Madaidaicin hanyoyin masana'antar injin injin lantarki ba sa farawa da ƙayyadaddun kayan aiki - suna farawa da ɓangaren da * ba zai yanke ba *, * ba zai riƙe haƙuri ba *, ko * ba zai tsira cikin sabis ba*. Mun gani akai-akai: cobalt-nickel famfo gidaje masu fashewa a karkashin 300-bar hawan keke; AMS 5387 nozzles gazawar maimaita juzu'i bayan maganin zafi; T800 alloy center shaft rollers sanye da rashin daidaituwa a cikin sa'o'in aiki 200. Waɗannan ba lahani ba ne na masana'anta. Waɗannan su ne rashin daidaituwa na tsarin kayan abu-kuma suna kashe lokaci, guntu, da aminci.
Lokacin da Injini na Al'ada Ya Kai Iyakarsa, Madaidaicin Mashin Injin Electrochemical Matakan Shiga ciki
Mashin ɗin lantarki (ECM) ba shine "mafi kyawun CNC ba." Yana da wani tushe daban-daban na tushen tsarin kimiyyar lissafi-mara lamba, babu kayan aiki, damuwa na inji. Wannan yana da mahimmanci lokacin da kuke cire abubuwa daga tauraruwar superalloys kamar cobalt-chrome ko bambance-bambancen Inconel na tushen nickel inda milling na gargajiya ke haifar da ƙananan fashe-fashe, burrs, ko raguwar damuwa a saman. A wurin aikinmu na yarda da ISO a cikin Qingdao, muna amfani da ECM ba a matsayin aiki kaɗai ba - amma a matsayin wanda aka yi niyya, haɗaɗɗen bayani a cikin cikakken madaidaicin aikin ɓangaren ƙarfe. Muna amfani da shi don gama mahimmin kwatancen ciki a kan gidaje na silinda na piston inda masana'antun ƙarshen ba za su iya isa ba, don lalata kujerun bawul masu matsa lamba ba tare da canza kiran GD&T ba, kuma don cimma daidaiton kauri na bango na ± 0.01 mm a cikin 360 ° na jujjuyawar winch cibiyar shaft abin nadi-wani abu na niƙa don yin kwafi a cikin tsari.
Amma ga abin da yawancin masu siye ke watsi da su: Nasarar ECM ya dogara da ƙasa akan injin kuma ƙari akan abubuwan da aka haɗa guda uku - ƙirar lantarki, amincin ƙirar cathode, da ikon sarrafa yawa na yanzu. Wani kuskuren cathode yana haifar da taper; Electrolyte wanda ba a busasshensa yana jujjuyawa pH kuma yana lalata saman ƙasa; saurin gudu mara daidaituwa yana haifar da rami na cikin gida. Muna tabbatar da kowane saitin akan ainihin sassan abokin ciniki - ba gwajin takardun shaida ba. Misali, lokacin da OEM na'ura mai aiki da karfin ruwa ta Turai tana buƙatar nisan ramin 0.05 mm mai maimaitawa a cikin matosai na AMS 5387, mun gudanar da gwaje-gwajen juzu'i guda 12 tare da ƙayyadaddun ƙididdiga da ƙirar ƙira-ba kawai CMM sikanin ba — don kulle cikin zafin lantarki, ƙimar ƙarfin lantarki, da tazarar tsakanin-electrode kafin fara samarwa.
Me yasa Haɗin Kai Tsaye Ya doke Shagunan "ECM-kawai" don Sassan Mahimmanci
Wasu dillalai suna siyar da ECM azaman sabis. Mun shigar da shi a cikin simintin-zuwa-ƙare ayyukan aiki-saboda babbar gazawar ECM ta faru *kafin* ɓangaren ya taɓa wankan lantarki. Rashin ƙarancin simintin simintin gyare-gyare? Porosity kusa da mahimmin farfajiyar hatimi? Rashin daidaituwar ƙwayar hatsi a cikin T800 gami? Waɗannan kurakuran suna haɓaka yayin ECM, ba ɓoye ba. Shi ya sa madaidaicin masana'antar injin ɗin mu na lantarki ke aiki a ƙarƙashin rufin rufin ɗaya tare da simintin saka hannun jari, CNC mai yawan axis, da ingantaccen magani mai zafi. Muna sarrafa dukan sarkar: albarkatun albarkatun kasa (dukkan cobalt-nickel gami da aka samo su tare da certs na niƙa), pre-machining stress cycles, da post-ECM passivation ko electropolissh wanda aka keɓance don juriya na lalata aiki-ba kawai kayan kwalliya ba.
Muna kuma ɗaukar GD&T ba azaman takarda ba-amma azaman taswirar ƙayyadaddun injin. Lokacin yin bitar zane-zane don bawul ɗin matsa lamba, muna ba da tuta a yankuna inda matsananciyar haƙurin bayanan martaba (misali, 0.02 mm UZ) ya ci karo da ma'anar gefen ECM mai yuwuwa. Maimakon kin amincewa da bugu, muna ba da shawarar hanyoyin haɗin gwiwar: injin-m tare da CNC, sannan ECM na 0.15 mm na ƙarshe don buga tsari na gaskiya da amincin saman. Wannan yana yanke lokacin sake zagayowar da kashi 37% tare da duk-ECM yayin saduwa da buƙatun ASME B16.34.
Tabbatar da Gaskiyar Duniya: Abin da ke Aiki (kuma Abin da Ba Ya Yi)
Abokan cinikinmu suna yin tambayoyi guda uku kafin ƙaddamar da ECM:
- "Za ku iya riƙe ± 0.005 mm akan diamita na 200 mm diamita?" Ee-idan sashin lissafi yana ba da izinin kwararar lantarki iri ɗaya kuma an daidaita cathode da ƙarfi. Muna yin wannan kullun akan tushen famfo don aikace-aikacen mai da iskar gas.
- "Mene ne mafi ƙarancin girman fasalin da kuka dogara da shi ke samarwa?" 0.12 mm ramummuka a cikin cobalt alloy nozzles, wanda aka tabbatar tare da metrology na SEM-ba tsinkayar gani ba.
- "Shin kuna goyan bayan allunan da ba daidai ba kamar T800?" Ee. Amma muna buƙatar cikakken tsarin sinadari da tarihin maganin zafi na kafin. Idan ba tare da wannan ba, gyare-gyaren sunadarai na electrolyte ya zama abin zato-da raguwar farashin hawan.
Mun ƙi kashi 11% na farkon RFQs-ba saboda gibin iyawa ba, amma saboda juzu'in juzu'i ko yanayin kayan abu yana sa ECM ya zama mara amfani. Zai fi kyau a ce "a'a" da wuri fiye da sadar da sashin da ya wuce dubawa amma ya gaza a gwajin filin.
Neman Gaba: Madaidaicin Ba A tsaye ba—Haka Ba Tsarin Mu Ba
Haƙiƙa daidaitaccen ƙarfin injin injin lantarki na nufin haɓakawa sama da daidaiton girma zuwa daidaita aikin aiki. A yanzu, muna cancantar sigogin pulsed-ECM don ingantattun kaifi a kan bayanan bayanan tushen turbine - da haɗa na'urori masu auna firikwensin layi don daidaita kwararar wutar lantarki ta atomatik yayin tafiyar dogon zagayowar. Har ila yau, muna faɗaɗa shaidar NADCAP na ɓangare na uku don ƙayyadaddun tsari na ECM, ba kawai yarda da ingancin gabaɗaya ba. Domin a cikin sassa kamar na'urorin lantarki na sararin samaniya ko famfo na ruwa, ba a auna "daidaici" a cikin microns kadai. Ana auna shi a cikin tsaka-tsakin lokaci tsakanin gazawar. A lokacin aiki. A cikin amana.
Idan aikinku na gaba ya ƙunshi abubuwan haɗin cobalt-nickel, tsarin bawul ɗin matsa lamba, ko al'ada superalloy geometries inda hanyoyin al'ada plateau-daidai electrochemical machining factory dole ne a ƙware gwaninta tun daga rana ta ɗaya. Ba a ƙara shi azaman tunani ba.
