Uma uzwa 'i-ultra precision machining', abantu abaningi bavele bafanekisele igumbi elihlanzekile, elilawulwa izinga lokushisa elinomshini onama-axis amaningi ukhala. Lokho kuyingxenye yakho, impela, kodwa futhi yilapho umbono oyiphutha ovamile uqala khona. Akukhona nje nge-nameplate yomshini noma ukulungiswa kwawo kwethiyori. Inselele yangempela, ingxenye ekugcina uphapheme ebusuku, ibambe lokho kubekezelela kwe-sub-micron hhayi kubhulokhi yokuhlola ye-aluminium ephelele, kodwa engxenyeni ye-Inconel 718 eqinile, engalingani ngemuva kocezu lwama-30, lapho i-thermal drift, ukuguga kwamathuluzi, ngisho nezinga lokushisa lesipholisi liqala ukuhlebela endlebeni yakho. Leso igebe phakathi kwe-spec sheet kanye nesitezi sesitolo. Ngibone amaphrojekthi amaningi kakhulu ekhubeka ngokuwuphatha njengento elula 'yokuthenga umshini ongcono kakhulu, thola izingxenye ezihamba phambili' isibalo. Iwuhlelo, isiyalo, futhi ngokungagwegwesi, ubuciko obuncane.
Isisekelo: Siqala Ngaphambi Kokuphenduka Kwe-spindle
Awukwazi ukukhuluma ngakho ukunemba kwe-ultra machining ngaphandle kokuthi uqale ukhulume ngalokho okufaka emshinini. Yilapho amashumi eminyaka okuhlangenwe nakho okubalulekile eba okungaxoxiswana khona. Sisebenza ngama-superalloy amaningi asuselwa ku-nickel kanye ne-cobalt endaweni yethu. Lawa akuwona amabhulokhi akho ajwayelekile angu-304. Inqubo yokulingisa—noma ngabe isikhunta segobolondo noma ukulingisa utshalomali esikwenzayo—ibeka isiteji. Ukucindezelwa kwangaphakathi, ukwakheka okusanhlamvu, ngisho ne-porosity encane evela ekubunjweni kungase kube amaphutha amakhulu uma uthatha amaphasi akalwa ngama-microns. Uhlelo oluphelele lwe-CNC alunamsebenzi uma okungenalutho kunokungezwani okufihlekile okukhulula i-mid-cut. Ngakho-ke, umthetho wethu wokuqala ukuphatha inqubo yokwenza imishini njengesinyathelo sokugcina, esibucayi ochungechungeni olude kakhulu. I-Foundry kanye nesitolo semishini akukwazi ukuba yizisele; kufanele bakhulume ulimi olufanayo lomlando oshisayo nokunciphisa ukucindezeleka.
Ngikhumbula iphrojekthi yendlu yezinzwa e-Monel K-500. Amaphrinti adinga ukubekezelelana kweqiniso okungu-0.005mm kwezinye izibhobo ezijulile ezinobubanzi obuncane. Ukubukwa kwe-investimenti kwakubukeka kukuhle. Kodwa ngesikhathi sokuqaliswa kwesihloko sokuqala, saba nokukhukhuleka okungavamile. Hhayi okuningi, kodwa kwanele ukususa ingxenye. Ngemuva kwezinsuku ezimbili zokujaha i-geometry yomshini kanye nokuphela kwethuluzi, sibuyele emuva kudatha yokusakaza. Inkinga bekuwumjikelezo wokukhipha isisombululo. Ibingaguquguquki, kodwa ukulungiswa ngesikhathi sokuphathwa kokushisa kwadala ingcindezi yokuqondisa ngendlela elinganisekayo kodwa engaguquki. Ukulungiswa kwakungekho kukhodi ye-CNC; bekuyi-tweak ekucushweni kwama-racking esithandweni ngaphambi kokuba ukusakaza kubone ithuluzi lomshini. Lokho ukucabanga kwesistimu.
Yingakho isizinda senkampani sibalulekile. Isitolo esivele sithenge amabhilidi eshalofini singase singahlangabezane nalokhu, noma singachitha amasonto silungisa inkinga esingayidalanga. Indlela yethu edidiyelwe ku QSY—ukusebenzisa iminyaka engamashumi amathathu kukho kokubili ukulingisa kanye nokwenza imishini—kusho ukuthi silawula okuguquguqukayo okwengeziwe kusukela ekuncibilikeni kuye phambili. Kuncane mayelana nokulungisa izinkinga futhi kumayelana nokuklama inqubo ukuze uzigweme. Isu lomshini womzimba we-sand-cast ductile iron valve liwumhlaba ngaphandle kwalelo lengxenye yokuhlinza yensimbi engagqwali enembile, ngisho noma kunjalo. CNC imishini isikhungo sigijima zombili.
Umshini Ungumdlali Nje; Inqubo inguMqondisi
Kulungile, ngakho-ke unokungenalutho okuzinzile, okungabikezelwa. Manje umshini. Ukuthatheka kuhlala kukumodeli entsha, eshesha kakhulu, enembe kakhulu. Futhi ungangizwa kabi, isigayo se-axis esingu-5 sokunemba okuphezulu esinamamotho aqondile kanye nempendulo ye-sub-micron iyamangalisa. Kodwa kuyisimangaliso somoya. Umsebenzi wangempela usezinhlelweni ezisizayo kanye nokulawulwa kwemvelo. Isisekelo sakho sibaluleke ngaphezu kokucaciswa kwencwajana. Isisekelo se-monolithic granite asiyona into ewubukhazikhazi; kuyisidingo. Iphansi ehlezi kulo lidinga ukuhlukaniswa kusukela ekudlidlizeni okuzungezile—ama-forklift, eminye imishini, ngisho nokuhamba kwezimoto ngaphandle kungaba isici.
Bese kuba nezinga lokushisa. Umthetho wesithupha ukuthi ukuguqulwa okungu-1°C kumitha yensimbi cishe kungama-microns angu-11.5 wokunwetshwa. Lapho usebenza endaweni ukunemba okuphezulu izinga, intaba leyo. Sigcina imvilophu engu-±0.5°C kuseli yethu enembayo. Kodwa akuwona nje umoya wegumbi. Izinga lokushisa elipholile lilawulwa ngokuqhubekayo. I-spindle ifudunyezwa ngomjikelezo othize ukuze ifinyelele ukulingana kwe-thermal. Size sivumele izinto ezingavuthiwe zihlale esitokisini amahora angama-24 ukuze zibe ngokwejwayelekile. Awuyona nje imishini yokwenza insimbi; uphethe lonke iqiniso layo elishisayo.
I-Tooling ingenye imbobo kanogwaja. Izigayo zokuphela kwe-carbide ezingaphandle kweshalofu ngeke ziyinqume, kuhloswe i-pun. Sikhuluma ngezibambi zamathuluzi aphendulwe idayimane, abhalansile ku-G2.5 noma okungcono. I-presetter yamathuluzi ayiyona into enhle ukuba nayo; ukulinganisa kwayo kusemqoka njenge-CMM. Futhi isinxephezelo sokugqoka kwamathuluzi akuwona umcimbi ohleliwe; kuwukucatshangelwa okuqhubekayo, kwesikhathi sangempela okusekelwe ekuqaphelweni komthwalo ophothayo kanye nokuhlaziywa kokuqedwa kwendawo. Uthuthukisa umuzwa ngakho. Umsindo wokusikwa uyashintsha, cishe ngokungabonakali, ngaphambi kokuthi izinombolo eziseqapheni zikutshele. Leyo ingxenye 'yobuciko'—ukwazi ukuthi uyithemba nini inzwa nokuthi uyithembe nini amathumbu akho, okuyiminyaka nje yokuqashelwa kwephethini.
Isilinganiso: Ijaji Elingathetheleli
Yilapho amaphupho ehlangana khona namaqiniso. Ungakholelwa impendulo yokuma komshini wakho konke okufunayo, kodwa ingxenye inhle kuphela nekhono lakho lokuyilinganisa. Ku ukunemba kwe-ultra machining, okokusebenza kwakho kwe-metrology kufanele kube ukuhleleka kobukhulu kunembe kakhudlwana kunokubekezelela okuqondiwe. I-CMM enokungaqiniseki okushiwo kwama-microns angu-1.5 ayanele ukubamba izici ezingu-5-micron. Sithembela kakhulu kuzifanisi zokubona ngokuskena nge-laser futhi senze abahloli bejometri ebucayi njengendawo yangempela kanye nephrofayela yendawo.
Imvelo engiyishilo yokwenza imishini? Kuyiqiniso eliphindwe kabili ekukalweni. Igumbi le-CMM linezalo, izilawuli ezishisayo eziqinile. Uphatha izingxenye ngamagilavu, hhayi nje ukuze uvale uwoyela, kodwa ukuze uvimbele ukushisa komzimba wakho ukuba kungawahlanekezeli phakathi nomjikelezo wokulinganisa wemizuzu engu-15. Ngibone iphinikhodi ye-gauge engu-50mm yehluleke ngenxa yokuthi umhloli uyibambe ngesandla esingenalutho isikhathi eside kakhulu ngaphambi kokulinganisa.
Izifundo ezithobisa kakhulu zivela ekungavumelani kokulinganisa. Sake saba nezingxenye zokunqatshelwa kwekhasimende ngokusekelwe kudatha yabo ye-CMM yangaphakathi, kuyilapho eyethu yayibonisa kahle ngaphakathi kokucaciswa. Ngemuva kweviki lokushuba, sithole umsuka: ama-algorithms afanelekile ahlukile kumaphakheji wesofthiwe we-CMM wokusungula ifreyimu yereferensi yedatha. Zombili zazilungile ngokwezibalo, kodwa zahumusha indawo yomhlaba wangempela ngendlela ehlukile. Isixazululo kwakuwukuqondanisa kuphrothokholi yokulinganisa kuqala, ngaphambi kokuthi kunqunywe ingxenye eyodwa. Manje, ngemisebenzi ebalulekile, sivame ukwabelana ngezinhlelo zokulinganisa futhi sizifanise. Kwaphendula ukungqubuzana kwaba ukubambisana.
Lapho Ingasebenzi: Inani Lokuhluleka
Akekho othanda ukukhuluma nge-scrap, kodwa ekuphusheni imingcele yokunemba, ufunda okuningi ekwakhiweni kunempumelelo. Ekuqaleni, saqala umsebenzi esikhungweni socwaningo esidinga izibuko zethusi ze-beryllium ezinomphetho ongcono kune-nanometers engu-10Ra. Besicabanga ukuthi izinqubo zethu zidayiwe. Sehlulekile. Ngokumangalisayo. Le nto yayiyiphupho elibi—inobuthi, idinga ukuphathwa ngendlela ekhethekile, futhi yayinezinsinsi ngendlela emangalisayo. Amathuluzi ethu amahle edayimane alayishwa ngokushesha. Isipholisa, esasibalulekile ekulawuleni ukushisa, sashiya izinsalela ezacekela phansi isiphetho ngesikhathi sokuhlanza.
Leyo phrojekthi yayiyiphoyinti le-pivot. Asizange nje silahle ithemba. Kwadingeka sibuyele ezimisweni zokuqala. Sigcine sisebenzise uhlelo lwe- near-dry machining (MQL) lwaleso sigaba sezinto ezithile futhi sashintshela kwelinye ithuluzi ledayimane elinamathelayo. Impumelelo iqhamuke ekukhulumeni nomhlinzeki wamathuluzi onolwazi embonini ye-optical, hhayi i-aerospace yethu evamile noma abathintwayo bezokwelapha. Kwakuyisikhumbuzo lokho ukunemba kwe-ultra machining akusona isizinda esisodwa; amasu avela kuma-semiconductors, ama-optics, kanye nokwenza amawashi kungadlulisa impova. Leso sifundo esibuhlungu, esibizayo manje sikwazisa ukuthi sibhekana kanjani nazo zonke izinto ezingavamile, ezingase-gummy, kusukela kuma-alloys athile akhethekile kuya kumapulasitiki asebenza kahle kakhulu.
Isici Somuntu Kwinqubo Yedijithali
Ngayo yonke le nkulumo ye-automation nokulawulwa kwemvelo, kulula ukucabanga ukuthi indima yomsebenzisi inciphile. Ngizophikisa okuphambene. Isethi yamakhono iyashintsha, kodwa iba bucayi kakhulu. Umhleli akagcini nje ngokubhala ikhodi ye-G; bakha imodeli eshisayo ekhanda labo, balindele ukucindezeleka, abakhethi nje indlela yamathuluzi kodwa indlela yokushisa. Umsebenzisi womshini ungaphansi komciphi-zinkinobho futhi ungoqapha amasistimu, ubheka izimpawu ezicashile—ushintsho oluncane emsindweni wokugeleza okupholile, ukuhluka okuncane kombala we-chip—okubonisa ukuthi kukhona okuphuma kupharamitha.
Ngo I-Qingdao Qiangsenyuan Technology Co., Ltd. (QSY), lokhu kujula yilokho umlando wethu weminyaka engama-30 omayelana nakho. Kuwulwazi lwezizwe oluqoqiwe. Umakadebona wemishini okwazi ukulalela into yokuphotha futhi athi, Ukulayisha kuqala okufakwe ngaphambili kuzwakala kulula, ngaphambi kokuthi noma yikuphi ukuhlaziywa kokudlidliza kuhlabe umkhosi. Unjiniyela wekhwalithi owaziyo ukuthi izinto eziningi ezithile, ngisho nangaphansi kokucaciswa, zingase zidinge ukuncishiswa kwezinga lokuphakela ngo-5% ngokusekelwe kumuzwa wamathumbu ovela emsebenzini ofanayo eminyakeni emihlanu edlule. Lokhu akuthathi isayensi esikhundleni senkolelo-ze; kuwumqondo womuntu owakhelwe phezu kwesisekelo sokubuka okujulile, okuphindaphindayo. Awukwazi ukwenza lokho ngokuzenzakalelayo. Ungakwazi ukukuhlakulela kuphela ngesikhathi nokwethemba.
Ngakho-ke, uma sibheka umdwebo wengxenye eyinkimbinkimbi—ake sithi, i-cobalt-chrome alloy orthopedic implant enezindawo eziyizimbotshana zokuhlanganiswa kwamathambo eduze nendawo yokukhuluma eqedwe isibuko—asiboni nje amajiyometri nokubekezelelana. Sibona indaba. Sibona isihlahla sokutshala imali esizokhula kuso, ukusebenza kwe-EDM okuthambile ukusihlukanisa, ukwelashwa kokushisa okunezigaba eziningi, futhi ekugcineni, okuthambile, okokugcina. ukunemba kwe-ultra machining amaphasi azochaza umsebenzi wawo. Isinyathelo ngasinye sazisa esokugcina. Lokho kuyiqiniso ngemuva kwe-buzzword. Akukhona ukuhlinzwa okukodwa; kuyifilosofi yokulawula, kusukela empahleni engavuthiwe kuya embikweni wokugcina wokuhlola.
