Ukufakwa Kwensimbi Eqinile Nge-PCBN Cutter

Ukufakwa kwensimbi eqinile nge-PCBN cutter

Eshumini leminyaka elidlule, ukunemba kwezingxenye zensimbi eziqinile ezinokufakwa kwe-polycrystalline cubic boron nitride (PCBN) kancane kancane kuthathe indawo yokugaya okuvamile. U-Tyler Economan, umphathi wamabhidi wobunjiniyela e-Index, e-U.S.A., uthe, “Ngokuvamile, ama-grooves kuyinqubo ezinzile enikeza ukunemba okuphezulu kobukhulu kunokugxusha. Kodwa-ke, abantu basafuna ukukwazi ukuqedela ucezu lomsebenzi ku-lathe. Kudingeka ukucutshungulwa okuhlukahlukene."

Izinto ezihlukene zokusetshenzwa eziye zaqiniswa zihlanganisa insimbi enesivinini esikhulu, i-die steel, i-bearing steel ne-alloy steel. Izinsimbi ezinensimbi kuphela ezingaqiniswa, futhi izinqubo zokuqina zivame ukusetshenziswa ezinsimbi zekhabhoni ephansi. Ngokwelashwa okuqinisayo, ubulukhuni bangaphandle be-workpiece bungenziwa buphakeme futhi bugqoke, kuyilapho ingaphakathi linokuqina okungcono. Izingxenye ezenziwe ngensimbi eqinile zihlanganisa ama-mandrel, ama-ekseli, izixhumi, amasondo okushayela, ama-camshafts, amagiya, ama-bushings, ama-drive shafts, ama-bearings, nokunye okunjalo.

Kodwa-ke, "izinto eziqinile" ziyisihlobo, zishintsha umqondo. Abanye abantu bacabanga ukuthi izinto zokusebenza ezinobunzima be-40-55 HRC ziyizinto eziqinile; abanye bakholelwa ukuthi ubulukhuni bezinto eziqinile kufanele kube yi-58-60 HRC noma ngaphezulu. Kulesi sigaba, amathuluzi e-PCBN angasetshenziswa.

Ngemuva kokuqina kokungeniswa, ungqimba oluqinile olungaphezulu lungafika ku-1.5mm ubukhulu futhi ubulukhuni bungafinyelela ku-58-60 HRC, kuyilapho izinto ezingaphansi koqweqwe olungaphezulu ngokuvamile zithambile kakhulu. Kulesi simo, kubalulekile ukuqinisekisa ukuthi ukusika okuningi kwenziwa ngaphansi kwesendlalelo esiqinile.

Amathuluzi omshini anamandla anele kanye nokuqina ayisimo esidingekayo sokugoba izingxenye eziqinile. Ngokusho kwe-Economan, “Lapho ithuluzi lomshini liqinile futhi linamandla, kulapho ukugoba okuqinile kwento eqinile kuyahamba kahle. Okwezinto zokusebenza ezinobunzima obungaphezu kuka-50 HRC, amathuluzi amaningi omshini wokukhanya awahlangabezani nezimo zokusika ezidingekayo. Uma umthamo womshini (amandla, i-torque, futhi ikakhulukazi ukuqina) weqiwe, umshini awukwazi ukuqedwa ngempumelelo."

I-Rigidity ibaluleke kakhulu kudivayisi yokubamba i-workpiece ngoba indawo yokuxhumana yonqenqema lokusika ne-workpiece inkulu ngesikhathi senqubo ye-grooving, futhi ithuluzi linengcindezi enkulu ku-workpiece. Lapho ubopha izinsimbi zokusebenza eziqinile, i-clamp ebanzi ingasetshenziswa ukuhlakaza indawo yokubopha. UPaul Ratzki, umphathi wezokumaketha weSumitomo Electric Hard Alloy Co., uthe, “Izingxenye ezizokwenziwa ngomshini kumele zisekelwe ngokuqinile. Lapho kwenziwa imishini eqinile, ukudlidliza nokucindezela kwethuluzi okukhiqizwayo kukhulu kakhulu kunalapho kwenziwa ama-workpieces ajwayelekile, okungase kuphumele ekubambeni kocezu lokusebenza. Ayikwazi ukundiza iphume emshinini, noma ibangele ukuthi i-CBN blade ihlehle noma iphuke."

I-shank ebambe i-grooving insert kufanele ibe mfushane ngangokunokwenzeka ukuze kuncishiswe i-overhang futhi kwandise ukuqina kwethuluzi. U-Matthew Schmitz, umphathi wemikhiqizo ye-GRIP e-Isca, uveza ukuthi ngokuvamile, amathuluzi e-monolithic afaneleka kakhulu ukugoba izinto eziqinile. Kodwa-ke, inkampani iphinde inikeze uhlelo lwe-modular grooving. "I-shank ye-modular ingasetshenziswa ezimweni zomshini lapho ithuluzi livame ukwehluleka kungazelelwe," usho kanje. “Akudingeki ukuthi ushintshe i-shank yonke, udinga nje ukufaka ingxenye engabizi kakhulu. I-shank ye-modular iphinde inikeze izinhlobonhlobo zezinketho zomshini. Isistimu ye-modular ye-Iskar's Grip ingafakwa emikhiqizweni eyahlukene eyahlukene. Ungasebenzisa isibambi samathuluzi esinama-blade angu-7 ahlukene emigqeni engu-7 yomkhiqizo noma iyiphi inombolo yezicucu ukuze kucutshungulwe okuhlukile Ulayini womkhiqizo ofanayo onobubanzi besikhala."

Iziphathi-mathuluzi ze-Sumitomo Electric zokubamba okufakiwe kohlobo lwe-CGA zisebenzisa indlela yokugoqa phezulu edonsa i-blade ibuyisele isibambi. Lesi sibambi siphinde sibe nesikulufu sokubopha eceleni ukuze sisize ukuthuthukisa ukuqina nokubamba nokwelula impilo yamathuluzi. Rich Maton, umsiziumphathi womnyango wokuklama wenkampani, uthe, "Lesi sibambi sethuluzi siklanyelwe ukugoqa izinsimbi zokusebenza eziqinile. Uma i-blade ihamba esibambi, i-blade iyaguga ngokuhamba kwesikhathi futhi impilo yethuluzi iyashintsha. Ngezidingo zemishini yokukhiqiza ephezulu yemoto imboni (ezifana nama-workpieces angu-50-100 noma angu-150 ngokusika ngakunye), ukubikezelwa kwempilo yamathuluzi kubaluleke kakhulu, futhi izinguquko empilweni yamathuluzi zingaba nomthelela omkhulu ekukhiqizeni."

Ngokwemibiko, i-Mitsubishi Materials' GY yochungechunge lwe-Tri-Lock modular grooving system iqhathaniswa ngokuqina nama-blade chucks abalulekile. Uhlelo lubamba ngokuthembekile ama-grooving blades ukusuka ezinhlangothini ezintathu (peripheral, front and top). Ukwakheka kwayo okubili kwesakhiwo kuvimbela i-blade ukuthi ingagudluki ngesikhathi i-grooving: i-projection emise okwe-V ivimbela i-blade ukuthi inganyakazi ezinhlangothini; ukhiye wokuphepha uqeda ukuhamba phambili kwe-blade okubangelwa amandla okusika ngesikhathi somshini we-slot.

Ukufakwa kwe-grooving okuvame ukusetshenziswa ezingxenyeni zensimbi eziqinile kuhlanganisa ukufaka okulula kwesikwele, okufakwayo okwenza, ukufaka okufakiwe, nokunye okunjalo. Ngokuvamile, imisele esikiwe idingeka ukuthi ibe nesiphetho esihle ngenxa yokuthi inengxenye yokukhwelana, kanti ezinye ziyi-O-rings noma i-snap ring grooves. Ngokuka-Mark Menconi, uchwepheshe wemikhiqizo kwaMitsubishi Materials, "Lezi zinqubo zingahlukaniswa zibe machining egroove engaphakathi kwe-diameter kanye ne-outer diameter groove machining, kodwa imisebenzi eminingi yokugoqa idinga ukusikwa okuhle, okuhlanganisa ukunemba kokuthinta okulula kusuka ekujuleni okungaba ngu-0.25 mm. ukusika okuphelele nokujula okungaba ngu-0.5mm."

I-grooving yensimbi eqinile idinga ukusetshenziswa kwamathuluzi anobunzima obuphezulu, ukumelana nokugqoka okungcono kanye nejometri efanelekile. Isihluthulelo ukuthola ukuthi ingabe i-carbide insert, i-ceramic insert noma i-PCBN insert kufanele isetshenziswe. USchmitz uthe, “Cishe ngihlala ngikhetha okufakwayo kwe-carbide lapho ngikhiqiza izingcezu zokusebenza ezinobunzima obungaphansi kwama-50 HRC. Kuma-workpiece anobunzima be-50-58 HRC, ukufakwa kwe-ceramic kuwukukhetha ukonga kakhulu. Kuphela uma i-workpiece ye-CBN ifaka kufanele kucatshangelwe ubulukhuni obufika ku-58 HRC. Ukufakwa kwe-CBN kulungele ngokukhethekile ukwenza izinto eziqinile eziphakeme kangako ngoba umshini wokukhanda awuyona into yokusika kodwa iyithuluzi/umsebenzi wokusebenza. Ncibilikisa impahla.

Ngokugujwa kwezingxenye zensimbi eziqinile ezinobunzima obungaphezu kuka-58 HRC, ukulawulwa kwe-chip akuyona inkinga. Njengoba i-grooving eyomile ivame ukusetshenziswa, ama-chips afana nothuli noma izinhlayiya ezincane kakhulu futhi angasuswa ngokushaywa ngesandla. UMaton weSumitomo Electric uthe, "Imvamisa, lolu hlobo lwe-swarf luzophuka luhlakazeke uma lushayisa noma yini, ngakho-ke ukuthintana kwe-swarf ne-workpiece ngeke kulimaze ucezu lokusebenza. Uma ubamba i-swarf, izophahlaza esandleni sakho."

Esinye sezizathu zokuthi kungani ukufakwa kwe-CBN kulungele ukusika okomile ukuthi nakuba ukumelana nokushisa kwabo kuhle kakhulu, ukusebenza kokucubungula kuyancipha kakhulu esimweni sokushintsha kwezinga lokushisa. I-Economan ithi, "Eqinisweni, lapho i-CBN ifaka ithintana nezinto zokusebenza, ikhiqiza ukushisa kokusika phezulu, kodwa ngenxa yokuthi ukufakwa kwe-CBN akuvumelani nezimo ezishintshayo zokushisa, kunzima ukupholisa ngokwanele ukugcina ukuqina okungaguquki. izinga lokushisa. Izwe. I-CBN inzima kakhulu, kodwa futhi i-brittle futhi ingase iqhume ngenxa yokushintsha kwezinga lokushisa."

Lapho usika izingxenye zensimbi ngobulukhuni obuphansi (ezifana ne-45-50 HRC) ngokufaka i-carbide enosimende, i-ceramic noma i-PCBN, ama-chips akhiqiziwe kufanele abe mafushane ngangokunokwenzeka. Lokhu kususa ngokuphumelelayo ukushisa kokusika ezintweni zamathuluzi ngesikhathi sokusika ngoba ama-chips angathwala inani elikhulu lokushisa.

Iskar's Schmitz futhi incoma ukuthi ithuluzi licutshungulwe esimweni "esihlanekezelwe". Wachaza, “Lapho ufaka ithuluzi ethuluzini lomshini, ithuluzi elikhethwa ngumakhi wethuluzi lomshini lifakwa ngokusika i-blade ibheke phezulu, njengoba lokhu kuvumelaukujikeleza kwe-workpiece ukufaka ingcindezi eya phansi kumzila wesitimela ukuze ugcine umshini uzinzile. Kodwa-ke, lapho i-blade isikwa ezintweni zokusebenza, ama-chips akhiwe angase ahlale phezu kwe-blade kanye ne-workpiece. Uma isibambi samathuluzi siphendulwa futhi ithuluzi ligxunyekwe libheke phansi, i-blade ngeke ibonakale, futhi ukugeleza kwe-chip kuzophuma ngokuzenzakalelayo endaweni yokusika ngaphansi kwesenzo samandla adonsela phansi."

Ukuqina kobuso kuyindlela elula yokuthuthukisa ubulukhuni bensimbi ye-carbon steel. Umgomo uwukwandisa okuqukethwe kwekhabhoni ekujuleni okuthile ngaphansi kobuso bento. Uma ukujula kwe-grooving kudlula ukushuba kongqimba oluqinile lwendawo, ezinye izinkinga zingase ziphakame ngenxa yokushintshwa kwe-grooving blade isuka kokuqinile iye kwethambile. Kuze kube manje, abakhiqizi bamathuluzi baye bahlakulela amamaki amaningana e-blade ezinhlobonhlobo zezinto zokusebenza.

U-Duane Drape, umphathi wezentengiso e-Horn (USA), uthe, “Uma sishintsha sisuka ekubeni lukhuni siyise kwethambile, umsebenzisi akafuni ngaso sonke isikhathi ukushintsha i-blade, ngakho kufanele sithole ithuluzi elingcono kakhulu lalolu hlobo lomshini. Uma kusetshenziswa ukufakwa kwe-carbide enosimende, kuzohlangabezana nenkinga yokuguga ngokweqile lapho i-blade isika indawo eqinile. I-blade. Singasebenzisa i-compromise: ukuqina okuphezulu kwe-carbide okufakwayo + okokugcotshwa okuphezulu kakhulu, noma amamaki athambile e-CBN afaka amamaki + okufakwayo okusika afanele ukusika izinto ezivamile (kunokuba machining oqinile)."

UDrape uthe, “Ungasebenzisa okufakiwe kwe-CBN ukusika ngempumelelo izinto zokusebenza ngobulukhuni be-45-50 HRC, kodwa i-blade geometry kufanele ilungiswe. Okufakiwe kwe-CBN okujwayelekile kune-chamfer engalungile onqenqemeni lokusika. Lesi sici se-CBN se-chamfer esinegethivu sithambile emshinini. Lapho i-workpiece isetshenziswa, impahla izoba nomthelela wokudonsa futhi impilo yamathuluzi izofinyezwa. Uma kusetshenziswa ibanga le-CBN elinobunzima obuphansi futhi ijiyomethri yonqenqema lokusika ishintshwa, impahla yokusebenza enobulukhuni be-45-50 HRC ingasikwa ngempumelelo."

I-S117 HORN grooving insert eyakhiwe inkampani isebenzisa ithiphu ye-PCBN, futhi ukujula kokusika kucishe kube ngu-0.15-0.2 mm lapho ububanzi begiya sisikwa kahle. Ukuze kuzuzwe umphumela omuhle, i-blade inendiza yokukhuhla emaphethelweni okusika ezinhlangothini zombili.

Enye inketho ukushintsha imingcele yokusika. Ngokusho kwe-Index's Economan, "Ngemva kokusika ungqimba oluqinile, imingcele yokusika emikhulu ingasetshenziswa. Uma ukujula okuqinile kungu-0.13mm noma u-0.25mm kuphela, ngemva kokusika kulokhu kujula, ama-blade ahlukene ayashintshwa noma usaqhubeka Sebenzisa i-blade efanayo, kodwa wandise imingcele yokusika ibe sezingeni elifanele."

Ukuze kuhlanganiswe uhla olubanzi lokucutshungulwa, amamaki e-PCBN blade ayakhula. Amabanga aphakeme okuqina avumela isivinini sokusika esisheshayo, kuyilapho amamaki anokuqina okungcono angasetshenziswa ezindaweni ezisebenza kakhulu ezingazinzile. Ngokusika okuqhubekayo noma okuphazamisekile, amamaki okufaka e-PCBN ahlukene angasetshenziswa. I-Maton ye-Sumitomo Electric yabonisa ukuthi ngenxa yokuqina kwamathuluzi e-PCBN, imiphetho ebukhali ijwayele ukucwiliswa lapho kwenziwa insimbi eqinile. "Kufanele sivikele umkhawulo wokusika, ikakhulukazi ekusikeni okuphazamisekile, umkhawulo wokusika kufanele ulungiswe kakhulu kunokusika okuqhubekayo, futhi i-engeli yokusika kufanele ibe nkulu."

Amamaki ka-Iskar asanda kuthuthukiswa e-IB10H kanye ne-IB20H aqhubeka andisa umugqa womkhiqizo we-Groove Turn PCBN. I-IB10H iyibanga elihle le-PCBN lokusika okuqhubekayo okuphakathi kuya kwesivinini esikhulu sensimbi eqinile; kuyilapho i-IB20H iqukethe izinhlamvu ze-PCBN zikasayizi wokusanhlamvu ocolekile nomaphakathi, ohlinzeka ukumelana nokuguga okuhle kanye nokumelana nomthelela. Ibhalansi ingakwazi ukumelana nezimo ezinzima zensimbi eqinile ephazamisekile. Imodi yokwehluleka evamile yethuluzi le-PCBN kufanele kube ukuthi unqenqema luyaphelakunokuqhekeka noma ukuqhekeka kungazelelwe.

Ibanga le-PCBN elakhiwe nge-BNC30G elethulwe yi-Sumitomo Electric lisetshenziselwa ukugoba okuphazanyiswe kwezinsimbi eziqinile. Ngokuqhubeka nokukhula, inkampani incoma ibanga layo le-BN250 le-universal blade. UMaton uthe, “Lapho usikwa ngokuqhubekayo, i-blade isikwa isikhathi eside, okuzokhipha ukushisa okukhulu okusikayo. Ngakho-ke, kuyadingeka ukusebenzisa i-blade enokumelana okuhle kokugqoka. Endabeni ye-grooving ngezikhathi ezithile, i-blade ingena ngokuqhubekayo futhi iphuma ekusikeni. Inomthelela omkhulu ithiphu. Ngakho-ke, kuyadingeka ukusebenzisa i-blade enokuqina okuhle futhi ingamelana nomthelela wesikhashana. Ngaphezu kwalokho, i-blade coating nayo iyasiza ekwandiseni impilo yamathuluzi."

Kungakhathaliseki ukuthi hlobo luni lwe-groove eyenziwa ngomshini, ama-workshops ngaphambilini ayethembele ekugayweni ukuze aqedele izingxenye zensimbi eziqinile zingaguqulwa zibe yi-grooving ngamathuluzi e-PCBN ukuze kwandiswe umkhiqizo. I-hard grooving ingafinyelela ukunemba kwe-dimensional efana nokugaya, kuyilapho kunciphisa kakhulu isikhathi somshini.