Uyigcina Kanjani I-Aluminium CNC Cutting Fluid Yempilo Yethuluzi Elide kanye Neswafi Yokuhlanza

 PFT, Shenzhen

Ukugcina i-aluminium efanelekile yokusika uketshezi lwe-CNC kuthinta ngokuqondile ukuguga kwamathuluzi kanye nekhwalithi yokuswayipha. Lolu cwaningo luhlola amaphrothokholi okulawulwa koketshezi ngokuhlolwa kwemishini elawulwayo nokuhlaziya uketshezi. Imiphumela ibonisa ukuthi ukuqapha kwe-pH okungaguquki (ibanga eliqondiwe 8.5-9.2), ukugcina ukugxila phakathi kuka-7-9% kusetshenziswa i-refractometry, nokusebenzisa ukuhlunga kwezigaba ezimbili (40µm okulandelwa ngu-10µm) kunweba impilo yamathuluzi ngesilinganiso esingu-28% futhi kunciphisa ukunamathela kwe-swarf ngo-73% uma kuqhathaniswa noketshezi olungalawulwa. I-skimming kawoyela we-tramp evamile (> 95% ukususwa masonto onke) kuvimbela ukukhula kwebhaktheriya nokungaqini kwe-emulsion. Ukuphatha uketshezi olusebenzayo kunciphisa izindleko zamathuluzi kanye nokuphelelwa yisikhathi komshini.

1. Isingeniso

I-CNC machining ye-aluminium idinga ukunemba nokusebenza kahle. Uketshezi olusikiwe lubalulekile ekupholiseni, ukugcobisa, nokukhipha ama-chip. Kodwa-ke, ukuwohloka koketshezi - okubangelwa ukungcola, ukukhula kwamagciwane, ukukhukhuleka okugxilile, nokunqwabelana kwamafutha e-tramp - kusheshisa ukuguga kwamathuluzi futhi kubeke engcupheni ukususwa kwe-swarf, okuholela ekwenyukeni kwezindleko kanye nesikhathi sokuphumula. Ngo-2025, ukwenza ngcono ukugcinwa koketshezi kuhlale kuyinselelo ebalulekile yokusebenza. Lolu cwaningo lulinganisa umthelela wezinqubo ezithile zokulungisa kubude besikhathi bamathuluzi nezici ze-swarf ekukhiqizweni kwe-aluminium yevolumu ephezulu ye-CNC.

2. Izindlela

2.1. Idizayini Yokuhlola Nomthombo Wedatha
Ukuhlolwa komshini okulawulwayo kwenziwa emasontweni ayi-12 kuma-CNC Mills ama-5 afanayo (Haas VF-2) acubungula i-6061-T6 aluminium. Uketshezi lokusika lwe-semi-synthetic (Brand X) lwalusetshenziswa kuyo yonke imishini. Umshini owodwa osebenza njengokulawula ngokulungiswa okujwayelekile, okusebenzayo (uketshezi luyashintsha kuphela uma lucekeleke phansi ngokubonakalayo). Abanye abane basebenzise iphrothokholi ehlelekile:

• Ukugxila:Kukalwa nsuku zonke kusetshenziswa i-digital refractometer (Atago PAL-1), elungiswe ibe ngu-8% ±1% ngokugxilisa ingqondo noma amanzi e-DI.

• i-pH:Kugadwa nsuku zonke kusetshenziswa imitha ye-pH elinganiselwe (Hanna HI98103), egcinwa phakathi kuka-8.5-9.2 kusetshenziswa izithasiselo ezigunyazwe umkhiqizi.

• Ukuhlunga:Ukuhlunga kwezigaba ezimbili: Isihlungi sesikhwama esingu-40µm silandelwa isihlungi se-cartridge esingu-10µm. Izihlungi zishintshile ngokusekelwe kumehluko wengcindezi (≥ 5 psi ukwanda).

• Ukususwa Kwamafutha E-Tramp:Umshicileli webhande usebenza ngokuqhubekayo; indawo ewuketshezi ihlolwa nsuku zonke, ukusebenza kahle kwe-skimmer kuqinisekiswa masonto onke (>95% okuhlosiwe kokususa).

• I-Make-up Fluid:Uketshezi oluxutshwe ngaphambili kuphela (ekugxilweni kuka-8%) olusetshenziselwa ukugcwalisa.

2.2. Ukuqoqwa Kwedatha Namathuluzi

• I-Tool Wear:I-Flank wear (VBmax) ilinganiswa emaphethelweni okusika ama-3-flute carbide end Mills (Ø12mm) kusetshenziswa isibonakhulu somenzi wamathuluzi (Mitutoyo TM-505) ngemva kwezingxenye ezingu-25. Amathuluzi athathelwe indawo ku-VBmax = 0.3mm.

• Ukuhlaziywa kwe-Swarf:I-swarf eqoqwe ngemva kweqoqo ngalinye. "Ukunamathela" kukalwe esikalini esingu-1 (okugeleza mahhala, komile) kuya ku-5 (okuhlanganisiwe, okunamafutha) ngama-opharetha angu-3 azimele. Isikolo esimaphakathi sirekhodiwe. Ukusatshalaliswa kosayizi we-chip kuhlaziywa ngezikhathi ezithile.

• Isimo Soketshezi:Amasampula oketshezi lwamasonto onke ahlaziywa ilebhu ezimele yokubala kwamagciwane (CFU/mL), okuqukethwe kukawoyela we-tramp (%), nokuqinisekiswa kwe-concentration/pH.

• Ukungasebenzi komshini:Irekhodelwe izinguquko zamathuluzi, ujamu ohlobene ne-swarf, nemisebenzi yokunakekela uketshezi.

3. Imiphumela & Ukuhlaziya

3.1. I-Tool Life Extension
Amathuluzi asebenza ngaphansi kwephrothokholi yokulungisa ehlelekile ayelokhu efika ekubalweni kwengxenye ephezulu ngaphambi kokudinga ukushintshwa. Isilinganiso sempilo yamathuluzi sikhuphuke ngo-28% (kusuka ezingxenyeni/ithuluzi eliwu-175 kuya kwezingu-224/ithuluzi elingaphansi kwephrothokholi). Umfanekiso 1 ubonisa ukuqhathaniswa kokugqoka kweflank okuqhubekayo.

3.2. Ukuthuthukiswa Kwekhwalithi Ye-Swarf
Izilinganiso zokunamathela kwe-Swarf zibonise ukwehla okukhulu ngaphansi kwephrothokholi ephethwe, okulinganiselwa ku-1.8 uma kuqhathaniswa no-4.1 wokulawula (ukunciphisa ngama-73%). Uketshezi olulawulwayo lukhiqize ukoma, ama-chips acwebile amaningi (Umfanekiso 2), okwenza ngcono kakhulu ukuphuma nokunciphisa ukuminya kwemishini. Isikhathi sokuphumula esihlobene nezinkinga ze-swarf sehle ngo-65%.

3.3. Ukuzinza kwe-Fluid
Ukuhlaziywa kwelebhu kuqinisekise ukusebenza kwephrothokholi:

• Izibalo zamagciwane zihlala zingaphansi kuka-10³ CFU/mL kumasistimu aphethwe, kuyilapho ukulawula kudlule u-10⁶ CFU/mL ngeviki lesi-6.

• Okuqukethwe kukawoyela we-tramp okulinganiselwa ku-<0.5% kuketshezi oluphethwe uma kuqhathaniswa. > no-3% ekulawuleni.

• Ukugxila kanye ne-pH kuhlale kuzinzile phakathi kwezigaba okuhlosiwe zoketshezi olulawulwayo, kuyilapho ukulawula kubonise ukukhukhuleka okuphawulekayo (ukugxila kwehlela ku-5%, i-pH yehlela ku-7.8).

*Ithebula 1: Izinkomba Zokusebenza Ezibalulekile – Iphethwe vs. Control Fluid*

4. Ingxoxo

4.1. Izindlela Zokushayela Imiphumela
Ukuthuthukiswa kuvela ngokuqondile ezenzweni zokunakekela:

• Ukugxila Okuzinzile ne-pH:Kuqinisekiswe ukuthambisa okungaguquki kanye nokuvimbela ukugqwala, kunciphisa ngokuqondile ukuguga nokuguga kwamakhemikhali kumathuluzi. I-pH eqinile ivimbele ukuwohloka kwama-emulsifiers, igcina ubuqotho boketshezi futhi ivimbele "ukumuncu" okwandisa ukunamathela kwe-swarf.

• Ukuhlunga Okusebenzayo:Ukususwa kwezinhlayiya zensimbi ezicolekile (inhlawulo ye-swarf) kwehlisa ukuguga okulimazayo kumathuluzi nasezintweni zokusebenza. Uketshezi oluhlanzekile nalo lwalugeleza ngokuphumelelayo ekupholiseni nasekuwasheni amashiphu.

• I-Tramp Oil Control:Amafutha e-tramp (kusuka ku-lube, i-hydraulic fluid) aphazamisa ama-emulsion, anciphisa ukusebenza kahle kokupholisa, futhi anikeze umthombo wokudla wamagciwane. Ukususwa kwayo kwakubalulekile ukuze kuvinjwe ukuqubuka nokugcina uketshezi luzinzile, kube negalelo elikhulu ekuhlanzeni i-swarf.

• Ukucindezelwa Amagciwane:Ukugcina ukugxilisa ingqondo, i-pH, nokususa amagciwane alambisa uwoyela we-tramp, ukuvimbela ama-acids ne-slime abakukhiqizayo okwehlisa ukusebenza koketshezi, ukugqwala kwamathuluzi, futhi kubangele iphunga elibi/i-swarf enamathelayo.

4.2. Imikhawulo kanye Nemiphumela Engokoqobo
Lolu cwaningo lugxile oketshezini oluthile (i-semi-synthetic) ne-aluminium alloy (6061-T6) ngaphansi kwezimo zokukhiqiza ezilawulwayo kodwa ezingokoqobo. Imiphumela ingase yehluke kancane ngoketshezi oluhlukile, ama-alloy, noma amapharamitha womshini (isb., ukwenziwa kwemishini enesivinini esikhulu). Kodwa-ke, izimiso ezibalulekile zokulawula ukuhlushwa, ukuqapha i-pH, ukuhlunga, nokususwa kukawoyela we-tramp zisebenza emhlabeni wonke.

• Izindleko Zokuqalisa:Idinga ukutshalwa kwezimali kumathuluzi okuqapha (i-refractometer, imitha ye-pH), amasistimu okuhlunga, nabashicileli.

• Umsebenzi:Idinga ukuhlolwa okuqondisiwe kwansuku zonke kanye nokulungiswa opharetha.

• I-ROI:Ukwenyuka okubonisiwe okungama-28% empilweni yamathuluzi kanye nokwehliswa ngo-65% kwesikhathi sokuphumula esihlobene ne-swarf kunikeza imbuyiselo ecacile ekutshalweni kwezimali, ukukhokha izindleko zohlelo lokunakekela kanye nempahla yokulawula uketshezi. Ukuncipha kokuvama kokuchithwa koketshezi (ngenxa yempilo ende ye-sump) kuwukonga okwengeziwe.

5. Isiphetho

Ukugcina i-aluminium CNC yokusika uketshezi akuyona inketho yokusebenza kahle; kuwumkhuba obalulekile wokusebenza. Lolu cwaningo lubonisa ukuthi iphrothokholi ehlelekile egxile ekugxiliseni kwansuku zonke nokuqapha i-pH (okuhlosiwe: 7-9%, pH 8.5-9.2), ukuhlunga kwezigaba ezimbili (40µm + 10µm), kanye nokususwa kukawoyela we-tramp okunolaka (>95%) kuletha izinzuzo ezibalulekile, ezilinganisekayo:

1. Impilo Yethuluzi Enwetshiwe:Ukukhuphuka okumaphakathi kwama-28%, kunciphisa ngqo izindleko zamathuluzi.

2. I-Swarf Yokuhlanza:Ukuncipha kokunamathela ngo-73%, kuthuthukisa kakhulu ukuphuma kwe-chip kanye nokunciphisa ukuminya kwemishini/isikhathi sokuphumula (ukunciphisa ngama-65%).

3. Uketshezi Oluzinzile:Kucindezelwe ukukhula kwebhaktheriya nokugcina ubuqotho be-emulsion.

Izimboni kufanele zibeke eqhulwini ukusebenzisa izinhlelo zokulawula uketshezi oluneziyalo. Ucwaningo lwesikhathi esizayo lungahlola umthelela wamaphakheji athile angeziwe ngaphansi kwale phrothokholi noma ukuhlanganiswa kwezinhlelo ezizenzakalelayo zokuqapha uketshezi lwesikhathi sangempela.