Uma uzwa 'imishini enembayo ephezulu', into yokuqala engena emakhanda abantu abaningi inombolo. Singakwazi ukubamba ukubekezelelana kuye kumayintshi angu-±0.001 noma Imishini yethu iyakwazi ukunemba kwe-sub-micron. Leyo yinkulumo yencwajana ecwebezelayo. Indaba yangempela, leyo ebalulekile esitezi sesitolo, iqala ngemva kokuthenga i-axis eyisigidi samadola. CNC imishini isikhungo. Yilapho ufunda ukunemba akukhona nje mayelana neshidi lomshini; yiketango. Iketango lokulawula izinga lokushisa, ukuguga kwamathuluzi, ukuqina kwe-fixture, ukuziphatha okubalulekile, kanye, ngokungananazi, nomuzwa womsebenzisi. Izitolo eziningi, ikakhulukazi lezo ezigxuma zisuka kokujwayelekile ziye emsebenzini 'wokunemba okuphezulu', ziyaphuthelwa lokho. Bacabanga ukuthi umshini wenza wonke umsebenzi. Leyo ithrekhi esheshayo eya kwezilahliwe ezibizayo.
Isisekelo: Akuyona nje i-CNC
Ngikubone izikhathi eziningi kakhulu. Isitolo sithola isikhungo semishini esisha, esisezingeni eliphezulu, sishaya ibhulokhi engu-304 etafuleni, futhi silindele ukuqedwa kwesibuko nokubhoreka okuhle. Bese bebiza ngezinkinga zokudlidliza noma ukukhukhuleka okushisayo. Umbuzo wokuqala engiwubuzayo manje awuphathelene nokudla kwabo kanye nesivinini; kumayelana nesisekelo sabo. Ngokwezwi nezwi. Ingabe iphansi liyi-monolithic slab ehlukanisiwe kwezinye izitshalo? Ngezinga lomsebenzi esiwenzayo endaweni yethu, njengamajiyometri ayinkimbinkimbi ezingxenyeni zamavalvu avela kuma-alloy akhethekile, ngisho neforklift ehamba ngamafithi angu-50 ingakwazi ukwethula ukundindizela okubonisa njengophawu lwengxoxo engu-0.0002. Awukwazi ukukuhlela lokho.
Bese kuba nesimo sezulu. Ukugijima a high ukunemba machining iseli lifana nokusebenzisa ilebhu ye-metrology. Sigcina indawo elawulwayo, ±2°F uma singakusiza. I-Aluminium nensimbi ziyakhula futhi zincipha ngaphezu kwalokho obungacabanga ngosuku. Uma uqala umsebenzi ekuseni uma kungu-68°F futhi uqedele ubukhulu obubalulekile emini uma kungu-74°F eduze kwewindi, ulahlekelwe ukunemba kwakho. Ngezibonelo zethu zokutshala izimali ezidinga ukwenziwa komshini kokugcina, lokhu akuxoxiswana ngakho. Ingxenye isivele idlule ku-wax, igobolondo, kanye nenqubo yokuthulula; ukuyikruqula esigabeni sokugcina se-CNC ngenxa yamazinga okushisa kuwukubhoboza kwamathumbu.
Futhi tooling. Yilapho umuzwa ungena khona. Ungaba ne-spindle engcono kakhulu eyenziwe e-Swiss, kodwa uma usebenzisa i-generic end mill emgqonyeni wenqwaba, khohlwa. Sithola amathuluzi akhethekile, anameka wezinto ezahlukene. Ukwenza i-alloy esekelwe ku-nickel njenge-Inconel isilwane esihlukile uma siqhathaniswa nensimbi ye-carbon. I-geometry yethuluzi, i-coating (i-AlTiN vs. TiAlN), isibalo somtshingo—konke kubalulekile ekuqedeni ukushisa nokuphuma kwe-chip. Ithuluzi eligugile alivezi nje isiphetho esibi; kusebenzisa ukushisa nokucindezela okwengeziwe, kusonta ingxenye nge-microscope. Ungase usabekezelelana, kodwa ukucindezeleka okuyinsalela kuzokuluma ngokuhamba kwesikhathi ngesikhathi somhlangano. Sifunde lokhu kabuhlungu eqeqebeni lezinto zokufakelwa kwezokwelapha ze-cobalt-chrome.
Inkumbulo Ebalulekile kanye Nomdanso Wemishini
Lena i-nuance ehlukanisa abenzi bezingxenye kusukela konjiniyela abanembile. Izinto zokwakha zinenkumbulo. Ama-castings, isinkwa sethu nebhotela e-Qingdao Qiangsenyuan Technology Co., Ltd. (QSY), kuyizibonelo eziyinhloko. Ukwakhiwa kwesikhunta segobolondo noma ukufakwa kwe-investimenti kuza emnyangweni we-CNC nokucindezeleka okungokwemvelo, okukhiyiwe kusukela kunqubo yokupholisa. Uma uvele uyibambe phansi bese uqala ukukhipha izinto ngobudlova, ukhulula lokho kucindezeleka ngokungalingani. Ingxenye izonyakaza, ngezinye izikhathi ngokuphawulekayo, khona kanye etafuleni.
Inqubo esiyithuthukisile, ngemva kwamaqoqo ambalwa ahlulekile kusenesikhathi, iwumdanso wokudlula okulula nokulandelana kwamasu. Singase sithathe ukusakaza, senze i-op enzima ukuze sifinyelele ku-0.050, bese siyiqaqa, siyikhulule, siyikhulule kuhhavini, bese siyilungisa kabusha ukuze iqedele kancane. Ngemuva kwalokho sizoya kowamanqamu, high ukunemba machining uyadlula. Yengeza izinyathelo, yengeza isikhathi, kodwa iyona ndlela kuphela yokuqinisekisa ukuzinza. Lokhu kubaluleke kakhulu ezigabeni ezinezindonga ezincane ezivamile ezingxenyeni ze-aerospace esike sizibambe. Iphutha lakudala ukujaha ukuphelela ekusetheni okukodwa; ngezinye izikhathi, kufanele uvumele ingxenye izinze phakathi kwezenzo.
I-Fixturing iyindlela yayo yobuciko. Okwengxenye eyinkimbinkimbi, e-asymmetrical investment-cast, ukudizayina okuqinile okunikeza ukusekela okuqinile ngaphandle kokunciphisa ukuhlanekezela kwe-clamping kuyindida. Sivamise ukusebenzisa amasistimu e-modular fixture kanye nemihlathi ethambile efakwe endaweni-okusho ukuthi sishicilela amaphrofayili emihlathi emshinini ofanayo ozokwenza ingxenye, okuqinisekisa ukuvumelana okuphelele. Isikhathi sokuqala sokutshala imali esikhokha kuwo wonke umsebenzi wokukhiqiza. Ngikhumbula iphrojekthi yendlu yephampu yasolwandle ngensimbi engagqwali eyi-duplex lapho idizayini yokuqala yokulungisa idale umnsalo ongu-0.0015. Kubonakale ku-CMM kuphela ngemuva kweqiniso. Sidizayine kabusha ukuze sisekele iwebhu yangaphakathi ngesikhathi somshini, okuxazulule. Ipulani ayizange isho lokho; isipiliyoni sakwenza.
I-Metrology Feedback Loop
Awukwazi ukulawula lokho ongakwazi ukukukala, kodwa futhi awukwazi ukuvumela ukulinganisa kukukhubaze. Umgomo awukona ukukala zonke izici kuzo zonke izingxenye—lokho akusimame. Umgomo uwukusungula iluphu yempendulo ethembekile phakathi komshini nedivayisi yokulinganisa. Izikena zethu ze-CMM kanye ne-laser akuzona nje ezokuhlola okokugcina; bangamathuluzi okuthuthukisa inqubo.
Uma sithola ingxenye entsha yomndeni, isho uchungechunge olusha lwemizimba yamavalvu ensimbi engagqwali yeklayenti, sizosebenzisa inqubo ye-athikili yokuqala esetshenziswa kakhulu. Umshini izingxenye ezinhlanu. Ngemuva kwawo wonke umsebenzi omkhulu, zilinganise. Hhayi nje ubukhulu obubalulekile, kodwa futhi bheka amaphethini—ingabe zonke izingxenye zikhukhuleka ku-Z-axis ngenani elingaguquki? Ingabe ikhona i-taper ku-bore ephakamisa ukuchezuka kwamathuluzi? Leyo datha ibuyela emuva kumhleli we-CNC. Singase silungise i-offset yamathuluzi, sishintshe ukuhleleka kokusebenza, noma sengeze i-spring pass. Le loop iguqula umshini usuke kumenzi wefa ongaboni ube uhlelo lokufunda. I CNC imishini inqubo iba ozinzile futhi ibikezelwe.
Kodwa kukhona ugibe lapha: ukuthembela ngokweqile ekufundweni kwedijithali. Ngezinye izikhathi, umuzwa ubalulekile. Umakhi wemishini onolwazi osebenzisa iphasi yokuqedela ku-titanium alloy angakwazi ukuzwa umehluko phakathi kokusikwa okubushelelezi naleyo eqala ukuxoxa. Uyakwazi ukubona umbala we-chip kanye nesakhiwo. Leyo mpendulo ethintekayo isheshayo. Ukulinda umbiko we-CMM ngemuva kwamahora amabili sekwephuze kakhulu. Ngakho siyabhalansisa. Umsebenzisi womshini unesethi yama-micrometer alinganisiwe namageji abhorekile esiteshini sakhe ukuze ahlolwe ngaphakathi kwenqubo yobukhulu obuyinhloko. Yileyo nhlanganisela yokunemba kwedijithali kanye ne-analog intuition egcina ikhwalithi iphezulu futhi iphansi.
Lapho Ukunemba Kuhlangabezana Nezinqubo Zefa
Umlando wenkampani yethu, eminyakeni engaphezu kwengu-30 ekulingiseni nasekukhiqizeni imishini, uletha inselele nenzuzo eyingqayizivele. Inselele ukuhlanganisa yesimanje high ukunemba machining okulindelwe ngezinqubo ze-legacy foundry. Ukukhishwa kwe-investimenti kungase kube kuhle, kodwa indawo yayo yedatha ingase ingafaneli kahle i-vacuum chuck ye-CNC. Kuye kwadingeka sisebenzele emuva ngezinye izikhathi, sisebenzisana nethimba lethu labasunguli ukuze siguqule idizayini yokulingisa kancane—sengeza isikhwama esincane samathuluzi, sicaba indawo engaphezulu ngokwanele ukubamba—ukuyenza ikwazi ukubekezelela izimo zesimanjemanje. Kuyingxoxo yangaphakathi phakathi kobuciko bokulingisa nesayensi yokwenza imishini.
Nokho, inzuzo iwulwazi olujulile lwezinto ezibonakalayo. Uma iklayenti lisithumelela umdwebo wengxenye ku-Monel noma ku-Hastelloy, asifundi nje ishidi lezinto ezibonakalayo. I-Foundry yethu ibilokhu ithulula lawa ma-alloys akhethekile amashumi eminyaka. Siyazi ukuthi ziziphatha kanjani ngesikhathi sokuqina, lapho i-porosity ingase ifihle khona, ukuthi isabela kanjani ekushiseni. Lokhu kwazisa isu lethu lomshini ngokushesha. Siyazi ukuthi u-Hastelloy usebenza kanzima njengohlanya, ngakho-ke sizohlelela amathuluzi abukhali, ukusebenzelana okungaguquki, futhi singalinge sivumele ithuluzi ukuthi lihlikihle. Lolo hlobo lokuqonda alukho ebhukwini lezandla ezijwayelekile; yinkumbulo yesikhungo. Kusivumela ukuthi sicaphune futhi senze imisebenzi eyinkimbinkimbi isitolo semishini esingase siyigweme.
Lokhu kusebenzisana yikho esikusebenzisa ku-QSY. Ikhasimende lingeza nomqondo, futhi singaliqondisa ekukhetheni izinto (kusuka ensimbini esakazwayo kuye kuma-alloys asekelwe ku-nickel), siye enqubweni efanele yokusakaza (isikhunta segobolondo sokugijima okukhudlwana, ukutshalwa kwezimali kobumo obuyinkimbinkimbi), futhi ekugcineni ngokusebenzisa CNC imishini inqubo eyenzelwe leyo nto kanye nejiyomethri ethile. Ukunemba akuwona umcabango osemuva; yakhelwe uchungechunge lokukhiqiza kusukela ekuqaleni. Leyo incazelo yangempela yokunemba okuphezulu kwengqikithi yokukhiqiza ehlanganisiwe. Akuwona umnyango; kuyifilosofi esukela ekukhunjweni kokuqala kuya ekukhishweni kokugcina.
Izindleko Zangempela Zokunemba Okuphezulu
Ekugcineni, iqiniso elimsulwa. Ukunemba okuphezulu kuyabiza, futhi kufanele kube njalo. Kubiza ngekhephithali (imishini, ukulawulwa kwesimo sezulu, i-metrology), ezintweni ezisetshenziswayo (amathuluzi akhethekile, okokupholisa ikhwalithi ephezulu), futhi ngaphezu kwakho konke, ngesikhathi nangobungcweti. Isikhathi somjikelezo sengxenye yokunemba sihlala siside. Kukhona ukusetha okwengeziwe, ukuhlola okwengeziwe, ukuphakela okunensayo kanye nesivinini sokugcina ubuqotho bendawo nokuzinza kobukhulu.
Sithola imibuzo ngaso sonke isikhathi lapho umthengi efuna ukubekezelelwa kwebanga le-aerospace ngamanani wempahla. Ukungafani. Iwebhusayithi yethu, i-tsingtaocnc.com, ibeka amakhono ethu ngokucacile, kodwa ingxoxo elandelayo imayelana nemfundo. Sichaza ukuthi kungani ukubamba indawo yeqiniso engu-0.0002 kumabhore amathathu ahlanganayo ekubunjweni kwensimbi engagqwali engu-17-4 PH kudinga izinyathelo ezithile futhi, ngakho-ke, izindleko ezithile. Kwesinye isikhathi, size seluleke iklayenti ukuthi lixegise ukubekezelelana uma kungasebenzi ngendlela ebucayi—kungalilondoloza u-30% engxenyeni yezindleko. Ukuba nguphathina kusho ukuthi kwesinye isikhathi ubatshela lokho abangakudingi, okwakha ukwethembana kunokuthembisa okungenzeki.
Ekugcineni, ukunemba okuphezulu kuwukuzibophezela. Kuwukuzibophezela ekulawuleni okuguquguqukayo wonke umuntu akuzibayo, ekutshaleni imali olwazini njengakuhardware, kanye nokuqonda ukuthi inombolo ephelele esikrinini iwumphumela wezinqumo eziyikhulu ezingaphelele, ezenziwe umuntu ezenziwa phansi esitolo. Kuyaxaka, kuyaphindaphinda, futhi kuyanelisa ngokujulile uma kuhlangene. Yilokho ngempela okukhokhelayo.
