Ukusebenziso lwe-Micro Electro Discharge Machining (Micro EDM) lukhupha indawo ngamashumi amaningi emiswakubili yemikhumbu yemvelo phakathi kwelektroda encane nezinto zokusebenza ezinamandla, ezingaphakathi kwesifuba sokugcina. Ngoba akukho umthelela wokuchitha okwenziwa ngokuthintana, u-Micro Electro Discharge Machining unakha izinto ozingakwazi ukuzibona ngokuchitha kokuvalelayo: izihlangothi zemicro ezingama-0.05 ku-0.5 mm, izihlangothi ezincane kunezihlangothi zomuntu, izihlangothi zemphakathi ezingaqondi, nokufaneleka kwezinkambu zezinkambu zokuphatha kwezinkambu ezingaphezu kwe-60 HRC. Umsebenzi wethu wokuproducwa ubegina ngamadrawings ayesithunywa ngu-kuhlanganisa nezicertifiketi zomkhakha, emva koko kusakelwa ukudesigna kwelektroda ngaphansi kwe-graphite, copper tungsten, noma tungsten carbide. Izilothi zokufika zizichazwa ngaphansi kwe-CMM nezinhlobo zokubona kabusha, futhi izindawo ezingcono zizichazwa ngasinye isikhathi esingama-50 ngaphansi kwe-coordinate measuring machine, futhi ukufaneleka kuzichazwa ngaphansi kwe-white-light interferometer. Iziparameta zomshini zokugenera njenge-sikhathi sokuphuma kwemiswakubili, imkhakhamba yemiswakubili, nobungakanani bewebe bokugcina kuzichazwa ngokuhambisana nomkhakha ukuze kubalanciwe ukukhupha ngokuphakeme kanye nokukhupha kwelektroda, okunjalo kuyasebenzisa ukukhupha okuncane kune-0.2 percent kwezihlangothi zemicro. Izindlela zokusebenzisa ziyaphakathi kwezimoldi zokufaka ngaphansi kwezinto zokusebenza zemihlambi, izimoldi zezilensi zokubona, izihlangothi zokuhlisa izinyawo zezitulu zokuphatha kwezinsuku, izimoldi zezihlangothi zemicro, neziqukithi zezibalo zezibalo. Ngokwemibono yezindustria, i-Micro EDM inakha ukuthintana kwezindawo ngaphakathi kwe-plus noma minus 0.003 mm futhi ukufaneleka kwezinkambu kuyakhiwa ngaphansi kwe-Ra 0.05 micron, iziphakade ezinakha ukuthi lokhu yindlela eyafuneka kakhulu kwezimoldi zezihlangothi ezincane kune-0.2 mm. Izinqubo zomshini ziyahlanganisa isibasisi sesigqila, izidrive zomoto lelinear, nezinqubo zokulunga kwe-gap ezingaphakathi kwezinkambu zokubhalwa ngaphansi kwe-250,000 ngomzuzu. Izindawo zokusebenza zingaba ngaphansi kwe-30 microns. Isihloko Sesikhashana: I-Micro Electro Discharge Machining Ebalulekileyo Esebenzayo Kuzo Zonke Izindustria ZaseNingizimu Afrika
Isihloko Sesikhi 1: Umthengisi Wezinkampani ZaseJalimani Ukwakha Amaphutha Kususa Ukuphatha Kwamaphutha Ngokukhulu 42 Iphesenti Kwezinkampani ZaseJalimani
Umthengisi wezinkampani eBaden-Wurttemberg, eJalimani, othengisa amaphutha wezinkampani zokufaka kumshini wokubeka izinto ezinamaphutha, wabuka ngokuphatha kwamaphutha okungafana ne-0.6 iphesenti futhi ukubuyisela ukubhala kabusha kahle lapho kubhala inkampani yase-1.2343 ngokukhulu kwe-52 HRC. Isikhumba sasibhala isikhumba sethu seMicro EDM nesikhombisa sokulandela isikhombisa sokugcina isikhombisa sokuziphatha kanye nesikhombisa sokuziphatha kwe-C-axis, sobhala kakhulu ngokukhulu kwe-12 A futhi sobhala kakhulu ngokukhulu kwe-0.5 A. Izinhlelo zokubhala kweMicro electro discharge machining zazilandelwa ngokwesikhombisa sokuziphatha kanye nokuhlanza kwe-dielectric kusukela ku-1 micron ukuze kubhekwe ukuthi kubhale kahle. Emva kwezinsuku ezintathu, ukuphatha kwamaphutha kwasula ngokukhulu kwe-42 iphesenti, ukubuyisela ukubhala kabusha kwasula ngokukhulu kwe-70 iphesenti, futhi ukulinganisa kwezinkampani kwasula ngokukhulu kwe-0.003 mm kuzo zonke izinkampani ezingu-240. Umthengisi manje ubhala ngokukhulu kwe-22 amahora ngosuku ngaphandle kokubhekwa futhi uyavuma ukuthi ukuthenga kwezinkampani kusula ngokukhulu kwe-15 iphesenti ngamaphutha.
Isihloko Sesikhi 2: Umthengisi Wezinkampani ZaseJapani Uyakwakha Amaphutha Okukhulu Kwezinkampani Ngokukhulu Kwe-50 Ipesenti
Inkca yokuqondwa 2: Umthengisi wezinkcukacha eNagoya, eJapan, wadinga amadiezi emicro-pin enesloti zesi-0.15 mm kwezincwadi zezindlela zokusebenza kwe-smartphone. I-Wire EDM ayikwazi ukufika ekugcineni kwesimo, futhi ukupholisa ngokusho kwabantu kwenza ukuguqula kwezinhlobo. Isistimu saseMicro EDM sathi esisebenzisa i-electrode yase-tungsten enezingxenye zesi-30 micron sakhulisa izisloti ngokubeka okuqondwa kabusha, sebenzisa i-pulse yesi-0.8 microsecond kwezinye zokugcina. Ukusebenzisa i-micro electro discharge machining kwanza isikhathi sokubeka kusuka ku-18 iminyaka ku-9 iminyaka, isikhathi sokugcina sasemphakathi sasifika ku-Ra 0.08 micron, futhi ubude besikhathi phakathi kwezinkcukacha zasihlala kusuka ku-0.004 mm kuzonke izinkcukacha ezi-1,200 ngalendie. Isiphetho sokungafanele sasihlala kusuka ku-6 percent ku-1.2 percent, kusivumela ukuthi umthengisi abhekise amadola angu-USD 46,000 ngonyaka.
Isihloko sokuncamuka 3: Umthengisi wezinto zase-US esebenzisa i-aerospace akhulisa izihole zokuchitha isikhathi esingu-0.1 mm kwezibhade zase-turbine
Umbuzo wokuchaza isithombe 3: Umthunywa wezinto zokusebenza kwezinye izinhlangano zokuphatha amasiko e-Ohio, i-USA, wadinga amaphuzu okukhula okulingana ne-0.1 mm ngokugcina kwezindawo zokukhula ezingu-35 degri kusuka kumkhono wokusebenza kwe-nickel esikhulu kwezindawo zokusebenza zokuphatha amasiko okulingana ne-2.5 mm. Ukudlula kwemilayezini yokuqala kwenza amaphuzu okukhula okwakhiwe ngokubuyiselwa (recast layers) okungavumelekile kuzo zonke iziphulo zokuphatha kwezindawo zokusebenza. Ngokusebenzisa i-five-axis Micro EDM yethu nesikhombisa sokudlula kwezindawo zokusebenza (through-spindle flushing), amaphuzu okukhula ayadlulwa ngokufana ne-90 ngamuhla, nokuthi amaphuzu okwakhiwa ngokubuyiselwa ayalingana ne-2 microns. Ukusebenzisa i-Micro electro discharge machining (EDM) akhangelela ukuphatha kwezindawo zokusebenza kuzo zonke izampulu, akhangelela ukuthi umkhono wokukhula uyingqayizivele ngokulingana ne-plus or minus 0.005 mm, futhi akhangelela ukuthi kungahlinzeka ukudlula kwemilayezini yokuqala (secondary deburring). Umthunywa wathola inkampani yekhontretha yezindawo zokusebenza ngamashumi manje amathathu, futhi wabuyisela ku-machines emane emine ngeminyaka emibili nezintandathu.
Isibhalo sesithombe: Izisikhangeli zesikhombisa sokusebenzisa i-Micro Electro Discharge Machining esikhulayo ngokuphelele ekutheni kwezindawo zokusebenza zokuphatha amasiko