Custom Metal Parts Manufacturing with 5-Axis Machining
Custom Metal Parts Manufacturing with 5-Axis Machining
Tus sau:PFT, Shenzhen
Abstract:Kev tsim khoom siab heev xav tau ntau dua, cov khoom siv hlau ua tau zoo nyob thoob plaws aerospace, kev kho mob, thiab lub zog. Qhov kev tshuaj ntsuam no ntsuas lub peev xwm ntawm niaj hnub 5-axis computer numerical control (CNC) machining hauv kev ua tau raws li cov cai no. Siv cov qauv ntsuas geometries tus neeg sawv cev ntawm cov impellers thiab turbine hniav, kev sim ua haujlwm tau ua piv txwv 5-axis piv rau cov qauv 3-axis ntawm aerospace-qib titanium (Ti-6Al-4V) thiab stainless hlau (316L). Cov txiaj ntsig ua kom pom qhov txo qis ntawm 40-60% hauv lub sijhawm ua haujlwm thiab kev txhim kho ntawm qhov roughness (Ra) txog li 35% nrog 5-axis ua, vim yog txo qis kev teeb tsa thiab kho cov cuab yeej kho kom zoo. Geometric raug rau cov yam ntxwv nyob rau hauv ± 0.025mm kam rau siab nce 28% nyob rau nruab nrab. Thaum xav tau qhov tseem ceeb ntawm kev tshaj lij thiab kev nqis peev, 5-axis machining enables txhim khu kev qha ntawm yav tas los geometries tsis ua tau zoo nrog superior efficiency thiab tiav. Cov peev txheej no txoj haujlwm 5-axis thev naus laus zis yog qhov tseem ceeb rau tus nqi siab, txoj kev cai hlau ib feem fabrication.
1. Taw qhia
Kev tsav tsheb tsis tu ncua rau kev ua kom zoo tshaj plaws thoob plaws kev lag luam xws li aerospace (yuav tsum sib zog, qhov chaw muaj zog), kev kho mob (yuav tsum tau siv biocompatible, tus neeg mob tshwj xeeb cog), thiab lub zog (xav tau cov khoom siv ua kua dej sib txuas) tau thawb cov ciam teb ntawm cov hlau tsis sib xws. Cov tsoos 3-axis CNC machining, txwv los ntawm kev txwv cov cuab yeej nkag thiab ntau qhov yuav tsum tau teeb tsa, tawm tsam nrog cov duab sib txawv, cov kab noj hniav sib sib zog nqus, thiab cov yam ntxwv xav tau cov kaum sab xis. Cov kev txwv no ua rau muaj kev cuam tshuam qhov tseeb, ncua sij hawm ntau lawm, tus nqi siab dua, thiab kev txwv tsim. Los ntawm 2025, lub peev xwm los tsim cov khoom siv tau zoo heev, cov khoom siv hlau ua tau zoo tsis yog khoom kim heev tab sis kev sib tw tsim nyog. Niaj hnub no 5-axis CNC machining, muab kev tswj ib txhij ntawm peb txoj kab ncaj nraim (X, Y, Z) thiab ob txoj kab sib hloov (A, B lossis C), nthuav tawm cov kev daws teeb meem. Cov cuab yeej no tso cai rau cov cuab yeej txiav mus rau qhov chaw ua haujlwm los ntawm txhua qhov kev taw qhia hauv ib qho kev teeb tsa, hauv paus kov yeej cov kev txwv nkag mus rau hauv 3-axis machining. Kab lus no tshuaj xyuas cov peev txheej tshwj xeeb, qhov txiaj ntsig zoo, thiab kev siv tswv yim txiav txim siab ntawm 5-axis machining rau kev cai hlau feem ntau lawm.
2. Cov txheej txheem
2.1 Design & Benchmarking
Ob qhov qauv ntsuas tau tsim los siv Siemens NX CAD software, embodying cov kev cov nyom hauv kev tsim khoom:
Impeller:Featuring complex, twisted hniav nrog siab nam piv thiab nruj clearances.
Turbine Hniav:Incorporating compound curvatures, nyias phab ntsa, thiab precision mounting nto.
Cov qauv tsim no txhob txwm sib koom ua ke undercuts, sib sib zog nqus hnab tshos, thiab cov yam ntxwv uas yuav tsum tau siv cov cuab yeej uas tsis yog orthogonal, tshwj xeeb yog tsom rau cov kev txwv ntawm 3-axis machining.
2.2 Khoom siv & khoom siv
Khoom siv:Aerospace-qib Titanium (Ti-6Al-4V, annealed mob) thiab 316L Stainless hlau raug xaiv rau lawv qhov tseem ceeb hauv kev thov thiab cov yam ntxwv sib txawv.
Tshuab:
5-Axis:DMG MORI DMU 65 monoBLOCK (Heidenhain TNC 640 tswj).
3-Axis:HAAS VF-4SS (HAAS NGC control).
Tooling:Coated khoom carbide kawg mills (ntau txoj kab uas hla, pob-qhov ntswg, thiab tiaj-kawg) los ntawm Kennametal thiab Sandvik Coromant tau siv rau roughing thiab xov. Txiav tsis tau (ceev, pub, qhov tob ntawm kev txiav) tau ua kom zoo rau ib qho khoom siv thiab lub peev xwm ntawm lub tshuab siv cov cuab yeej tsim cov lus pom zoo thiab kev tswj xyuas kev txiav.
Kev ua haujlwm:Kev cai, precisely machined modular fixtures kom nruj clamping thiab rov ua dua qhov chaw rau ob lub tshuab hom. Rau qhov kev sim 3-axis, qhov uas xav tau kev sib hloov tau manually repositioned siv precision dowels, simulating cov khw hauv pem teb xyaum. Qhov kev sim 5-axis siv lub tshuab tag nrho kev sib hloov muaj peev xwm nyob rau hauv ib qho kev teeb tsa.
2.3 Kev Tshawb Fawb & Kev Tshawb Fawb
Lub Sijhawm Cycle:Ntsuas ncaj qha los ntawm lub tshuab timers.
Nto Roughness (Ra):Ntsuas siv Mitutoyo Surftest SJ-410 profileometer ntawm tsib qhov chaw tseem ceeb hauv ib feem. Peb qhov chaw tau machined ib yam khoom / tshuab ua ke.
Geometric Accuracy:Tshawb xyuas siv Zeiss CONTURA G2 tswj kev ntsuas tshuab (CMM). Qhov loj me thiab geometric kam rau ua (flatness, perpendicularity, profile) tau muab piv rau CAD qauv.
Kev txheeb cais:Qhov nruab nrab qhov tseem ceeb thiab tus qauv sib txawv tau suav rau lub sijhawm voj voog thiab Ra ntsuas. Cov ntaub ntawv CMM tau txheeb xyuas rau qhov sib txawv ntawm qhov loj me thiab qhov kam rau ua raws.
Table 1: Kev sim teeb tsa cov ntsiab lus
| Element | 5-Axis teeb tsa | 3-Axis teeb tsa |
|---|---|---|
| Tshuab | DMG MORI DMU 65 monoBLOCK (5-Axis) | HAAS VF-4SS (3-Axis) |
| Fixturing | Ib qho kev cai fixture | Ib qho kev cai fixture + phau ntawv rotations |
| Tus naj npawb ntawm kev teeb tsa | 1 | 3 (Impeller), 4 (Turbine Hniav) |
| CAM Software | Siemens NX CAM (Multi-axis toolpaths) | Siemens NX CAM (3-axis toolpaths) |
| Kev ntsuas | Mitutoyo SJ-410 (Ra), Zeiss CMM (Geo.) | Mitutoyo SJ-410 (Ra), Zeiss CMM (Geo.) |
3. Cov txiaj ntsig & Kev Ntsuam Xyuas
3.1 Efficiency nce
5-axis machining pom tau tias txuag lub sijhawm. Rau lub titanium impeller, 5-axis ua txo lub sij hawm voj voog los ntawm 58% piv rau 3-axis machining (2.1 teev vs. 5.0 teev). Stainless hlau turbine hniav pom qhov txo qis 42% (1.8 teev vs. 3.1 teev). Cov txiaj ntsig no feem ntau tshwm sim los ntawm kev tshem tawm ntau qhov kev teeb tsa thiab cuam tshuam nrog kev tuav tuav / rov kho lub sijhawm, thiab ua kom muaj txiaj ntsig zoo dua nrog kev txiav ntev dua, tsis tu ncua vim kev kho cov cuab yeej zoo.
3.2 Kev Txhim Kho Nto Zoo
Nto roughness (Ra) zoo ib yam nrog 5-axis machining. Nyob rau ntawm qhov nyuaj ntawm cov hniav ntawm cov titanium impeller, qhov nruab nrab Ra qhov tseem ceeb txo los ntawm 32% (0.8 µm vs. 1.18 µm). Cov kev txhim kho zoo sib xws tau pom ntawm stainless hlau turbine hniav (Ra txo los ntawm 35%, qhov nruab nrab 0.65 µm vs. 1.0 µm). Qhov kev txhim kho no yog vim muaj peev xwm tswj tau qhov tsis tu ncua, kev pom kev txiav kev sib cuag lub kaum sab xis thiab txo cov cuab yeej vibration los ntawm cov cuab yeej zoo dua qub hauv cov cuab yeej luv luv.
3.3 Geometric Accuracy Enhancement
CMM tsom xam tau lees paub qhov tseeb geometric qhov tseeb nrog 5-axis ua. Qhov feem pua ntawm cov yam ntxwv tseem ceeb tuav nyob rau hauv qhov nruj ± 0.025mm kam rau ua tau nce ntau: los ntawm 30% rau titanium impeller (ua tiav 92% kev ua raws li 62%) thiab 26% rau cov hniav hlau stainless (ua tiav 89% ua raws li 63%). Qhov kev txhim kho no tshwm sim ncaj qha los ntawm kev tshem tawm cov kev ua yuam kev uas tau qhia los ntawm ntau qhov kev teeb tsa thiab phau ntawv hloov pauv yuav tsum tau ua hauv 3-axis txheej txheem. Cov yam ntxwv xav tau cov ces kaum sib txuas tau pom qhov ua tau zoo tshaj plaws.
*Daim duab 1: Sib piv Kev Ntsuas Kev Ntsuas (5-Axis vs. 3-Axis)*
4. Kev sib tham
Cov txiaj ntsig tau pom tseeb tsim cov txiaj ntsig zoo ntawm 5-axis machining rau txoj kev cai hlau qhov chaw. Qhov kev txo qis hauv lub sijhawm voj voog txhais ncaj qha mus rau tus nqi qis ib feem thiab muaj peev xwm ntau lawm. Kev txhim kho saum npoo tiav txo lossis tshem tawm cov kev ua tiav theem nrab xws li tes polishing, txo cov nqi ntxiv thiab cov sij hawm ua cov hmoov txhuas thaum txhim kho qhov sib xws. Kev dhia hauv geometric raug yog qhov tseem ceeb rau kev ua haujlwm siab xws li lub tshuab aerospace lossis kev kho mob cog, qhov chaw ua haujlwm thiab kev nyab xeeb yog qhov tseem ceeb.
Cov txiaj ntsig zoo no feem ntau tshwm sim los ntawm lub peev xwm tseem ceeb ntawm 5-axis machining: ib txhij multi-axis txav ua rau kev teeb tsa ib leeg. Qhov no tshem tawm kev teeb tsa yuam kev thiab lub sijhawm ua haujlwm. Tsis tas li ntawd, kev siv cov cuab yeej zoo txuas ntxiv mus rau kev taw qhia (tsim qhov zoo tshaj plaws nti thauj khoom thiab txiav quab yuam) txhim kho qhov chaw tiav thiab tso cai rau cov tswv yim ua kom nruj dua qhov twg cov cuab yeej rigidity tso cai, pab txhawb kom nce nrawm.
Txawm li cas los xij, qhov kev coj ua zoo yuav tsum lees paub cov kev txwv. Lub peev peev rau lub tshuab muaj peev xwm 5-axis thiab cov cuab yeej tsim nyog yog qhov siab dua rau cov khoom siv 3-axis. Programming complexity nce exponentially; tsim kom muaj txiaj ntsig zoo, tsis muaj kev sib tsoo-dawb 5-axis toolpaths xav tau cov kws tshaj lij CAM programmers thiab cov software sophisticated. Kev simulation thiab kev txheeb xyuas yog qhov yuav tsum tau ua ua ntej machining. Fixturing yuav tsum muab ob qho tib si rigidity thiab txaus clearance rau tag nrho cov rotational mus txawv tebchaws. Cov xwm txheej no nce qib kev txawj xav tau rau cov neeg ua haujlwm thiab cov programmers.
Qhov kev cuam tshuam qhov tseeb yog qhov tseeb: 5-axis machining excels rau cov nqi siab, cov khoom siv nyuaj uas nws qhov zoo hauv kev ceev, zoo, thiab muaj peev xwm ua kom pom tseeb qhov kev ua haujlwm siab dua thiab kev nqis peev. Rau qhov yooj yim dua, 3-axis machining tseem pheej yig dua. Kev vam meej nyob rau hauv kev nqis peev hauv ob qho tib si thev naus laus zis thiab cov neeg ua haujlwm txawj, nrog rau CAM thiab cov cuab yeej simulation. Kev sib koom ua ke thaum ntxov ntawm kev tsim, tsim engineering, thiab lub khw muag khoom yog qhov tseem ceeb rau kev ua kom muaj peev xwm ntawm 5-axis thaum tsim cov khoom tsim khoom (DFM).
5. Cov lus xaus
Niaj hnub nimno 5-axis CNC machining muab cov kev daws teeb meem zoo tshaj plaws rau kev tsim khoom, siab precision kev cai hlau qhov chaw piv rau cov txheej txheem 3-axis. Cov txiaj ntsig tseem ceeb tau lees tias:
Qhov tseem ceeb Efficiency:Lub voj voog lub sij hawm txo qis ntawm 40-60% los ntawm kev teeb tsa ib leeg thiab cov cuab yeej ua kom zoo.
Txhim khu kev ua tau zoo:Nto roughness (Ra) kev txhim kho txog li 35% vim kev pom cov cuab yeej taw qhia thiab kev sib cuag.
Superior Accuracy:Qhov nruab nrab 28% nce nyob rau hauv tuav qhov tseem ceeb geometric kam rau ua nyob rau hauv ± 0.025mm, tshem tawm qhov yuam kev los ntawm ntau yam teeb tsa.
Cov thev naus laus zis tso cai rau kev tsim cov geometries sib sib zog nqus (cov kab noj hniav sib sib zog nqus, cov kab noj hniav, cov kab sib txuas, cov kab nkhaus) uas ua tsis tau zoo lossis ua tsis tau nrog 3-axis machining, ncaj qha hais txog cov kev xav tau ntawm aerospace, kev kho mob, thiab lub zog.
Txhawm rau kom ua tiav cov nyiaj rov qab los ntawm kev nqis peev hauv 5-axis muaj peev xwm, cov tuam txhab lag luam yuav tsum tsom mus rau qhov nyuaj siab, qhov muaj txiaj ntsig siab uas qhov tseeb thiab lub sijhawm txhuas yog qhov tseem ceeb ntawm kev sib tw. Kev ua haujlwm yav tom ntej yuav tsum tshawb txog kev sib koom ua ke ntawm 5-axis machining nrog rau kev ntsuas kev ntsuas rau lub sijhawm tiag tiag thiab kev kaw lub voj machining, ntxiv txhim kho qhov tseeb thiab txo cov khoom seem. Kev tshawb fawb txuas ntxiv mus rau cov tswv yim kho kom haum rau kev siv 5-axis yooj yim rau cov ntaub ntawv nyuaj xws li Inconel lossis hardened steels kuj nthuav qhia cov kev taw qhia tseem ceeb.
