Izitolo ezinquma ukunwebeka zibe izimakethe ezintsha zivame ukugqugquzelwa ukuthi zengeze imishini emisha yokwenza imishini noma zamukele izinqubo ezintsha zokwenza imishini ukuze zisekele imizamo yazo. Odabeni lwe-True Die, amagxathu ewathathile ukuze ihlukanise ukunikezwa kwemikhiqizo yayo ngokukhiqiza amathuluzi ayindilinga anembayo wezinhlelo zokusebenza zokwenza amashidi-insimbi edonsa kanzima kuholele ekuthuthukiseni isu elisebenzayo lokujika kanzima. Umgomo wawuwukuqeda isidingo sokugaya okungaphakathi kwedayimitha (ID) kanye nobubanzi bangaphandle (OD) bokugaya (ngokuyinhloko) impushana eqinile eyindilinga yamathuluzi ajikelezayo asukela ku-64 HRC, okuyenza ikwazi ukuzuza amazinga aphezulu okususwa kwezinto kuyilapho ifanisa lokho ukugaya okungafinyelelwa mayelana nokugxila, ukuphela kwendawo kanye nokunemba kobukhulu. Lokho ekwenzile kusukela ngaleso sikhathi, ukusungula amandla okuguqula amadayamitha aqinile kanye nerediya ukuya ku-±0.0002-intshi ukunemba.

Eqinisweni, izingxenye ezimbili zemishini esanda kufakwa esitolo sase-Zeeland, eMichigan ziyizikhungo zokuguqula ezathengwa kakhulu ukuze zijike kanzima. U-Mitch Stahl unguchwepheshe wezobuchwepheshe we-True Die, kanye no-Chris McCleary, umxhumanisi wezinguquko, bahola ithimba lochwepheshe bemishini ekusunguleni isu lesitolo elisebenza kanzima. Ngamafuphi, uthi indlela yesitolo ifinyelela emiqondweni emithathu exhumene: ukusungula ukuqina kwenqubo yonke, ukusebenzisa izinhlobo ezifanele zamathuluzi okusika nokusebenzisa idatha yokusika efanele.

Igama elingukhiye lapha lixhumene. UMnu. Stahl ugcizelela ukuthi ukusebenzisa eyodwa noma emibili kuphela yale miqondo ngeke kusebenze; konke kufanele kuqondiswe ngendlela efanele ukuze kuguquguquke kanzima. “Kubalulekile futhi ukunaka imininingwane emincane lapho ubeka inqubo efana nalena,” uyaphawula.

Iqiniso Lifa, ngaphambili eyayiyi-Contour Tool and Engineering ngaphambi kokuba ithole leyo nkampani ngo-2015, inobuchwepheshe bokuklama, ukukhanda nokuhlanganisa isikhunta sokujova epulasitiki kanye namasethi okufa aqhubekayo. Inezinhlobonhlobo zemishini yokwenza imishini endaweni yayo engu-10,000-square-foot, okuhlanganisa izigayo ze-CNC, izikhungo zokujika, imishini yokugaya, kanye nemishini ye-EDM yocingo kanye ne-sinker.

UBrian Brown, umongameli weTrue Die, uthi imboni yokwakhiwa kwensimbi edonsa kanzima imele ithuba lokuthi isitolo sishintshe sibe yimakethe entsha ehambisana nezinye ezisisebenzelayo. "Ubuchwepheshe bethu bokusebenzisa isitembu esijulile basibeke endaweni ehlukile njengabahlinzeki bamathuluzi, okusenza sikwazi ukuletha izixazululo ezibambekayo namathuluzi asebenza kahle kakhulu emakethe," kusho uMnu. Brown. “Ngeminyaka engaphezu kwekhulu yesipiliyoni esihlangene ekwakhiweni, ekuthuthukisweni nasekukhiqizweni kwezitembu ezidwetshiwe, besilungiselelwe kahle ngokuziqonda ngokugcwele izidingo eziyingqayizivele zaleyo mboni.”

Ngesikhathi sokuthenga, i-Contour yayikhiqiza isikhunta kuphela futhi iyafa. Ukuthuthukisa ubudlelwano bamasu nenkampani egxilile yokugxiviza enikwe amandla kanye namakhasimende amabili engeziwe anikeze ukuhlukahluka kanye nethuba lokukhula ngokushesha, isitolo sifeze kahle iminikelo yaso ngokusungula lokho uMnu. Brown akubiza ngokuthi "umnyango wemininingwane," ohlinzeka ngezingxenye ngazinye zamathuluzi amasha nakhona ajulile adonsayo kanye nemishini yokuhlanganisa ezenzakalelayo. Eqinisweni, imininingwane esebenzayo njengamanje imele amaphesenti angama-50 okuthengiswa kwesitolo, futhi inkampani ikhule cishe ngamaphesenti angama-700 kule minyaka emibili selokhu yangena emakethe yemininingwane.

Lokhu kusetshenziswa kwamathuluzi ayindilinga kusetshenziswa kumafa ayinkimbinkimbi, aqhubekayo futhi ajulile asetshenziselwa ukwakha izingxenye (imvamisa eyi-cylindrical) kusuka kushidi lensimbi (ngokuvamile insimbi engagqwali), ngokuyinhloko ezintweni ezisetshenziswayo zezimoto, njengezingxenye zikaphethiloli, amabhuleki namasistimu e-airbag. “Ekuqaleni besicabanga ukuthi kuzodingeka sithenge umshini wokugaya onekhono ukuze sithole ukubekezelelana futhi siqedele ukusebenzisa amathuluzi adingekayo,” kusho uMnu. "Nokho, ngenxa yokuhlangenwe nakho kwakhe ngokuphenduka okunzima, uMnu. Stahl uphakamise ukuthi inqubo yokuguqula kanzima izofeza ukunemba kwamathuluzi adingekayo futhi ibone ukuphuma ngokushesha kunokugaya ngenxa yamazinga aphezulu okususwa kwezinto. Ukwengeza, singase futhi siguqule ngokuphumelelayo amaphrofayili ayinkimbinkimbi ezintweni eziqinile ezingabiza ukuvimbela ukugaya futhi ngokunokwenzeka kudinge imisebenzi yokugaya ifomu."

Ngenxa yokuthi i-True Die iyisitolo semisebenzi, osayizi bayo benqwaba bamathuluzi ayindilinga baphansi (ngokuvamile bahluka kusuka kusiqephu esisodwa kuya kweziyisithupha), futhi ukuxubana komkhiqizo wayo kuphezulu. Ubude bethuluzi bungasukela kumayintshi angu-20 nobubanzi busuka ku-0.1 kuye ku-12 amayintshi, futhi izinguqulo eziningi zinezilinganiso eziphakeme zobude ukuya kububanzi (L:D).

Isitolo ngokuyinhloko sidala amathuluzi ayindilinga kusuka ku-barstock ye-powder metal alloys, enziwe ngezinhlayiya ezihlanganisiwe zezinsimbi ezihlukahlukene kanye nezici ze-alloying. “Iresiphi” yensimbi eyimpushana incindezelwa ibe yifomu ye-barstock esitolo iqale isebenze esimweni sayo esithambile noma “esiluhlaza” ngaphambi kokwelashwa ngokushisa, okuhlanganisa izinhlayiya ngazinye ukuze kwakhiwe ingxenye eqinile. Kuye ngokuthi i-powder metal alloy ethize, ubulukhuni be-tooling esimweni esiluhlaza abunakwa futhi bungenziwa ngokuphumelelayo ngokusebenzisa izindlela zokuguqula ezivamile. Nokho, ngemva kokwelapha ukushisa, ubulukhuni bethuluzi bungafinyelela ku-64 HRC. Izinsimbi ezijwayelekile eziyimpushana emishinini yezitolo zihlanganisa i-CPM 3V, 9V kanye ne-10V, kanye ne-M2 ne-M4.

I-True Die ngokuvamile ishiya cishe intshi engu-0.010 kuya ku-0.012 yesitoko esengeziwe ngemva kokuvula ithuluzi esimweni esiqinile ukuze kuvunyelwe amaphasi alandelayo aphenduphenduka kanzima. Ingase ishiye isitoko esiningi ezingxenyeni ezivame ukuwohloka kabi ngemva kokwelapha ukushisa, njengalezo ezine-L:D ephezulu. Endabeni ye-warpage ebalulekile, inselele ayikona kakhulu ukuzuza ukubekezelela usayizi, kodwa kunalokho ukubekezelela okuqinile kwe-concentricity. “Ngezinye izikhathi kuba nzima kakhulu ukwenza ingxenye esontekile iqonde kunokuba ifinyelele usayizi,” kusho uMnu. Stahl.

Izikhungo ezimbili zakamuva zokujika i-True Die ezithengelwe ukujika kanzima ziyi MazakAmamodeli we-Quick Turn Nexus 250 II aneziteshi ezingu-12 ze-turrets (zingenazo iziteshi zamathuluzi abukhoma). Eyokuqala yale mishini yathengwa ngo-Ephreli 2016 kanti eyesibili kamuva ngalowo nyaka ngo-Agasti, futhi banikeza ukuqina kwesitolo esidingekayo ukuze kwakhiwe isisekelo senqubo yayo yokuguqula kanzima, kusho uMnu Stahl.

NgokukaMike Utter, ummeleli ovela emsabalali wamathuluzi womshini Imishini ye-Addy(Grand Rapids, Michigan), abadayisele imishini ku-True Die, amasistimu wabo we-MX hybrid roller guide anegalelo elikhulu ekuqineni kwawo. Uyachaza: "Lolu hlelo luphinde luphathe ngokuphumelelayo amandla omthwalo osindayo, ngenxa yokuthi kukhona ukuguquguquka okuncane okunwebekayo ngama-roller, futhi ahlinzeka ngezinga eliphezulu lokudambisa amandla, okunweba impilo yamathuluzi. Futhi ihlanganisa umklamo wohlobo lwe-X olusabalalisa kahle umthwalo ngezindlela ezine-i-radial (ngokuhamba kwewashi nangokuphikisana newashi), ihlehlisa i-radial ne-lateral-futhi inciphisa amaphutha okubuyisela emuva lapho wenza amakhona." Ngaphezu kwalokho, injini yokuphotha ebalulekile esetshenziswa yile mishini kuthiwa inikeza ukugxila okungcono ngesikhathi sokusika umthwalo osindayo kunemishini enama-spindle aqhutshwa ngamabhande.

UMnu. Stahl uthi kubaluleke kakhulu ukucabangela ukuqina kwamathuluzi okusebenza nokusika ngesikhathi sokuguqula kanzima. Ukubhekana nokwangaphambili, isitolo sisebenzisa ama-collets esikhundleni semihlathi ukuze sinikeze ukuxhumana okungaphezulu kwendawo ne-barstock. "Ngaphezu kwalokho, ukugoqa okuhambisanayo kulula ukukufeza ngoba akukho ukuphakamisa umhlathi usebenzisa ama-collets," kusho uMnu. Stahl. “Zonke izindawo zokukhwelana kumele zihlanzeke, futhi, okuhlanganisa nendawo yokusebenza, ikholethi kanye nekhala lokuphotha.”

I-True Die isebenzisa i- HardingeIsistimu ye-FlexC eshintsha ngokushesha yekholethi emishinini yayo ye-Nexus (kanye nezinye izindawo eziningi zokujika esitolo), ehlinzeka ngesamba esiphelele esibonisiwe sokuphuma (TIR) ngaphakathi kwamayintshi angu-0.0004. I-FlexC iphinde isheshise ukusetha nokushintsha ngokuhamba kwesikhathi uma iqhathaniswa nama-chucks emihlathi avamile. Le sistimu ifaka phakathi ukuhlanganiswa kokukhweza okuphothayo, amakhanda ekholari, kanye nesikrufu sesandla esinokukhululwa kwe-trigger esetshenziselwa ukufaka noma ukushintsha amakhanda ekholethi uma i-chuck yomshini isendaweni engavaliwe.

Amakhanda ekholethi aqukethe izingxenye zensimbi eqinile ezihlanganiswa inqubo ye-vulcanization. Ngenxa yokuthi ayikho i-collet shank, izingxenye ze-collet zihlala zifana nesitoko. I-Parallel clamping kuthiwa kunciphisa isitokwe “push back” futhi kudinga amandla amancane okudonsa ukuze kuzuzwe amandla okubamba afanayo nama-collets avamile. Lolu hlelo lungakwazi ukuthwala amadayamitha ebha asukela kumayintshi angu-3.25, futhi ikhanda elivamile le-FlexC lekholethi linobubanzi obubambelelayo obungu-±0.020 intshi obuncane futhi bukhulu kunosayizi walo ovamile ukuze kuhlangatshezwane nokwehluka kosayizi we-barstock ngaphandle kokushintshela ku-collet enosayizi ohlukile. Isitolo sisebenzisa ama-chuck emihlathi emithathu kanye neyisithupha kumadayamitha omsebenzi omkhulu kuno-3.25 amayintshi.

Ukuqinisekisa ukuqina kwethuluzi lokusika, kubalulekile okokuqala ukubeka abasiki endaweni efanele yesikhungo samathuluzi, kuchaza uMnu. McCleary. "Ukuba kude nendawo nge-intshi engu-0.002 nje kungabangela ingxoxo nokudlidliza," usho kanje. "Futhi, lapho ububanzi be-workpiece buncane, ukuphakama kwesikhungo samathuluzi kubaluleke kakhulu." Lokho kungenxa yokuthi, uma kubhekwa ibanga lethuluzi elifanayo kude nesikhungo se-workpiece, ingxenye yephutha iyanda ngamadayamitha amancane ocezu lokusebenza.

Ukuphuma kwethuluzi kanye ne-overhang kumphathi wamathuluzi kufanele kuncishiswe, nakho. Imvamisa into enqumayo wukucaciswa kwethuluzi lokuphenduka kwe-OD uma usebenzisa isitokwe esingemuva nokujula kwembobo lapho ama-ID ayisicefe. "Uma i-hangout iholela ekudlidlizeni, isinyathelo sokuqala ukuguqula isivinini kanye nokuphakelayo," uMnu. McCleary uyachaza. "Isinyathelo esilandelayo kungaba ukucabangela ithuluzi elihlukile lokusika elifaka ikhala noma i-edge prep."

Cishe kuzo zonke izimo, i-True Die isebenzisa amathuluzi okusika i-cubic boron nitride (CBN) ukuze ijike kanzima, ngokuyinhloko isuka. I-Sumitomo. Isitolo sithole ukuthi i-CBN ihlala isikhathi eside kune-ceramics yezinto eziqinile kakhulu, iyaphindaphindeka futhi ingasebenza ngokupholisa. I-tradeoff ukuthi abasiki be-CBN babiza ngaphezu kwe-ceramic. Ngokuvamile, isebenzisa ibanga le-Sumiboron BNC200 ngokusikeka okuqhubekayo kanye nebanga le-BNC300 lokusika okuphazamisekile (cishe amaphesenti angu-25 wamathuluzi ayindilinga aphazamise ukusikeka). Lokhu okufakwayo kuthiwa kunikeza ibhalansi enhle yokuphuka nokungagugi, futhi zifaka i-titanium aluminium nitride (TiAlN) enamathela.

I-True Die isebenzisa okufakwa okumise okwedayimane okusuka ku-25 kuya ku-80 degrees (imvamisa ebonisa i-geometry engalungile) kanye ne-nose radii esukela ku-0.004 kuya ku-0.031 intshi. Ukufakwa okungu-55-degree kuvame ukusetshenziselwa ukujika kwe-OD, okunerediyasi yekhala engu-0.030-intshi ukuze kwenziwe ama-roughing kanye nerediyasi yekhala engu-0.015-intshi yokuqedela umsebenzi. Ukufakwa kwedayimane okunamandla okungu-80-degree kusetshenziselwa ukusikeka okuphazamiseke kakhulu. Ngemisebenzi eyisicefe, isitolo sivamise ukusebenzisa ukufakwa kwe-80-degree enejiyomethri eqondile.

UMnu. McCleary uthi kukhona ukuhwebelana lapho kukhethwa phakathi kokufakwayo okunegeometries engalungile noma ephozithivu. “Sithole ukuthi okufakwe ngejiyomethri engalungile kunamandla kunokufakwa kwe-positive-geometry futhi kungaphenywa ukuze kunikeze imiphetho emine esebenzisekayo,” uyachaza. Kodwa-ke, lezi zinto ezifakiwe zidala ingcindezi yokusika futhi zinikeza imvume encane. Ukufakwa kwe-positive-geometry kusikeka ngokukhululeka kakhudlwana futhi kunemvume eyengeziwe, kodwa kuwumkhawulo wokusika obuthakathaka.

Ngokuphathelene nedatha esikiwe, awekho amanani aqinile azo zonke izinhlelo zokusebenza eziguqukayo kanzima ku-True Die, njengoba zihluka kuye ngohlobo lwempahla, ukuqina, i-workpiece L:D, izimo zokusika nokunye. Isitolo singase sihambe size sifike ku-150 sfm ngokusikeka okuphazamiseke kakhulu ezintweni eziqinile kakhulu kuze kufike ku-550 sfm ezintweni ezithambile ezinobulukhuni obulinganiselwe.

UMnu. Stahl uthi ukujula okujwayelekile kokusika (DOC) isitolo esikusebenzisa ekuqedeni imisebenzi kungu-0.003 kuya ku-0.004 intshi, nakuba abamele amathuluzi okusika baphakamise ukuthi i-DOC kufanele okungenani ibe inani lekhala lekhala lethuluzi. Kodwa-ke, i-True Die ithole ukuthi, kwezinye izimo, njengalapho i-workpiece L:D ingaphezu kuka-20:1, ukucindezela kokusikwa okujulile kungabangela ukuchezuka okukhulu kakhulu kwe-workpiece futhi ngokuvamile kuyivimbele ekubambeni ukubekezelelana. Lokhu kucindezela kungadlulisela ngisho nokucindezeleka engxenyeni, kubangele ukuba igoqe.

Ngokushiya intshi engu-0.010 kuye ku-0.012 yesitoko ukuze isuswe ngemva kokwelapha ukushisa, amaphasi amathathu okujika aqinile angenziwa noma eduze kwe-DOC engu-0.003- noma engu-0.004-inch efanayo. Ngaleyo ndlela, ingcindezi yethuluzi iyafana ngephasi ngayinye.

"Uma ingxenye yangaphambilini iguqulelwe ku-spec, opharetha kufanele akwazi ukuhlehlisa ithuluzi ngenani eliphelele lesitoko esisanda kususwa, ukuze ithuluzi lizobe lingakwazi ukushwiba ingxenye," kuchaza uMnu. Stahl. “Khona-ke, kuyindaba yokuthatha iphasi lokuqala ukwethula indawo enhle yokukala indawo yokusebenza, ukuthatha iphasi yesibili bese ukala ukuze uqiniseke ukuthi umsebenzi uyaphinda, bese uthatha iphasi lokugcina ukuletha isiqephu sokugcina.”

Ukusebenzisa le ndlela kwenza isitolo sikwazi ukuphusha ithuluzi kuze kube yilapho liyeka ukuphindaphinda. Ukugqoka kujwayelekile futhi kulindelwe, futhi kungaphathwa inqobo nje uma okufakiwe kugqokwe ngenani eliphindaphindekayo. Nokho, okufakiwe kufanele kushintshwe noma kukhonjiswe onqenqemeni olusha uma unqenqema lwamanje lungaphindi.

Ngaphandle kokusikeka okuphazamisekile, isitolo sisebenza ngokupholisa cishe kuzo zonke izimo. Isebenzisa into epholile ukuze ingashisi ama-chips noma inikeze ukuthambisa, kodwa kunalokho ukugcina ingxenye ipholile. "Ngezinye izikhathi sizoqondisa ukugeleza okupholisayo kude nethiphu ye-inert, ngisho nangaphesheya kwengxenye kwezinye izimo," kusho uMnu McCleary. "Izinsimbi zensimbi ezinobulukhuni obuphezulu zikhiqiza ukushisa okuningi lapho ziphenduka kanzima kangangokuthi ukunwebeka okushisayo okuvela ekushiseni kungadlula ukubekezelela kwethu okuvumelekile. Futhi, uma isipholile singasetshenziswa, opharetha kuzodingeka apholise ucezu lokusebenza ngemva kokulujika kanzima ngaphambi kokululinganisa. Ukusebenzisa into epholile kusenza sikwazi ukukala ingxenye ngokushesha." Isitolo asikusebenzisi okokupholisa amanxeba ukusikeka okuphazamisekile ngenxa yokuthi kungenzeka kube khona ukuphuka okushisayo konqenqema lokusika.

Omunye wemishini emibili ye-Quickturn Nexus ye-True Die ubekelwe umsebenzi ojikajika kanzima, kanti omunye usetshenziswa ngezinye izikhathi lapho umthamo udingeka ukuze ujike okuvamile. Eqinisweni, uMnu. Stahl ukholelwa ukuthi kubalulekile ukunikela isikhungo sokuguqula izinqubo zokuguqula kanzima uma kungenzeka. “Uma unomsebenzi wokugcwalisa ishejuli yomshini ngokusebenza kanzima kokuqeda, kungani-ke ushaye lowo mshini ngokuwugaxa ngawo, futhi?” uyabuza. "Esikhathini eside, kungcono ugcine umshini owodwa ugxile ekujikeni kanzima, njengoba ngikholwa ukuthi welula ubude besikhathi lowo mshini ongakwazi ukwenza leyo misebenzi enembile. Futhi, ikuvumela ukuthi ugcine wonke amathuluzi afanele okujika, abheke futhi ayisicefe emisiwe emshinini, osheshisa ukusetha. Lokho kusho, akusebenzi ngaso sonke isikhathi ukwenza umshini wesitolo uguqule kanzima, ikakhulukazi ngevolumu ephansi."