Slotting Of Hardened Karfe Tare da PCBN Cutter

Slotting na taurin karfe tare da PCBN abun yanka

A cikin shekaru goma da suka gabata, daidaitattun sassa na ƙarfe mai tauri tare da abubuwan da ake saka polycrystalline cubic boron nitride (PCBN) ya maye gurbin niƙa na gargajiya a hankali. Tyler Economan, manajan injiniyan bayyani a Index, Amurka, ya ce, “Gaba ɗaya, niƙa ramuka tsari ne mai tsayin daka wanda ke ba da daidaito mai girma fiye da tsagi. Koyaya, har yanzu mutane suna son samun damar kammala aikin a kan lathe. Ana buƙatar sarrafawa iri-iri."

Daban-daban workpiece kayan da aka taurare sun hada da high gudun karfe, mutu karfe, hali karfe da gami karfe. Ƙarfe na ƙarfe ne kawai za a iya taurare, kuma ana amfani da matakan taurare akan ƙananan karafa na carbon. Ta hanyar jiyya na hardening, za a iya sanya taurin waje na workpiece mafi girma da kuma sawa, yayin da ciki ya fi dacewa. Sassan da aka yi da ƙarfe mai tauri sun haɗa da mandrels, axles, connectors, wheel wheels, camshafts, gears, bushings, tuƙi tuƙi, bearings, da makamantansu.

Koyaya, "kayan wuya" dangi ne, canza ra'ayi. Wasu mutane suna tunanin cewa kayan aiki tare da taurin 40-55 HRC kayan aiki ne masu wuya; wasu sun yi imanin cewa taurin kayan aiki ya kamata ya zama 58-60 HRC ko mafi girma. A cikin wannan rukunin, ana iya amfani da kayan aikin PCBN.

Bayan induction hardening, saman taurare Layer na iya zama har zuwa 1.5mm lokacin farin ciki da taurin zai iya kai 58-60 HRC, yayin da kayan da ke ƙasa da saman Layer yawanci yafi laushi. A wannan yanayin, yana da mahimmanci don tabbatar da cewa yawancin yankan ana yin su a ƙasa da ƙasa mai tauri.

Kayan aikin injin tare da isassun ƙarfi da tsauri sune yanayin da ake buƙata don tsaga sassa masu tauri. A cewar Economan, “Mafi kyawun ƙarfin injin na'urar kuma mafi girman ƙarfin, mafi kyawun tsinke kayan taurara. Don kayan aikin aiki tare da taurin sama da 50 HRC, kayan aikin injin haske da yawa ba sa saduwa da yanayin yanke da ake buƙata. Idan karfin injin (ikon, juzu'i, musamman tsauri) ya wuce, ba za a iya kammala aikin cikin nasara ba."

Rigidity yana da matukar mahimmanci ga na'urar da ke riƙe da kayan aiki saboda yanayin lamba na yankan gefen tare da kayan aiki yana da girma a lokacin aikin tsagi, kuma kayan aiki yana haifar da matsananciyar matsa lamba akan aikin. A lokacin da clamping taurara karfe workpieces, m matsa za a iya amfani da su watsar da clamping surface. Paul Ratzki, manajan tallace-tallace na Sumitomo Electric Hard Alloy Co., ya ce, “Dole ne a tallafa wa sassan da za a yi injin. Lokacin da ake yin taurare kayan, girgizar girgiza da matsa lamba na kayan aiki da aka haifar sun fi girma fiye da lokacin da ake yin gyare-gyare na yau da kullun, wanda zai iya haifar da ƙulla kayan aiki. Ba za a iya tashi daga cikin injin ba, ko kuma sa ruwan CBN ya guntu ko ma ya karye."

Ƙunƙarar da ke riƙe da abin da ake sakawa ya kamata ya zama gajere gwargwadon yuwuwar don rage wuce gona da iri da ƙara tsaurin kayan aiki. Matthew Schmitz, manajan samfuran GRIP a Isca, ya nuna cewa gabaɗaya, kayan aikin monolithic sun fi dacewa da tsagi kayan da aka taurare. Koyaya, kamfanin kuma yana ba da tsarin tsagi na zamani. "Za a iya amfani da shank na zamani a cikin yanayin injina inda kayan aikin ke da wuyar gazawar kwatsam," in ji shi. "Ba dole ba ne ka maye gurbin shank gaba ɗaya, kawai kuna buƙatar maye gurbin kayan da ba shi da tsada. Modular shank kuma yana ba da zaɓuɓɓukan injina iri-iri. Ana iya shigar da tsarin na'ura na Iskar's Grip a cikin samfura daban-daban. Kuna iya amfani da mariƙin kayan aiki tare da ruwan wukake daban-daban 7 don layin samfuri 7 ko kowane adadin ruwan wukake don aiki daban-daban Layin samfurin iri ɗaya tare da faɗin ramin."

Masu riƙe kayan aikin Sumitomo Electric don riko nau'in nau'in nau'in CGA suna amfani da hanyar daɗaɗɗen sama wanda ke jan ruwa baya cikin mariƙin. Wannan mariƙin kuma yana fasalta dunƙule ƙulle-ƙulle don taimakawa haɓaka kwanciyar hankali da tsawaita rayuwar kayan aiki. Rich Maton, mataimakimanajan sashen zane na kamfanin, ya ce, "Wannan mariƙin kayan aiki an tsara shi ne don tsangwama na kayan aiki masu wuyar gaske. Idan ruwan ya motsa a cikin mariƙin, ruwan zai ci gaba da ɗaukar lokaci kuma rayuwar kayan aiki ta canza. masana'antu (kamar 50-100 ko 150 workpieces a kowane yanki), tsinkayar rayuwar kayan aiki yana da mahimmanci musamman, kuma canje-canje a rayuwar kayan aiki na iya yin tasiri mai mahimmanci akan samarwa."

A cewar rahotanni, Mitsubishi Materials' GY jerin Tri-Lock na zamani tsarin tsagi yana da kwatankwacin tsayin daka zuwa gaɓoɓin ruwa. Tsarin ya dogara da riƙon tsagi daga wurare uku (na gefe, gaba da sama). Tsarin tsarinsa guda biyu yana hana ruwa daga gudun hijira a lokacin tsagi: tsinkayar nau'in V yana hana ruwa daga motsawa zuwa bangarorin; Maɓallin aminci yana kawar da motsi na gaba na ruwan wuka da aka yi ta hanyar yankan ƙarfi yayin aikin mashin ɗin.

Abubuwan da aka saba amfani da su don ɓangarorin ƙarfe masu tauri sun haɗa da sassaƙaƙan madauri, ƙirƙirar abun da ake sakawa, abubuwan da aka saka, da makamantansu. Gabaɗaya, ana buƙatar raƙuman da aka yanke don samun kyakkyawan yanayin gamawa saboda suna da rabon mating, wasu kuma O-rings ko tsagi na zobe. A cewar Mark Menconi, samfur ƙwararren a Mitsubishi Materials, "Wadannan matakai za a iya raba ciki diamita tsagi machining da kuma m diamita tsagi machining, amma mafi yawan grooving ayyuka na bukatar lafiya yankan, ciki har da haske taba madaidaici daga game da 0.25 mm zurfin yanke. Yanke to. cikakken yanke tare da zurfin kusan 0.5mm."

Ƙarƙashin ƙarfe na ƙarfe yana buƙatar amfani da kayan aiki tare da taurin mafi girma, mafi kyawun juriya da juriya mai dacewa. Makullin shine a gano ko yakamata a yi amfani da abin saka carbide, abin saka yumbu ko abin saka PCBN. Schmitz ya ce, "Kusan koyaushe ina zabar abubuwan saka carbide lokacin da ake yin kayan aiki tare da taurin ƙasa 50 HRC. Don kayan aiki tare da taurin 50-58 HRC, abubuwan saka yumbu zaɓi ne na tattalin arziki sosai. Sai kawai lokacin da CBN ke saka kayan aiki ya kamata a yi la'akari da taurin har zuwa 58 HRC. Abubuwan da aka saka na CBN sun dace musamman don kera irin waɗannan abubuwa masu wuyar gaske saboda injin ɗin ba kayan yankan kayan aiki bane amma kayan aiki / kayan aiki ne. Narke kayan.

Don tsaga sassan ƙarfe masu tauri tare da taurin sama da 58 HRC, sarrafa guntu ba matsala bane. Tun da busasshiyar bushewa yawanci ana amfani da su, kwakwalwan kwamfuta sun fi kama da ƙura ko ƙananan ƙwayoyin cuta kuma ana iya cire su ta hanyar bugun hannu. Sumitomo Electric's Maton ya ce, "Yawanci, irin wannan tawadar takan wargaje ne idan ta buge wani abu, don haka tuntuɓar swarf ɗin da kayan aikin ba zai lalata kayan aikin ba, idan ka kama ɗimbin, za su fasa a hannunka."

Ɗaya daga cikin dalilan da ya sa na'urorin CBN suka dace don yanke bushewa shi ne, duk da cewa juriya na zafi yana da kyau sosai, aikin sarrafawa yana raguwa sosai a yanayin yanayin zafi. Economan ya ce, "A gaskiya, lokacin da CBN ke hulɗa da kayan aiki, yana haifar da zafi na yankewa a kan tip, amma saboda abin da CBN ya yi ba shi da sauƙi don canza yanayin zafi, yana da wuya a yi sanyi sosai don kula da kullun. zafin jiki. Jiha CBN yana da wahala sosai, amma kuma yana da karyewa kuma yana iya fashe saboda canjin yanayi."

Lokacin yankan sassa na ƙarfe tare da ƙananan tauri (kamar 45-50 HRC) tare da siminti carbide, yumbu ko abubuwan PCBN, kwakwalwan da aka samar yakamata su kasance gajere gwargwadon yiwu. Wannan yadda ya kamata ya kawar da zafi na yankewa a cikin kayan aiki a lokacin aikin yankewa saboda kwakwalwan kwamfuta na iya ɗaukar zafi mai yawa.

Iskar's Schmitz kuma ya ba da shawarar cewa a sarrafa kayan aikin a cikin yanayin "juyawa". Ya bayyana cewa, “Lokacin da ake saka na’ura a kan na’ura, ana sanya kayan aikin da maginin ya fi so ne ta hanyar yanke fuska, saboda hakan yana ba da damar.jujjuya aikin aikin don aiwatar da matsa lamba na ƙasa akan layin dogo don kiyaye injin ɗin ya tsaya. Koyaya, lokacin da aka yanke ruwa a cikin kayan aikin, kwakwalwan da aka kafa na iya kasancewa akan ruwan wukake da kayan aikin. Idan an juyar da mariƙin kayan aiki kuma kayan aikin yana hawa sama, ba za a iya ganin ruwa ba, kuma guntuwar za ta kuɓuta kai tsaye daga yankin yanke ƙarƙashin aikin nauyi."

Ƙarƙashin ƙasa hanya ce mai sauƙi don inganta taurin ƙananan ƙarfe na carbon. Ka'idar ita ce ƙara abun ciki na carbon a wani zurfin ƙasa a ƙarƙashin saman kayan. Lokacin da zurfin tsagi ya wuce kauri na saman da aka taurare, wasu matsaloli na iya tasowa saboda canjin tsagi daga abu mai wuya zuwa abu mai laushi. Don wannan karshen, masana'antun kayan aiki sun haɓaka maki da yawa don nau'ikan kayan aiki daban-daban.

Duane Drape, manajan tallace-tallace a Horn (Amurka), ya ce, "Lokacin da canza daga abu mai wuya zuwa abu mai laushi, mai amfani ba koyaushe yana son canza ruwa ba, don haka dole ne mu nemo mafi kyawun kayan aiki don irin wannan injin. .Idan aka yi amfani da injin siminti na siminti, za a gamu da matsalar yawan lalacewa lokacin da ruwa ya yanke tsattsauran wuri, idan aka yi amfani da abin da CBN ya dace da yankan kayan da ya dace don yanke sassa mai laushi, yana da sauƙi a lalata ta. Za mu iya amfani da wani sulhu: high taurin carbide abun da ake sakawa + super lubricated coatings, ko in mun gwada da taushi CBN saka maki + yankan abun da ake sakawa dace da yankan gama gari (maimakon machining mai wuya)."

Drape ya ce, "Kuna iya amfani da abubuwan da aka saka na CBN don yanke kayan aiki yadda ya kamata tare da taurin 45-50 HRC, amma dole ne a gyara joometry na ruwa. Abubuwan da ake sakawa na CBN na yau da kullun suna da mummunan chamfer akan yankan gefen. Wannan madaidaicin chamfer na CBN ya fi laushi zuwa na'ura. Lokacin da aka yi amfani da kayan aikin aiki, kayan za su sami tasirin cirewa kuma za a gajarta rayuwar kayan aiki. Idan aka yi amfani da darajar CBN tare da ƙananan tauri kuma an canza geometry na yanki, kayan aikin da ke da taurin 45-50 HRC za a iya samun nasarar yanke shi."

Saka S117 HORN da kamfanin ya ƙera yana amfani da tip na PCBN, kuma zurfin yanke shine kusan 0.15-0.2 mm lokacin da faɗin gear ya yanke daidai. Don cimma kyakkyawan sakamako mai kyau, ruwa yana da jirgin sama mai gogewa akan kowane yanki na yanke a bangarorin biyu.

Wani zaɓi shine canza sigogin yanke. A cewar Index's Economan, "Bayan yanke ta cikin Layer mai tauri, ana iya amfani da manyan sigogin yanke. Idan zurfin taurara shine kawai 0.13mm ko 0.25mm, bayan yanke ta cikin wannan zurfin, ko dai ana maye gurbin ruwan wukake daban-daban ko har yanzu ana amfani da ruwa iri ɗaya, amma ƙara sigogin yanke zuwa matakin da ya dace.

Domin rufe kewayon sarrafawa, PCBN maki yana ƙaruwa. Makin taurin mafi girma yana ba da izinin yanke saurin sauri, yayin da maki tare da ingantacciyar ƙarfi za a iya amfani da su a cikin wuraren sarrafawa marasa ƙarfi. Don ci gaba ko yanke yanke, ana iya amfani da makin saka PCBN daban-daban. Sumitomo Electric's Maton ya yi nuni da cewa saboda gazawar kayan aikin PCBN, kaifi yankan gefuna suna da saurin yin guntuwa yayin da ake yin taurin karfe. "Dole ne mu kare gefen yanke, musamman a cikin yanke yanke, ya kamata a shirya yankan fiye da ci gaba da yankewa, kuma kusurwar yanke ya kamata ya fi girma."

Sabon ci gaba na Iskar IB10H da IB20H maki ya kara fadada layin samfurin Groove Turn PCBN. IB10H ne mai kyau-grained PCBN sa ga matsakaici zuwa high gudun ci gaba da yankan taurare karfe; yayin da IB20H ya ƙunshi nau'in hatsi mai kyau da matsakaici na PCBN, yana ba da juriya mai kyau da juriya mai tasiri. Ma'auni na iya jure yanayin da ya fi ƙarfin ƙarfin ƙarfe da aka katse yanke. Yanayin gazawar al'ada na kayan aikin PCBN ya kamata ya zama abin yankewa ya ƙaremaimakon tsagewa kwatsam ko tsagewa.

Makin PCBN mai rufi na BNC30G wanda Sumitomo Electric ya gabatar ana amfani da shi don tsagaita wuta na kayan aikin ƙarfe na ƙarfe. Don ci gaba da tsagi, kamfanin yana ba da shawarar ƙimar BN250 ta duniya. Maton ya ce, “Lokacin da ake ci gaba da yin yankan, ana yanke ruwan wuka na dogon lokaci, wanda zai haifar da yanke zafi mai yawa. Sabili da haka, wajibi ne a yi amfani da ruwa tare da juriya mai kyau. A cikin yanayin tsagi na tsaka-tsaki, ruwan wukake yana shiga yana fita yankewa. Yana da babban tasiri a kan tip. Sabili da haka, wajibi ne a yi amfani da wuka mai kyau tare da tauri mai kyau kuma zai iya jure wa tasiri na tsaka-tsaki. Bugu da ƙari, murfin ruwa yana taimakawa wajen tsawaita rayuwar kayan aiki."

Ba tare da la'akari da nau'in tsagi da ake yin inji ba, tarurrukan da a baya suka dogara da niƙa don gama sassan ƙarfe masu tauri za a iya jujjuya su zuwa tsintsiya tare da kayan aikin PCBN don haɓaka yawan aiki. Tsagi mai wuya na iya cimma daidaiton girman girman kwatankwacin nika, yayin da rage lokacin injina sosai.