Ukwenziwa Kwezingxenye Zensimbi Ngokwezifiso nge-5-Axis Machining
Ukwenziwa Kwezingxenye Zensimbi Ngokwezifiso nge-5-Axis Machining
Umbhali:PFT, Shenzhen
Abstract:Ukukhiqiza okuthuthukile kudinga izingxenye zensimbi eziyinkimbinkimbi, ezinemba kakhulu kuyo yonke imikhakha ye-aerospace, yezokwelapha, namandla. Lokhu kuhlaziya kuhlola amandla esimanjemanje wokulawula izinombolo zekhompuyutha ye-5-axis (CNC) ekuhlangabezaneni nalezi zidingo. Kusetshenziswa i-benchmark geometries emele ama-impeller ayinkimbinkimbi nama-turbine ama-turbine, ukuhlolwa komshini kwenziwa kuqhathaniswa nezindlela ze-axis ezi-5 ngokumelene ne-3-eksisi evamile ku-titanium yebanga le-aerospace (Ti-6Al-4V) nensimbi engagqwali (316L). Imiphumela ibonisa ukuncishiswa kuka-40-60% esikhathini somshini kanye nokuthuthukiswa kwe-surface roughness (Ra) kufika ku-35% ngokucubungula kwe-axis engu-5, okudalwe ukusetha okuncishisiwe kanye nokuma kwethuluzi okuthuthukisiwe. Ukunemba kwejiyomethri ezicini ezingaphakathi kokubekezelelana okungu-±0.025mm kukhuphuke ngo-28% ngokwesilinganiso. Ngenkathi idinga ubuchwepheshe obuphambili bokuhlela kanye nokutshalwa kwezimali, ukwenziwa kwemishini kwe-5-axis kunika amandla ukukhiqizwa okuthembekile kwamajometri ayengenzeki ngaphambilini asebenza kahle kakhulu futhi aqedele. Lawa makhono abeka ubuchwepheshe be-axis engu-5 njengento ebalulekile ekwenziweni kwengxenye yensimbi yangokwezifiso enenani eliphezulu, eyinkimbinkimbi.
1. Isingeniso
Umfutho ongapheli wokuthuthukisa ukusebenza kuzo zonke izimboni ezifana ne-aerospace (idinga izingxenye ezilula, eziqinile), ezokwelashwa (ezidinga izimila ezihambisana ne-biocompatible, eziqondene nesiguli), namandla (okudinga izingxenye eziyinkimbinkimbi zokubamba uketshezi) kweqe imingcele yobunkimbinkimbi bengxenye yensimbi. Imishini ye-CNC ye-3-eksisi evamile, evinjelwa ukufinyelela okulinganiselwe kwamathuluzi kanye nokusetha okuningi okudingekayo, idonsa kanzima ngamakhontosi ayinkimbinkimbi, imigodi ejulile, nezici ezidinga ama-engeli ahlanganisiwe. Le mikhawulo ibangela ukunemba okonakalisiwe, izikhathi zokukhiqiza ezandisiwe, izindleko eziphezulu, nemikhawulo yedizayini. Ngo-2025, amandla okwenza izingxenye zensimbi eziyinkimbinkimbi kakhulu, ezinembayo kahle akusaseyona into ewubukhazikhazi kodwa isidingo sokuncintisana. Imishini yesimanje ye-CNC ye-5-eksisi, enikeza ukulawula ngasikhathi sinye izimbazo eziqondile ezintathu (X, Y, Z) kanye nezimbazo ezimbili ezijikelezayo (A, B noma C), kuveza isisombululo soguquko. Lobu buchwepheshe buvumela ithuluzi lokusika ukuthi lisondele kucezu lokusebenza lisuka kunoma iyiphi indlela ekusetheni okukodwa, ngokuyisisekelo linqoba imikhawulo yokufinyelela etholakala kumishini ye-3-eksisi. Lesi sihloko sihlola amakhono athile, izinzuzo ezibaliwe, nokucatshangelwa kokusebenza okusebenzayo kwemishini ye-5-eksisi yokukhiqiza ingxenye yensimbi yangokwezifiso.
2. Izindlela
2.1 Ukudizayina kanye nokulinganisa
Izingxenye ezimbili zokuma zaklanywa kusetshenziswa isofthiwe ye-Siemens NX CAD, ehlanganisa izinselele ezivamile ekukhiqizeni ngokwezifiso:
I-Impeller:Ifaka ama-blade ayinkimbinkimbi, asontekile anokulingana okuphezulu nokucaciswa okuqinile.
I-Turbine Blade:Ihlanganisa ama-curvature ahlanganisiwe, izindonga ezincane, nezindawo zokukhweza ezinembayo.
Le miklamo ifake ngamabomu ama-undercuts, amaphakethe ajulile, nezici ezidinga ukufinyelela kwethuluzi elingelona i-orthogonal, eqondise ngokuqondile imikhawulo yomshini we-3-axis.
2.2 Izinto zokwakha nezisetshenziswa
Izinto zokwakha:I-Aerospace-grade Titanium (Ti-6Al-4V, isimo esihlanganisiwe) kanye ne-316L Stainless Steel zikhethiwe ngokuhambisana kwazo ekusetshenzisweni okudingayo nezici zomshini ezihlukile.
Imishini:
5-I-eksisi:DMG MORI DMU 65 monoBLOCK (Heidenhain TNC 640 control).
3-I-eksisi:I-HAAS VF-4SS (i-HAAS NGC control).
Amathuluzi:Izigayo eziqinile ezinamekwe ze-carbide (amadayamitha ahlukahlukene, ikhala lebhola, ne-flat-end) ezivela e-Kennametal nase-Sandvik Coromant zasetshenziselwa ukugoqa nokuqeda. Amapharamitha okusika (isivinini, okuphakelayo, ukujula kokusikwa) athuthukiswa ngamakhono wento ngayinye kanye nomshini kusetshenziswa izincomo zomkhiqizi wamathuluzi kanye nokusikeka kokuhlola okulawulwayo.
Ukusebenza:Ukulungiswa kwemodular okungokwezifiso, okwenziwe ngomshini ngokunembile kuqinisekise ukugoqa okuqinile kanye nendawo ephindaphindwayo kuzo zombili izinhlobo zemishini. Ocwaningweni lwe-3-eksisi, izingxenye ezidinga ukuzungezisa zabekwa kabusha kusetshenziswa amadowels anembayo, ezilingisa umkhuba ojwayelekile waphansi wesitolo. Ukuhlola kwama-axis angu-5 kusebenzise amandla omshini wokuzungeza agcwele ngaphakathi kokusetha okukodwa.
2.3 Ukutholwa Kwedatha Nokuhlaziywa
Isikhathi Somjikelezo:Kukalwa ngokuqondile ngezibali sikhathi zomshini.
Ukuma Kobuso (Ra):Kukalwa kusetshenziswa i-Mitutoyo Surftest SJ-410 profilometer ezindaweni ezinhlanu ezibalulekile ingxenye ngayinye. Izingxenye ezintathu zenziwe ngomshini ngenhlanganisela yezinto/umshini ngamunye.
Ukunemba Kwejiyomethri:Kuskenwe kusetshenziswa umshini wokulinganisa wokuhlanganisa we-Zeiss CONTURA G2 (CMM). Ubukhulu obubalulekile nokubekezelelana kwejiyomethri (i-flatness, perpendicularity, iphrofayili) kwaqhathaniswa namamodeli e-CAD.
Ukuhlaziywa Kwezibalo:Amanani amaphakathi nokuchezuka okujwayelekile kubalwe ngesikhathi somjikelezo kanye nezilinganiso zika-Ra. Idatha ye-CMM yahlaziywa ukuze ichezuke kubukhulu obujwayelekile kanye namazinga okuthobelana nokubekezelelana.
Ithebula 1: Isifinyezo Sokusetha Isilingo
| Isici | 5-Ukusethwa kwe-eksisi | 3-Ukusethwa kwe-eksisi |
|---|---|---|
| Umshini | I-DMG MORI DMU 65 monoBLOCK (5-Axis) | I-HAAS VF-4SS (3-Axis) |
| Ukulungisa | Ukulungiswa kwangokwezifiso okukodwa | Ukulungiswa kwangokwezifiso okukodwa + ukuzungezisa okwenziwa ngesandla |
| Inombolo Yokusetha | 1 | 3 (Impeller), 4 (Turbine Blade) |
| Isoftware ye-CAM | I-Siemens NX CAM (Izindlela zamathuluzi ze-Multi-eksisi) | I-Siemens NX CAM (izindlela zamathuluzi ezi-3-eksisi) |
| Isilinganiso | I-Mitutoyo SJ-410 (Ra), Zeiss CMM (Geo.) | I-Mitutoyo SJ-410 (Ra), Zeiss CMM (Geo.) |
3. Imiphumela & Ukuhlaziya
3.1 Izinzuzo Zokusebenza Ngekhono
Imishini ye-axis engu-5 ibonise ukonga isikhathi esiningi. Ku-titanium impeller, ukucubungula kwe-axis engu-5 kunciphise isikhathi somjikelezo ngo-58% uma kuqhathaniswa nemishini ye-axis engu-3 (amahora angu-2.1 vs. amahora angu-5.0). I-stainless steel turbine blade ibonise ukuncishiswa kwe-42% (amahora angu-1.8 vs. amahora angu-3.1). Lezi zinzuzo zibangelwe ngokuyinhloko ekususeni ukusetha okuningi nesikhathi sokuphatha/sokulungisa kabusha esihlobene, kanye nokunika amandla izindlela zamathuluzi ezisebenza kahle kakhulu ngokusikeka okude, okuqhubekayo ngenxa yokuma kwethuluzi okuthuthukisiwe.
3.2 Ukuthuthukiswa Kwezinga Lomhlaba
Ubulukhuni bobuso (Ra) buthuthukisiwe ngokuqhubekayo ngomshini we-5-axis. Ezindaweni eziyinkimbinkimbi ze-blade ye-titanium impeller, amanani amaphakathi e-Ra ehle ngo-32% (0.8 µm vs. 1.18 µm). Ukuthuthukiswa okufanayo kubonwe ku-blade ye-turbine yensimbi engagqwali (i-Ra yehliswe ngo-35%, isilinganiso esingu-0.65 µm vs. 1.0 µm). Lokhu kuthuthukiswa kubalulwe ekhonweni lokugcina i-engeli yokuxhumana yokusika engaguquki, efanele kanye nokunciphisa ukudlidliza kwethuluzi ngokuqina okungcono kwamathuluzi ezandiso zamathuluzi ezifushane.
3.3 Ukuthuthukiswa Kokunemba KweJiyomethri
Ukuhlaziywa kwe-CMM kuqinisekise ukunemba okuphakeme kwejometri ngokucubungula kwe-axis engu-5. Iphesenti lezici ezibucayi ezigcinwe ngaphakathi kokubekezelelana okuqinile ± 0.025mm lenyuke kakhulu: ngo-30% ku-titanium impeller (ukuthola ukuhambisana no-92% vs. 62%) kanye no-26% wensimbi yensimbi engagqwali (ukuzuza ukuthobela okungu-89% vs. 63%). Lokhu kuthuthukiswa kuvela ngokuqondile ekususweni kwamaphutha anqwabelene alethwe ukusetha okuningi kanye nokubeka kabusha okwenziwa ngesandla okudingekayo kunqubo ye-axis engu-3. Izici ezidinga ama-engeli ahlanganisiwe zibonise izinzuzo zokunemba ezimangalisa kakhulu.
*Umfanekiso 1: Amamethrikhi Okusebenza Okuqhathanisayo (5-Axis vs. 3-Axis)*
4. Ingxoxo
Imiphumela iqinisekisa ngokucacile izinzuzo zobuchwepheshe zemishini ye-5-axis yezingxenye zensimbi zangokwezifiso eziyinkimbinkimbi. Ukwehliswa okukhulu kwesikhathi somjikelezo kuhumusha ngokuqondile izindleko eziphansi zengxenye ngayinye kanye nokwanda komthamo wokukhiqiza. Ukuqedwa kwendawo okuthuthukisiwe kunciphisa noma kuqede imisebenzi yesibili yokuqedela njengokupholisha ngesandla, ukwehlisa izindleko ezengeziwe kanye nezikhathi zokuhola kuyilapho kuthuthukisa ukufana kwengxenye. Ukweqa ekunembeni kwejiyomethri kubalulekile ezinhlelweni zokusebenza ezisebenza kahle njengezinjini ze-aerospace noma izimila zezokwelapha, lapho umsebenzi wengxenye nokuphepha kubaluleke kakhulu.
Lezi zinzuzo ngokuyinhloko zivela emandleni ayinhloko omshini we-5-axis: ukunyakaza okuhambisanayo kwama-multi-eksisi okuvumela ukucutshungulwa kokusetha okukodwa. Lokhu kuqeda amaphutha adalwe ukusetha kanye nesikhathi sokuphatha. Ngaphezu kwalokho, ukuqondisa kwethuluzi elilungile eliqhubekayo (ukugcina umthwalo we-chip ofanele namandla okusika) kuthuthukisa ukuphela kwendawo futhi kuvumela amasu omshini anolaka lapho ukuqina kwamathuluzi kuvumela, okunikela enzuzweni yesivinini.
Nokho, ukutholwa okungokoqobo kudinga ukuvuma ukulinganiselwa. Imali yokutshalwa kwezimali yomshini onamandla wama-axis angu-5 kanye namathuluzi afanelekile aphezulu kakhulu kunemishini ye-3-eksisi. Ubunkimbinkimbi bezinhlelo bukhula ngokuqhubekayo; ukukhiqiza izindlela zamathuluzi ezisebenza kahle, ezingashayisani ze-5-eksisi kudinga abahleli bezinhlelo ze-CAM abanekhono eliphezulu kanye nesofthiwe eyinkimbinkimbi. Ukulingisa nokuqinisekisa kuba yizinyathelo eziyisibopho ngaphambi komshini. Ukulungisa kufanele kunikeze kokubili ukuqina kanye nemvume eyanele yokuhamba okugcwele kokujikeleza. Lezi zinto ziphakamisa izinga lekhono elidingekayo kubaqhubi nabahleli bohlelo.
Okushiwo okusebenzayo kusobala: ukwenziwa kwemishini ye-5-axis kuyadlula inani eliphezulu, izingxenye eziyinkimbinkimbi lapho izinzuzo zakhona ngesivinini, ikhwalithi, nekhono zithethelela ukusebenza okuphezulu nokutshalwa kwezimali. Ezingxenyeni ezilula, umshini we-3-axis uhlala ukonga kakhulu. Impumelelo incike ekutshaleni imali kukho kokubili ubuchwepheshe kanye nezisebenzi ezinekhono, kanye ne-CAM eqinile namathuluzi okulingisa. Ukusebenzisana kwangaphambi kwesikhathi phakathi komklamo, ubunjiniyela bokukhiqiza, kanye nesitolo semishini kubalulekile ukuze kusetshenziswe ngokugcwele amakhono e-axis emi-5 ngenkathi kwakhiwa izingxenye ze-manufacturability (DFM).
5. Isiphetho
Imishini yesimanje ye-CNC ye-5-eksisi ihlinzeka ngesixazululo esivelele ngokumangalisayo sokukhiqiza izingxenye zensimbi ezinembayo ezinembe kakhulu uma kuqhathaniswa nezindlela zendabuko ze-eksisi engu-3. Okutholakele okubalulekile kuqinisekisa:
Ukusebenza Okubalulekile:Ukwehliswa kwesikhathi somjikelezo ngo-40-60% ngomshini wokusetha okukodwa nezindlela zamathuluzi ezithuthukisiwe.
Ikhwalithi Ethuthukisiwe:Ukuthuthukiswa kokuqina kobuso (Ra) okungafika ku-35% ngenxa yokuma kwethuluzi nokuthintana.
Ukunemba Okuphezulu:Isilinganiso sokunyuka esingu-28% ekubambeni ukubekezelelana okubalulekile kwejiyomethri phakathi kuka-±0.025mm, sisusa amaphutha ekusetheni okuningi.
Ubuchwepheshe buvumela ukukhiqizwa kwamajiyometri ayinkimbinkimbi (imigodi ejulile, ama-undercuts, amajika ayinhlanganisela) angenzeki noma angenzeki ngomshini we-3-axis, ebhekana ngqo nezidingo eziguqukayo zemikhakha ye-aerospace, yezokwelapha, kanye namandla.
Ukuze kwandiswe imbuyiselo ekutshalweni kwezimali emandleni e-5-eksisi, abakhiqizi kufanele bagxile ezingxenyeni eziyinkimbinkimbi, ezinenani eliphezulu lapho ukunemba nesikhathi sokuhola kuyizici ezibalulekile zokuncintisana. Umsebenzi wesikhathi esizayo kufanele uhlole ukuhlanganiswa kwemishini ye-5-axis ne-in-process metrology yokulawula ikhwalithi yesikhathi sangempela kanye nemishini evala iluphu, kuthuthukiswe ukunemba nokunciphisa izilahliwe. Ucwaningo oluqhubekayo kumasu omshini wokujwayela asebenzisa ukuguquguquka kwe-axis engu-5 ezintweni ezilukhuni ukuya emshinini njenge-Inconel noma izinsimbi eziqinile nazo ziveza inkomba ebalulekile.
