Tsika Metal Zvikamu Kugadzira ne5-Axis Machining
Tsika Metal Zvikamu Kugadzira ne5-Axis Machining
Munyori:PFT, Shenzhen
Abstract:Kugadzirwa kwepamberi kunoda kuwedzera kuomarara, yakakwirira-chaiyo simbi zvikamu munzvimbo dzeaerospace, zvekurapa, uye simba zvikamu. Ongororo iyi inoongorora kugona kweazvino 5-axis komputa nhamba yekudzora (CNC) machining mukuzadzisa izvi zvinodiwa. Tichishandisa mabhenji ejeometri anomiririra emagetsi akaomarara uye turbine blades, machining miedzo yakaitwa ichienzanisa 5-axis kupesana nechinyakare 3-axis nzira pane aerospace-giredhi titanium (Ti-6Al-4V) uye simbi isina tsvina (316L). Mhedzisiro inoratidza kudzikiswa kwe40-60% munguva yekugadzira uye kushata kwepamusoro (Ra) kuvandudzwa kunosvika 35% ne5-axis process, zvichikonzerwa nekudzikiswa kwesetups uye optimized maturusi ekutarisa. Kurongeka kwejometri yezvimiro mukati me ± 0.025mm kushivirira kwakawedzera ne28% paavhareji. Kunyange ichida hunyanzvi hwepamberi hwekuronga uye kudyara, 5-axis machining inogonesa kugadzirwa kwakavimbika kweyaimbove isingagoneki geometries nehunyanzvi hwepamusoro uye kupera. Aya masimba anoisa 5-axis tekinoroji seyakakosha kune yakakwirira-kukosha, yakaoma tsika simbi chikamu chekugadzira.
1. Nhanganyaya
Kudhiraivha kusingadzoreki kwekuita optimization mumaindasitiri akaita seaerospace (inoda kurerusa, zvikamu zvakasimba), zvekurapa (zvinoda biocompatible, ma implants akanangana nemurwere), uye simba (rinoda zvinhu zvakaoma zvinobata mvura) zvakasundira miganhu yesimbi chikamu chakaoma. Yechinyakare 3-axis CNC machining, inomanikidzwa neyakaganhurirwa maturusi ekushandisa uye akawanda anodiwa setups, anonetsekana neakaomesesa contours, yakadzika cavities, uye maficha anoda makomboni makona. Izvi zvipingamupinyi zvinoguma nekukanganisika kwechokwadi, nguva yakawedzerwa yekugadzira, mutengo wakakwira, uye zvirambidzo zvekugadzira. Pakazosvika 2025, kugona kugadzira zvakanyanya kuomarara, simbi dzesimbi nemazvo hazvichisiri zveumbozha asi zvinofanirwa kukwikwidza. Yemazuva ano 5-axis CNC machining, ichipa panguva imwe chete kutonga kwematemo matatu ane mutsara (X, Y, Z) uye maviri anotenderera matemo (A, B kana C), inopa inoshandura mhinduro. Iyi tekinoroji inobvumira chishandiso chekucheka kuti chiswedere kune workpiece kubva kune chero nzira mune imwe chete setup, zvakanyanya kukunda zvipingamupinyi zvekuwana zviri mu3-axis machining. Ichi chinyorwa chinoongorora iyo chaiyo kugona, quantified mabhenefiti, uye inoshanda mafungidziro e5-axis machining ekugadzirwa kwesimbi chikamu chetsika.
2. Nzira
2.1 Dhizaini & Benchmarking
Zvikamu zviviri zvebhenji zvakagadzirirwa kushandisa Nokia NX CAD software, inosanganisira matambudziko akajairika mukugadzira tsika:
Impeller:Inoratidzira yakaoma, yakamonyoroka mablades ane yakakwira chimiro uye yakaomesesa clearances.
Turbine Blade:Kubatanidza makomboni curvature, madziro akatetepa, uye nemazvo anokwirisa nzvimbo.
Aya madhizaini akabatanidzwa nemaune ma undercuts, mahomwe akadzika, uye maficha anoda asiri-orthogonal maturusi ekuwana, akanyatso kunanga zvipimo zve3-axis machining.
2.2 Zvishandiso & Zvishandiso
Zvekushandisa:Aerospace-giredhi Titanium (Ti-6Al-4V, annealed condition) uye 316L Stainless Steel zvakasarudzwa maererano nekukosha kwazvo mukudiwa kwekushandisa uye akasiyana machining maitiro.
Machina:
5-Axis:DMG MORI DMU 65 monoBLOCK (Heidenhain TNC 640 control).
3-Axis:HAAS VF-4SS (HAAS NGC control).
Tooling:Zvigayo zvakavharidzirwa zvakasimba zvecarbide (madhayamita akasiyana-siyana, bhora-mhino, uye kupera-kumagumo) kubva kuKennametal neSandvik Coromant akashandiswa kuita rough nekupedza. Kucheka paramita (kumhanya, chikafu, kudzika kwekucheka) kwakagadziridzwa pachinhu chimwe chete uye kugona kwemuchina uchishandisa kurudziro yemugadziri wezvishandiso uye yakadzorwa bvunzo yekucheka.
Workholding:Tsika, yakanyatsogadzirwa modular zvigadziriso zvakava nechokwadi chakaomarara clamping uye inodzokororwa nzvimbo kune ese ari maviri muchina mhando. Kune iyo 3-axis miyedzo, zvikamu zvinoda kutenderedzwa zvakaiswa pamaoko pachishandiswa madhoweri chaiwo, kutevedzera muitiro wepasi pechitoro. Iyo 5-axis miyedzo yakashandisa iyo muchina izere kutenderera kugona mukati meimwe chete yekuseta.
2.3 Kuwana Data & Kuongorora
Cycle Time:Kuyerwa zvakananga kubva muchina nguva.
Kushata Kwepamusoro (Ra):Kuyerwa uchishandisa Mitutoyo Surftest SJ-410 profilometer panzvimbo shanu dzakakosha pachikamu. Zvikamu zvitatu zvakagadzirwa pane zvinhu / musanganiswa wemuchina.
Kururama kweGeometric:Yakaongororwa uchishandisa Zeiss CONTURA G2 coordinate measuring machine (CMM). Zviyero zvakakosha uye kushivirira kwejometri (kufuratira, perpendicularity, chimiro) zvakaenzaniswa neCAD modhi.
Statistical Analysis:Avhareji yemitengo uye kutsauka kwakajairwa kwakaverengerwa nguva yekutenderera uye zviyero zveRa. CMM dhata yakaongororwa kutsauka kubva pazviyero zvezita uye kushivirira kutevedza mareti.
Tafura 1: Yekuedza Setup pfupiso
| Element | 5-Axis Setup | 3-Axis Setup |
|---|---|---|
| Machine | DMG MORI DMU 65 monoBLOCK (5-Axis) | HAAS VF-4SS (3-Axis) |
| Kugadzirisa | Single custom fixture | Single custom fixture + manual kutenderera |
| Nhamba yeSetups | 1 | 3 (Impeller), 4 (Turbine Blade) |
| CAM Software | Siemens NX CAM (Multi-axis toolpaths) | Siemens NX CAM (3-axis maturusi enzira) |
| Kuyera | Mitutoyo SJ-410 (Ra), Zeiss CMM (Geo.) | Mitutoyo SJ-410 (Ra), Zeiss CMM (Geo.) |
3. Migumisiro & Analysis
3.1 Kubudirira Kuwana
5-axis machining yakaratidza kuchengetedza kwakanyanya nguva. Kune titanium impeller, 5-axis processing yakaderedzwa nguva yekutenderera ne58% ichienzaniswa ne3-axis machining (2.1 maawa vs. 5.0 maawa). Stainless steel turbine blade yakaratidza kuderedzwa kwe42% (1.8 maawa vs. 3.1 maawa). Izvi zvakawanikwa zvakakonzerwa nekubvisa akawanda setups uye yakabatana manyore kubata / kugadzirisa zvakare nguva, uye kugonesa mamwe anoshanda maturusi nzira neakareba, anoenderera kucheka nekuda kweakagadziridzwa maturusi ekutarisa.
3.2 Kuvandudza Hunhu Hwepamusoro
Surface roughness (Ra) inogara ichivandudzwa ne5-axis machining. Panzvimbo dzakaoma dzeblade dzetitanium impeller, avhareji yeRa values yakaderera ne32% (0.8 µm vs. 1.18 µm). Kuvandudzwa kwakafanana kwakaonekwa pane Stainless steel turbine blade (Ra yakaderedzwa ne35%, inokwana 0.65 µm vs. 1.0 µm). Kuvandudzwa uku kunokonzerwa nekugona kuchengetedza nguva dzose, yakakwana yekucheka yekuona kona uye kuderedzwa kwechishandiso vibration kuburikidza nekusimba kwechishandiso mune mapfupi maturusi ekuwedzera.
3.3 Geometric Accuracy Enhancement
Ongororo yeCMM yakasimbisa kurongeka kweiyo geometric ne5-axis kugadzirisa. Nhamba yezvikamu zvakakosha zvakachengetwa mukati meiyo yakaoma ± 0.025mm kushivirira yakawedzera zvakanyanya: ne30% yetitanium impeller (kuwana 92% kutevedza vs. 62%) uye ne26% yesimbi isina tsvina (kuwana 89% kutevedzera vs. 63%). Kuvandudzwa uku kunobva zvakananga kubva mukubviswa kwemhosho dzekuwedzera dzakaunzwa neakawanda setups uye bhuku repositioning inodiwa mu3-axis process. Zvimiro zvinoda makomboni emakona zvakaratidza zvakanyanya kushamisa budiriro.
*Mufananidzo 1: Kuenzanisa Kwekuita Metrics (5-Axis vs. 3-Axis)*
4. Kukurukurirana
Mhedzisiro yacho inosimbisa zvakanakira hunyanzvi hwe5-axis machining yezvikamu zvakaoma zvesimbi. Iwo akakosha kudzikiswa kwenguva yekutenderera anoshandura zvakananga kudzika pachikamu-mutengo uye kuwedzera kwekugadzira kugona. Iyo yakagadziridzwa pamusoro pekupedzisira inoderedza kana kubvisa yechipiri kupedzisa mashandiro senge kupukuta nemaoko, kuwedzera kudzikisa mitengo uye nguva dzekutungamira uku uchiwedzera kuwirirana kwechikamu. Kusvetuka mukurongeka kwejometri kwakakosha kune yakakwirira-inoshanda senge injini dzemuchadenga kana maimplants ekurapa, uko chikamu chekushanda uye chengetedzo zvakakosha.
Aya mabhenefiti anonyanya kusimuka kubva pakugona kweiyo 5-axis machining: panguva imwe chete yakawanda-axis kufamba kunogonesa single-setup process. Izvi zvinobvisa kukanganisa-kukonzeresa zvikanganiso uye nguva yekubata. Uyezve, kuenderera kwakaringana kwechishandiso chekutarisa (kuchengeta chakanakira chip mutoro uye masimba ekucheka) inosimudzira kupedzisa kwepamusoro uye inobvumira mamwe ane hukasha machining marongero apo kusimba kwechishandiso kunobvumira, zvichibatsira kukurumidza kuwana.
Zvisinei, kugamuchirwa kunoshanda kunoda kubvuma miganhu. Iyo capital investimendi yemuchina unokwanisa 5-axis muchina uye yakakodzera tooling yakakwira zvakanyanya pane ye3-axis michina. Programming yakaoma inowedzera exponentially; kugadzira inoshanda, kudhumhana-isina 5-axis maturusi enzira inoda hunyanzvi hweCAM programmers uye software yakaoma. Simulation uye verification inova nhanho dzinosungirwa usati wagadzira. Kugadzirisa kunofanirwa kupa zvese kuomarara uye kubvumidzwa kwakakwana kwekufamba kwakazara kutenderera. Izvi zvinhu zvinosimudza hunyanzvi hunyanzvi hunodiwa kune vanoshanda nevagadziri.
Chirevo chinoshanda chakajeka: 5-axis machining inokunda yemhando yepamusoro, yakaoma zvikamu uko zvakanakira mukumhanya, mhando, uye kugona zvinopembedza iyo yepamusoro mashandiro epamusoro nekudyara. Kune zvikamu zvakareruka, 3-axis machining inoramba ichinyanya hupfumi. Kubudirira kunoenderana nekudyara mune zvese tekinoroji uye vashandi vane hunyanzvi, pamwe neCAM yakasimba uye maturusi ekuenzanisa. Kudyidzana kwekutanga pakati pedhizaini, kugadzira mainjiniya, uye chitoro chemuchina kwakakosha kukwirisa zvizere 5-axis kugona uku uchigadzira zvikamu zvekugadzira (DFM).
5. Mhedziso
Yemazuva ano 5-axis CNC machining inopa inoratidziro yepamusoro mhinduro yekugadzira yakaoma, yakakwirira-chaiyo tsika simbi zvikamu zvichienzaniswa neyakajairwa 3-axis nzira. Zvakawanikwa zvakakosha zvinosimbisa:
Kubudirira Kwakakosha:Kudzikiswa kwenguva yekutenderera kwe40-60% kuburikidza ne-single-setup machining uye yakagadziridzwa maturusi nzira.
Hunhu hwakavandudzwa:Surface roughness (Ra) kuvandudzwa kweanosvika makumi matatu neshanu muzana nekuda kwekwakaringana maturusi ekutarisa uye kubata.
Kunyatsorurama:Avhareji ye28% yekuwedzera mukubata kwakakosha kushivirira kwejometri mukati me ± 0.025mm, kubvisa zvikanganiso kubva kune akawanda setups.
Tekinoroji inogonesa kugadzirwa kweakaoma matekinoroji ejometri (yakadzika mhango, undercuts, makomisheni macurves) ayo asingagoneki kana asingagoneke ne3-axis machining, achigadzirisa zvakananga kushanduka kuri kuda kweaerospace, zvekurapa, uye simba zvikamu.
Kuti uwedzere kudzoka pakudyara mune 5-axis kugona, vagadziri vanofanirwa kutarisa kune yakakwira-yakaomesesa, yakakwirira-yakakosha zvikamu uko kurongeka uye nguva yekutungamira zvinhu zvakakosha zvemakwikwi. Basa remangwana rinofanirwa kuongorora kubatanidzwa kwe5-axis machining ne-in-process metrology ye-real-time quality control uye kuvhara-loop machining, kuwedzera kusimbisa uye kuderedza zvimedu. Kuenderera mberi netsvagurudzo mumagadzirirwo emagetsi ekugadzirisa 5-axis kuchinjika kwezvinhu zvakaoma-ku-muchina seInconel kana simbi dzakaomeswa zvinopawo gwara rakakosha.
