Xa abantu abaninzi besiva 'umatshini ochanekileyo', bacinga kwangoko ngonyamezelo oluqinileyo, mhlawumbi ±0.001 okanye ngaphantsi, kunye nokucwebezela, ukugqibezela okungenasiphako. Leyo yinguqulelo yencwadana. Inyaniso, intsingiselo yemihla ngemihla, kukuba ukubetha loo manani sisiqingatha sedabi-isiqingatha esilula, ngokunyanisekileyo. Owona mceli mngeni kukwenza inxalenye engalinganisi nje ngokufanelekileyo kwi-CMM kodwa iphinda isebenze ngokugqibeleleyo phantsi komthwalo, kwiqondo lobushushu, okanye emva kwemijikelo eyiwaka. Ndibone imizobo emininzi kakhulu apho injineli ichaze unyamezelo oluqina ngakumbi kunokuba luyimfuneko, luqhuba ixabiso linyuke ngama-300% ngenzuzo eyithiyori kuphela. Akukhona nje malunga nekhono lomatshini; imalunga nokuqonda into ekufuneka yenziwe yinxalenye. Kulapho amashumi eminyaka okuphatha izinto ezahlukeneyo, ukusuka kwintsimbi elula ukuya kwi-nightmarish cobalt-based alloys, ihlawula. Uqala ukuphuhlisa ukuvakalelwa kukuba isinyithi sifuna ukwenza ntoni, apho sinokuphuma khona, okanye indlela udonga olubhityileyo olunokuthi luncokole ngayo kungakhathaliseki ukuba indlela yakho yesixhobo igqibelele kangakanani.
Isiseko: Iqala ngokuCasa
Awunakho ukuchaneka komatshini kwi-casting embi. Lo ngumgibe wokuqala kwaye uxhaphake kakhulu. Ndiye ndafumana abathengi basithumelele ushicilelo lwecandelo elintsonkothileyo, befuna ukuchaneka kwenqanaba le-micron kulo lonke uphawu, kodwa ukuphosa ekrwada abakunikezelayo kugcwele amabala aqinileyo, ukushwabana kwe-porosity, okanye ukutyeba okungangqinelaniyo eludongeni. Lidabi eloyiswa kwasekuqaleni. Indlela yethu ku Qingdao Qiangsenyuan Technology Co., Ltd. (QSY) idityanisiwe kuba silawula umphambili. Ngaphezulu kweminyaka engama-30 kokubini ukuphosa kunye noomatshini, siyibona yonke inkqubo. Ngokomzekelo, xa sisenza iqokobhe ngundo ukuphosa okanye utyalo mali ngaphakathi endlini, sele sicwangcisa ukulungiswa komatshini. Sinokongeza isitokhwe esincinci kwindawo ebalulekileyo, kungekuphela nje ukucoca, kodwa ukuqinisekisa ukuba kukho izinto eziqinileyo, ezilinganayo zokuzibandakanya. Kuvakala kulula, kodwa olu lungelelwaniso luthintela i-90% yeentloko ezibuhlungu emva kwexesha.
Thatha umzimba wevalvu yecandelo leoli kunye negesi, elenziwe ngealloyi esekwe nickel. Ezi ngxubevange zinzima ngenkohlakalo kwizixhobo. Ukuba umphezulu we-as-cast unokufakwa kwesanti okanye ipokotho yerhasi kanye apho ufuna ubuso obugqibeleleyo bokutywina, uchitha indawo ebiza kakhulu. Ngokulawula lonke ikhonkco ukusuka kumgangatho we-Foundry ukuya kwi CNC Machining embindini, siyakwazi ukulungisa inkqubo yokugalela-njengokulungisa ubushushu bokugalela okanye ukhuko lokungunda-ukuvelisa i-workpiece engasondekanga nje ngokomda, kodwa isandi sesakhiwo somatshini. Ayingomlingo lo; ngamava abuhlungu ajike abe yinkqubo eqhelekileyo. Ufunda ukuba zeziphi iipateni ezithanda ukugqwetheka kwaye ubuyekeze kwisigaba soyilo lokungunda, ixesha elide ngaphambi kokuba i-chip yokuqala isikwe.
Kukho umahluko obonakalayo evenkileni. Ukuphosa okuvela kwinkqubo oyiqondayo kunye nokulawula inobuntu obuqikelelwayo kumatshini. Uyazi kakuhle ukuba iya kusabela njani kumandla okubamba, apho uxinzelelo olushiyekileyo lunokuzifihla khona. Ukuphosa kwangaphandle kuhlala kuyimfihlakalo de uqale ukusika. Kuye kwafuneka ukuba siphuhlise amaqhinga athile okubamba utyalo-mali olunodonga olucekethekileyo ukunqanda ukugqwetheka, ngamanye amaxesha sisebenzisa izixhaso ze-low-melt-point filler ngexesha lomatshini. Ezi ayizozisombululo zeencwadi; luhlobo lwamaqhinga owafumana emva kokukrazula amaqhekeza ambalwa kwaye uhlafunwa ngumphathi wemveliso.
Izinto eziphathekayo yiBoss
Thetha kunoma yimuphi umatshini ngetyuwa, kwaye baya kukuxelela: izinto eziphathekayo zilawula yonke into. Ukucwangcisa, ukukhetha izixhobo, isantya kunye nokutya, kunye neqhinga lokupholisa-konke kuphuma kwinto oyisikayo. Siqhuba i-gamut ukusuka intsimbi ukuya intsimbi engenasici nakwimimandla yangaphandle ye cobalt-based kwaye ialloys esekwe nickel. Usapho ngalunye luziphatha okwesilwanyana esahlukileyo.
Oomatshini bentsimbi erhubuluzayo kakuhle; iqhekeza iitshiphusi ezintle, ezimfutshane. 316 ingenastainless, kwelinye icala, ifuna ukusebenza nzima kwaye ifake itshungama yakho ukuba uthambile kakhulu. Kodwa ii-superalloys? Leyo yiligi eyahlukileyo. Azinzima nje; bagcina amandla abo kumaqondo aphezulu, oku kuthetha ukuba balwa nesixhobo sokusika yonke indlela. Ubushushu abungeni kwitshiphu; ingena kwisixhobo, ekhokelela kwicratering ekhawulezileyo kunye nokusilela. Kwangoko, satshisa nge-fortune encinci kwi-carbide end mills sizama umatshini we-Monel component usebenzisa iiparitha ezisebenzela i-alloy steel. Isandi sasiphosakele—isandi esiphakamileyo endaweni ye-hum engaguqukiyo. Ukusilela kucwangciso; sasiyiphatha njengenye intsimbi eqinileyo. Ngoku, siyazi ukuba ifuna izixhobo ezikhethekileyo, ezibukhali, ezipholisiweyo, isantya esisezantsi sokusika, i-high-pressure coolant ejoliswe ngqo kumda wokusika, kunye nokuseta okungqongqo kakhulu. Nayiphi na incoko iya kusibulala ngokukhawuleza isixhobo.
Olu lwazi lwezinto eziphathekayo lwazisa ngokuthe ngqo inkqubo yethu kwi QSY. Kwiprojekthi ebandakanya ubushushu obuphezulu be-cobalt alloy turbine seal, khange sivele sicaphule umatshini. Saqala ngenkomfa yezinto eziphathekayo. Leliphi ibakala? Bubuphi ubunzima bayo obuqhelekileyo bokuphosa? Ngaba bekukho imiba eyaziwayo ngemvula ye-carbide kwimida yeenkozo? Eli nqanaba leenkcukacha limisela ukuba umsebenzi unenzuzo okanye unobungozi. Sinokude siqhube ikhuphoni elincinane lovavanyo kuqala ukucofa iiparamitha phambi kokuba uchukumise eyona ndlela yokusasa. Iyacotha ngaphambili, kodwa ikhusela inkunkuma eyintlekele, engafumanekiyo kamva.
Inkohliso yomatshini ogqibeleleyo
Kukho intsomi egqubayo yokuba ukuthenga iziko elitsha kraca, elinesigidi seedola ezine-axis machining zisombulula zonke. ngokuchanekileyo machining iingxaki. Sisixhobo esimangalisayo, kodwa sisixhobo nje. Ndikhe ndabona iivenkile ezinoomatshini abadala, abacothayo zivelisa amacandelo angaguqukiyo, akumgangatho ophezulu kunevenkile eselumelwaneni enazo zonke izixhobo zamva nje. Ngoba? Ngenxa yokuba iqela liyayiqonda i-quirks yomatshini wabo. Bayazi ukuba i-Z-axis kumatshini 3 inokukhula okuncinci kwe-thermal emva kweeyure ezimbini zexesha lokusebenza, ngoko bayayibuyekeza. Banobuchule bokusebenza kumacandelo abo athile.
Ukuchaneka kwangempela kuvela kwinkqubo, kungekhona nje i-spindle. Kukuko ekulinganisweni kweprobe, ukucoceka kwetaper yesibambi, ukuzinza kwebhloko yesiseko, kunye nolawulo lokusingqongileyo evenkileni. Ukutshintsha kweqondo lobushushu le-10 degrees Fahrenheit ngaphezulu kokutshintsha kunokuphosa imilinganiselo kwindawo enkulu. Oku sikufunde kabuhlungu ngokwenza isitena esikhulu senjini yedizili. Imilinganiselo ethathwe ngentsasa epholileyo yayidlula, kodwa iitshekhi ezifanayo kubushushu basemva kwemini zaziphumile. Inxalenye ngokwayo yayisanda. Kuye kwafuneka siphumeze ummandla wokuhlola olawulwa yimozulu size sivumele iinxalenye ukuba zibe kwimeko yesiqhelo kwiqondo lobushushu eliqhelekileyo ngaphambi kokuba sityikitye okokugqibela.
Ngaphaya koko, i-automation yazisa eyayo eyahlukileyo. Indawo yokulayisha ingalo yerobhothi inokwazisa ulungelelwaniso olungaguqukiyo lwe-0.0002 ukuba ayidityaniswanga ngokugqibeleleyo. Ukusukela ukuchaneka kuyimfazwe eqhubekayo ngokuchasene nesigidi esiguquguqukayo esincinci. Umatshini ngomnye wabo. Kwiziko lethu, sichitha ixesha elininzi kwi-metrology kunye nolawulo lwenkqubo njengoko sisenza ekusikeni okwenyani. Ngumsebenzi ongathandekiyo, osemva kwe-scenes owenza ukunyamezelana okukhanyayo kwenzeke.
Xa Ukulunga Kwanele Kugqibelele
Oku kunokuvakala njengenkohliso, kodwa inqanaba eliphezulu le ngokuchanekileyo machining Ubuchule kukwazi ukuba ungaleqi nini ukuchaneka ngokupheleleyo. Ukubambelela ngobumfama kuzo zonke iindawo ezikushicilelo kunokuba yinkcitho enkulu yexesha kunye nemali. Umlinganiselo osebenzayo-njengendawo yokunyuka komngxuma oza kusebenzisa iwasha kunye nebholithi-akufuneki ukuba ubanjwe kwishumi (.0001). Ukuyibamba kumawaka amabini (.002) kukholisa ukuba ngaphezu kokwaneleyo kwaye kunokufezekiswa ngokupasa okunye endaweni yesithathu.
Ixabiso lokwenyani esilinikayo njengeqabane, onokulibona kwimbali yeprojekthi https://www.tsingtaocnc.com, ikulolu hlobo lwexabiso lobunjineli. Umxhasi weza kuthi enenxalenye yelifa-i-hydraulic manifold-eyayisoloko isenziwa ngoomatshini ukuze kunyanyezelwe ngokumangalisayo kuwo wonke umhlaba. Yayibiza kwaye inexesha elide lokuhamba. Sibuze ngomsebenzi wayo. Kwavela iidayamitha ezintathu kuphela kwaye ukutywinwa kobuso obuthe tyaba kwakubaluleke ngokwenene kuxinzelelo lwemfezeko. Sicebise ukukhulula ukunyamezela kwiimpawu zangaphandle ezingasebenziyo kunye nepateni yomngxuma webholithi. Umxhasi wayethandabuza kodwa wavuma ukuba kuqhutywe ityala. Inxalenye iqhutywe ngokufanayo ekuvavanyeni, kodwa iindleko zehla nge-40% kwaye ixesha lomatshini lanqunyulwa phakathi. Asizange siyenze ibe mandundu; siyenze yakrelekrele.
Oku kufuna ukuzithemba kunye nengxoxo enzulu kunye neenjineli zabathengi. Imalunga nokutshintsha ugxininiso ukusuka ekwenzeni ushicilelo ukuya ekusombululeni ingxaki. Ngamanye amaxesha, esona sisombululo sichanekileyo silula ngokulula esingahlawulisi imida yetekhnoloji. Imalunga nokusebenzisa umzamo apho ibalulekileyo.
Umba woLuntu kwiNkqubo yeDijithali
Ngaphandle kwayo yonke i-CAD/CAM, i-automation, kunye ne-propinging engaphakathi, iliso lomatshini onobuchule kunye ne-intuition ayinakubuyiselwa. Isikrini sinokubonisa indlela yesixhobo egqibeleleyo, kodwa asiluva utshintsho kwisandi xa isixhobo siqala ukuba buthuntu okanye xa itshiphu ingaphumi kakuhle. Ayikuboni ukuguquka kwebala okuncinci kwitshiphu ebonisa ukuba uvelisa ubushushu obuninzi kakhulu kwisikiwe.
Ndikhumbula umsebenzi wokulungisa i-impeller entsonkothileyo ngentsimbi engatyiwayo. Olu cwangciso lwaqinisekiswa, izixhobo zokusebenza zazintsha, kodwa kwicandelo lokuqala, ukugqiba kwindawo egobileyo kwakuyoyikeka—izaliswe ziincoko. Isoftware ye-CAM yenze i-stepover efanayo ngokugqibeleleyo, kodwa ukutshintsha i-angle yokuzibandakanya kuloo contour yayibangela ukungcangcazela. Umdwelisi wenkqubo, isandla esidala, akazange atshintshe nje isantya kunye nokutya. Wajonga inxalenye, wabona ukubandakanyeka kwe-cutter, kwaye wayihlela ngesandla indlela yesixhobo ukuhluka i-stepover kunye nokwazisa ukugqithwa okuncinci kwindawo eyingxaki. Yayingesosisombululo sencwadi; yayisisisombululo sobugcisa. Isoftware yodwa ayikwazanga ukufumanisa oko; kwathatha umntu oqondayo zombini i-physics yokusika kunye nejometri yenxalenye.
Le yinkcubeko esizama ukuyigcina. Oomatshini kunye nesoftware zizixhobo ezandisa amandla ethu, kodwa azithathi ndawo isigwebo. Itshekhi yokugqibela isoloko ingumntu one-micrometer, umvavanyi wokugqiba umphezulu, kunye neminyaka yamava esazi ukuba inxalenye elungileyo ibonakala kwaye ivakalelwa njani. Loo nto ibambekayo, i-sensory feedback loop iseyeyona nto iphambili yokutshekisha i-QC, ngakumbi kwiindibano ezinzima apho kufanelekile kwaye ziziva zibalulekile njengamanani. Ngulo mxube wetekhnoloji kunye nobuchule bobugcisa obuchaza inyani ngokuchanekileyo machining, ukuguqula ukuphosa okukrwada kube yinto ethembekileyo, esebenzayo.
