Kutsegula Kwa Chitsulo Cholimba Ndi PCBN Wodula

Kutsegula kwachitsulo cholimba ndi chodula cha PCBN

M'zaka khumi zapitazi, kukokomeza kwazitsulo zolimba zokhala ndi polycrystalline kiyubic boron nitride (PCBN) kwalowa m'malo mwa kugaya kwachikhalidwe. Tyler Economan, woyang'anira uinjiniya ku Index, USA, adati, "Nthawi zambiri, ma grooves ndi njira yokhazikika yomwe imapereka kulondola kwapamwamba kuposa kugwetsa. Komabe, anthu akufunabe kumaliza ntchitoyo pa lathe. Kukonzekera kosiyanasiyana kumafunika."

Zida zosiyanasiyana zogwirira ntchito zomwe zawumitsidwa zikuphatikizapo zitsulo zothamanga kwambiri, zitsulo zakufa, zitsulo zokhala ndi alloy zitsulo. Zitsulo zachitsulo zokha zimatha kuumitsidwa, ndipo njira zowumitsa nthawi zambiri zimagwiritsidwa ntchito pazitsulo zotsika za carbon. Kupyolera mu chithandizo choumitsa, kuuma kwa kunja kwa workpiece kumatha kupangidwa kukhala apamwamba komanso kuvala, pamene mkati mwake muli kulimba bwino. Zigawo zopangidwa ndi zitsulo zolimba zimaphatikizapo mandrels, ma axles, zolumikizira, mawilo oyendetsa, ma camshafts, magiya, ma bushings, ma shafts, ma fani, ndi zina zotero.

Komabe, "zida zolimba" ndi wachibale, kusintha lingaliro. Anthu ena amaganiza kuti zida zogwirira ntchito zolimba za 40-55 HRC ndi zida zolimba; ena amakhulupirira kuti kuuma kwa zinthu zolimba kuyenera kukhala 58-60 HRC kapena kupitilira apo. Pagulu ili, zida za PCBN zitha kugwiritsidwa ntchito.

Pambuyo pakuwumitsidwa kowumitsidwa, mawonekedwe owuma pamtunda amatha kufika 1.5mm wandiweyani ndipo kuuma kumatha kufika 58-60 HRC, pomwe zinthu zomwe zili pansi pamadzi zimakhala zofewa kwambiri. Pankhaniyi, m'pofunika kuonetsetsa kuti ambiri kudula kumachitika pansi pamwamba oumitsa wosanjikiza.

Zida zamakina zokhala ndi mphamvu zokwanira komanso zolimba ndizofunikira pakupukusa magawo olimba. Malinga ndi Economan, "Kulimba kwa chida cha makina ndi mphamvu zowonjezera mphamvu, m'pamenenso kupukuta kwa zinthu zolimba kumakhala kosavuta. Pakuti workpiece zipangizo ndi kuuma oposa 50 HRC, ambiri kuwala makina zida sizimakwaniritsa zofunika kudula mikhalidwe. Ngati mphamvu yamakina (mphamvu, torque, makamaka kulimba) ipitilira, makinawo sangathe kumaliza bwino. "

Kukhazikika ndikofunika kwambiri kwa chipangizo chogwiritsira ntchito workpiece chifukwa kukhudzana pamwamba pa m'mphepete mwa kudula ndi workpiece ndi kwakukulu panthawi ya grooving, ndipo chidacho chimakhala ndi vuto lalikulu pa workpiece. Mukamangirira zida zolimba zachitsulo, chotchinga chachikulu chingagwiritsidwe ntchito kubalalitsira malo omangira. A Paul Ratzki, woyang'anira zamalonda wa Sumitomo Electric Hard Alloy Co., adati, "Zigawo zomwe zimapangidwira ziyenera kuthandizidwa mwamphamvu. Pamene Machining zipangizo anaumitsa, kugwedera ndi chida kuthamanga kwaiye ndi zazikulu kuposa pamene Machining workpieces wamba, zomwe zingachititse workpiece clamping. Sitingawuluke pamakina, kapena kupangitsa kuti tsamba la CBN lipume kapena kusweka."

Shank yomwe imagwira choyikapo grooving iyenera kukhala yayifupi momwe mungathere kuti muchepetse kuchulukira ndikuwonjezera kulimba kwa zida. Matthew Schmitz, manejala wa zinthu za GRIP ku Isca, akuwonetsa kuti nthawi zambiri, zida za monolithic ndizoyenera kukulitsa zida zolimba. Komabe, kampaniyo imaperekanso ma modular grooving system. "Shank modular angagwiritsidwe ntchito machining zinthu kumene chida sachedwa kulephera mwadzidzidzi," iye akutero. "Simukuyenera kusintha shank yonse, muyenera kungosintha chinthu chotsika mtengo. The modular shank imaperekanso njira zosiyanasiyana zopangira makina. Iskar's Grip modular system imatha kukhazikitsidwa muzinthu zosiyanasiyana. Mutha kugwiritsa ntchito chogwirizira chokhala ndi masamba 7 osiyanasiyana pamizere 7 yazinthu kapena masamba angapo kuti musinthe mosiyanasiyana Mzere womwewo wokhala ndi slot wide.

Ogwiritsa ntchito a Sumitomo Electric pogwira zoyika zamtundu wa CGA amagwiritsa ntchito njira yokhotakhota pamwamba yomwe imakokera tsambalo kuti libwerere muchosungira. Chogwirizirachi chimakhalanso ndi zomangira zam'mbali kuti zithandizire kukonza kukhazikika komanso kukulitsa moyo wa chida. Rich Maton, wothandiziraWoyang'anira dipatimenti ya dipatimenti ya dipatimenti yamakampani, adati, "Chida ichi chapangidwira grooving of workpieces owumitsidwa. Ngati tsamba likuyenda mu chotengera, tsambalo limavala pakapita nthawi ndipo moyo wa chida umasintha. Pazofunikira zamakina apamwamba kwambiri pamagalimoto. makampani (monga 50-100 kapena 150 workpieces pachimake), kulosera za moyo wa zida ndizofunikira kwambiri, ndipo kusintha kwa moyo wa zida kumatha kukhudza kwambiri kupanga."

Malinga ndi malipoti, Mitsubishi Materials 'GY mndandanda wa Tri-Lock modular grooving system ikufanana ndi kusakhazikika kwa ma chucks ophatikizika. Dongosololi limagwira bwino ma grooving masamba kuchokera mbali zitatu (zotumphukira, kutsogolo ndi pamwamba). Mapangidwe ake awiri amalepheretsa kuti tsambalo lisasunthike panthawi ya grooving: mawonekedwe a V amalepheretsa kuti tsambalo lisasunthike kumbali; fungulo lachitetezo limathetsa kusuntha kwatsogolo kwa tsamba chifukwa cha mphamvu yodulira panthawi ya slot.

Zomwe zimagwiritsidwa ntchito nthawi zambiri pazigawo zazitsulo zowuma zimaphatikizapo zoyikapo ma square square, zoyikapo, zoyikapo, ndi zina zotero. Nthawi zambiri, ma groove odulidwa amafunikira kuti akhale omaliza bwino chifukwa ali ndi gawo lokweretsa, ndipo ena ndi O-rings kapena snap ring grooves. Malinga ndi a Mark Menconi, katswiri wazogulitsa ku Mitsubishi Materials, "Njirazi zitha kugawidwa m'magawo amkati amkati mwa groove machining ndi m'mimba mwake m'mimba mwake, koma ma grooving ambiri amafunikira kudula bwino, kuphatikiza kukhudza kuzama kochokera ku kuya kwa 0.25 mm. Dulani mpaka kudula kwathunthu ndi kuya pafupifupi 0.5mm."

Kuyika kwachitsulo cholimba kumafuna kugwiritsa ntchito zida zolimba kwambiri, kukana kuvala bwino komanso geometry yoyenera. Chinsinsi ndicho kudziwa ngati choyikapo cha carbide, choyikapo ceramic kapena choyikapo PCBN chiyenera kugwiritsidwa ntchito. Schmitz adati, "Nthawi zonse ndimasankha zoyikapo za carbide ndikamapanga makina olimba omwe ali pansi pa 50 HRC. Kwa zogwirira ntchito zolimba za 50-58 HRC, zoyikapo za ceramic ndizosankha zachuma kwambiri. Pokhapokha ngati cholumikizira cha CBN chikuyika chikuyenera kuganiziridwa ngati kuuma mpaka 58 HRC. Zoyikapo za CBN ndizofunikira makamaka pakukonza zida zolimba kwambiri chifukwa makina opangira sizinthu zodulira koma mawonekedwe a chida / chogwirira ntchito. Sungunulani zakuthupi.

Pakukula kwa zitsulo zolimba zolimba ndi kuuma kopitilira 58 HRC, kuwongolera chip sivuto. Popeza grooving youma imagwiritsidwa ntchito, tchipisi zimakhala ngati fumbi kapena tinthu tating'ono kwambiri ndipo zimatha kuchotsedwa ndi kuwomba pamanja. Maton wa Sumitomo Electric adati, "Nthawi zambiri, swarf yamtunduwu imasweka ndikusweka ikagunda chilichonse, kotero kukhudzana kwa swarf ndi workpiece sikungawononge chogwirira ntchito.

Chimodzi mwa zifukwa zomwe CBN amaika ndi oyenera kudula youma ndi chakuti ngakhale kutentha kukana ndi zabwino kwambiri, processing ntchito yafupika kwambiri pa nkhani ya kusinthasintha kutentha. Economan akuti, "M'malo mwake, choyikapo cha CBN chikalumikizana ndi zida zogwirira ntchito, chimatulutsa kutentha kwa kudula pansonga, koma chifukwa choyikapo cha CBN sichingagwirizane ndi kusintha kwa kutentha, zimakhala zovuta kuziziritsa mokwanira kusunga nthawi zonse. kutentha. Boma. CBN ndi yovuta kwambiri, koma ndi yolimba kwambiri ndipo imatha kusweka chifukwa cha kusintha kwa kutentha."

Mukadula zitsulo zolimba kwambiri (monga 45-50 HRC) zokhala ndi simenti ya carbide, ceramic kapena PCBN, tchipisi chopangidwa chiyenera kukhala chachifupi momwe mungathere. Izi zimachotsa bwino kutentha kwa kudula mu zida za zida panthawi yodula chifukwa tchipisi zimatha kunyamula kutentha kwakukulu.

Iskar's Schmitz amalimbikitsanso kuti chidacho chisinthidwe mu "inverted" state. Iye anafotokoza kuti, “Poika chida pamakina, chida chomwe womanga chida amachikonda chimayikidwa podula tsambalo m’mwamba, chifukwa izi zimathandizakuzungulira kwa workpiece kuti awononge kutsika pansi pa njanji yamakina kuti makina azikhala okhazikika. Komabe, pamene tsamba ladulidwa muzopangira zogwirira ntchito, tchipisi topangidwa titha kukhalabe pa tsamba ndi chogwirira ntchito. Ngati chogwiritsira ntchito chitembenuzidwira ndipo chidacho chitakwera mozondoka, tsambalo silidzawoneka, ndipo kutuluka kwa chip kumatuluka kuchokera kumalo odulidwa pansi pa mphamvu yokoka. "

Kuwumitsa pamwamba ndi njira yosavuta yowonjezera kuuma kwachitsulo chochepa cha carbon. Mfundo yake ndi kuonjezera zomwe zili mu carbon pa kuya kwina kwake pansi pa zinthuzo. Pamene kuya kwa grooving kupitirira makulidwe a pamwamba ouma wosanjikiza, mavuto ena angabwere chifukwa cha kusintha kwa tsamba la grooving kuchoka ku chinthu cholimba kupita ku chinthu chofewa. Kuti zimenezi zitheke, opanga zida apanga angapo tsamba masamba mitundu yosiyanasiyana ya workpiece zipangizo.

Duane Drape, woyang'anira malonda ku Horn (USA), adati, "Mukasintha kuchoka ku chinthu cholimba kupita ku chinthu chofewa, wogwiritsa ntchito nthawi zonse safuna kusintha tsamba, choncho tiyenera kupeza chida chabwino kwambiri cha makina amtunduwu. Ngati choyikapo cha simenti cha carbide chikugwiritsidwa ntchito, chidzakumana ndi vuto la kuvala kwambiri pamene tsamba likudula malo olimba. Titha kugwiritsa ntchito kunyengerera: zoyikapo za carbide zolimba kwambiri + zokutira zothira mafuta kwambiri, kapena zofewa za CBN zoyika magiredi + zodulira zoyenera kudula zida wamba (osati makina olimba)."

Drape adati, "Mutha kugwiritsa ntchito zoyika za CBN kuti mudule zida zogwirira ntchito ndi kuuma kwa 45-50 HRC, koma geometry ya tsamba iyenera kusinthidwa. Zolemba zodziwika bwino za CBN zimakhala ndi chamfer yoyipa pamphepete. Kuyika kwa chamfer CBN iyi ndi yofewa pamakina. Chidutswa cha workpiece chikagwiritsidwa ntchito, zinthuzo zimakhala ndi mphamvu yokoka ndipo moyo wa chida udzafupikitsidwa. Ngati kalasi ya CBN yokhala ndi kuuma pang'ono ikugwiritsidwa ntchito ndipo geometry ya m'mphepete mwake ikasinthidwa, zida zogwirira ntchito zolimba za 45-50 HRC zitha kudulidwa bwino.

S117 HORN grooving insert yopangidwa ndi kampaniyo imagwiritsa ntchito nsonga ya PCBN, ndipo kuya kwa kudula kuli pafupifupi 0.15-0.2 mm pamene m'lifupi mwa gear imadulidwa ndendende. Kuti akwaniritse bwino pamwamba pake, tsambalo liri ndi ndege yowonongeka kumbali zonse ziwiri.

Njira ina ndikusintha magawo odulira. Malingana ndi Index's Economan, "Mutatha kudula muzitsulo zolimba, magawo akuluakulu odula angagwiritsidwe ntchito. Ngati kuya kolimba kuli kokha 0.13mm kapena 0.25mm, mutatha kudula mwakuya uku, mwina masamba osiyanasiyana amasinthidwa kapena kugwiritsabe ntchito tsamba lomwelo, koma onjezani magawo odulira pamlingo woyenera.

Pofuna kuphimba osiyanasiyana processing, PCBN tsamba giredi zikuchulukirachulukira. Magiredi olimba kwambiri amalola kuthamanga kwachangu, pomwe magiredi okhala ndi kulimba bwino atha kugwiritsidwa ntchito m'malo osakhazikika. Pa kudula mosalekeza kapena kusokonezedwa, magiredi osiyanasiyana a PCBN angagwiritsidwenso ntchito. Sumitomo Electric a Maton ananena kuti chifukwa cha brittleness wa zida PCBN, lakuthwa kudula m'mphepete sachedwa chipping pamene Machining anaumitsa zitsulo. "Tiyenera kuteteza m'mphepete mwake, makamaka pakudula kosokonekera, m'mphepete mwake muyenera kukonzedwa kuposa kudula mosalekeza, ndipo mbali yodulira iyenera kukhala yayikulu."

Makalasi atsopano a Iskar a IB10H ndi IB20H amakulitsanso mzere wake wazinthu za Groove Turn PCBN. IB10H ndi bwino-grained PCBN kalasi kwa sing'anga ndi mkulu liwiro mosalekeza kudula zitsulo zolimba; pomwe IB20H imakhala ndi njere za PCBN zabwino komanso zapakatikati, zomwe zimapereka kukana kovala bwino komanso kukana mphamvu. The bwino akhoza kupirira mikhalidwe yovuta kwambiri zitsulo anasokoneza kudula. Njira yolephereka yachida cha PCBN iyenera kukhala yocheperakoosati kusweka mwadzidzidzi kapena kusweka.

Gulu la BNC30G lopangidwa ndi PCBN lomwe linayambitsidwa ndi Sumitomo Electric limagwiritsidwa ntchito posokoneza zitsulo zolimba zachitsulo. Pakukula kosalekeza, kampaniyo imalimbikitsa kalasi yake ya BN250 universal blade. Maton adati, "Podula mosalekeza, tsambalo limadulidwa kwa nthawi yayitali, zomwe zimapangitsa kutentha kwambiri. Choncho, m'pofunika kugwiritsa ntchito tsamba ndi kukana kuvala bwino. Pankhani ya grooving yapakatikati, tsambalo limalowa ndikutuluka mosalekeza. Zimakhudza kwambiri nsonga. Chifukwa chake, ndikofunikira kugwiritsa ntchito tsamba lolimba bwino ndipo limatha kupirira kugunda kwapakatikati. Kuphatikiza apo, zokutira zamasamba zimathandizanso kukulitsa moyo wa zida. "

Mosasamala kanthu za mtundu wa groove womwe umapangidwa, zokambirana zomwe poyamba zinkadalira kugaya kuti amalize zida zachitsulo zolimba zimatha kusinthidwa kukhala grooving ndi zida za PCBN kuti ziwonjezere zokolola. Kupukuta molimba kumatha kukwaniritsa kulondola kofanana ndi kugaya, pomwe kumachepetsa kwambiri nthawi yopanga makina.