Izahlulo zesiko Metal Ukwenziwa kunye 5-Axis Machining

Izahlulo zesiko Metal Ukwenziwa kunye 5-Axis Machining

Umbhali:PFT, Shenzhen

Inkcazo:Ukwenziwa kwemveliso ekwinqanaba eliphezulu kufuna izinto ezintsonkothileyo, ezichaneke kakhulu kumacandelo e-aerospace, ezonyango, kunye namandla. Olu hlalutyo luvavanya amandla olawulo lwamanani lwekhompyutha ye-5-axis yangoku (CNC) ekufezekiseni ezi mfuno. Kusetyenziswa umlinganiselo wejometri omele izijikelezisi ezintsonkothileyo kunye neencakuba ze-iturbine, ulingo lomatshini lwenziwa kuthelekiswa neendlela ezi-5-axis ezichasene nezithethe ze-3-axis kwi-aerospace-grade titanium (Ti-6Al-4V) kunye nentsimbi engatyiwa (316L). Iziphumo zibonisa ukuncipha kwe-40-60% kwixesha le-machining kunye ne-surface roughness (Ra) ukuphuculwa ukuya kuthi ga kwi-35% kunye ne-5-axis processing, ngenxa yokunciphisa ukuseta kunye nokuqhelaniswa kwesixhobo esiphuculweyo. Ukuchaneka kwejiyometri kwiimpawu ezingaphakathi kwe-±0.025mm zokunyamezelana kunyuke ngama-28% ngokomndilili. Ngelixa ifuna ubuchwephesha benkqubo yangaphambili kunye notyalo-mali, i-5-axis machining yenza ukuba imveliso ethembekileyo yeejiyometri ebingenzeki ngaphambili isebenze ngokugqwesileyo kunye nokugqiba. Ezi zakhono zibeka itekhnoloji ye-5-axis njengeyimfuneko kwixabiso eliphezulu, elintsonkothileyo lokwenziwa kwenxalenye yentsimbi yesiko.

1. Intshayelelo
Ukuqhuba okungayekiyo ukulungiselela ukwenziwa komsebenzi kuwo wonke amashishini afana ne-aerospace (ifuna ukukhanya, iindawo ezomeleleyo), ezonyango (ezifuna ukufakelwa kwe-biocompatible, ukufakwa kwesigulane ngokuthe ngqo), kunye namandla (idinga amacandelo okuphatha ulwelo oluntsonkothileyo) ityhale imida yobunzima benxalenye yesinyithi. Ubuchwephesha be-CNC be-3-axis bemveli, bunyanzelwa kukufikelela kwesixhobo esilinganiselweyo kunye nokuseta ezininzi ezifunekayo, ukulwa neecontours ezintsonkothileyo, imingxuma enzulu, kunye neempawu ezifuna i-engile edibeneyo. Le mida ibangela ukuchaneka okuchanekileyo, amaxesha awandisiweyo emveliso, iindleko eziphezulu, kunye nezithintelo zoyilo. Ngo-2025, ukukwazi ukwenza iintsimbi ezintsonkothileyo, ezichanekileyo ngokufanelekileyo ayiseyiyo into yodidi kodwa yimfuneko yokhuphiswano. I-5-axis ye-CNC ye-machining yanamhlanje, inikezela ngokulawulwa kwangaxeshanye kwee-axes ezintathu ezinqamlekileyo (X, Y, Z) kunye nee-axes ezimbini ezijikelezayo (A, B okanye C), zinika isisombululo sokuguqula. Le teknoloji ivumela isixhobo sokusika ukuba sisondele kwi-workpiece ukusuka kulo naliphi na icala kwiseto enye, ngokusisiseko ukoyisa imida yokufikelela ekhoyo kwi-3-axis machining. Eli nqaku livavanya ubuchule obuthile, izibonelelo ezilinganisiweyo, kunye neengqwalasela ezisebenzayo ze-5-axis machining kwimveliso yecandelo lentsimbi yesiko.

2. Iindlela
2.1 Uyilo kunye nokuBenchmarking
Amacandelo amabini ebhentshi ayilwa kusetyenziswa isoftware ye-Siemens NX CAD, equka imingeni eqhelekileyo kwimveliso yesiko:

I-Impeller:Ifaka iincakuba ezintsonkothileyo, ezijijekileyo ezinomlinganiselo ophezulu wemiba kunye nokukhutshwa okuqinileyo.

I-Turbine Blade:Ukubandakanya i-curvatures edibeneyo, iindonga ezibhityileyo, kunye nomgangatho ochanekileyo wokunyuka.
Olu yilo lufakwe ngamabomu ii-undercuts, iipokotho ezinzulu, kunye neempawu ezifuna ukufikelela kwesixhobo esingenalo i-orthogonal, ngokukodwa ekujoliswe kuyo imida ye-3-axis machining.

2.2 IiMathiriyeli neZixhobo

Izixhobo:I-Titanium ye-Aerospace-grade (i-Ti-6Al-4V, imeko edibeneyo) kunye ne-316L ye-Stainless Steel zikhethwe ngenxa yokubaluleka kwazo kwizicelo ezifunwayo kunye neempawu ezicacileyo zomatshini.

Oomatshini:

I-5-Axis:DMG MORI DMU 65 monoBLOCK (Heidenhain TNC 640 ulawulo).

3-Axis:I-HAAS VF-4SS (ulawulo lwe-HAAS NGC).

izixhobo:Izingqusho eziqinileyo ezigqunywe ngecarbide (iidayamitha ezahlukeneyo, impumlo yebhola, kunye nesiphelo esicaba) ezisuka eKennametal naseSandvik Coromant zisetyenziselwe ukurhabaxa nokugqiba. Iiparamitha zokusika (isantya, ukondla, ubunzulu bokusika) zalungiswa ngokwezinto eziphathekayo kunye namandla omatshini kusetyenziswa iingcebiso zomenzi wesixhobo kunye nokucuthwa kovavanyo olulawulwayo.

Ukusebenza:Isiko, izilungiso zeemodyuli ezenziwe ngoomatshini ziqinisekise ukubanjwa okuqinileyo kunye nendawo ephindaphindwayo kuzo zombini iindidi zoomatshini. Kulingo lwe-3-axis, iinxalenye ezifuna ujikelezo zibekwe ngokutsha kusetyenziswa iidowels ezichanekileyo, zilinganisa ukuziqhelanisa nomgangatho wevenkile. Ulingo lwe-5-axis lusebenzise isakhono esipheleleyo sokujikeleza komatshini ngaphakathi kolungiselelo olulodwa.

2.3 Ukufunyanwa kweDatha noHlahlelo

Ixesha lomjikelo:Ilinganiswe ngokuthe ngqo kwizibali-xesha zoomatshini.

Uburhabaxa boMphezulu (Ra):Ukulinganiswa kusetyenziswa i-Mitutoyo Surftest SJ-410 iprofilometer kwiindawo ezintlanu ezibalulekileyo ngenxalenye nganye. Amalungu amathathu ayenziwe ngoomatshini ngokwezinto eziphathekayo/ukudityaniswa komatshini.

Ukuchaneka kweJiyometri:Iskenwe kusetyenziswa iZeiss CONTURA G2 yokulungelelanisa umatshini wokulinganisa (CMM). Imilinganiselo ebalulekileyo kunye nokunyamezelana kwejometri (i-flatness, i-perpendicularity, iprofayili) yathelekiswa nemizekelo ye-CAD.

Uhlalutyo lweenkcukacha-manani:Amaxabiso e-avareji kunye nokutenxa ngokwemigangatho kubalwe ixesha lomjikelo kunye nemilinganiselo yeRa. Idatha ye-CMM yahlaziywa ukutenxa kwimilinganiselo yokulinganisa kunye nemilinganiselo yokuthotyelwa kokunyamezela.

Itheyibhile 1: IsiShwankathelo sokuSeta loMfuniselo

3. Iziphumo & Uhlalutyo
3.1 Iinzuzo zobuchule
I-5-axis machining ibonise ukonga ixesha elininzi. Kwi-titanium impeller, i-5-axis processing yanciphisa ixesha lokujikeleza nge-58% xa kuthelekiswa ne-3-axis machining (iiyure ze-2.1 vs. 5.0 iiyure). I-stainless steel turbine blade ibonise ukunciphisa kwe-42% (iiyure ze-1.8 vs. 3.1 iiyure). Ezi nzuzo zibangelwa ikakhulu ekupheliseni ukusetwa okuninzi kunye nokuphatha ngesandla/ukulungisa ixesha elihambelanayo, kunye nokwenza iindlela zesixhobo ezisebenza ngokufanelekileyo nezineendlela ezinde, eziqhubekayo ngenxa yokuqhelaniswa nesixhobo.

3.2 UPhuculo loMgangatho woMphezulu
Uburhabaxa bomphezulu (Ra) buphuculwe ngokuqhubekayo ngomatshini we-5-axis. Kwimiphezulu yeblade entsonkothileyo yesishukumisi setitanium, umndilili wamaxabiso eRa ehle ngama-32% (0.8 µm vs. 1.18 µm). Uphuculo olufanayo lubonwe kwiblayidi yeinjini yentsimbi (i-Ra yancitshiswa ngama-35%, i-avareji ye-0.65 µm vs. 1.0 µm). Olu phuculo lubangelwa kukukwazi ukugcina i-angle yoqhagamshelwano ethe gqolo, eyiyeyona ilungileyo kunye nokunciphisa ukungcangcazela kwesixhobo ngokusebenzisa ukuqina kwesixhobo esingcono kwizandiso ezimfutshane zesixhobo.

3.3 Ukwandiswa kokuChaneka kweJiyometri
Uhlalutyo lwe-CMM luqinisekisile ukuchaneka kwejometri ephezulu kunye ne-5-axis processing. Ipesenti yeempawu ezibalulekileyo ezigcinwe ngaphakathi kokunyamezela okungqongqo ± 0.025mm kunyuke kakhulu: nge-30% ye-titanium impeller (ukufumana i-92% yokuthotyelwa kwe-92% kunye ne-62%) kunye ne-26% ye-blade yensimbi engenasici (ukufumana i-89% yokuthotyelwa kwe-63%). Olu phuculo luvela ngokuthe ngqo ekupheliseni iimpazamo eziqokelelweyo eziveliswe ngokuseta ezininzi kunye nokubekwa ngokutsha kwencwadana okufunekayo kwinkqubo ye-3-axis. Iimpawu ezifuna ii-engile ezidityanisiweyo zibonise eyona nzuzo imangalisayo yokuchaneka.

*Umzobo 1: Iimetriki zokuSebenza ngokuthelekisayo (5-Axis vs. 3-Axis)*

4. Ingxoxo
Iziphumo ziseka ngokucacileyo iingenelo zobugcisa ze-5-axis machining yeendawo eziyinkimbinkimbi zentsimbi yesiko. Ukunciphisa okubalulekileyo kwixesha lomjikelo kuguqulela ngokuthe ngqo kwiindleko eziphantsi kwinxalenye nganye kunye nokwanda kwamandla okuvelisa. Ukugqitywa komphezulu ophuculweyo kunciphisa okanye kuphelisa imisebenzi yokugqiba okwesibini njengokupolisha kwezandla, ukuthoba ngakumbi iindleko kunye namaxesha okukhokela ngelixa uphucula ukuhambelana kwenxalenye. Ukutsiba kokuchaneka kwejometri kubaluleke kakhulu kwizicelo ezisebenza ngokuphezulu njengeenjini ze-aerospace okanye izifakelo zonyango, apho umsebenzi wenxalenye kunye nokhuseleko zibaluleke kakhulu.

Ezi zibonelelo zivela ngokuyintloko kwisakhono esingundoqo se-5-axis machining: intshukumo ngaxeshanye ye-multi-axis ivumela ukusetwa okukodwa. Oku kuphelisa iimpazamo ezibangelwa ukusetha kunye nexesha lokuphatha. Ngaphaya koko, ukuqhelaniswa nesixhobo esiqhubekayo (ukugcina umthwalo wetshiphu ofanelekileyo kunye namandla okusika) kwandisa ukugqitywa komphezulu kwaye kuvumela amaqhinga omatshini abukhali ngakumbi apho ubungqongqo besixhobo buvumela, igalelo kwinzuzo yesantya.

Nangona kunjalo, ukwamkelwa okusebenzayo kufuna ukuvuma imida. Utyalo-mali oluyinkunzi kumatshini ohamba ne-5-axis kunye nezixhobo ezifanelekileyo ziphezulu kakhulu kunezixhobo ze-3-axis. Ukuntsonkotha kweprogram kuyanda kakhulu; ukuvelisa iindlela zesixhobo ezisebenza kakuhle, ezingangqubaniyo ezi-5 zifuna abadwelisi benkqubo beCAM abanezakhono eziphezulu kunye nesoftware entsonkothileyo. Ukulinganisa kunye nokuqinisekisa kuba ngamanyathelo anyanzelekileyo phambi komatshini. Ukulungiswa kufuneka kubonelele ngokungqongqo kunye nokukhutshwa okwaneleyo kohambo olujikelezayo olupheleleyo. Ezi zinto ziphakamisa umgangatho wezakhono ezifunekayo kubaqhubi kunye nabadwelisi beprogram.

Intsingiselo esebenzayo icacile: i-5-axis machining igqwesa kwixabiso eliphezulu, amacandelo anzima apho iinzuzo zayo ngesantya, umgangatho, kunye nokukwazi ukuthethelela ukusebenza okuphezulu kunye notyalo-mali. Kwiindawo ezilula, i-3-axis machining ihlala inoqoqosho ngakumbi. Impumelelo ixhomekeke kutyalo-mali kuzo zombini itekhnoloji kunye nabasebenzi abanezakhono, kunye ne-CAM eyomeleleyo kunye nezixhobo zokulinganisa. Intsebenziswano kwangethuba phakathi koyilo, ubunjineli bokuvelisa, kunye nevenkile yomatshini ibalulekile ukuze kuxhaswe ngokupheleleyo amandla e-5-axis ngelixa kuyilwa iinxalenye zokwenziwa kwezinto (DFM).

5. Isiphelo
I-5-axis ye-CNC ye-machining yanamhlanje ibonelela ngesisombululo esibalaseleyo sokwenza izinto ezintsonkothileyo, ezichanekileyo eziphezulu zentsimbi yesiko xa kuthelekiswa neendlela zemveli ze-3-axis. Iziphumo eziphambili ziqinisekisa:

Ukusebenza okuBalulekileyo:Ukunciphisa ixesha lomjikelo we-40-60% ngokucwangciswa komatshini omnye kunye neendlela eziphuculweyo zezixhobo.

Umgangatho owomeleziweyo:Uburhabaxa bomphezulu (Ra) buphuculwe ukuya kuthi ga kwi-35% ngenxa yesixhobo sokuqhelanisa kunye noqhagamshelwano.

Ukuchaneka okuPhezulu:Umyinge we-28% yokunyuka kokubamba ukunyamezela kwejometri ebalulekileyo ngaphakathi kwe-± 0.025mm, ukuphelisa iimpazamo kwii-setups ezininzi.
Itekhnoloji yenza kube lula ukuveliswa kweejiyometri ezintsonkothileyo (imingxuma enzulu, i-undercuts, i-curves egobileyo) engenakwenzeka okanye engenakwenzeka ngomatshini we-3-axis machining, ukujongana ngqo neemfuno eziguqukayo ze-aerospace, amacandelo ezonyango, kunye namandla.

Ukwandisa imbuyekezo kwi-investment kwi-5-axis capability, abavelisi kufuneka bagxininise kwi-high-complexity, iindawo zexabiso eliphezulu apho ukuchaneka kunye nexesha elihamba phambili zizinto ezibalulekileyo zokukhuphisana. Umsebenzi wexesha elizayo kufuneka uhlolisise ukudityaniswa kwe-5-axis machining kunye ne-process metrology yokulawula umgangatho wexesha langempela kunye ne-closed-loop machining, ngakumbi ukuphucula ukuchaneka kunye nokunciphisa i-scrap. Uphando oluqhubekayo kwizicwangciso ze-machine eziguquguqukayo ezixhasa ukuguquguquka kwe-5-axis kwizinto ezinzima-kumatshini ezifana ne-Inconel okanye iintsimbi eziqiniweyo nazo zibonisa ulwalathiso oluxabisekileyo.