Ƙarfe na Musamman na Ƙarfe tare da Machining 5-Axis

Ƙarfe na Musamman na Ƙarfe tare da Machining 5-Axis

Marubuci:PFT, Shenzhen

Takaitawa:Masana'antu na ci gaba suna buƙatar ƙara haɗaɗɗiya, ingantattun abubuwan ƙarfe na ƙarfe a cikin sararin samaniya, likitanci, da sassan makamashi. Wannan bincike yana ƙididdige iyawar sarrafa mashin ɗin kwamfuta na zamani 5-axis (CNC) wajen biyan waɗannan buƙatun. Amfani da alamar geometries wakilin hadaddun impellers da turbine ruwan wukake, machining gwajin da aka kwatanta kwatanta 5-axis da na gargajiya 3-axis hanyoyin a kan Aerospace-grade titanium (Ti-6Al-4V) da bakin karfe (316L). Sakamako yana nuna raguwar 40-60% a cikin lokacin injina da haɓakar yanayin ƙasa (Ra) har zuwa 35% tare da sarrafa axis 5, wanda aka danganta ga raguwar saiti da ingantaccen daidaitawar kayan aiki. Daidaiton Geometric don fasali tsakanin ± 0.025mm haƙuri ya ƙaru da 28% akan matsakaita. Yayin da ake buƙatar ƙwarewar shirye-shirye na gaba da saka hannun jari, 5-axis machining yana ba da damar samar da ingantaccen tsarin geometries na baya wanda ba zai yuwu ba tare da inganci da ƙarewa. Waɗannan iyawar suna sanya fasahar axis 5 azaman mahimmanci don ƙima mai ƙima, ƙirƙira ɓangaren ƙarfe na al'ada.

1. Gabatarwa
Tufafin da ba ya dawwama don haɓaka aiki a cikin masana'antu kamar sararin samaniya (neman sassauƙa, sassa masu ƙarfi), likitanci (na buƙatar abin da ya dace, takamaiman majinyata), da kuzari (buƙatar hadaddun abubuwan sarrafa ruwa) ya tura iyakoki na sarkar ƙarfe. 3-axis CNC machining na al'ada, ƙuntatawa ta hanyar iyakantaccen damar kayan aiki da saitin da ake buƙata da yawa, gwagwarmaya tare da ƙugiya mai ma'ana, rami mai zurfi, da fasalulluka waɗanda ke buƙatar kusurwoyi masu fa'ida. Waɗannan iyakoki suna haifar da ƙayyadaddun daidaito, tsawaita lokacin samarwa, farashi mafi girma, da ƙuntatawa ƙira. Zuwa shekarar 2025, ikon kera hadaddun, madaidaicin sassa na karfe da inganci ba kayan alatu bane amma gasa dole ne. CNC 5-axis na zamani, yana ba da ikon sarrafa gatura guda uku (X, Y, Z) da gatari biyu na juyawa (A, B ko C), yana ba da mafita mai canzawa. Wannan fasaha yana ba da damar kayan aikin yanke don kusanci aikin aiki daga kusan kowane shugabanci a cikin saitin guda ɗaya, da gaske yana shawo kan iyakokin damar shiga cikin mashin ɗin 3-axis. Wannan labarin yana nazarin ƙayyadaddun iyawa, ƙididdige fa'idodi, da la'akari da aiwatar da aiwatarwa na 5-axis machining don samar da ɓangaren ƙarfe na al'ada.

2. Hanyoyi
2.1 Tsare-tsare & Tsara
An ƙirƙira sassan ma'auni guda biyu ta amfani da software na Siemens NX CAD, wanda ke tattare da ƙalubalen gama gari a masana'antar al'ada:

Mai rugujewa:Yana nuna hadaddun, igiyoyi masu murɗaɗɗe tare da madaidaicin al'amari mai girma da tsattsauran sharewa.

Turbine Blade:Haɗa madaidaitan lanƙwasa, ganuwar sirara, da madaidaicin filaye masu hawa.
Waɗannan ƙira-ƙira da gangan sun haɗa ɓangarori, aljihu mai zurfi, da fasalulluka waɗanda ke buƙatar samun damar kayan aikin da ba na orthogonal ba, musamman maƙasudin iyakokin 3-axis machining.

2.2 Kayayyaki & Kayan aiki

Kayayyaki:Titanium-grade Aerospace (Ti-6Al-4V, annealed condition) da 316L Bakin Karfe an zaɓi don dacewarsu cikin buƙatun aikace-aikace da takamaiman halaye na inji.

Injina:

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

3-Axis:HAAS VF-4SS (HAAS NGC iko).

Kayan aiki:An yi amfani da injina na ƙarshen ƙarfe mai ƙarfi (diamita daban-daban, hanci-hanci, da lebur-ƙarshen) daga Kennametal da Sandvik Coromant don yin roughing da ƙarewa. Yanke sigogi (gudun, ciyarwa, zurfin yanke) an inganta su ta kowane abu da ƙarfin injin ta amfani da shawarwarin masana'antun kayan aiki da yanke gwajin sarrafawa.

Yin aiki:Na al'ada, daidaitattun kayan gyara na'ura sun tabbatar da matsananciyar matsawa da wuri mai maimaitawa don nau'ikan injin biyu. Don gwaje-gwajen axis 3, sassan da ke buƙatar juyawa an sake sanya su da hannu ta amfani da madaidaicin dowels, suna yin kwaikwayon al'adar bene na shago. Gwaje-gwajen axis 5 sun yi amfani da cikakken ikon jujjuyawar injin a cikin saitin kayan aiki guda ɗaya.

2.3 Samun Bayanai & Bincike

Lokacin Zagayowar:An auna kai tsaye daga masu ƙidayar na'ura.

Tashin Lafiya (Ra):An auna ta amfani da mitutoyo Surftest SJ-410 profilometer a wurare biyar masu mahimmanci kowane bangare. An ƙera sassa uku a kowane haɗin kayan / inji.

Daidaiton Geometric:Ana dubawa ta amfani da na'ura mai daidaitawa ta Zeiss CONTURA G2 (CMM). An kwatanta ma'auni mai mahimmanci da juriya na geometric (lalata, daidaituwa, bayanin martaba) akan ƙirar CAD.

Binciken Kididdiga:An ƙididdige matsakaicin ƙima da daidaitattun sabani don lokacin zagayowar da ma'aunin Ra. An yi nazarin bayanan CMM don karkacewa daga ƙima mai ƙima da ƙimar yarda da haƙuri.

Tebur 1: Takaitacciyar Saitin Gwaji

3. Sakamako & Nazari
3.1 Nagartar Ƙarfafawa
5-axis machining ya nuna babban tanadin lokaci. Don impeller titanium, 5-axis aiki ya rage lokacin sake zagayowar da 58% idan aka kwatanta da 3-axis machining (2.1 hours vs. 5.0 hours). Gilashin turbine na bakin karfe ya nuna raguwar 42% (1.8 hours vs. 3.1 hours). Waɗannan nasarorin da farko sun samo asali ne daga kawar da saiti da yawa da haɗin gwiwar hannu/sake gyara lokaci, da kuma ba da damar ingantattun hanyoyin kayan aiki tare da tsayin daka, ci gaba da yanke saboda ingantaccen daidaitawar kayan aiki.

3.2 Ingantacciyar Ingantaccen Tsarin Sama
Tsawon saman (Ra) ya inganta akai-akai tare da injinan axis 5. A kan hadaddun ruwan wukake na impeller titanium, matsakaiciyar ƙimar Ra ta ragu da 32% (0.8 µm vs. 1.18 µm). An ga irin wannan haɓakawa akan injin turbine na bakin karfe (Raguwa ya ragu da 35%, matsakaicin 0.65 µm vs. 1.0 µm). Ana danganta wannan haɓakawa ga ikon kula da tsayin daka, madaidaicin tsinke kusurwar lamba da rage girgiza kayan aiki ta mafi kyawun rigidity na kayan aiki a cikin gajeriyar kari na kayan aiki.

3.3 Haɓaka Daidaitaccen Geometric
Binciken CMM ya tabbatar da ingantaccen daidaiton geometric tare da sarrafa axis 5. Adadin mahimman abubuwan da aka gudanar a cikin stringent ± 0.025mm haƙuri ya karu sosai: ta 30% don impeller titanium (cimmakon 92% yarda da 62%) da 26% don bakin karfe (cimma 89% yarda vs. 63%). Wannan haɓakawa ya samo asali ne kai tsaye daga kawar da kurakurai masu tarawa waɗanda aka gabatar ta hanyar saiti da yawa da sake sanyawa na hannu da ake buƙata a cikin tsarin axis 3. Siffofin da ke buƙatar kusurwoyi masu haɗaɗɗiya sun nuna mafi girman samun daidaiton daidaito.

*Hoto na 1: Ma'aunin Aiki na Kwatancen (5-Axis vs. 3-Axis)*

4. Tattaunawa
Sakamakon ya tabbatar da fa'idodin fasaha na 5-axis machining don sassan ƙarfe na al'ada. Mahimman raguwa a lokacin sake zagayowar yana fassara kai tsaye zuwa ƙananan farashin kowane ɓangare da ƙara ƙarfin samarwa. Ingantacciyar ƙarewar saman yana rage ko kawar da ayyukan gamawa na biyu kamar goge hannu, ƙara rage farashi da lokutan jagora yayin haɓaka daidaiton sashi. Tsalle cikin daidaiton geometric yana da mahimmanci don aikace-aikacen ayyuka masu girma kamar injinan sararin samaniya ko na'urorin dasa shuki, inda aikin sashi da aminci ke da mahimmanci.

Waɗannan fa'idodin da farko sun taso ne daga ainihin iyawar 5-axis machining: motsi na axis da yawa na lokaci guda yana ba da damar sarrafa saiti ɗaya. Wannan yana kawar da kurakurai da aka haifar da saitin da lokacin gudanarwa. Bugu da ƙari kuma, ci gaba da mafi kyawun daidaitawar kayan aiki (cire madaidaicin nauyin guntu da yanke runduna) yana haɓaka ƙarewar ƙasa kuma yana ba da damar ƙarin dabarun sarrafa kayan aiki inda ƙarfin kayan aiki ya ba da izini, yana ba da gudummawa ga samun saurin sauri.

Koyaya, tallafi na zahiri yana buƙatar yarda da iyakoki. Babban jari don injin axis 5 mai iya aiki da kayan aiki masu dacewa ya fi na kayan aikin axis 3. Matsalolin shirye-shirye yana ƙaruwa sosai; samar da ingantaccen, hanyoyin kayan aikin axis 5 mara- karo yana buƙatar ƙwararrun masu shirye-shiryen CAM da ƙwararrun software. Kwaikwayo da tabbatarwa sun zama matakan dole kafin yin injin. Gyara dole ne ya samar da duka biyun tsayuwa da isasshiyar izini don cikakken tafiye-tafiyen juyi. Waɗannan abubuwan suna haɓaka matakin ƙwarewar da ake buƙata don masu aiki da masu shirye-shirye.

Ma'anar aiki a bayyane yake: 5-axis machining ya ƙware don ƙima mai ƙima, hadaddun abubuwan haɗin gwiwa inda fa'idodinsa cikin sauri, inganci, da iyawa ke tabbatar da mafi girman aiki da saka hannun jari. Don mafi sauƙi sassa, 3-axis machining ya kasance mafi tattali. Nasarar ta ta'allaka ne akan saka hannun jari a cikin fasaha da ƙwararrun ma'aikata, tare da ƙwararrun CAM da kayan aikin kwaikwayo. Haɗin kai na farko tsakanin ƙira, injiniyoyin masana'anta, da kantin injin yana da mahimmanci don haɓaka ƙarfin axis 5 gabaɗaya yayin ƙirar sassa don ƙira (DFM).

5. Kammalawa
5-axis CNC machining na zamani yana ba da ingantaccen bayani mai mahimmanci don masana'anta hadaddun, madaidaicin sassa na ƙarfe na al'ada idan aka kwatanta da hanyoyin 3-axis na gargajiya. Babban binciken ya tabbatar:

Mahimman Ƙarfi:Rage lokacin zagaye na 40-60% ta hanyar injin saiti guda ɗaya da ingantattun hanyoyin kayan aiki.

Ingantacciyar inganci:Haɓaka ƙaƙƙarfan saman (Ra) har zuwa 35% saboda ingantacciyar daidaitawar kayan aiki da lamba.

Mafi Girma Daidai:Matsakaicin haɓaka 28% a cikin riƙon juriyar juzu'i mai mahimmanci tsakanin ± 0.025mm, kawar da kurakurai daga saiti da yawa.
Fasahar tana ba da damar samar da ingantattun geometries (zurfafa cavities, undercuts, mahadi masu lankwasa) waɗanda ba su da amfani ko kuma ba za su yiwu ba tare da mashin ɗin 3-axis, kai tsaye magance buƙatun buƙatun sararin samaniya, likitanci, da sassan makamashi.

Don haɓaka dawowa kan saka hannun jari a cikin iyawar 5-axis, masana'antun yakamata su mai da hankali kan haɓaka mai ƙarfi, sassa masu ƙima inda daidaito da lokacin jagora sune mahimman abubuwan gasa. Ayyukan da ke gaba ya kamata su bincika haɗin gwiwar 5-axis machining tare da tsarin tsarin aiki don sarrafa ingancin lokaci na ainihi da kuma rufe madaidaicin machining, ƙara haɓaka daidaito da rage raguwa. Ci gaba da bincike kan dabarun sarrafa kayan aiki masu daidaitawa wanda ke ba da damar sassaucin axis 5 don kayan aiki masu wahala-zuwa injin kamar Inconel ko taurin ƙarfe shima yana ba da jagora mai mahimmanci.