Sarrafa CNC na haɗadden titanium

Alloys na titanium sun sami suna a matsayin “karfe na zamani na sararin samaniya” saboda haɗakar halayensu na musamman, wanda ya sa su zama ba za a iya maye gurbinsu ba a aikace-aikacen masu buƙatar babban aiki a fannoni daban-daban na masana'antu. Duk da cewa halayensu na musamman suna ba da manyan fa'idodi, suna kuma haifar da ƙalubale na musamman a aikin CNC wanda ke buƙatar ilimi na musamman, dabaru, da kayan aiki. Wannan labarin yana ba da cikakken bayani game da aikin CNC na alloys na titanium, yana rufe muhimman halayensu, rukunansu na gama gari, ƙalubalen aikin CNC, mafi kyawun hanyoyi, aikace-aikace, da abubuwan da ya kamata a yi la'akari da su.

Muhimman Siffofi da Amfanin Hadadden Titanium

Hadadden titanium yana fice saboda jerin kaddarorin inganci da ke sa a fi so sosai wajen muhimman aikace-aikace:

• Rabo na ƙarfi da nauyi na musamman: Sassan titanium suna gasa da ƙarfin jan wasu bakin ƙarfe yayin da nauyinsu kusan rabin ne—sun fi na 40% nauyi kawai Aluminiyamu kuma 40% ya fi ƙarfe sauƙi—wanda hakan ya sa su dace da masana'antu inda rage nauyi ya fi muhimmanci ba tare da rage ƙarfin gine-gine ba.
• Ƙarfin juriya ga lalacewaTitanium yana samar da wani layin oxide mai kariya idan ya fuskanci iska, wanda zai iya gyara kansa, yana ba shi damar jure lalacewa daga ruwan teku, sinadarai, da muhallai masu tsauri. Wannan kaddarar ta sa ya zama zaɓi na farko a aikace-aikacen teku, sarrafa sinadarai, da na waje da bakin teku.
• Dacewar halittaBa mai guba ba kuma yana dacewa da nama na ɗan adam, haɗaɗɗun titanium suna ingiza haɗin ƙashi da implants (osseointegration), wanda ya sa ake amfani da su sosai a na'urorin likitanci da na haƙori.
• Ƙarfin jure zafi mai yawaTare da matsayi mai nisa na narkewa, titanium yana ci gaba da riƙe ƙarfinsa da daidaitonsa ko da a yanayin zafin da ya yi tsanani, yana dacewa da injunan jirgin sama na jet, sassan roket, da kayan aikin masana'antu masu zafi sosai.
• Iyawar sake sarrafawaTitanium ana iya sake sarrafa shi gaba ɗaya, yana daidaita da kyawawan dabi'un kera na dorewa yayin da yake riƙe da muhimman halayensa.

Jiragen titanium na gama gari don sarrafa CNC

Titanium yana samuwa a kusan rukuni 40 na ASTM, ciki har da titanium mai tsarki na kasuwanci (rukuni 1–4) da hadadden titanium (rukuni 5 da sama), kowannensu an tsara shi don takamaiman aikace-aikace:

• Daraja ta 1 (Mai Tsarki a Kasuwanci, Cike da Karancin Iska)Yana ba da ƙarfi sosai wajen jure tsatsa, juriya ga bugun tasiri mai ƙarfi, da sauƙin sarrafawa, kodayake ba shi da ƙarfi kamar sauran matakai. Ana amfani da shi wajen sarrafa sinadarai, na'urorin musayar zafi, tsarin cire gishiri daga ruwa, sassan motoci, firam ɗin jirgin sama, da na'urorin likitanci.
• Daraja ta 2 (Mai Tsarki na Kasuwanci, da Adadin Iskar Oxygen na Al'ada)Ya fi Grade 1 ƙarfi, yana da ƙarfin juriya ga tsatsa, sassauci mai kyau, sauƙin siffanta, sauƙin walda, da sauƙin sarrafa injina. Ana amfani da shi a cikin firam ɗin jirgin sama, injunan jirgin sama, sarrafa sinadaran hydrocarbon, kayan aikin teku, na'urorin likita, da kera chlorate.
• Daraja ta 3 (Mai Tsarki a Kasuwanci, Cike da Isasshen Iska)Yafi wahalar a kera fiye da Daraja ta 1 da ta 2, amma yana da ƙarfi sosai, yana da juriya ga tsatsa, kuma yana da kyau wajen sarrafa injina. Ana yawan amfani da shi a fannoni na sararin samaniya, na ruwa, da na kiwon lafiya.
• Daraja ta 4 (Mai Tsarki a Kasuwanci, Cike da Isasshen Oksijin)Mafi ƙarfi a cikin matakan titanium na tsarki, tare da ƙarfin juriya ga tsatsa. Yana buƙatar saurin ciyarwa mai yawa, saurin aiki mai jinkiri, da yawan kwararar mai sanyaya saboda wahalar sarrafawa. Ana amfani da shi wajen kera tankunan cryogenic, na'urorin musayar zafi, tsarin hydraulic, firam ɗin jirgin sama, kayan aikin tiyata, da kayan aikin teku.
• Daraja ta 5 (Ti6Al4V): An fi amfani da wannan haɗin titanium a duniya (yana ɗaukar kusan rabin amfani da titanium a duniya), an haɗa shi da aluminium 6% da vanadium 4%. Yana daidaita juriya ga lalacewa mai ƙarfi da kuma kyakkyawar iya siffa, amma ba shi da kyau wajen sarrafa injina. Ya dace da tsarin jikin jirgi, injunan jirgi, samar da wutar lantarki, na'urorin likita, kayan aikin teku/na waje da ruwa, da tsarin hydraulic.
• Daraja ta 6 (Ti5Al-2.5Sn)Yana da kyakkyawar damar walda, kwanciyar hankali, da ƙarfi a zafin jiki mai girma tare da matsakaicin ƙarfi ga haɗadden titanium. Ana amfani da shi wajen riƙe iskar mai/propellant a roket, firam ɗin jirgin sama, injin jet, da motocin sararin samaniya.
• Daraja ta 7 (Ti-0.15Pd)Ana yawan ɗaukar shi a matsayin mai tsarki amma yana ɗauke da ƙananan adadin palladium, yana ba da ƙarfi wajen jure tsatsa, sauƙin walda, da sauƙin siffanta (ko da yake ƙarfin sa ya fi ƙasa fiye da sauran haɗaɗɗun ƙarfe). Ana amfani da shi a sarrafa sinadarai da sassan kayan aikin samarwa.
• Daraja ta 11 (Ti-0.15Pd)Yana kama da Grade 7, yana da ƙwarin juriya ga tsatsa, sassauci, da sauƙin siffanta, amma ƙarfinsa ya fi ƙasa. Ana amfani da shi a aikin cire gishiri daga ruwa, a aikace-aikacen teku, da kuma a masana'antar kera chlorate.
• Daraja ta 12 (Ti0.3Mo0.8Ni)Yana ba da ƙarfi mai yawa a zafin jiki mai girma, sauƙin walda, da juriya ga tsatsa, amma ya fi tsada fiye da sauran haɗaɗɗun ƙarafa. Ya dace da aikace-aikacen hydrometallurgical, sassan jirgin sama da na jirgin ruwa, da na musayar zafi.
• Daraja ta 23 (Ti6Al4V-ELI)Yana ba da kyakkyawar siffa, juriya ga lanƙwasawa, ƙarfi mai kyau wajen tsagewa, da cikakkiyar dacewa da jiki, amma ba shi da kyau wajen sarrafawa da injina. Ana yawan amfani da shi a cikin na'urorin gyaran hakora, sanduna da dunƙule-dunƙule na orthopediki, ƙugiyoyin tiyata, da igiyoyin orthopediki.

Kalubale a sarrafa kayan haɗin titanium ta CNC

Duk da fa'idodinsu, haɗaɗɗun titanium suna haifar da ƙalubale na musamman da ke buƙatar hanyoyi na musamman:

• Ƙarancin gudanar da zafiTitanium yana fitar da zafi a hankali, wanda ke haifar da taruwar zafi a wuri guda yayin aikin injina. Wannan ba wai kawai yana hanzarta lalacewar kayan aiki ba, har ma yana haifar da haɗarin karkatar da sashin aiki, ƙara taurin sashin aiki saboda aikin injina, har ma da haɗarin wuta.
• Ƙarfin halin yin aiki tukuruKayan yana tauri cikin sauri lokacin da aka yi masa ƙarfin yankan, wanda ke sanya yankan na gaba ya fi wahala kuma ke ƙara matsin lamba ga kayan aiki.
• Sassauci da girgizaƘarfin titanium ya ɓoye sassaucinsa, wanda zai iya haifar da girgiza (chattering) yayin sarrafa kayan. Wannan yana buƙatar ingantattun tsarin riƙe aiki da tsayayyun saitunan injin don kiyaye daidaito.
• Tsani da Gefen da Ya Taru (BUE)Halayen mannewa na titanium, musamman a cikin matakan kasuwanci na tsarki, yana sa ya manne da kayan yankan, yana haifar da BUE da galling. Wannan yana rage ingancin yankan, yana rage tsawon rayuwar kayan aiki, kuma yana raunana kyakkyawan kamannin saman.
• Gargajiya kayan aikiTsayin ƙarfi da ƙarfin gogayya na titanium suna haifar da saurin lalacewar kayan aiki, wanda ke buƙatar kayan aiki masu ɗorewa da rufi masu ƙarfi.

Hanyoyin sarrafa kayan inji, shawarwari da dabaru

Don shawo kan waɗannan ƙalubale da tabbatar da sakamako mai inganci, waɗannan kyawawan hanyoyin aiki na gaba sun zama dole:

Zaɓin Kayan Aiki da Rufi

• Yi amfani da kayan yankan da aka yi da carbide mai ɗorewa ko bakin ƙarfe mai saurin gudu (HSS) da aka lullube da tungsten, carbon, da vanadium, waɗanda za su iya riƙe tauri har zuwa 600℃.
• Zaɓi rufin kayan aiki da aka ƙera don sarrafa titanium, kamar Titanium Aluminum Nitride (TiAlN), Aluminum Titanium Nitride (AlTiN Nano), ko Titanium Carbo-Nitride (TiCN). Waɗannan rufin suna samar da wani layin oxide mai kariya a zafin jiki mai yawa, suna rage yaduwar zafi, suna ƙara santsi, kuma suna hana makale. HVTI End Mill na HLW (wanda aka inganta don yankan ƙasa mai inganci) da rufin Aplus zaɓuɓɓuka ne masu kyau don tsawaita rayuwar kayan aiki da inganta aikinsu.

Riƙe kayan aiki da kwanciyar hankali

• Yi amfani da tsarin riƙe aiki mai ƙarfi da aminci don rage lankwasawa da girgiza na sashin aiki. Guji yanke-yanke da aka katse kuma ka sa kayan aikin ya kasance cikin motsi a kowane lokaci yayin hulɗa da sashin aiki—zaman a cikin ramuka da aka huda ko tsayawa kusa da bangon da aka sassaka yana haifar da zafi mai yawa da lalacewar kayan aiki.
• Yi amfani da end mill mai diamita na tsakiyar bututu mafi girma, rage tsawon ɓangaren da ke rataye tsakanin hancin spindle da ƙarshen kayan aiki, sannan ka tabbatar da ciyarwa da saurin aiki masu daidaito don rage girgiza.

Sanyaya da Shafawa

• Yi amfani da matsa lamba mai ƙarfi da yawan ruwan sanyaya mai kyau wajen shafawa da sanyaya (misali, ruwan sanyaya na emulsion) don rushe zafi, wanke ƙananan sassa na ƙarfe da hana BUE da ƙonewa. Jagoranci kwararar ruwan sanyaya kai tsaye zuwa saman yankan don samun ingantaccen sakamako.

Dabarun sarrafa injin da sigogi

• Yi amfani da nika tudu (maimakon nika na gargajiya) don rage yaduwar zafi zuwa sashin aiki. Nikar tudu na samar da ƙananan yankakken ƙarfe da ke farawa masu kauri sannan su yi siriri, yana inganta fitar zafi zuwa waɗannan yankakken ƙarfe kuma yana tabbatar da yanke mai tsabta.
• Yi amfani da ƙananan saurin yanke (yawanci mita 18–30 a minti / ƙafa 60–100 a minti) tare da ƙarin saurin ciyarwa da manyan nauyin yankakken ƙwaya don rage taruwar zafi da ƙarfafar aiki. Daidaita saurin bisa ga matakin titanium, kayan aiki, da ƙarfin injin.
• Don yankan shiga da fita, lanƙwasa kayan aikin a hankali cikin kayan aiki ko yi amfani da chamfers don a hankali ƙara ko rage matsa lamba, rage girgizar kayan aiki da tsagewar kayan aiki.
• Yi amfani da kayan aiki masu ƙaramin diamita don ƙara fallasa su ga iska da ruwan sanyaya, wanda ke ba gefen yankan damar yin sanyi tsakanin yankan.
• Sauƙaƙa siffofi masu rikitarwa a ƙirar sassa (misali, manyan radius, daidaitaccen kaurin bango, gujewa zurfin aljihu) don sauƙaƙe aikin injina da rage matsin lamba ga kayan aiki.

Sashe na La'akari da Zane

• Yi amfani da software na CAD/CAM (misali, tare da kayan aikin kwaikwayo kamar ANSYS) don ƙirƙirar sassa daidai da samar da hanyoyin motsin kayan aiki. An tsara kayan riƙewa da jiggi yadda ya kamata suna da matuƙar muhimmanci wajen kiyaye kwanciyar hankali da daidaito.
• Haɗa ka'idojin ƙira don iya kerawa (DFM) — HLW na ba da ra'ayoyin DFM (ta hanyar AI da na ɗan adam) don inganta ƙirar sassa dangane da inganci, ƙwarewa, da araha.

Amfanin sassan titanium da CNC ta sarrafa

Sassan titanium da aka sarrafa da CNC suna da muhimmanci ga masana'antu da dama masu buƙata sosai:

• Fasahar sararin samaniyaBabban mai amfani da titanium, ana amfani da shi a cikin sassan kujerun jiragen sama, sanduna, sassan turubain, bawuloli, tsarin samar da iskar oxygen, jikin jirgi, da sassan roketa. Nauyinsa kaɗan da juriya mai ƙarfi ga zafi suna ba da damar amfani da mai yadda ya kamata da kuma ingantaccen aiki a saurin supersonic.
• Kiwon Lafiya da na haƙoraAna amfani da haɗin titanium mai dacewa da jiki a maye gurbin haɗin kugu, gwiwa, gwiwar hannu da kafada, a dunƙulen ƙashi, na haƙori da na ƙashin kai, sandunan daidaita kashin baya, shigar da kai na ƙashin cinyar ƙafa, sandunan orthopedik, ƙugiyoyin tiyata da kuma kambi, gada da shigar haƙori.
• Soja da TsaroAn yi amfani da shi a fannin sararin samaniya na soja, makaman roka, bam-bam, jiragen ruwa ƙarƙashin ruwa, motocin ƙasa (don juriya ga harbin balistik), da kayan aikin sojin ruwa.
• Na ruwa/Na sojin ruwaYa dace da sandunan propela na tsarkake ruwan teku, kayan aikin hakar albarkatu a karkashin teku, kayan ɗaurewa, robot na karkashin ruwa, na'urorin musayar zafi na teku, propela, da tsarin bututu—ta amfani da juriya ga tsatsa da hasken nauyi.
• Na motaAna amfani da shi wajen rage nauyi da cinye mai, tare da aikace-aikace a bawuloli, bazaran bawuloli, sandunan piston na injin, masu riƙe, da piston na caliper na birki.
• Kayayyakin Masu AmfaniAn fi amfani da shi a kayan wasanni (sandunan golf, firam ɗin keke, sandunan baseball, raket ɗin tennis, kayan zango) da kayan ado (agogo, firam ɗin gilashin ido, zobon aure, sarƙoƙi) saboda haske da kyakkyawan kamanninsa.
• Sarrafa sinadaraiAna amfani da shi a cikin na'urorin musayar zafi, tsarin cire gishiri daga ruwa, da sassan kayan aikin samarwa saboda juriya ga tsatsa.

Zaɓuɓɓukan kammala saman

Kammala saman yana inganta aiki, ɗorewa, da kyawun sassan titanium da CNC ta sarrafa:

• AnodizationZaɓi na gama gari da ke ƙara juriya ga tsatsa, rage ƙarin nauyi, rage gogayya, da inganta kamanni.
• Kammala na InjinGogewa, fashewar ƙwayoyi, da goga don rage ƙurƙushewar saman da samun yanayin da ake so.
• Rufi: rufin PVD, rufin foda, chrome, da electrophoresis don ƙarin kariya da ingantaccen aiki.
• Sauran magunguna: Fenti don keɓancewa ta fuskar kyau. HLW na ba da zaɓuɓɓuka har zuwa guda 6 na sarrafa bayan-aiwatarwa, ciki har da fashewar ƙwayoyi, rufewar foda, sarrafa injin mai santsi, da gogewa.

Abubuwan da suka shafi tattalin arziki

Farashin titanium mai tsada (sakamakon tsauraran ƙa'idodin inganci da ƙaruwa buƙata) yana buƙatar ingantaccen tsara rage kuɗi:

• Yi kwatancen farashin titanium da na madadin (misali, bakin ƙarfe, aluminium) don aikace-aikace marasa muhimmanci.
• Inganta tsawon rayuwar kayan aiki, lokacin sarrafawa, da amfani da kayan don rage sharar.
• Bin diddigi da rage farashin kayan aiki, ruwan sanyaya, aiki, makamashi, da sarrafa sharar.
• Yi amfani da tsawon rai da ɗorewar titanium don samun ajiyar kuɗi na dogon lokaci. Cibiyar sadarwar HLW mai na'urorin niƙa da juya sama da 1,600 tana tabbatar da farashi masu gasa da samarwa mai inganci ga umarnin ƙarami da masu rikitarwa.

Matakan Tsaro da Ka'idodin Masana'antu

Hanyoyin Tsaro

• Sanya kayan kariya na mutum (PPE) don rage haɗari daga tarkacen da ke tashi, ruwan sanyaya, da haɗarin wuta.
• Bi ka'idojin da suka dace na sarrafawa da ajiya na kayan titanium, ruwan sanyaya, da barbashi.
• Aiwatar da matakan hana barkewar wuta da shirye-shiryen amsa gaggawa, domin zafi mai yawa na iya haifar da haɗarin wuta.
• Yi gyaran injin akai-akai kuma horar da masu aiki kan hanyoyin aiki da injin cikin aminci.
• Ku zubar da ƙananan sassa na titanium, ruwan sanyaya, da shara yadda ya kamata don tabbatar da aminci a wurin aiki da bin ƙa'idodin muhalli.

Ka'idodin Masana'antu da Takardun Shaida

Don tabbatar da inganci da amintuwa, sarrafa titanium ta CNC yana bin ƙa'idodin masana'antu masu tsauri da takardun shaida:

• Ka'idodin ASTM: ASTM B265 (sandar titanium/takarda/faranti), ASTM F136 (sakin tiyata Ti6Al4V ELI), ASTM F1472 (sakin tiyata Ti6Al4V).
• Ka'idodin ISO: ISO 5832-2 (sakan titanium marar haɗe-haɗe), ISO 5832-3 (sakan haɗin Ti6Al4V), ISO 9001 (tsarin gudanar da inganci), ISO 13485 (tsarin gudanar da ingancin na'urorin likita).
• Ka'idodin SAE: SAE AMS 4911 (faranti/sashi/allon Ti6Al4V da aka yi masa annealing).
• Takardun ShaidaAS9100 (gudanar da inganci na jiragen sama/sararin samaniya/tsaro) yana da matuƙar muhimmanci ga sassan jiragen sama da sararin samaniya.

Ayyukan Injin CNC na HLW don Hadadden Titanium

HLW tana ba da cikakkun ayyukan sarrafa CNC don haɗaɗɗun titanium, ta amfani da kayan aiki na zamani (3-axis da 5-axis CNC milling, turning, drilling, boring) da ƙwarewa don samar da sassa masu inganci tare da saurin kammala aiki (galibi ƙasa da kwanaki 10). Iyawarmu sun haɗa da:

• Aikin injina na musamman na titanium matakai 1–5, 7, 11, 12, 23, da sauran haɗaɗɗun ƙarafa.
• Ra'ayi na DFM (AI da ɗan adam nan take) don inganta ƙirar sassa dangane da yiwuwar kera, farashi, da inganci.
• Zaɓuɓɓuka daban-daban na ƙarewar saman don cika buƙatun aiki da na kyau.
• Bin ka'idojin masana'antu (ASTM, ISO, SAE) da takardun shaida (ISO 9001, AS9100, ISO 13485) don aikace-aikace masu muhimmanci.
• Farashi mai gasa da ƙarfin samarwa mai sassauci don biyan buƙatun ƙaramin adadi da siffofi masu rikitarwa tare da matakan daidaito masu ƙanƙanci (±0.125 mm / ±0.005″).

Don fara, ɗora fayil ɗin CAD (.STL) ɗinka a dandalin HLW don samun farashi nan take. Don tambayoyi, tuntube mu a 18664342076 ko info@helanwangsf.com. HLW na da himma wajen taimaka maka shawo kan ƙalubalen sarrafa titanium ta CNC da samar da sakamako na musamman ga ayyukanka masu buƙatu mafi ƙarfi.