Yadda ake Kula da Ruwan Yanke Aluminum CNC don Tsawon Rayuwar Kayan aiki da Swarf Mai Tsafta

 PFT, Shenzhen

Kula da mafi kyawun yanayin yankan ruwa na CNC na aluminum yana tasiri kai tsaye ga lalacewa da ingancin swarf. Wannan binciken yana kimanta ka'idojin sarrafa ruwa ta hanyar gwaje-gwajen injin sarrafawa da bincike na ruwa. Sakamako ya nuna cewa daidaiton pH saka idanu (kewayon manufa 8.5-9.2), kiyaye maida hankali tsakanin 7-9% ta amfani da refractometry, da aiwatar da tacewa dual-stage (40µm wanda ke biye da 10µm) yana haɓaka rayuwar kayan aiki ta matsakaicin 28% kuma rage swarf stickiness da 73% idan aka kwatanta da ruwan da ba a sarrafa ba. Tushen mai na yau da kullun (> 95% cirewar mako-mako) yana hana haɓakar ƙwayoyin cuta da rashin kwanciyar hankali. Gudanar da ruwa mai inganci yana rage farashin kayan aiki da rage lokacin injin.

1. Gabatarwa

CNC machining na aluminum yana buƙatar daidaito da inganci. Yanke ruwa yana da mahimmanci don sanyaya, mai, da fitar da guntu. Koyaya, lalatawar ruwa - lalacewa ta hanyar gurɓatawa, haɓakar ƙwayoyin cuta, ɗimbin ɗimbin yawa, da tarin mai - yana haɓaka lalata kayan aiki kuma yana daidaita kawar da swarf, yana haifar da ƙarin farashi da raguwar lokaci. Zuwa shekarar 2025, inganta aikin gyaran ruwa ya kasance babban kalubalen aiki. Wannan binciken yana ƙididdige tasirin ƙayyadaddun ƙa'idodin kulawa akan kayan aiki tsawon rayuwa da halayen swarf a cikin samar da CNC mai girma na aluminum.

2. Hanyoyi

2.1. Tsarin Gwaji & Tushen Bayanai
An gudanar da gwaje-gwajen mashin ɗin da aka sarrafa sama da makonni 12 akan injinan CNC iri ɗaya guda 5 (Haas VF-2) sarrafa 6061-T6 aluminum. An yi amfani da ruwa mai yankan roba (Brand X) a duk injuna. Na'ura ɗaya tana aiki azaman sarrafawa tare da daidaitaccen gyare-gyare, mai amsawa (yana canza ruwa kawai lokacin da ya lalace a bayyane). Sauran huɗun sun aiwatar da ƙa'idar da aka tsara:

• Hankali:Ana aunawa yau da kullun ta amfani da refractometer na dijital (Atago PAL-1), wanda aka daidaita zuwa 8% ± 1% tare da mai da hankali ko DI ruwa.

• pH:Kulawa yau da kullun ta amfani da mitar pH (Hanna HI98103), ana kiyaye shi tsakanin 8.5-9.2 ta amfani da abubuwan da aka yarda da masana'anta.

• Tace:Tace-mataki-biyu: Tacewar jakar 40µm sannan tacewar harsashi 10µm. Tace sun canza dangane da bambancin matsa lamba (≥ 5 psi karuwa).

• Cire Mai:Belt skimmer yana aiki akai-akai; Ana duba saman ruwa kowace rana, an tabbatar da ingancin skimmer kowane mako (> 95% burin cirewa).

• Ruwan Gyaran Jiki:Ruwan da aka riga aka haɗa kawai (a 8% maida hankali) wanda aka yi amfani da shi don ƙarawa.

2.2. Tarin Bayanai & Kayan aiki

• Kayan aiki:Flank wear (VBmax) wanda aka auna akan gefuna na farko na 3-flute carbide end Mills (Ø12mm) ta amfani da na'ura mai ƙira (Mitutoyo TM-505) bayan kowane sassa 25. An maye gurbin kayan aiki a VBmax = 0.3mm.

• Binciken Swarf:Swarf da aka tattara bayan kowane tsari. "Stikiness" wanda aka ƙididdige kan sikelin 1 (mai gudana kyauta, bushe) zuwa 5 (kumburi, maiko) ta masu aiki masu zaman kansu 3. Matsakaicin makin da aka rubuta. Ana bincika girman girman guntu lokaci-lokaci.

• Yanayin Ruwa:Samfurori na ruwa na mako-mako wanda wani dakin bincike mai zaman kansa ya bincika don ƙididdigar kwayan cuta (CFU/ml), abun cikin mai na tarko (%), da ƙaddamarwa/pH tabbaci.

• Lokacin Mashin:An yi rikodin don sauye-sauyen kayan aiki, matsi masu alaƙa da swarf, da ayyukan kiyaye ruwa.

3. Sakamako & Nazari

3.1. Tool Life Extension
Kayan aikin da ke aiki ƙarƙashin ƙa'idodin kulawa da aka tsara sun kai ƙididdiga mafi girma kafin a buƙaci musanyawa. Matsakaicin rayuwar kayan aiki ya karu da 28% (daga sassa 175 / kayan aiki a cikin sarrafawa zuwa sassa 224 / kayan aiki a ƙarƙashin yarjejeniya). Hoto na 1 yana kwatanta kwatankwacin ci gaba da lalacewa.

3.2. Swarf Ingantacciyar Inganta
Mahimman ƙima na Swarf sun nuna raguwa mai ban mamaki a ƙarƙashin ƙa'idar da aka gudanar, matsakaicin 1.8 idan aka kwatanta da 4.1 don sarrafawa (raguwa 73%). Ruwan da aka sarrafa ya samar da bushewa, ƙarin guntu mai ƙwanƙwasa (Hoto na 2), yana haɓaka ƙaura sosai da rage cunkoson inji. Rage lokacin da ke da alaƙa da lamuran swarf ya ragu da kashi 65%.

3.3. Kwanciyar Ruwa
Binciken Lab ya tabbatar da ingancin ka'idar:

• Ƙididdigar ƙwayoyin cuta sun kasance ƙasa da 10³ CFU/ml a cikin tsarin sarrafawa, yayin da sarrafa ya wuce 10⁶ CFU/ml ta mako na 6.

• Matsakaicin abun cikin mai na tramp <0.5% a cikin ruwan da aka sarrafa vs.> 3% a cikin sarrafawa.

• Tattaunawa da pH sun kasance barga a cikin jeri na manufa don sarrafa ruwa, yayin da kulawar ya nuna ɗimbin ɗigogi (ƙarfin hankali yana raguwa zuwa 5%, pH yana faɗuwa zuwa 7.8).

*Table 1: Maɓallai Masu Nuna Ayyukan Aiki - Gudanarwa vs. Ruwan Sarrafa*

4. Tattaunawa

4.1. Sakamako Tuki Makanikai
Abubuwan haɓakawa sun samo asali ne kai tsaye daga ayyukan kulawa:

• Tsayayyen Taro & pH:Tabbatar da daidaiton mai da hana lalata, kai tsaye yana rage lalacewa da lalacewa akan kayan aikin. Stable pH ya hana rushewar emulsifiers, kiyaye mutuncin ruwa da kuma hana "souring" wanda ke ƙara swarf adhesion.

• Tace mai inganci:Cire ƙaƙƙarfan barbashi na ƙarfe (swarf fines) ya rage lalacewa akan kayan aiki da kayan aiki. Ruwa mai tsafta kuma yana gudana da inganci don sanyaya da kuma wanke guntu.

• Kula da Mai:Man fetur na tramp (daga hanyar lube, ruwa mai ruwa) yana rushe emulsions, yana rage yawan sanyi, kuma yana samar da tushen abinci ga kwayoyin cuta. Cire shi yana da mahimmanci don hana bazuwar ruwa da kiyaye kwanciyar hankali, yana ba da gudummawa sosai ga swarf mai tsabta.

• Ciwon Kwayoyin cuta:Tsayar da maida hankali, pH, da kuma kawar da ƙwayoyin cuta masu fama da yunwa, hana acid da slime da suke samarwa wanda ke lalata aikin ruwa, kayan aikin lalata, da haifar da ƙamshi mai banƙyama/swarf.

4.2. Iyaka & Tasirin Aiki
Wannan binciken ya mayar da hankali kan takamaiman ruwa (Semi-synthetic) da aluminum gami (6061-T6) a ƙarƙashin sarrafawa amma yanayin samarwa na gaske. Sakamako na iya bambanta dan kadan tare da ruwaye daban-daban, gami, ko sigogin injina (misali, injina mai saurin gaske). Koyaya, ainihin ƙa'idodin sarrafa taro, kulawar pH, tacewa, da kawar da mai suna aiki a duk duniya.

• Kudin aiwatarwa:Yana buƙatar saka hannun jari a cikin kayan aikin sa ido (refractometer, pH mita), tsarin tacewa, da skimmers.

• Aiki:Yana buƙatar ladabtar duba kullun da daidaitawa ta masu aiki.

• ROI:Ƙarfafa 28% da aka nuna a cikin rayuwar kayan aiki da 65% raguwa a cikin raguwa da ke da alaka da swarf suna ba da kyakkyawar dawowa kan zuba jari, kashe farashin tsarin kulawa da kayan sarrafa ruwa. Rage mitar zubar da ruwa (saboda tsawon rayuwa) ƙarin ceto ne.

5. Kammalawa

Kula da ruwan yankan CNC na aluminum ba zaɓi bane don ingantaccen aiki; aiki ne mai mahimmanci. Wannan binciken ya nuna cewa ƙayyadaddun ƙa'idodin da ke mai da hankali kan maida hankali na yau da kullun da kulawar pH (manufa: 7-9%, pH 8.5-9.2), tacewa mai dual-mataki (40µm + 10µm), da cirewar mai mai ƙarfi (> 95%) yana ba da mahimmanci, fa'idodi masu aunawa:

1. Rayuwar Kayan Aiki:Matsakaicin haɓaka na 28%, rage farashin kayan aiki kai tsaye.

2. Swarf Mai Tsafta:73% raguwa a cikin mannewa, haɓaka ƙaurawar guntu da rage cunkoson injin / lokacin raguwa (rage 65%).

3. Tsayayyen Ruwa:Ci gaban ƙwayoyin cuta da kiyaye amincin emulsion.

Ya kamata masana'antu su ba da fifiko wajen aiwatar da shirye-shiryen sarrafa ruwa mai ladabtarwa. Bincike na gaba zai iya gano tasirin takamaiman fakitin ƙari a ƙarƙashin wannan ƙa'idar ko haɗin tsarin sa ido na ruwa na lokaci-lokaci mai sarrafa kansa.