A HLW, muna sake fasalta ƙa'idodin kera kayayyaki masu daidaito sosai ta hanyar sabis ɗin CNC Wire EDM (Electrical Discharge Machining) na zamani. A matsayin jagora na duniya a fannin sarrafa kayan daidaito, muna amfani da fasahar Wire EDM ta ci gaba don samar da sassa masu rikitarwa da ƙuntataccen daidaito waɗanda ke cika buƙatun da suka fi tsanani na masana'antu daga na sararin samaniya da na'urorin likita zuwa ƙirar mold da na'urorin lantarki. Ba kamar aikin sarewar gargajiya ba, tsarin CNC Wire EDM ɗinmu yana dogara ne akan sakin wutar lantarki da aka sarrafa—ba aɗaɓa jiki, babu matsin lamba na kayan aiki, da daidaito marar misaltuwa. Haɗe da ƙwarewar injiniyan HLW, tsauraran matakan kula da inganci, da hanyar aiki mai mai da hankali ga abokin ciniki, muna mayar da ƙira masu ƙalubale zuwa sassa masu aiki mai girma waɗanda ke haɓaka ƙirƙira.
Menene CNC Wire EDM?
CNC Wire EDM (Wire Electrical Discharge Machining) wata ce Tsarin kera ta hanyar cire kayan ba tare da taɓawa ba wadda ke gogewa kayan da ke ɗaukar wutar lantarki ta amfani da walƙiyoyin lantarki masu yawan mitar tsakanin siririn igiyar lantarki da ake ci gaba da ciyarwa da kuma sashin aiki. Ba kamar sarrafa kayan gargajiya (misali, niƙa, juya) da ke dogaro da kayan yankan zahiri ba, Wire EDM na amfani da kuzarin zafi daga fitar wutar lantarki don cire ƙananan barbashin kayan, yana ba da damar ƙirƙirar siffofi masu rikitarwa da matakan daidaito masu matuƙar ƙanƙanta.
Muhimman Rukuni na Wire EDM (Mayar da Hankali na HLW)
HLW ya ƙware a Slow Wire EDM (SWEDM)—ma'aunin zinariya na daidaito—tare da tsarin EDM na waya matsakaici na ci gaba, an tsara su don bukatun ayyuka daban-daban:
- Slow Wire EDM (SWEDM)Yana da yankan sassa da yawa (ginin farko + ƙarewa), zagayowar ruwa mara ions, da sarrafa ƙarfin waya daidai sosai. Ya dace don matakan daidaito masu matuƙar ƙarfi (±0.0005 mm) da ƙarewar saman mafi inganci (Ra ≤ 0.1 μm).
- EDM na waya matsakaiciYana daidaita sauri da daidaito, ya dace da samarwa mai matsakaicin yawa tare da iyakokin ±0.002 mm da kammalawar saman Ra ≤ 0.4 μm.
Duk fasahohin biyu suna da manyan fa'idodi: babu amfani da ƙarfin inji, dacewa da kayan da aka ƙarfafa, da ikon yanke siffofi masu rikitarwa na ciki da na waje—wannan yana sanya su ba za a iya maye gurbinsu ba a aikace-aikacen da injin gargajiya ba zai iya ba.
Yadda HLW CNC Wire EDM ke Aiki: Zurfin Nazarin Fasaha
Tsarin CNC Wire EDM na HLW haɗin gwiwa ne na kayan aiki na zamani, manhajoji, da daidaiton injiniya. A ƙasa akwai cikakken bayani kan fasahar, sassa, da tsarin aiki:
Muhimman Sassa na Tsarin Wire EDM na HLW
Tarin injunan Wire EDM na mu, wadanda ke jagorantar masana'antu (ciki har da jerin Sodick AQ da Makino U32i), an sanye su da muhimman sassa da ke tabbatar da daidaito da sahihanci:
- Wayar elektrodHLW yana amfani da wayoyi masu aiki sosai (diamita 0.05–0.3 mm) da aka tsara musamman don kayan aiki da aikace-aikace:
- Wayoyin tagulla/brass: Mai araha don yanke kayan aiki na gabaɗaya (karfe, aluminium).
- Wayoyin molibdenum: ƙarfi mai yawa na jan waya don yanke daidai sassa masu kauri.
- Zaren tagulla da aka lullube da zinc: Ingantacciyar tasirin walƙiya da juriya ga lalacewa don kammala aiki da sauri.
- Jagororin AlmasTabbatar da madaidaiciyar layin waya da kwanciyar hankali, rage lankwasawa ko da a lokacin yankan abubuwa masu rikitarwa.
- Tsarin Ruwa Marar Kwayoyin CajiYana tacewa da zagayawa ruwan da aka cire ions a zafin 15–25°C zuwa:
- Sanyaya sashin aiki da waya (don hana karkatar zafi).
- Zubar da ƙwayoyin abubuwan da suka lalace (don kauce wa sake ajiyewa).
- Yi rufi ga tazara tsakanin waya da abin aiki (don ba da damar sakin wuta da aka sarrafa).
- Tsarin Sarrafa CNCFanuc 31i-B ko Siemens Sinumerik controllers tare da kwaikwayon 3D, daidaita saurin ciyarwa ta atomatik, da inganta G-code. Yana tallafawa haɗin layi na axis huɗu da axis biyar (multi-axis machining) don sassa marasa daidaito.
- Tsarin saka waya ta atomatik (AWT)Yana ba da damar aiki ba tare da kulawa ba (24/7) tare da dawo da zaren a ƙasa da daƙiƙa 10—abin muhimmanci ga samarwa mai yawa da sassa masu rikitarwa da yawa yankan.
Tsarin aikin sarrafa kayan injin mataki-mataki
- Zane & Shirye-shiryeAbokan ciniki suna gabatar da fayilolin CAD (STEP, IGES, DXF, ko STL). Injiniyoyin HLW suna gudanar da nazarin Tsara don Yiwuwar Kera (Design for Manufacturability, DFM) don inganta hanyoyin kayan aiki, rage lalacewar waya, da rage lokutan zagaye. Software na CAM (misali Mastercam WireEDM) yana samar da G-code mai daidai don tsarin CNC.
- SaitawaAn matse kayan aiki (kayan wutar lantarki) a kan na'urar daidaitacce, sannan an saka wayar elektrod ta cikin jagororin lu'u-lu'u. An nutse wurin aiki cikin ruwan da aka cire kwayoyin halitta.
- Farkon Fitar Wutar LantarkiAna aikawa da bugun wuta mai ƙarfi (100–300V) tsakanin waya (katoda) da kayan aiki (anoda), wanda ke ƙirƙirar tashar plasma a cikin tazara (0.02–0.05mm). Kowace walƙiya (tsawon 1–10μs) tana haifar da zafin jiki har zuwa 10,000°C, tana tururuwa da lalata ƙananan barbashin kayan.
- Motsi da aka sarrafaTsarin CNC yana jagorantar waya a kan hanyar da aka shirya, yana daidaita saurin ciyarwa (0.1–50 mm/min) bisa kaurin kayan da rikitarwarsa. Injin masu axis da yawa suna karkatar da waya (har zuwa ±30°) don yanke mai sirara ko ƙirar 3D.
- Kammala yankan sau da yawa: Don ayyukan SWEDM, HLW yana yin yankan 2–5:
- Yankan farko: Cire 90% na ƙarin kayan (da sauri, da matsakaicin daidaito).
- Yankan kusan kammala: Yana inganta siffa (haƙƙoƙin juriya ±0.002 mm).
- Yankan ƙarshe: Yana cimma juriya ta ƙarshe (±0.0005 mm) da ƙarewar saman (Ra ≤ 0.1 μm).
- Binciken InganciSassa suna fuskantar binciken 100% ta amfani da na'urorin aunawa masu daidaitaccen tsarin (CMMs), na'urorin kwatanta haske, da na'urorin gwajin ƙaurin saman. Ana samar da Binciken Sashi na Farko (FAI) ga duk sabbin oda.
Babban fa'idodin HLW CNC Wire EDM
Ayyukan Wire EDM na HLW sun fice saboda daidaitonsu, sassaucinsu, da amintarsu—suna magance matsalolin da injin gargajiya ba zai iya warwarewa ba:
1. Daidaitattun matakai masu matuƙar ƙanƙanci & Ingantaccen kammalawar saman
- Yankin juriya: ±0.0005 mm (0.5 μm) don SWEDM; ±0.002 mm don Wire EDM matsakaici—ya zarce ƙa'idodin masana'antu (ISO 2768-IT1).
- Kammala saman: Ra ƙimar ƙananan 0.08μm (ƙarewar madubi) don sassa na likitanci da na sararin samaniya, yana kawar da buƙatar ƙarin sarrafawa (misali, niƙa, gogewa).
2. Babu matsin lamba na injiniya ko karkatar kayan
Tun da babu wata hulɗa ta zahiri tsakanin waya da abin aiki, tsarin Wire EDM na HLW:
- Yana gujewa alamomin kayan aiki, burrs, da ƙarfin damuwa da ya rage—mai muhimmanci ga sassa masu bango siriri (har zuwa kaurin 0.1 mm) da kayan da ke da rauni wajen jurewa.
- Yana kiyaye ƙarfi da siffar kayan, yana mai dacewa da sassa da aka yi wa maganin zafi ko aka taƙaƙƙaƙƙa (har zuwa 65 HRC).
3. Tsananin rikitarwa da 'yancin ƙira marasa misaltuwa
Wire EDM yana ƙware wajen yanke siffofin yanka da ba zai yiwu da kayan aikin gargajiya ba:
- Kusurwoyi masu kaifi a ciki (radius 0°, iyakance ne kawai ta diamita na waya).
- Siffofi masu rikitarwa, ramuka, da ramuka-ciki (misali, sassan ƙira, ƙananan sassa).
- Yankan lanƙwasawa (0–30°) da bayanan siffar 3D (misali, takalman turbin na jiragen sama).
- Ramuka marasa fita da siffofi na ciki ba tare da takunkumin samun dama ba.
4. Babban Daidaito da Kayan Aiki (Kayan da ke ɗauke da wutar lantarki)
Tsarin Wire EDM na HLW yana sarrafa duk kayan da ke ɗaukar wuta, ba tare da la'akari da ƙarfin su ba:
| Rukuni na kayan | Misalai | Fa'idodin Sarrafa HLW |
|---|---|---|
| Hadadden Karfe Mai Ƙarfi | Titaniyam (Ti-6Al-4V), Inconel 718, Hastelloy | Saurin yanke mai jinkiri da sarrafa bugun da ke daidaitawa don hana fashewar kayan |
| Kauran kayan aiki da ƙarfe masu tauri | H13, D2, bakin ƙarfe 440C (60–65 HRC) | Ba a buƙatar yin sarrafa kayan a gaba—yana yanke kayan da aka ƙara ƙarfi kai tsaye |
| Tagulla da Laton | Tagulla mara iskar oxygen, tagulla na jirgin ruwa | Ingantaccen haɗuwar walƙiya don yanke cikin sauri da daidaito |
| Haɗaɗɗun aluminium | 6061, 7075 | Karancin karkatar zafi tare da ruwan sanyaya mai sarrafa zazzabi |
| Masu Gudanarwa Haɗe-haɗe | Polimeri da aka ƙarfafa da carbon-fiber (CFRP) masu ƙwayoyin gudanar da wutar lantarki | Na'urorin ɗaurewa na musamman don hana rabuwar layuka |
Lura: HLW ba ya sarrafa kayan da ba sa watsawa wuta (misali: filastik, gilashi, itace). Don waɗannan, muna ba da shawarar sabis ɗin yankan laser ko yankan da ruwa mai matsa lamba.
5. Ƙarfi na faɗaɗawa ga duk ƙarar samarwa
- Ƙirƙirar samfurin farkoSaitin sauri (komawa cikin awanni 24–48) da ƙarancin kuɗin kayan aiki don ƙananan tarin (sassa 1–10).
- Samfurin yawan ƙarfiAiki ba tare da kulawa ba tare da AWT da na'urorin ɗora sassa na robot, yana rage lokacin zagaye har zuwa 40% idan aka kwatanta da saiti na hannu.
- Gudanar da na musammanShirye-shirye mai sassauci don ƙirar musamman, ba tare da ƙaramin adadin oda (MOQ) ba.
Iyakokin CNC Wire EDM (da yadda HLW ke rage su)
Duk da cewa Wire EDM ba shi da misaltuwa wajen daidaito, yana da wasu iyakoki na asali—wadanda HLW ke magancewa da ƙwarewar fasaha:
- Rigauwar saurin sarrafawa: Matsakaicin saurin yanke yana tsakanin 10–200 mm²/min (gwargwadon kayan da kauri). HLW yana inganta wannan da:
- Na'urorin samar da bugun wuta masu inganci sosai (suna rage tsawon lokacin walƙiya).
- Sarrafa a cikin rukuni da aiki awanni 24 a rana, kwanaki 7 a mako.
- Hanyoyin haɗe-haɗe (misali, cire babban yanki da niƙa, kammala da Wire EDM).
- Manyan Kudin AyyukaKayan amfani (waya, matattarai, ruwa mara sinadaran) da amfani da makamashi suna ƙara wa farashi. HLW na daidaita wannan da:
- Tsarin sake sarrafa wayoyi ( rage sharar da kashi 30%).
- Na'urori masu adana makamashi (motoci masu ƙimar IE4).
- Ragowar farashi bisa yawan odar samarwa.
- Bukatun Kayan Mai GudanarwaGa sassan da ba sa ɗaukar wutar lantarki, HLW na ba da ayyuka masu cike gibin (laser, waterjet) kuma zai iya ba da shawara kan maye gurbin kayan (misali, rufin mai ɗaukar wutar lantarki).
HLW CNC Wire EDM: Aikace-aikacen Masana'antu
Ana amincewa da sassan Wire EDM na HLW a masana'antu da ke buƙatar daidaito mara sassauci:
1. Sararin samaniya da Tsaro
- Sassa: Guntun turbin, bakin famfon mai, akwatin na'urar gano sigina, ƙugiyoyin jirgin sama.
- Bukatun: Hadiye ±0.001 mm, juriya ga zafin jiki mai yawa, da bin ka'idojin AS9100.
- Fa'idar HLW: na'urar Wire EDM mai axis biyar don samfuran 3D masu rikitarwa da takardun bin diddigi (takardun shaida na kayan, rahotannin bincike).
2. Na'urorin kiwon lafiya
- Sassa: kayan aikin tiyata (scalpel, forceps), sassan da za a iya dasa a jiki (skru na titanium, braket na gyaran hakora), akwatunan na'urorin gano cuta.
- Abubuwan da ake buƙata: kayan da suka dace da jiki, ƙarewar madubi (Ra ≤ 0.1μm), da takardar shaida ta ISO 13485.
- Fa'idar HLW: Tsare-tsare masu dacewa da ɗakin tsafta da tsarin sanyaya ruwa da ba sa gurbata.
3. Kera moldi da die
- Sassa: Saka-saka na ƙwanƙwaron allurar roba, matattaran bugawa, matattaran fitarwa, elektrod na EDM.
- Bukatun: kusurwa masu kaifi, ramuka masu rikitarwa, da ɗorewa don samarwa mai yawa.
- Fa'idar HLW: SWEDM don sassaka mold tare da juriya na ±0.0005 mm, yana tabbatar da daidaitaccen maimaitawar sashi.
4. Na'urorin lantarki da ƙaramin kera
- Sassa: ƙananan haɗaɗɗun na'urori, sandunan gwajin na'ura, kayan marufin semikondakta, kayan ɗaure PCB.
- Abubuwan da ake buƙata: siffofin ƙanana (har zuwa 0.1 mm), maimaituwa mai ƙarfi, da rashin lalacewar kayan.
- Fa'idar HLW: waya mai matuƙar siriri (diamita 0.05 mm) da ƙwarewar micro-EDM don siffofi ƙasa da milimita.
5. Na Motoci (Mai Babban Aiki)
- Sassa: kayan gear na watsawa, sassan tsarin mai, sassan motar motocin lantarki (EV).
- Abubuwan da ake buƙata: juriya ga lalacewa, daidaitattun matakai na dacewa, da ingancin farashi.
- Fa'idar HLW: EDM na waya matsakaici don samarwa mai yawa tare da inganci mai daidaito.
CNC Wire EDM da Sauran Hanyoyin Sarrafa Karfe: Binciken Kwatananci
HLW tana taimaka wa abokan ciniki su zaɓi ingantaccen hanyar sarrafa injin da ta dace da bukatunsu. A ƙasa akwai cikakken kwatancen Wire EDM da wasu zaɓuɓɓuka na gama gari:
| Fasali | CNC Wire EDM (HLW) | Niƙa ta CNC | Yankan laser | Yankan ruwan famfo |
|---|---|---|---|---|
| Hanyar tuntuɓa | Ba a taɓa (fitar wutar lantarki) | Yankan zahiri | Ba taɓawa ba (na zafi) | Ba taɓawa ba (jet mai gogewa) |
| Dacewar kayan | Kayan da ke watsawa lantarki kawai | Yawancin kayan (karfe, filastik, itace) | Kai, filastik, kayan haɗe-haɗe | Kusan duk kayan (karfe, dutse, gilashi) |
| Jurewa | ±0.0005–±0.002mm | ±0.005–±0.01mm | ±0.01–±0.05mm | ±0.02–±0.1mm |
| Kammala saman | Ra 0.08–0.4μm (ba tare da burr ba) | Ra 0.8–3.2μm (watakila yana buƙatar ƙarin kammalawa) | Ra 1.6–6.3μm (yankin da zafi ya shafa) | Ra 0.8–2.4μm (HAZ mafi ƙanƙanci) |
| Rikitarwa | Ya dace da kusurwa masu kaifi da siffofin 3D | An takaita shi ta hanyar diamita na kayan aiki (kusurwoyi zagaye) | Yana da kyau don layukan 2D, amma ba shi da kyau don kusurwa masu kaifi. | Yana dacewa da kayan masu kauri, iyakance ne ta faɗin feshin ruwa |
| Sauri | Jinkiri (10–200 mm²/min) | Da sauri (100–1,000 mm²/min) | Mai sauri sosai (500–5,000 mm²/min) | Tsaka-tsaki (50–300 mm²/min) |
| Mafi kyau don | Daidaito, sassa masu rikitarwa (na sararin samaniya, na kiwon lafiya) | Aikin injina na gabaɗaya, mai yawa | Babban tarin, sassa na 2D | Kayan da suka yi kauri, sassan da ba sa watsawa wutar lantarki |
Tabbacin Inganci da Takardun Shaida na HLW
Inganci shi ne ginshiƙin ayyukan HLW. Ayyukan CNC Wire EDM ɗinmu suna da tallafi daga:
- Takardun Shaida: ISO 9001:2015 (ƙera gabaɗaya), AS9100D (sararin samaniya), ISO 13485 (na'urorin likita).
- Kula da Tsarin Kididdiga (SPC)Kula a ainihin lokaci da yawan tsawa, ƙarfin ja na waya, da zafin ruwan sanyaya don kiyaye daidaito.
- Gwaji marar lalatawa (NDT): Gwajin ultrasonic (UT) da binciken X-ray don muhimman sassa.
- Cikakken bin diddigiAn sanya wa kowane sashi lamba ta musamman, wadda ke haɗa shi da tarin kayan albarkatu, bayanan samarwa, da rahotannin bincike.
- Daidaita na'uraDaidaitawa ta shekara-shekara da ƙungiyoyi na uku da aka amince da su don tabbatar da daidaiton spindle da daidaitawar waya.
Nemi farashi don aikin CNC Wire EDM ɗinka
Kun shirya amfani da sabis na Wire EDM na CNC mai matuƙar daidaito na HLW? Ga yadda ake farawa:
- Aika ƙirarka: Aika fayilolin CAD (STEP, IGES, DXF, ko STL) zuwa wire-edm-quote@hlw-machining.com.
- Bayar da cikakkun bayanai game da aikin: Haɗa:
- Takaddun kayan (nau'i, tauri, kauri).
- Adadi (samfurin gwaji, ƙaramin yawa, ko babban yawa).
- Tolerance da buƙatun ƙarewar saman (misali, ±0.001 mm, Ra 0.1 μm).
- Bukatun sarrafa bayan aiwatarwa (misali, maganin zafi, shafawa da tagulla, tsabtacewa).
- Jadawalin isarwa da bukatun takaddun shaida (misali, AS9100, ISO 13485).
- Karɓi farashi na musammanƘungiyar injiniyoyinmu za ta duba buƙatarku kuma ta ba da ƙididdiga mai cikakken bayani cikin awanni 12 (ayyuka na yau da kullum) ko awanni 24 (ƙira mai rikitarwa).
- Tuntuɓar DFM kyautaMuna ba da inganta ƙira kyauta don rage kuɗaɗe, inganta lokutan isarwa, da tabbatar da yiwuwar kerawa.
Don tambayoyi masu gaggawa ko tallafin fasaha, tuntuɓi ƙungiyar injiniyan tallace-tallacenmu a +86-18664342076 (ko lambar tuntuɓar yankinku)—muna nan a shirye 24/7 don tallafawa aikin ku.
A HLW, ba mu tsaya kawai wajen sarrafa sassa ba—muna samar da daidaito mai inganci da za ku iya dogaro da shi, tare da ƙwarewa mai mahimmanci. Yi haɗin gwiwa da mu don samfurin CNC Wire EDM da ke mayar da ƙirarku mafi ƙalubale zuwa gaskiya.
Tuntube mu a yau: info@helanwangsf.com | https://helanwangsf.com/