Idan kun ji labarin EDM kuma kuna mamakin abin da ke faruwa, kun zo wurin da ya dace. Wannan tsari, kuma aka sani da Injin fitar da wutar lantarkiYana ba da damar ƙirƙira haɗaɗɗun geometries a cikin kayan aiki masu wuyar gaske ba tare da kayan aikin jiki ya taɓa kayan aikin ba. A wasu kalmomi, kayan aiki ba ya yanke: walƙiya yana yin aikin.
A cikin wannan jagorar za ku fahimta Menene EDM, ta yaya yake aiki, waɗanne nau'ikan da ke wanzu, waɗanne kayan aiki na iya yin injin?Za ku koyi lokacin da ya dace a yi amfani da shi, menene farashi ya ƙunsa, da yadda ya kwatanta da injinan gargajiya. Hakanan za ku ga abubuwan da ke tattare da shi, tsarin aiki na mataki-mataki, da amsoshin tambayoyin gama-gari, duk an gabatar da su a bayyane kuma ta halitta don sauƙaƙe samun abin da kuke buƙata.
Menene EDM (Machining Discharge Machining)?
EDM wata dabara ce ta cire kayan ta amfani da makamashin thermal: sarrafawar fitar da wutar lantarki tsakanin lantarki da kayan aiki Ana amfani da shi don narke da vaporized ƙananan sassa na ƙarfe. Yana aiki ne kawai tare da kayan sarrafawa ko semiconducting, don haka robobi, itace, gilashi, ko yumbu masu hana ruwa ba su dace ba.
Babban ƙarfinsa shine a tsari ba tare da lamba na inji baTunda babu wani ƙarfi mai yankewa, ana rage nakasawa a cikin sassa masu laushi, ganuwar bakin ciki ko kunkuntar cikakkun bayanai, kuma ana samun kyakkyawan yanayin da ya ƙare tare da buƙatar haƙuri.
Game da asalinsa, an san tasirin wutar lantarki tun daga karni na 18, amma a cikin 1940s ne masana kimiyyar Soviet suka yi. B. da N. Lazarenko Sun É“ullo da da'irar maimaituwar fitarwa a cikin matsakaicin dielectric wanda ya sanya injin sarrafawa mai inganci. A karshen shekarun 60, fasahar fitar da wutar lantarki ta waya (EDM) ta tashi bayan bayyanar injinan kasuwanci na farko, kuma tun daga wannan lokacin fasahar ta ci gaba da bunkasa. balagagge da kuma haÉ—a CNC iko, Multi-axis da aiki da kai.
Yadda yake aiki: daga bugun wutar lantarki zuwa cire kayan aiki
A cikin kowane nau'in EDM, ƙa'ida ɗaya ce: na'urar lantarki (waya, sanda, ko lantarki mai siffa) an kawo kusa da aikin aiki, yana riƙe da rabuwar microscopic. Janareta yana amfani da bugun jini wanda ke haifar da a walƙiya tsakanin lantarki da yankiMatsakaicin zafin jiki na gida zai iya kaiwa tsari na 14.500 zuwa 21.500 °F, wanda ya isa ya narke da vaporize kayan a takamaiman wurare.
Tsarin yana faruwa sau dubbai a sakan daya. Ruwan dielectric (takamaiman mai ko Ruwan da ba shi da kyau wanda ke aiki azaman insulator da sanyayaYana fitar da ɓangarorin da suka rushe, yana daidaita fitar, kuma yana hana tartsatsin da ba a so. A halin yanzu, tsarin servo yana sarrafa rabuwa don kula da tartsatsi a mafi kyawun wurinsa, kuma janareta yana daidaita sigogi kamar ƙarfin lantarki, halin yanzu, mita, har ma da siffar bugun jini.
Rashin lamba yana rage saura damuwa da burrs; duk da haka, wani bakin ciki "recast" Layer yana samuwa a saman, don haka a cikin sassa masu mahimmanci yana da kyau daidaita kuzarin wucewar ƙarshe don inganta daidaiton ƙarfe da gamawa.
Mahimman abubuwan da ke cikin injin EDM
Bayan firam da axles, injin injin fitarwa na lantarki (EDM) yana haÉ—a tsarin da yawa waÉ—anda ke ba da damar daidaito da maimaita aikin; kowannensu yana da takamaiman aiki. m ga karshe ingancin.
Samar da wutar lantarki da janareta na bugun jini
Yana iko da tsarin kuma yana haifar da tartsatsi. Yana tsarawa. ƙarfin lantarki, halin yanzu, mita, da tsawon lokacin bugun jini dangane da aiki: roughing, Semi-finishing, ko karewa. Kyakkyawan daidaitawa yana da mahimmanci don daidaita ƙimar farawa, lalacewa ta lantarki, da ƙarewar ƙasa.
Electrodes
A cikin sinker EDM, na'urar lantarki ta sake haifar da rami da za a yi amfani da shi a cikin mummunan; a cikin waya EDM, lantarki shine waya mai kyau sosai, kuma a cikin hakowa, shi ne bututu mai ɗaukar nauyi ta inda dielectric kuma ke gudana. Kayan aiki na yau da kullun: graphite, jan ƙarfe, jan ƙarfe-tungsten, tungsten, tagulla, da gami da alaƙa, kowanne yana da nasa kaddarorin. daidaita tsakanin conductivity, sa juriya da machinability.
Dielectric tsarin
Ita ce "matsakaici" mai aiki. Yana iya zama mai (mafi kowa a cikin sinkers) ko deionized ruwa (na al'ada a cikin waya EDM). Yana sanyaya, yana cire É“angarorin, yana daidaita tashar fitarwa, kuma yana rage gajerun kewayawa. Ya haÉ—a da tanki, famfo, masu tacewa, kuma, a cikin injina da yawa. tsarin sanyaya don sarrafa zafin ruwa.
Servocontrol da sarrafa lambobi
Ikon servo yana daidaita rata (rabuwa) tsakanin lantarki da kayan aiki a cikin ainihin lokacin don tabbatar da ingantaccen walƙiya da kwanciyar hankali, yayin da CNC ke yin kida. yanayi, karkarwa, lokutan zazzagewa da aiki tareWannan haɗin yana ba da garantin daidaito da maimaitawa koda cikin cikakkun bayanai masu kyau.
Jagora, shugabanni da na'urorin haÉ—i
Wire EDM yana amfani da jagororin sama da ƙananan waɗanda ke riƙe da matsayi na waya; daidaitarsu da tsayin tsayin su suna ba da damar yin aiki tare da sassa daban-daban masu girma dabam. tsawo kuma ku yi yankan kusurwa dangane da Z-axis. Na'urar kuma tana haɗa tankin aiki, famfo, kayan gyarawa, ma'auni (voltmeter/ammeter) da, sau da yawa, tsarin fitar da barbashi / tacewa.
Nau'in EDM da abin da kowanne ake amfani dashi
Dangane da lissafin lissafi, girman fasalin, da ƙarewar da ake so, nau'in ɗaya ko wani zai fi dacewa. Dukkansu suna da ka'idar zaizayar wutar lantarki iri ɗaya, amma kayan aikin lantarki da ... yankan dabarun.
EDM ta hanyar shiga (sinker, nutsewa ko rami)
Ana amfani da na'urar lantarki mai siffar da ake so (wanda aka yi da graphite ko jan karfe, alal misali), wanda aka saka a cikin kayan aiki don "kwafi" wannan lissafin. Yana da manufa hanya domin hadaddun cavities, zurfafa veins, sosai matsi na ciki sasanninta da cikakkun bayanai waɗanda ba su yiwuwa ko kuma masu tsada sosai don cimma su tare da hanyoyin al'ada. Bugu da ƙari kuma, yana rage bayan aiwatarwa da ake buƙata don haɓaka ƙarewa ko taurare saman.
Yawanci yana aiki da nitsewa a cikin man dielectric kuma yana ba da iko mai kyau a cikin wuraren 3D, yana mai da shi madaidaicin a ciki. ya mutu, molds da kayan aiki na babban hadaddun. Ƙarfinsa da wuya ya dogara da taurin kayan.
Waya EDM (machining na fitar da wutar lantarki)
Yana amfani da waya mai É—orewa mai kyau, yawanci 0,05 zuwa 0,35 mm a diamita, wanda "sanya" kayan ta hanyar tartsatsi yayin da dielectric (ruwan deionized) sanyaya da fitar da barbashiYana da manufa don madaidaicin kwandon 2D, kuma tare da karkatar da hankali game da Z kuma, a cikin cibiyoyi masu ci gaba, tare da gatari 5.
Yana buƙatar rami mai zaren farko kuma yana iya samarwa kawai ta cavities, ba makaho. Yana ba da damar ƙananan radiyo na ciki (iyakance da diamita na waya), ingantacciyar daidaito a cikin naushi, mutu da mota, abubuwan haɗin sararin samaniya, likita da hakori.
EDM (hakowa EDM)
Na musamman a cikin ƙananan ramuka da zurfi, madaidaiciya, ramuka marasa burr. Yana amfani da na'urorin lantarki na tubular waɗanda ke sauƙaƙe kwararar dielectric ta kayan aiki don kwashe kayan. Yana iya cimma diamita a kusa 0,0015" (≈0,038 mm) ko mafi girma, har ma da ma'auni mai girman gaske.
Babban fa'idodin: drills ba tare da karkata ba akan saman lanƙwasa ko karkatacce, taurin kayan ba ya shafa, kuma ya bar irin wannan kyakkyawan gamawa wanda, a yawancin lokuta, yana aiki azaman abin birgima ba tare da post-machining ba. Ana amfani da ita don fara waya a cikin waya EDM, cire fashe fafutuka, da ƙirƙirar tashoshi masu sanyaya a cikin injin turbine.
Bambance-bambancen da kari: Multi-axis, micro-EDM da EDM milling
Yaushe ya dace don zaɓar EDM?
Akwai yanayi inda EDM ya kasance a fili mafi kyawun zaɓi: lokacin da geometries ba zai yiwu a yi niƙa ko juya ba tare da murdiya ba, lokacin da kayan yana da wuyar gaske, ko kuma lokacin da makasudin shine cimma takamaiman kama. mafi girma, gamawa mara buri.
- Haƙa ƙananan ramuka da ramuka masu zurfi sosai tare da m tolerances.
- Yanke extrusions, sifofin rotary, da hadaddun kwane-kwane na 2D tare da babban daidaito.
- Ƙirƙirar ɓarna na 3D cavities a cikin kyawon tsayuwa kuma ya mutu, tare da zurfin jijiya da kusurwoyi masu tsauri na ciki.
- Zane akan kayan wuya (misali, tungsten ko carbide).
- Cire fashewar famfo ko rawar jiki ba tare da lalata kayan aikin ba, ko da a cikin kayan da aka yi da zafi.
Fa'idodi da iyakancewa
EDM ya fito waje don daidaiton girmansa, rashin damuwa na inji, da a high-matakin surface gamaAmma ba harsashi na azurfa ba ne, kuma yana da mahimmanci a san illolinsa.
- Ribobi: tsarin da ba a tuntuɓar ba wanda ke rage nakasawa; haƙuri mai matukar buƙata (a kan tsari na ± 0,0002 ″); yuwuwar sarrafa kayan aiki masu wuyar gaskeYanke mai zurfi da kwanciyar hankali; ƙananan burs; ƙananan ƙarancin kayan aiki idan aka kwatanta da yankan na al'ada; yuwuwar "kashe fitilu" ta atomatik.
- Yarda: a hankali lokutan taya fiye da injinan gargajiya; bai dace da kayan da ba su da iko; yawan amfani da wutar lantarki; babban inji da farashin aiki (electrodes, waya, dielectric); Layer da aka rufe na iya buƙatar wucewar ƙarewa; a cikin waya EDM, ba za a iya yin kogon makafi ba, kuma ƙananan radius na ciki yana iyakance ta zaren diamitaBa a sake yin kusurwoyi masu kaifi daidai ba.
Abubuwan da suka dace
Kusan duk karafa da kayan aiki za a iya sarrafa su. Daga cikin mafi yawansu akwai... karfe (ciki har da taurare da bakin karfe)jan karfe, aluminum, tagulla, graphite, titanium, tungsten carbide, Kovar, zinariya da azurfa.
A cikin superalloys na tushen nickel (Inconel, Hastelloy) EDM yana aiki da dogaro; tare da high-tsarki nickels amfani da ko'ina a aeronautics, da zaɓin lantarki da sigogi Yana da maɓalli don kiyaye tsayayyen ƙimar farawa da ƙarewar inganci.
Hannun masana'antu da sassa
Injin fitar da wutar lantarki (EDM) ya zama kayan aiki da ba makawa a sassan da madaidaici da kayan aiki masu wahala suke da mahimmanci, tare da yin fice a cikin sararin samaniya, mota, likita da kuzari.
- Jirgin sama: turbin ruwan wukake, injectors, abubuwan sanyaya, kayan tallafi na tsari da gidaje na avionics tare da haƙuri mai mahimmanci.
- Kera motoci da masu mutuwa: naushi, yankan, extrusion da zurfin zane ya mutu, hadaddun ya mutu da ma'auni.
- Likita da hakori: dasawa da na'urorin tiyata tare da cikakkun bayanai na mintuna da gama ba burr.
- Electronics/Semiconductors: masu haÉ—awa, gidaje da daidaitattun sassa tare da kyau kwane-kwane.
- Makamashi da sauran wurare: machining na sassa don makamashin nukiliya / iska, R&D da aikace-aikace soja da kayayyakin more rayuwa.
Farashin: zuba jari, aiki da yawan aiki
Kafin ka yi sauri don siyan injin EDM, la'akari da ma'auni tsakanin zuba jari, farashin sarrafawa, da nauyin aiki, saboda zaɓin. yana da tasiri kai tsaye akan riba.
Zuba jari a cikin injina
Zuba jari na farko yana da girma, musamman ga sabbin samfura. Don gajerun gudu, ƙayyadaddun farashin kowane yanki na iya yin sama, don haka yana da kyau a... nazarin aikin aiki da dawowa ana tsammanin.
Kudin aiki da kayan aiki
Electrodes, waya, dielectric ruwa, tacewa, da wutar lantarki suna da hannu. Duk da haka, sharar gida yawanci kasa da a cikin injina, don haka farashin albarkatun kasa na iya zama ƙasa. karin abun ciki a yawancin aikace-aikace.
Maintenance da ma'aikata
Kamar kowace na'ura mai ma'ana, tana buƙatar kiyaye kariya (tace, jagorori, ƙira). Bugu da ƙari, aikinsa yana buƙatar gogaggen ma'aikataWannan yana ƙara farashin aiki amma yana tasiri inganci da lokaci.
Yawan aiki da lokacin jagora
Don sassa masu rikitarwa waɗanda ke buƙatar saiti masu yawa a cikin mashin ɗin al'ada, EDM na iya kammala aikin a cikin saiti ɗaya, rage kurakurai da lokutan jagora. Duk da haka, tsarin da kanta ya fi hankali fiye da CNC a cikin roughing na manyan kundin, don haka tsarawa yana da mahimmanci.
Kayan aiki da zaɓin mai kaya
A cikin masana'anta na sinker lantarki, farashin samar da na'urorin lantarki na iya zama mahimmanci idan girman batch ɗin ƙanƙanta ne. Idan kun fita waje, nemi masu kaya da su babban wurin shakatawa na plumb bobs, kirtani da drillsKyakkyawan sadarwa, amintaccen lokuta da iya aiki don girman sashin ku da rikitarwa.
EDM tare da injinan gargajiya
Wadannan matakai guda biyu ba koyaushe suke yin takara ba; sau da yawa sukan kara wa junansu. A cikin kyawon tsayuwa, alal misali, abu ne na gama gari don preform tare da niƙa CNC da tace gefuna tare da ... waya lantarki fitarwa inji.
- EDM: mara lamba, ƙarancin murdiya, madaidaicin madaidaici kuma m gamaYana aiki tare da kayan aiki mai wuyar gaske; yana da hankali kuma yana da farashin sa'a mafi girma.
- Na al'ada: sauri don babban farawa, mafi m a cikin kayan (ya haɗa da waɗanda ba direbobi ba), ƙananan farashin sa'a; na iya haifar da damuwa da burrs, kuma yana da wahalar isa ga wasu sasanninta na ciki.
HaÉ—in kai tare da CNC da daidaitaccen software
CNC shine ke dubawa wanda ke haɗa ƙira da na'ura: yana fassara trajectories zuwa ƙungiyoyin axis da yana sarrafa zazzagewaA cikin EDM na waya, yin amfani da gatura na U/V ya zama ruwan dare don yankan taper, kuma a cikin EDM mai-axis, ana ƙara jujjuya don ƙarin ƙayyadaddun geometries.
- CAD/CAM: Yana haifar da takamaiman geometries da hanyoyin kayan aiki (ciki har da diyya na waya da dabarun da suka gabata).
- Kwaikwayo: gani da ingantawa kafin yanke don gano karo da rashin inganci.
- Sa ido kan tsari: yana daidaita sigogin halin yanzu, ƙarfin lantarki, da bugun bugun jini a cikin ainihin lokaci.
- Ƙirƙirar hanya: sarrafa bayanai/fitarwa, mafi ƙarancin radii, da ingancin ingancin gama.
Gudun aikin mataki-mataki
Ko da yake kowane iyali (threading, plumb bob, hakowa) yana da nuances, ainihin kwarara yana da kama da haka kuma yana taimakawa wajen fahimtar abin da ke faruwa a cikin baho na aiki a kowane sake zagayowar. saukewa da fitarwa.
- Shiri: workpiece, lantarki / waya, dielectric ruwa, m kayan aiki da CNC shirin shirye.
- Kayyadewa da daidaitawa: an riƙe yanki, ana la'akari da tsaro tazarar farko Dama.
- Gudanar da Dielectric: an cika ruwa / samarwa ( nutsewa ko jet ), tare da tacewa mai aiki.
- Ƙaddamar da shirin: CNC tana daidaita gatari da zazzagewa; servo yana daidaita rabuwa a ainihin lokacin.
- Cire kayan abu: kowane walƙiya yana narkewa / yana vaporizes barbashi waɗanda dielectric ja daga; ana maimaita shi har sai an kammala roughing da gamawa.
Abubuwan da EDM ya yi nasara ta hanyar zabtarewar ƙasa
Akwai ayyukan da injin fitarwa na lantarki (EDM) shine kawai mafi kyawun zaɓi: mai zurfi da tsayin daka, m ciki sasannintam geometries, hade tare da riga-kafi magani don hana nakasawa, da kuma kerar da ƙwaƙƙwaran ƙira waɗanda suna jure wa ƙarin zagayawa tare da ƴan canji.
Kayan aikin fitar da wutar lantarki (EDM) yana sanya wutar lantarki da gaske don yin aiki don amfanin ku: lokacin da injin ɗin na yau da kullun ya ragu saboda taurin, lissafi, ko haɗarin nakasawa, wannan tsari ba wai kawai yana ba ku damar kera ɓangaren ba, amma don yin haka tare da Fitaccen daidaito da ƙarewahaɗawa tare da CAD / CAM, sarrafa kansa da sarrafa tsari don inganta lokutan jagora, inganci da maimaitawa.
