye-Wire EDM Iyenza Kanjani: Izinhlobo Zokukhuphuka Okuphephile Kungaphakathi

Yini I-Wire EDM? Isihloko Esingcono

I-Wire EDM isenzo ngokudala amaspark elethu kancane kusukela kwiwire ephakathi neyomaterial oyakuchithwa. Iwire, okungenjalo iyakhiwa kwi-brass noma kwi-copper kanye neyobude engama-0.004 kuya kuma-0.012 inches, iyethu amandla kancane okuqala ukuthi kuthathwe amaqhekeza amancane wemetal yinto engenakushapingi. Okuqinisekile kuyisampula ukuthi kungena kona ukuthintana ngokwembono, ngakho ke amathuluzi ayaphela ukuthi athintelwe kanti yomaterial ingena kona ukuthi ithinte amandla okushintshwa kwezindawo. Ngokuthi kunezinto eziphambili, i-Wire EDM iyisampula ukusebenzisa kakhulu xa usebenza nezimaterial ezikhulu njenge-Inconel noma i-hardened tool steels okungena kona ukusebenzisa izindlela zokusebenza ngokwembono.

Indima yomkhiqizo-wire kanye ne-dielectric fluid kwenkulungelo yematerial

I-elektroda yamakhwire ikhokhela izinkumbo ezimbili - iyasebenza njengeyokuthumela kwelekthrisithi futhi iyakheka kumaqo ngokwesibonelo. Xa iyalandela imindleke ethunyelwe khona, iyasekwa ngaphakathi kwezinye izindwangu zemali ezingapheliwe noma uhlangwane olukhishwe kweholayidi. Yini leyo ndwangu ikwenza? Ukuqala, iyakhokha indawo iyasebenze ngokuthi kungapheliwe ukwakhiwa kwe-ionization. Kanselwa, iyasebenza ukulula okuthiwa yizinto ezithathwe ngempela kusukela kwenziwe amaqo amasha. Futhi, iyakhuphuka konke leyo ndwangu okuyenza konke kakhokele kwekheka kahle. Xa konke ikhona kusebenza ngempela, singasebenzisa amandla kwezinye izinsuku ezineke ukunciphisa kwezimala kusuka ku-0.8 kuya ku-1.6 microinches. Futhi leyo ngaphandle kwezimala? Ziyadinga kancane kusuka ku-0.012 inches, okuyinkinga kakhulu ngokwezinye izinkumbonkulu.

Yini i-CNC Control Systems Ikwenza Ukunciphisa Futhi Ukuvulwa

Imicabha ye-wire EDM ngoku enokuthiwa kuma-tolerance we-±0.0001 inch ngokusebenza kwezinhlelo zokudonga (CNC) zazo ezibangela konke okuqala kusukela ekuxhunyaniseni isantya se-wire, ukuphuma kwezishishini fanye nokuhamba kwamandla. Le micabha ngokwemfanelo inezinhlelo eziphumelelayo ezokwenza izilungiselelo zokudonga ngokuhlolwa kwehleli yazo nezobuphakeme. Ngakolunye uhlango, izinhloti zokuxhuma zikunceda ukubekisa i-wire ngokucacile kakhulu kwezibini ezincane kune-micron. Thatha isifundo sokudlulisela kwezinhlanzi. Xa kudluliselwa le micabha yesloti yoturbine, abasebenzisa balela ukulandwa ngokushesha kwamashishini ukulandela ukulinganisa kwezibini kumathuba we-0.001 mm ngemva kwezomphakathi wokudlulisela. Le mikhawulo ehlukile kakhulu xa kudluliselwa amaqhinga ofanele akwazi ukuthambeka ngokucacile kakhulu ngokulinganisa kwezimo eziphakeme.

Izicaba Ezinhloko Zomcabha We-Wire EDM: Ukuqondisa Okucacile Neziko Rokusebenza

Izicaba Ezinhloko Zomcabha We-Wire EDM: I-Wire Electrode, Ifluyidi Yedielekthiriki, Isinyathelo Sevamthombi, Nezinhlelo CNC Yokudonga

Xa kufika kakhulu kuye ngokuthi yini i-machine engxenye yemoto yasebenza ngokuphakade, kukhona amanye amaphela amathathu okufanele asebenze ngokucophele. Okokuqala, sinayo i-wire electrode, okungenzeka ukuthi yenziwe ngokwezinkca noma ngokwezinkca ongenhlanhlaniswa ngiyasini. Lokhu kwenza lezi zixhobo zokuxubha zokwelapha zokuthi kuthinte ngokuphazamisekile ngokuthi kuthinta kancane kancane. Kuye nobunye obulayi obudingi obhede ngazo zonke, ngokuvamile ngu-mhlane wokuxuba. Kwenza amathathu amathathu ngalinye: ukulinda kakhulu xa kuthintwa, ukuthishela konke okuncane okwezililo, nokusiza ekugcineni lokho kancane kakhulu lapho kuthintwa. Ukwenza konke lokhu kusebenza ngu-inyukelo yokwenzeka yokuphazamisa okuthumela izinkomba zokuxubha ukuze kuthinte ngokuphakade. Ngakolunye icala, i-CNC control system iyathatha lezi zifanekiso ezinhle zase-CAD bese iyawenza ukuxhumiwa okuphakade kwire, ukufinyelela kwezinkinga ezincane njengo-0.005 milimita. Ukuqaphela konke lokhu bese ukuthini owawuyona? Ikhilomithi elikhanayo yokuthinta ngokuphakade kwezililo ngaphandle kokuthintana nazo, noma xa ziyinkimbinkimbi njengo-300 milimita.

Ukuqonda kwe-Fluid Dynamics kanye nokuthiphisa kwezinto eziqinileyo (Ra) ukwenza kahle

Isigubu sekwaba lelihlwempu lekubona kakhulu kungaphandle kakhona lelihlwempu liphumelela ngokuphi. Lapho izinhlobo zokuxhumana nezinhlobo ziphumelela ngokulandelana, kunceda ukuthola kahle kwezindlela eziphansi, okungathi kunezindlela eziphansi ezincane kakhulu zokuthiwa kwezindlela eziphansi. Abakhubazi abaningi bafumene ukuthi kubaluleke ukuba kunesigubu sekwaba phakathi kwemibili 8 kuya 12 litere ngemizuzu ngokuthi kunceda ukuthi kwehlise izinkinga zokuthiwa kwezindlela. Le ndlela leyise kubona kakhulu kwezindlela eziphansi ngaphansi kukaRa 0.8 microns noma lapho kusebenzisa izindlela eziphansi. Ngokugcina ukuba kunesigubu sekwaba esikhatsiwe ngokuphelele, abakhubazi abaningi bakhuthaza ukuthola izinhlobo ezinhle zokuthola izindlela eziphansi ezine microns ezingama-5. Lezi zinhlobo zicela ukuthi kwehlise izindlela eziphansi, okungathi kungaba yinkinga kakhulu ngenxa yokuthi izindlela eziphansi ziphansi kakhulu zokuthiwa kwezindlela eziphansi ezincane zokuthiwa kwezindlela eziphansi.

Ukunyola Kwamandla kanye Nokukhulisa Impulsi: Ukuqinisekisa Isilinganiso Sokususa Kwamandla (MRR) kanye Ne-overcut

Imithombo yesindleko yaqa kusebenzisa iteknoloji yokuqondisa ipilse okwenza abasebenzisi bakwazi ukulungisa ngokushesha amandla aphakathi kwe-0.5 kuya kwe-32 ampele kanye nezimanga zepilse phakathi kwe-0.1 kuya kwe-200 mikhathwana. Xa kusebenza ngeziloyi zeluminyum, ukwanda kweqilingo lokusebenza kungakweselula ukwanda kohlukumelela kwamagugu ngemathuba ye-20 kuya kwe-40%, hhoname lokhu kuthinta izindleko ngoba ukunciphisa kungadla ngokushesha ngemathuba ye-0.015 kuya kwe-0.03 milimitha. Ngendlela enye, xa ababhili bakhetha amapilse amancane kwezindleko engeyona 2 ampele, bafumana amagugu amathathu kakhulu kuzindlela zetiyitani noma kwezixhobo ezimfushane ngaphansi kwe-0.4 mikhathwana, hhoname ngokwengeza isikhathi eside sokugaya. Ukutholwa kweqembu eliphelele liphakade kakhulu kumathuba asemandleni njengokwenza izilimi zetayela, ngqo xa kuyindlela yokwenza izilimi zetayela lapho ukwanele kwezibalo ngaphakathi kwe-0.01 mm kungakuhlanganisa phakathi kwehlonipho kanye nehlazeni kumisebenzi wokuthanda.

Imithwanciso nezinhlobo zokukhulisa ukusebenza okuphumelelayo kwamanzi

Isilinganiso esifanelekileyo sombane wamanzi, okungenani phakathi kwe-8 ne-12 Newtons, sisebenza ngokwengeza nezinhlobo zokukhulisa ukuze ubuke indlela yokukhupha ngokuphelele kwezinyathelo. Xa izinhlobo zisalela ngemva kokuqala kude, izinkolela zombane zokuxhasa zisusa ukuthi kungcola okungaphumelela kakhulu. Lokhu kuthula kakhulu ukuphula kamanzi, ngokungenani kwezingu-70% xa kusebenzela nezinhlobo ezinzima njengaleyo ye-Inconel 718 esikhathalwa ukukhuphwa ngendlela ejwayelekile. Izinhlobo eziyinhlanzi ezifakwe ngemidindle encane kakhulu ziyokukhulisa ukuthi zibe nezinkinga ezingcolile kakhulu, okungu-2 micrometers, okungaba yinkinga ebalulekile xa kusebenzela kwenqamulelo nezindlela ezinhle. Ngalezi zinhlobo ezinhle ezifakwe, abasebenzisi kungasebenza ngokuphelele kwezinyathelo ezingu-200 ngenyaka engenakuphansi, okungaba yinkinga ebalulekile kakhulu kwezokwenza izinto ezisemaphakamweni ezifakwe kubuso obalulekile kakhulu njengaleyo yokwenza izinto ezisemaphakamweni.

Ukulayisha Imithi Eziphakeme Ngokusebenzisa i-Wire EDM: Ukulandelana Nezinkinga Emandeni Wesiloyi

Isendelo ye-Wire EDM ekulayisheni imithi esiloyi neziphakeme njengesi Tool Steel ne-Inconel

Izimakhine ze-Wire EDM idlaya imithi okungasebenzi yezindlela zokulayisha eziphambene, cogna imithi esiloyi njenge D2 ne H13, Inconel 718, futhi le titanium alloys esiloyi. Inqubo yonke isebenza ngokushisa phakathi kwezilithroda, kungenjalo ukulayisha imithi ngaphandle kokuthinta ngqo. Noma lapho kusebenzela okuphakeme kangcono ukuya kuma 65 HRC kwi-skala ye-Rockwell, isimo sekhona sibeke. Kwezimali ezifamatelwa kwezinhloso zokulwa nezimo eziphambene njengokwezindlela zokudlula noma ukwenza izimboni, lokhu kungaba yindlela ebaluleke kakhulu. Izikhululo zetarbine ngokuphambene kakhulu zisebenzisa lezi zimo ngoba izindlela zokwenza izinkimbini zokudlula zingase kuthinte noma kuthinte isimo esifinyelelayo se-alloy.

Ukwehla Okuncane Nezindlela Zokulayisha Ngaphandle Kokuthinta Ngqo: Imiphakathi Yekhono Lokulwa

Ukusebenza kwe-Wire EDM kuhluke kula metode ezinye kuba akakho ukusebenzisa umoya ngqo noma ukwenza izonile zokwanda zokuthi zithinte ubunzima bokwelaphi. Ngokuvalela ezinye iingcambu zokwelaphi ezingcono sibonile eziphumelelayo apha. Inqaku laseqile ukuthatha ukuthi ukuthambwa kwezilungu kubola ngama-92% xa sebenzisa i-Wire EDM kunokuba sebenzisa ukugcina ngolaser ngokwesicatshulwa saseqile saseqile ngo-2022. Le nkqubo yokuqondisa kakhulu kwiindawo ezijulwa ngokwelaphi nezinye iingeni zokwelaphi. Xa izinto zilinda ubunzima bokwelaphi, izinto ezileli kusebenza ngakumbi ngokwemfushane kwaye zilinda ngokwengeziweyo.

Ukugcina kwe-Overcut kunye nokucinca kwezibini kwi-Wire EDM: Ukuphatha i-Tolerances kwiingcambu ezilungileyo

Ukuqina imithwalo ye-±0.005 mm kumatholi edolophini kudinga ukulawula ngempumelelo i-energic spark kunoma yisiphi isantya se-wire. IiCNC ezininzi zokwenyelisa ngokuzenzekelayo iziqiniseko ezifanayo nezokugcina kanye nezokufusha okuphakathi ukuthi kuthintwe kahle kakhulu - okuqukethwe kakhulu xa kudluliselwa amageometri amaningi okudlulisela noma amaisikali.

Isicathami: Ukudlulisela kwe-Wire EDM kweTitanium kwiinkxenye zokugcina

Isicathami esiphakeme esidlulileyo sabonise ukudlulisela kwe-wire EDM ukudlulisela amageometri edolophini kweTitanium ngokungcono (Ra) ye 0.4 µm kunoma yisiphi isantya esiyindawo ±0.008 mm . Imicelo yabo yekhuphela ukudlulisela kwezokugcina, yekhuphela amaxesha ekuqaleni ngokuphindwa kabini 34% ngelishayela kwiindlela zokuhlanjwa zokugcina eziphambene ne-AS9100.

Ukuqina kwezinto eziphezulu kwaye ukugqithisa ngempumelelo kwiWire EDM

Ukudlulisela Okuphezulu kwezinto eziphezulu ngokuphindwa kabini kwezinye i-micron

Izinhini zokwenza umgca ngoku zingasebenza ngokwengeza ubalulekile kakhulu ngokulingana no ± 0.002 mm (ngokungenhla kwezinkundla 0.00008) xa kusebenzwa nezindleke ezikhululekileyo ezijwayelekileyo njengokwehlulelwa kwehlulelwano okanye i-Inconel, okwaziwa ukuthi kubona kakhulu kunezindleko eziningi zokusebenzela ngokujwayelekile. Yini engqondweni le mpumelelo? Ezi zinhini zicabanga ezinkimbini zokuxhumana ngokwezifiso kanye nezinhlelo zokulungisa izinkimba zokunqanda ngokushesha, kanye nezinhlelo ezingasebenzi ngokulandelana nezindleko zokunqanda okuphumelela kuzo. Noma ithini izindleko zokwenza izindleke ezincane kakhulu kwezinyawo zokulayela izinhlofe. Abasebenzisa kudinga ukuthi kuzwele kakhulu ukuthi kungenzeka ukulayela amandla ngendlela engcono. I-Wire EDM isebenza ngendlela engcono, ibhala amandla kwezinye ngokulingana no Ra 0.8 microns ngokwesibonelo ngaphandle kokudinga ukulungisa ngokwengeza izinyathelo ezintsha emuva kwalokho.

Ukulungiswa kwezinto (Ra) Ngokulungisa I-Parameter

Abasebenzisi bakulela ubunzima befasile ngokwenza utshintsho kwiimithambo ethathu ebalulekileyo:

Ukulungisa lezi zinhlobo kunciphisa ukungenamaphoyisa kwezinyezi nge-42% kuzinto ezikhakanye ngaphandle kokugcina isivinini sokususa amagugu (MRR) we-18 mm³/min.

Isimo: Imiphumelelo evela kuncikezela ukulawula ngokuzithutha kuhlelele indawo yokuphathwa kwezilinganiso

Imicabango ye-conrol engenakukhona iyaguqula umthamo ngokusebenzisa ithuba le-machine learning ukubona nokulungisa izinkinga zokubhola phakathi kwezicathami. Lo tekinthekhi ibheka izinto ezithile njengokuba yini elekthrisithi ephakathi kwezilithrodi, lapho umthwana wokubhola ubuyeke, futhi kuthi yini esekwa nezinhlanzi ezithile ezisemhlabeni, bese kubuyekeza amandla ngokwesibonelo. Inkampani yokwenza izicathami zemoto yasemaphoyisa amaphoyisa amaphoyisa ngokuphindwa kabili lapho bengena kusebenzisa le micabango engenakukhona kwezinyoka zokunyela. Okuqukethwe yinkimbinkimbi yalo ukuthi kungakhokelela ukubhola okukhulu okuthula kungavumele ukuguqulwa kwe-0.01 mm ngekuphela okuphezulu okudinga kuphela 0.002 mm okuphumelelayo. Lokhu kusho ukuthi abasebenzisi kungakhiwa ukubhola okuphezulu okuphezulu ngokwesibonelo ngendlela enye engavumele ukuguqula ukuseta ngokuphindwe, okuthatha inani lesikhathi nezimali.

Imisebenziso Yonke Indvlo: Indvlo Yokuhlonipha, Yomedhu, Noma Imisebenziso Yokusebenza

Izimakhine zokugcina ngokwe-EDM zibeke yindlela eculawulekileyo kuzo zikhala zokwenza izinto ezingcono kakhulu ngokwezimali ezikhuphwe. Imisebenzi yabo yokugcina engaqhingi eliqinile kanye nezikhundla ezingaphezu kwe-micron ikhuluma ngemiphakathi emibili ngemigwa emathathu:

I-Aerospace: Izinjini zokunqatha nezilayili zokuguquguquka ezidinga ukukhula okuphezulu

Kwemfanelo yezokwelapha, isebenti se-EDM sasebenza kakhulu ekwenzeni izinyawo zokuphatha nezinkawuli zokulayela izimpawu ezinesimo elikhulu njenge-Inconel 718. Lezi zimpawu ezisebenzisa nikeli zingasebenzi ngemva kwezindleko eziphezulu, zikhona kahle noma lapho izindleko ziphefumula amaphurenhaiti angama-1,400 (okungu-760 Celsius). Okuqondile kakhulu ngokusebenza kwe-EDM yindlela ngazo akunakho ukushaywa komoya wakhe lapho kuchithwa. Lokhu kusiza ukungena kwezindlela zokuphazinywa eziphansi eziphakeme kakhulu futhi kuhlinza izindlela zokulayela ngemiphumela engcono engu-0.0005 inches noma ngalokho. Lapho sibheka izicelo eziphathwe khona kusona amanye amaphrojekthi azokwelapha, abasebenzisa amanye amakampani bafundile ukuthi uma baya ku-EDM ekwenzeni amapusi apholile kuzinyawo zokuphatha, lokhu kuthula amandla okuphazimba ngemiphumela engu-2/3 kuphela kunoma isebentiswe izindlela zokulayela ngokwezibonelo ezifanayo.

Izempilo: Izinto ezizokwethwa kugqokwe nezinsiza zokuphiswa ezidinga iqhutywa nezimiphumela engcono

Abaproduka bokugcina bemedical device bavame sebenzisa i-5-micron repeatability ye EDM wire ukwenza kwezimpilo ezingenelungelo ngokusebenzisa i-titanium nezinto zokwenza i-osteoconductive surface textures nezicathami zokusebenzisa edge radii phansi kuka-10µm. Le ndlela isula amapulishi okupolisha ngokwesibonelo abangasebenzisa 12-15% okungabi ngeyona into kwezokuproduka izinto ezingenelungelo ngokusebenzisa i-stainless steel.

I-Automotive: Ukwenza okuphawu kanye nekuphumelela kwezimoldi ngokuchazwe kwezinto

Abasebenzisi bokuphumelela kwe-automotive bavame sebenzisa izinhini zokwenza i-EDM wire ukukhupha izimoldi zokwenza i-hardened tool steel for complex headlight reflectors nezinto zokuxhumana. Le ndlela ikhupha amadegree e-draft angles up to 45° kuma-carbide trim dies ngelokhu kuthutha kakhulu kwezinye i-surface finishes phansi kuka-Ra 0.4µm—okudingekayo kwekuphumelela kwezinjani ngokuphelelwa ngaphandle kwezindlela zokupost-process.

Imibuzo Evame Ukubuzwa

Yeyiphi indlela ephambene yokusebenzisa i-Wire EDM?

Ukusebenza kuka Wire EDM kukhona ukunciphisa izinto ngaphandle kokuqhapa, ukwephula ukugcina kwezixhobo nokunciphisa ukugcina komkonto kuzo izinto eziqinisiweyo. Lokhu kungcono xa usebenza nezinto ezikhulu ezingekho ukulaywa ngokwemvelo.

Yintoni i-Wire EDM yenziwa ukuba yilungiselelweyo?

I-Wire EDM iyilungisa ngokusebenzisa izicathami zokubala (CNC), ezingaba ngamagqwaliso afanayo nezispeed zewire, ukuphula kwegciwane, nokuhamba kwezinye. Ii-algorithm ezinhle ziyilungisa izilungiso ngokwesicathu nokubhaliweyo, ukuvumela ukunciphisa ngokucophelela.

Yiyo ndima iwire electrode kunye nedielectric fluid kwi-Wire EDM?

I-Wire electrode iselela umoya kunye nokuphula izinto, ngelixa i-dielectric fluid isebenza njenge-insulator, ishiya amagciwane, iyacoca indawo ukungavule ukuba kwezindlela ezifutshane.

Ngaba i-Wire EDM inokwenza izinto eziphambene nomkonto?

Yebo, i-Wire EDM ikhona nezinhlelo yokuphepha amathimba athola ukukhula okuphezulu njengokwehliswa nezindlela zokwenza izindlela zokukhupha kungaba nezindlela zokukhupha, kubona ukuthi isimo seyayi sikhulu singasebenzi.

Yiziphi izinkampani eziphumelela kakhulu nge-Wire EDM?

Izinkampani ezifanayo nezokudla, izokudla, nezokudla ziphumelela kakhulu nge-Wire EDM fomule yokwenza amathaski afuna ukuphepha okuphezulu nezinhlelo eziphumelelayo, kanye nezindlela zokukhupha, izinhlelo zokuchitha, nezinhlelo zokudla ezinhle.