Kupanga Zigawo Zazitsulo Zamwambo Ndi 5-Axis Machining

Kupanga Zigawo Zazitsulo Zamwambo Ndi 5-Axis Machining

Wolemba:PFT, Shenzhen

Chidule:Zopanga zapamwamba zimafuna zida zachitsulo zovuta kwambiri, zolondola kwambiri pazamlengalenga, zamankhwala, ndi mphamvu. Kusanthula uku kuwunika kuthekera kwa makina amakono a 5-axis computer Numberal control (CNC) pokwaniritsa izi. Pogwiritsa ntchito ma benchmark geometries oyimira zowunikizira zovuta ndi masamba a turbine, kuyesa kwa makina kunachitika kuyerekeza njira za 5-axis motsutsana ndi chikhalidwe cha 3-axis pa titaniyamu yamlengalenga (Ti-6Al-4V) ndi chitsulo chosapanga dzimbiri (316L). Zotsatira zikuwonetsa kuchepetsedwa kwa 40-60% mu nthawi yopangira makina komanso kuuma kwapamtunda (Ra) mpaka 35% ndi 5-axis processing, chifukwa cha kuchepetsedwa kukhazikitsidwa komanso kukhathamiritsa kwa zida. Kulondola kwa geometric pazinthu zomwe zili mkati mwa ± 0.025mm kulolerana zidakwera ndi 28% pafupifupi. Ngakhale ikufunika ukadaulo wotsogola wamapulogalamu komanso kuyika ndalama, makina a 5-axis amathandizira kupanga kodalirika kwa ma geometri omwe sanatheke m'mbuyomu ndikuchita bwino kwambiri komanso kumaliza. Kuthekera kumeneku kumapangitsa ukadaulo wa 5-axis kukhala wofunikira pakupangira zitsulo zamtengo wapatali, zovuta zopanga.

1. Mawu Oyamba
Kuthamangitsidwa kosalekeza kwa kukhathamiritsa kwa magwiridwe antchito m'mafakitale onse monga zamlengalenga (zofuna zopepuka, zolimba), zachipatala (zofuna ma implants ogwirizana ndi ma biocompatible, okhudzana ndi odwala), ndi mphamvu (zofuna zigawo zovuta zogwirira ntchito zamadzimadzi) zakankhira malire a gawo lachitsulo. Makina achikhalidwe a 3-axis CNC, omwe amakhala ndi zida zochepa komanso kuyika kangapo kofunikira, amalimbana ndi ma contour ocholora, maenje akuya, ndi mawonekedwe omwe amafunikira ma angles apawiri. Zolepheretsa izi zimabweretsa kulakwitsa kolondola, nthawi yayitali yopanga, kukwera mtengo, ndi kuletsa mapangidwe. Pofika chaka cha 2025, kuthekera kopanga ziwiya zachitsulo zovuta kwambiri, zolondola bwino sikukhalanso zapamwamba koma ndizofunikira zopikisana. Makina amakono a 5-axis CNC, omwe amapereka kuwongolera munthawi yomweyo nkhwangwa zitatu zozungulira (X, Y, Z) ndi nkhwangwa ziwiri zozungulira (A, B kapena C), zimapereka yankho losintha. Ukadaulo uwu umalola chida chodulira kuti chiyandikire chogwiriracho kuchokera mbali iliyonse pakukhazikitsa kamodzi, ndikugonjetsa malire omwe ali mu 3-axis Machining. Nkhaniyi ikuyang'ana luso lapadera, ubwino wowerengeka, ndi zofunikira zogwiritsira ntchito makina a 5-axis kuti apange gawo lachitsulo.

2. Njira
2.1 Kupanga & Benchmarking
Zigawo ziwiri zoyeserera zidapangidwa pogwiritsa ntchito pulogalamu ya Nokia NX CAD, zomwe zikuphatikiza zovuta zomwe zimachitika pakupanga makonda:

Chochititsa:Zokhala ndi masamba ovuta, opindika okhala ndi mawonekedwe apamwamba komanso zololeza zolimba.

Mtundu wa Turbine:Kuphatikiza ma curvature apawiri, makoma owonda, ndi malo okwera bwino.
Mapangidwe awa amaphatikizira mwadala ma cutcuts, matumba akuya, ndi zinthu zomwe zimafuna kugwiritsa ntchito zida zosagwiritsa ntchito orthogonal, makamaka kutsata malire a 3-axis Machining.

2.2 Zida & Zida

Zida:Titanium ya Aerospace-grade (Ti-6Al-4V, annealed condition) ndi 316L Stainless Steel anasankhidwa chifukwa cha kufunikira kwawo pakugwiritsa ntchito movutikira komanso mawonekedwe apadera a makina.

Makina:

5-Njira:DMG MORI DMU 65 monoBLOCK (Heidenhain TNC 640 control).

3-Njira:HAAS VF-4SS (HAAS NGC control).

Zida:Mphero zolimba zomata za carbide (madiameter osiyanasiyana, mphuno ya mpira, ndi malekezero athyathyathya) ochokera ku Kennametal ndi Sandvik Coromant anagwiritsidwa ntchito pokometsa ndi kumaliza. Kudula magawo (liwiro, chakudya, kuya kwa kudula) adakometsedwa pazakuthupi ndi luso la makina pogwiritsa ntchito malingaliro opanga zida ndi mabala owongolera.

Kugwira ntchito:Zosintha mwachizolowezi, zomangika ndendende zimatsimikizira kulimba kolimba komanso malo obwerezabwereza amitundu yonse yamakina. Pamayesero a 3-axis, magawo omwe amafunikira kasinthasintha adasinthidwanso pamanja pogwiritsa ntchito ma dowels olondola, kutengera zomwe zimachitika m'sitolo. Mayeso a 5-axis adagwiritsa ntchito makinawo kuti azitha kuzungulira pakukhazikitsa kumodzi.

2.3 Kupeza Data & Kusanthula

Nthawi Yozungulira:Kuyesedwa molunjika kuchokera ku makina owerengera nthawi.

Pamwamba Pamwamba (Ra):Kuyesedwa pogwiritsa ntchito Mitutoyo Surftest SJ-410 profilometer pa malo asanu ovuta pagawo lililonse. Magawo atatu adapangidwa pamakina azinthu / makina.

Kulondola kwa Geometric:Kujambula pogwiritsa ntchito makina oyezera a Zeiss CONTURA G2 (CMM). Miyeso yovuta ndi kulolerana kwa geometric (kutsika, perpendicularity, mbiri) anafaniziridwa ndi zitsanzo za CAD.

Statistical Analysis:Avereji yamitengo ndi mipatuko yokhazikika idawerengeredwa pa nthawi yozungulira komanso miyeso ya Ra. Deta ya CMM idawunikidwa kuti ikhale yosiyana ndi miyeso yodziwika bwino komanso mitengo yololera.

Gulu 1: Chidule cha Kukonzekera Mwachidule

3. Zotsatira & Analysis
3.1 Kupindula Mwachangu
Makina a 5-axis adawonetsa kupulumutsa nthawi. Kwa titaniyamu impeller, 5-axis processing inachepetsa nthawi yozungulira ndi 58% poyerekeza ndi 3-axis Machining (maola 2.1 vs. 5.0 maola). Tsamba lachitsulo chosapanga dzimbiri linawonetsa kuchepetsa 42% (maola 1.8 vs. 3.1 maola). Kupindula kumeneku kudachitika makamaka chifukwa chochotsa kukhazikitsidwa kangapo ndi nthawi yolumikizirana ndi manja / kukonzanso, ndikuthandizira njira zogwirira ntchito zokhala ndi zida zazitali, zodulira mosalekeza chifukwa cha kukhathamiritsa kwa zida.

3.2 Kupititsa patsogolo Ubwino Wapamwamba
Kukula kwapamtunda (Ra) kumasinthidwa mosalekeza ndi makina a 5-axis. Pamalo ovuta a tsamba la titaniyamu, pafupifupi ma Ra amatsika ndi 32% (0.8 µm vs. 1.18 µm). Kusintha kofananako kunawoneka pazitsulo zazitsulo zosapanga dzimbiri (Ra kuchepetsedwa ndi 35%, pafupifupi 0.65 µm vs. 1.0 µm). Kuwongolera uku kumabwera chifukwa chakutha kukhalabe osasunthika, momwe mungadulire bwino komanso kuchepetsa kugwedezeka kwa zida kudzera pakukhazikika kwa zida pazowonjezera zazifupi.

3.3 Kuwongolera Kulondola kwa Geometric
Kusanthula kwa CMM kunatsimikizira kulondola kwapamwamba kwa geometric ndi 5-axis processing. Kuchuluka kwa zinthu zovuta zomwe zimagwiritsidwa ntchito mkati mwa kulekerera kolimba kwa ± 0.025mm kunakula kwambiri: ndi 30% kwa titaniyamu impeller (kukwaniritsa 92% kutsata vs. 62%) ndi 26% kwa tsamba lachitsulo chosapanga dzimbiri (kukwaniritsa 89% kutsata vs. 63%). Kuwongolera uku kumachokera mwachindunji pakuchotsa zolakwika zochulukirapo zomwe zimayambitsidwa ndi kukhazikitsidwa kangapo ndikuyikanso pamanja komwe kumafunikira munjira ya 3-axis. Zomwe zimafunikira makona apawiri zidawonetsa kupindula kolondola kwambiri.

*Chithunzi 1: Magwiridwe Ofananirako (5-Axis vs. 3-Axis)*

4. Kukambitsirana
Zotsatira zimatsimikizira bwino luso la 5-axis Machining pazinthu zovuta zachitsulo. Kuchepetsa kwakukulu kwa nthawi yozungulira kumasulira mwachindunji kutsika mtengo wagawo limodzi ndikuwonjezera mphamvu yopangira. Kutsirizitsa kwapamwamba kumachepetsa kapena kuthetsa ntchito zomaliza zachiwiri monga kupukuta m'manja, kumachepetsanso ndalama ndi nthawi zotsogolera kwinaku mukupititsa patsogolo kusasinthasintha. Kudumphira mu kulondola kwa geometric ndikofunikira pakugwiritsa ntchito bwino kwambiri ngati injini zazamlengalenga kapena zoyika zachipatala, pomwe magwiridwe antchito ndi chitetezo ndizofunikira kwambiri.

Ubwinowu umachokera ku kuthekera kwapakatikati kwa 5-axis Machining: munthawi yomweyo ma multi-axis kusuntha komwe kumathandizira kukhazikitsidwa kamodzi. Izi zimachotsa zolakwika zokhazikitsidwa ndi nthawi yosamalira. Kuphatikiza apo, kugwiritsa ntchito zida zabwino mosalekeza (kusunga chip katundu ndi mphamvu zodulira) kumawonjezera kutha kwapamwamba ndikulola njira zamakanika zamakina momwe zida zimaloleza, zomwe zimathandizira kupindula mwachangu.

Komabe, kulera kothandiza kumafuna kuvomereza zolephera. Ndalama zogulira makina a 5-axis ndi zida zoyenera ndizokwera kwambiri kuposa zida za 3-axis. Kuvuta kwa mapulogalamu kumawonjezeka kwambiri; kupanga zida zogwira ntchito bwino, zopanda kugunda kwa 5-axis zimafuna akatswiri aukadaulo a CAM ndi mapulogalamu apamwamba. Kuyerekezera ndi kutsimikizira kumakhala masitepe ofunikira musanayambe kupanga. Kukonzekera kuyenera kupereka kukhazikika komanso chilolezo chokwanira paulendo wonse wozungulira. Zinthu izi zimakweza luso lofunikira kwa ogwiritsa ntchito ndi opanga mapulogalamu.

Tanthauzo lake ndi lodziwikiratu: 5-axis Machining imapambana pazigawo zamtengo wapatali, zovuta zomwe ubwino wake mu liwiro, khalidwe, ndi kuthekera kwake zimatsimikizira kuwonjezereka kwa ntchito ndi ndalama. Kwa magawo osavuta, makina a 3-axis amakhalabe otsika mtengo. Kupambana kumatengera kuyika ndalama muukadaulo komanso akatswiri aluso, limodzi ndi CAM yamphamvu ndi zida zoyeserera. Kugwirizana koyambirira pakati pa mapangidwe, uinjiniya wopanga, ndi malo ogulitsira makina ndikofunikira kuti muthe kukulitsa luso la 5-axis pomwe mukupanga magawo opanga manufacturability (DFM).

5. Mapeto
Makina amakono a 5-axis CNC amapereka njira yabwino kwambiri yopangira zida zachitsulo, zolondola kwambiri poyerekeza ndi njira zachikhalidwe za 3-axis. Zotsatira zazikulu zimatsimikizira:

Kuchita Mwachangu:Kuchepetsa nthawi yozungulira 40-60% kudzera pakukhazikitsa kamodzi kokha komanso njira zokometsera.

Ubwino Wokwezedwa:Kukula kwapamtunda (Ra) kuwongolera mpaka 35% chifukwa cha mawonekedwe abwino a zida ndi kulumikizana.

Kulondola Kwambiri:Kuwonjezeka kwapakati pa 28% pakusunga kulekerera kofunikira kwa geometric mkati mwa ± 0.025mm, kuchotsa zolakwika pakukhazikitsa kangapo.
Ukadaulowu umathandizira kupanga ma geometries odabwitsa (mabowo akuya, mapindikidwe opindika, ma curve apawiri) omwe ndi osatheka kapena osatheka ndi makina a 3-axis, kuthana ndi zomwe zikufunika kusintha kwa gawo lazamlengalenga, zamankhwala, ndi mphamvu.

Kuti achulukitse kubweza ndalama mu 5-axis kuthekera, opanga ayenera kuyang'ana kwambiri zovuta, zamtengo wapatali zomwe kulondola ndi nthawi yotsogolera ndizofunikira kwambiri pampikisano. Ntchito yamtsogolo iyenera kufufuza kusakanikirana kwa makina a 5-axis ndi-in-process metrology kuti athe kuwongolera khalidwe la nthawi yeniyeni ndi makina otsekedwa, kupititsa patsogolo kulondola ndi kuchepetsa zidutswa. Kafukufuku wopitilira munjira zosinthika zamakina zomwe zimathandizira kusinthasintha kwa 5-axis pazovuta zamakina monga Inconel kapena zitsulo zolimba kumaperekanso njira yofunikira.