Ukufakwa kwentsimbi eQinisiweyo ngePCBN Cutter

Ukufakwa kwentsimbi eqinile kunye ne-PCBN cutter

Kwiminyaka elishumi edlulileyo, ukuchaneka kwegrooving yamalungu entsimbi eqinile kunye ne-polycrystalline cubic boron nitride (PCBN) efakelwayo kuye kwathatha indawo kancinane yokusila. UTyler Economan, umphathi wezobunjineli obhidayo kwi-Index, e-USA, uthe, “Ngokubanzi, iigrooves yinkqubo ezinzile ebonelela ngokuchaneka okuphezulu kunokugrumba. Nangona kunjalo, abantu basafuna ukukwazi ukugqiba i-workpiece kwi-lathe. Kuyafuneka iintlobo ezahlukeneyo zokusetyenzwa.

Izinto ezahlukeneyo zokusebenza eziye zaqiniswa zibandakanya isantya esiphezulu sentsimbi, intsimbi yokufa, intsimbi yokuthwala kunye nentsimbi yealloy. Iintsimbi zentsimbi kuphela zinokuqiniswa, kwaye iinkqubo zokuqina zidla ngokusetyenziswa kwiintsimbi zekhabhoni eziphantsi. Ngonyango olunzima, ubunzima bangaphandle bomsebenzi bunokwenziwa phezulu kwaye bunxibe, ngelixa ingaphakathi linobunzima obungcono. Amacandelo enziwe ngentsimbi eqinile ibandakanya i-mandrels, i-axles, izihlanganisi, amavili okuqhuba, i-camshafts, i-gear, i-bushings, i-shafts drives, i-bearings, kunye nokunye okunjalo.

Nangona kunjalo, "izinto ezilukhuni" zihambelana, zitshintsha ingcamango. Abanye abantu bacinga ukuba izixhobo zokusebenza ezinobunzima be-40-55 HRC zizinto ezinzima; abanye bakholelwa ukuba ubunzima bezinto ezinzima kufuneka zibe yi-58-60 HRC okanye ngaphezulu. Kolu luhlu, izixhobo zePCBN zinokusetyenziswa.

Emva kokuqina kwe-induction, umaleko owenziwe lukhuni ungafikelela kwi-1.5mm ubukhulu kwaye ukuqina kunokufikelela kwi-58-60 HRC, ngelixa izinto ezingaphantsi komgangatho ongaphezulu zihlala zithambile kakhulu. Kule meko, kubalulekile ukuqinisekisa ukuba uninzi lokusika lwenziwa ngaphantsi komgangatho olukhuni.

Izixhobo zoomatshini ezinamandla okwaneleyo kunye nokuqina yimeko efunekayo ye-grooving yeendawo ezinzima. Ngokuka-Economan, “Okukhona ukuqina kwesixhobo somatshini kunye nokunyuka kwamandla, kokukhona ukugrunjwa kakuhle kwesixhobo esomeleleyo. Kwizixhobo zokusebenza ezinobunzima obungaphezulu kwe-50 HRC, izixhobo ezininzi zomatshini wokukhanya azihlangabezani neemeko zokusika ezifunekayo. Ukuba umthamo womatshini (amandla, itorque, kwaye ngakumbi ukuqina) ugqithisiwe, umatshini awunakugqitywa ngempumelelo. "

Ukuqina kubaluleke kakhulu kwisixhobo sokubamba i-workpiece kuba indawo yoqhagamshelwano yomgca wokusika kunye ne-workpiece inkulu ngexesha lenkqubo ye-grooving, kwaye isixhobo senza uxinzelelo olukhulu kwi-workpiece. Xa ucinezela izixhobo zokusebenza zentsimbi, i-clamp ebanzi ingasetyenziselwa ukusasaza umphezulu wokubamba. UPaul Ratzki, umphathi wezentengiso weSumitomo Electric Hard Alloy Co., uthe, “Iindawo eziza kwenziwa ngoomatshini kufuneka zixhaswe ngokuqinileyo. Xa kusetyenzwa izinto eziqinileyo, ukungcangcazela kunye noxinzelelo lwesixhobo oluveliswayo zikhulu kakhulu kunaxa kusetyenzwa izixhobo zokusebenza eziqhelekileyo, ezinokukhokelela ekubambeni kwecwecwe. Awukwazi ukubhabha ngaphandle komatshini, okanye ubangele ukuba i-CBN blade itshiphu okanye yophuke.

I-shank ebambe i-grooving insert kufuneka ibe mfutshane kangangoko ukunciphisa i-overhang kunye nokwandisa ukuqina kwesixhobo. UMateyu Schmitz, umphathi weemveliso ze-GRIP e-Isca, ubonisa ukuba ngokubanzi, izixhobo ze-monolithic zifanelekile ngakumbi kwi-grooving yezinto ezilukhuni. Nangona kunjalo, inkampani ikwabonelela ngenkqubo ye-grooving modular. "I-shank ye-modular ingasetyenziselwa kwiimeko zomatshini apho isixhobo sinokusilela ngokukhawuleza," utshilo. “Akunyanzelekanga ukuba utshintshe yonke i-shank, kufuneka utshintshe into ebiza kancinci. I-shank yemodyuli ikwabonelela ngeendlela ezahlukeneyo zokukhetha. Inkqubo yemodyuli ye-Iskar's Grip inokufakwa kwiintlobo ezahlukeneyo zeemveliso. Ungasebenzisa isibambi sesixhobo esineencakuba ezisi-7 ezahlukeneyo zemigca yeemveliso ezisi-7 okanye naliphi na inani leeblade zokusetyenzwa okwahlukileyo Umgca wemveliso ofanayo nobubanzi beslot.

Izixhobo ze-Sumitomo zoMbane zokubamba ukufaka uhlobo lwe-CGA zisebenzisa indlela yokudibanisa ephezulu etsala iblade ibuyele kwisibambi. Esi sibambeli sikwabonisa isikrufu esisecaleni sokunceda ukuphucula uzinzo kunye nokwandisa ubomi besixhobo. Rich Maton, umncedisiumphathi wesebe loyilo lwenkampani, wathi, "Lo mphathi wesixhobo senzelwe i-grooving of workpieces lukhuni. Ukuba i-blade ishukuma kwisibambi, i-blade igugile ngokuhamba kwexesha kwaye ubomi besixhobo buyatshintsha. Kwiimfuno eziphezulu zemveliso yemoto. imboni (ezifana ne-50-100 okanye i-150 ye-workpieces ngokusika), ukuqikelelwa kobomi besixhobo kubaluleke kakhulu, kwaye utshintsho kubomi besixhobo lunokuba nefuthe elikhulu kwimveliso."

Ngokweengxelo, uthotho lweMitsubishi Materials 'GY inkqubo yemodyuli ye-Tri-Lock ye-grooving ithelekiseka ngokungqongqo kunye nee-chucks ezidibeneyo. Inkqubo ibamba ngokuthembekileyo ii-blades ze-grooving ukusuka kumacala amathathu (i-peripheral, front and top). Uyilo lwalo olubini lwesakhiwo luthintela ukuba i-blade isuswe ngexesha le-grooving: i-V-shaped projection ivimbela i-blade ukuba ihambe emacaleni; isitshixo sokhuseleko siphelisa ukuhamba phambili kwe-blade okubangelwa amandla okusika ngexesha lokwenziwa kwe-slot machining.

Ukufakwa kwe-grooving ngokuqhelekileyo kwiingxenye zetsimbi eziqinileyo ziquka ukufakwa kwesikwere esilula, ukufakwa kokwenza, ukufakwa kwe-slotted, kunye nokunye okunjalo. Ngokuqhelekileyo, iigrooves ezisikiweyo zifuneka ukuba zibe nokugqiba okulungileyo ngenxa yokuba zinesahlulo sokukhwelana, kwaye ezinye ziyi-O-rings okanye i-snap ring grooves. NgokukaMark Menconi, ingcali yeemveliso kwiMitsubishi Materials, "Ezi nkqubo zinokwahlulwa zibe yi-machining yangaphakathi ye-groove machining kunye ne-diameter yangaphandle ye-groove machining, kodwa uninzi lwemisebenzi yokucoca ifuna ukusika kakuhle, kubandakanya ukuchaneka kokucofa ukukhanya ukusuka malunga ne-0.25 mm ubunzulu bokusika. ukusika okupheleleyo ngobunzulu obumalunga ne-0.5mm."

I-grooving yentsimbi eqinile idinga ukusetyenziswa kwezixhobo ezinobunzima obuphezulu, ukuchasana okungcono kokugqoka kunye nejometri efanelekileyo. Isitshixo kukufumanisa ukuba ingaba i-carbide insert, i-ceramic insert okanye i-PCBN ifakwe kufuneka isetyenziswe. USchmitz uthe, "Phantse ndihlala ndikhetha ukufaka i-carbide xa ndisenza izixhobo zokusebenza ezinobunzima obungaphantsi kwe-50 HRC. Kwizixhobo zokusebenza ezinobunzima be-50-58 HRC, ukufakwa kwe-ceramic lukhetho olunoqoqosho kakhulu. Kuphela xa i-workpiece ye-CBN ifakela kufuneka ithathelwe ingqalelo ngenxa yobunzima ukuya kuma-58 HRC. Ufakelo lwe-CBN lufaneleke ngokukodwa ukwenza izinto ezinjalo ezilukhuni kakhulu ngenxa yokuba umatshini wokutshiza ayisiyonto yokusika kodwa isixhobo / ujongano lomsebenzi. Nyibilikisa imathiriyeli.

Kwi-grooving yamacandelo entsimbi eqinile kunye nobunzima obungaphezulu kwe-58 HRC, ulawulo lwe-chip aluyongxaki. Ekubeni i-grooving eyomileyo idla ngokusetyenziswa, ii-chips zifana nothuli okanye iincinci ezincinci kwaye zinokususwa ngokubetha ngesandla. U-Sumitomo Electric's Maton uthe, "Ngokuqhelekileyo, olu hlobo lwe-swarf luya kuphuka kwaye luqhekeke xa lubetha nantoni na, ngoko ukudibana kwe-swarf kunye ne-workpiece akuyi kuwonakalisa umsebenzi. Ukuba ubambe i-swarf, baya kutyumza esandleni sakho."

Esinye sezizathu zokuba ukufakwa kwe-CBN kukulungele ukusika okomileyo kukuba nangona ukuxhathisa ubushushu kukuhle kakhulu, ukusebenza kokucubungula kuncitshiswe kakhulu kwimeko yokutshintsha kweqondo lokushisa. I-Economan ithi, "Enyanisweni, xa i-CBN ifakela idibene nezinto zokusebenza, ivelisa ubushushu bokusika kwincam, kodwa ngenxa yokuba i-CBN ifakela ingaguquguqukiyo kutshintsho lweqondo lokushisa, kunzima ukupholisa ngokwaneleyo ukugcina rhoqo. ubushushu. Umbuso. I-CBN inzima kakhulu, kodwa iphinde ibe brittle kwaye inokugqabhuka ngenxa yotshintsho lobushushu. "

Xa usika iindawo zetsimbi ezinobunzima obuphantsi (ezifana ne-45-50 HRC) kunye ne-carbide ene-cemented, i-ceramic okanye i-PCBN ifaka, ii-chips eziveliswayo kufuneka zibe zifutshane kangangoko kunokwenzeka. Oku kususa ngokufanelekileyo ukushisa kokusika kwisixhobo sesixhobo ngexesha lokusika ngenxa yokuba ii-chips zinokuthwala ubushushu obukhulu.

I-Iskar's Schmitz ikwacebisa ukuba isixhobo siqhutywe kwimeko "eguqulweyo". Ucacisile, “Xa ufaka isixhobo kwisixhobo somatshini, isixhobo esikhethwa ngumakhi womatshini sifakwa ngokusika iblade ijonge phezulu, njengoko oku kuvumelaukujikeleza kwendawo yokusebenza ukwenza uxinzelelo olusezantsi kuloliwe womatshini ukugcina umatshini uzinzile. Nangona kunjalo, xa i-blade isikwa kwizinto zokusebenza, iitshiphu ezibunjiweyo zinokuhlala kwi-blade kunye ne-workpiece. Ukuba umnini wesixhobo uphendulwe kwaye isixhobo siphakanyiswe phezulu, i-blade ayiyi kubonakala, kwaye ukuhamba kwe-chip kuya kuphunyuka ngokuzenzekelayo kwindawo yokusika phantsi kwesenzo sobunzima."

Ukuqina komphezulu yindlela elula yokuphucula ukuqina kwentsimbi ephantsi yekhabhoni. Umgaqo kukunyusa umxholo wekhabhoni kubunzulu obuthile phantsi kobuso bezinto eziphathekayo. Xa ubunzulu be-grooving budlula ubukhulu bomgangatho owenziwe lukhuni, ezinye iingxaki zinokuvela ngenxa yokutshintsha kwe-grooving blade ukusuka kwizinto ezinzima ukuya kwizinto ezithambileyo. Ukuza kuthi ga ngoku, abavelisi bezixhobo baye baphuhlisa amabakala amaninzi eblade kwiindidi ezahlukeneyo zemathiriyeli yomsebenzi.

UDuane Drape, umphathi wentengiso eHorn (e-USA), uthe, “Xa utshintsha ukusuka kwinto enzima ukuya kwinto ethambileyo, umsebenzisi akasoloko efuna ukutshintsha iblade, ke kufuneka sifumane esona sixhobo silungileyo solu hlobo lomatshini. Ukuba i-carbide ifake i-cemented isetyenzisiweyo, iya kuhlangabezana nengxaki yokugqoka ngokugqithiseleyo xa i-blade inquma indawo enzima. blade. Singasebenzisa compromise: high hardness carbide inserts + super lubricated coatings, okanye i-CBN ethambileyo ifake amabakala + ukufakwa kokusika okufanelekileyo ukusika izinto eziqhelekileyo (kunokuba machining nzima)."

UDrape uthe, "Ungasebenzisa i-CBN yokufaka ukusika ngokufanelekileyo izixhobo zokusebenza ezinobunzima be-45-50 HRC, kodwa ijiyometri yeblade kufuneka ihlengahlengiswe. Ufakelo oluqhelekileyo lwe-CBN lune-chamfer engalunganga kwi-edge yokusika. Le chamfer negative CBN ufakelo ithambile kumatshini. Xa i-workpiece isetyenzisiwe, izinto eziphathekayo ziya kuba nefuthe lokukhupha kwaye ubomi besixhobo buya kufinyezwa. Ukuba ibakala le-CBN elinobulukhuni obuphantsi lisetyenziswa kwaye ijometri yomgca wokusika itshintshiwe, i-workpiece material enobunzima be-45-50 HRC inokunqunyulwa ngempumelelo."

I-S117 HORN ifake i-grooving ephuhliswe yinkampani isebenzisa i-PCBN tip, kwaye ubunzulu bokusika bu malunga ne-0.15-0.2 mm xa ububanzi begiya bunqunywe ngokuchanekileyo. Ukuze kuphunyezwe ukugqiba umgangatho omhle, i-blade ine-scraping plane nganye kwimida yokusika kumacala omabini.

Enye inketho kukutshintsha iiparamitha zokusika. Ngokutsho kwe-Index's Economan, "Emva kokusika umaleko oqinileyo, iiparamitha zokusika ezinkulu zinokusetyenziswa. Ukuba ubunzulu obunzima buyi-0.13mm okanye i-0.25mm kuphela, emva kokusika ngobu nzulu, mhlawumbi iiblade ezahlukeneyo zitshintshwa okanye zisekho Sebenzisa i-blade efanayo, kodwa ukwandisa iiparitha zokusika ukuya kwinqanaba elifanelekileyo."

Ukuze kugutyungelwe uluhlu olubanzi processing, PCBN blade amabakala ziyanda. Amanqanaba aphezulu obunzima avumela isantya sokusika ngokukhawuleza, ngelixa amabakala anobunzima obungcono anokusetyenziswa kwiindawo zokucwangcisa ezingazinzanga. Ukusika okuqhubekayo okanye okuphazamisekileyo, amabakala ahlukeneyo okufaka i-PCBN nawo angasetyenziswa. I-Sumitomo Electric's Maton yabonisa ukuba ngenxa yobunzima bezixhobo ze-PCBN, imiphetho ebukhali yokusika iyakwazi ukutshiza xa kusenziwa intsimbi eqinile. "Kufuneka sikhusele umda wokusika, ngakumbi ekusikeni okuphazamisekileyo, umphetho wokusika kufuneka ulungiswe ngaphezu kokusikwa ngokuqhubekayo, kwaye i-angle yokusika kufuneka ibe nkulu."

Amabakala e-Iskar asanda kuphuhliswa i-IB10H kunye ne-IB20H yandisa ngakumbi umgca wemveliso we-Groove Turn PCBN. I-IB10H inqanaba le-PCBN elichanekileyo eliphakathi ukuya kwisantya esiphezulu sokusika ngokuqhubekayo kwentsimbi eqinile; ngelixa i-IB20H iquka iinkozo zePCBN ezilungileyo neziphakathi, ezibonelela ngokumelana nokunxiba okufanelekileyo kunye nokuchasana kwempembelelo. Ibhalansi inokumelana neemeko ezinzima zentsimbi ekhuni iphazamise ukusika. Imowudi yokungaphumeleli eqhelekileyo yesixhobo se-PCBN kufuneka ibe kukuba umphetho wokusika uyaphelakunokuba ngokukhawuleza ukuqhekeka okanye ukuqhekeka.

Ibakala le-PCBN le-BNC30G eligqunywe yi-Sumitomo Electric lisetyenziselwa ukuphazamisa i-grooving ye-workpieces yentsimbi eqinile. Ukuqhubeka nokugrumba, inkampani icebisa iBN250 ibakala leblade jikelele. UMaton uthe, "Xa usika ngokuqhubekayo, i-blade iyasikwa ixesha elide, eliya kuvelisa ubushushu obuninzi bokusika. Ngoko ke, kuyimfuneko ukusebenzisa i-blade enokumelana nokunxiba kakuhle. Kwimeko ye-grooving ephakathi, i-blade ingena ngokuqhubekayo kwaye iphuma ekusikeni. Inempembelelo enkulu kwincam. Ngoko ke, kuyimfuneko ukusebenzisa i-blade ngokuqina okulungileyo kwaye inokumelana neempembelelo eziphazamisayo. Ukongeza, ukugquma kweblade kukwanceda ukwandisa ubomi besixhobo. "

Kungakhathaliseki ukuba luhlobo luni lwe-groove eyenziwa ngoomatshini, iiworkshops eziye zathembela ekusileni ukugqiba iinxalenye zetsimbi ezinobunzima zingaguqulwa zibe yi-grooving kunye nezixhobo ze-PCBN zokwandisa imveliso. I-hard grooving inokufikelela ukuchaneka komda xa kuthelekiswa nokusila, ngelixa kunciphisa kakhulu ixesha lomatshini.