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Some of the valuable NON-CONVENTIONAL MANUFACTURING processes AGS-TECH Inc offers are ELECTROCHEMICAL MACHINING (ECM), SHAPED-TUBE ELECTROLYTIC MACHINING (STEM) , I-PULSED ELECTROCHEMICAL MACHINING (PECM), ELECTROCHEMICAL GINDING (ECG), IZINQUBO ZOKUSHISA IHYBRID.

I-ELECTROCHEMICAL MACHINING (ECM) iyindlela yokukhiqiza engajwayelekile lapho insimbi isuswa khona ngenqubo ye-electrochemical. I-ECM iyindlela yokukhiqiza ngobuningi, esetshenziselwa ukwenza izinto zokwakha eziqine kakhulu nezinto okunzima ukuzisebenzisa kusetshenziswa izindlela ezijwayelekile zokukhiqiza. Amasistimu we-electrochemical-machining esiwasebenzisela ukukhiqiza ayizikhungo zemishini ezilawulwa ngamanani ezinamanani aphezulu okukhiqiza, ukuguquguquka, ukulawula okuphelele kokubekezelelana kwe-dimensional. Imishini ye-Electrochemical iyakwazi ukusika ama-engeli amancane futhi amise okwenqaba, amakhonsana ayinkimbinkimbi noma izimbotshana ezinsimbi eziqinile nezingavamile njenge-titanium aluminides, i-Inconel, i-Waspaloy, ne-nickel ephezulu, i-cobalt, ne-rhenium alloys. Kokubili amajiyometri angaphandle nangaphakathi angenziwa ngomshini. Ukuguqulwa kwenqubo ye-electrochemical machining isetshenziselwa imisebenzi efana nokujika, ukubheka, ukupetula, i-trepanning, ukwenza iphrofayela lapho i-electrode iba ithuluzi lokusika. Izinga lokukhishwa kwensimbi liwumsebenzi kuphela wezinga lokushintshisana kwe-ion futhi alithintwa amandla, ukuqina noma ukuqina kocezu lokusebenza. Ngeshwa indlela ye-electrochemical machining (ECM) ilinganiselwe ezintweni ezisebenza ngogesi. Elinye iphuzu elibalulekile okufanele licatshangelwe ngokuthumela inqubo ye-ECM ukuqhathanisa izakhiwo zemishini yezingxenye ezikhiqiziwe nalezo ezikhiqizwa ezinye izindlela zomshini.

I-ECM isusa izinto esikhundleni sokuyengeza ngakho-ke ngezinye izikhathi ibizwa ngokuthi ''i-reverse electroplating''. Ifana ngandlela thize ne-electrical discharge machining (EDM) ngokuthi amandla aphezulu adluliswa phakathi kwe-electrode nengxenye, ngenqubo yokukhipha impahla ye-electrolytic ene-electrode eshajwa kabi (cathode), uketshezi oluqhutshwayo (i-electrolyte), kanye ne-electrolyte. i-conductor workpiece (i-anode). I-electrolyte isebenza njengesithwali samanje futhi iyisisombululo sikasawoti esingaphili esisebenza kakhulu njengesodium chloride exutshwe futhi incibilike emanzini noma i-sodium nitrate. Inzuzo ye-ECM ukuthi akukho ukugqoka kwamathuluzi. Ithuluzi lokusika le-ECM liqondiswa endleleni oyifunayo eduze nomsebenzi kodwa ngaphandle kokuthinta ucezu. Ngokungafani ne-EDM, noma kunjalo, azikho izinhlansi ezidaliwe. Amazinga aphezulu okususwa kwensimbi nokuqedwa kwesibuko kuyenzeka nge-ECM, ngaphandle kokucindezeleka okushisayo noma komshini okudluliselwa engxenyeni. I-ECM ayibangeli noma yimuphi umonakalo oshisayo engxenyeni futhi njengoba kungekho amandla amathuluzi akukho ukuhlanekezela engxenyeni futhi akukho ukugqoka kwamathuluzi, njengoba kungaba njalo ngemisebenzi evamile yomshini. Ku-electrochemical machining cavity okukhiqizwa isithombe sowesifazane sokukhwelana kwethuluzi.

Enqubweni ye-ECM, ithuluzi le-cathode lihanjiswa endaweni yokusebenza ye-anode. Ithuluzi elibunjiwe ngokuvamile lenziwa ngethusi, ithusi, ithusi noma insimbi engagqwali. I-electrolyte ecindezelwe iphonswa ngezinga eliphezulu ekushiseni okumisiwe ngokusebenzisa amaphaseji ethuluzi eliya endaweni esikwayo. Izinga lokuphakelayo liyafana nenani elithi ''ukwenziwa kuncibilike'' kokokusebenza, futhi ukunyakaza kwe-electrolyte esikhaleni se-tool-workpiece kugeza ama-ion ensimbi kude ne-anode yocezu lokusebenza ngaphambi kokuba zithole ithuba lokunamathisela ethuluzini le-cathode. Igebe phakathi kwethuluzi nomsebenzi liyahlukahluka phakathi kwama-micrometer angu-80-800 kanye nokunikezwa kwamandla e-DC ebangeni elingu-5 – 25 V igcina ukuminyana kwamanje phakathi kuka-1.5 – 8 A/mm2 wendawo esebenza ngomshini. Njengoba ama-electron ewela igebe, impahla evela ku-workpiece iyancibilika, njengoba ithuluzi lakha umumo oyifunayo endaweni yokusebenza. Uketshezi lwe-electrolytic luthwala i-hydroxide yensimbi eyakhiwe phakathi nale nqubo. Imishini yezentengiselwano ye-electrochemical enamandla amanje phakathi kuka-5A no-40,000A iyatholakala. Izinga lokususwa kwezinto ekwenziweni kwemishini ye-electrochemical lingavezwa kanje:

 

MRR = C x I xn

 

Lapha MRR=mm3/min, I=okwamanje kuma-ampere, n=ukusebenza kahle kwamanje, C=impahla engaguquki ku-mm3/A-min. I-C engaguquki incike ku-valence yezinto ezihlanzekile. Lapho i-valence iphakeme, inani eliphansi liphansi. Ezinsimbi eziningi iphakathi kuka-1 no-2.

 

Uma i-Ao isho indawo ephambanayo efanayo eyenziwa ngomshini kagesi ngo-mm2, izinga lokuphakelayo elingu-f ku-mm/min lingavezwa ngokuthi:

 

F = MRR / Ao

 

Izinga lokuphakelayo f yijubane i-electrode engena ngayo endaweni yokusebenza.

 

Esikhathini esidlule bekunezinkinga zokunemba kobukhulu obuphansi kanye nemfucuza engcolisa imvelo evela emisebenzini yomshini we-electrochemical. Lezi ziye zanqotshwa kakhulu.

 

Ezinye zezicelo zomshini we-electrochemical wezinto ezisezingeni eliphakeme yilezi:

 

- Imisebenzi ye-Die-Sinking. Ukucwila emanzini kuwukwenza imishini - imigodi yokufa.

 

- Ukumba izinsimbi ze-jet engine turbine, izingxenye ze-jet-engine kanye namabhomu.

 

- Ukumba izimbobo ezincane eziningi. Inqubo ye-electrochemical machining ishiya indawo engena-burr.

 

- Ama-Steam turbine blades angenziwa ngomshini ngaphakathi kwemingcele eseduze.

 

- Ukuze kukhishwe izindawo ezingaphezulu. Ekulayini, i-ECM isusa izilinganiso zensimbi ezisele ezinqubweni zomshini bese ithuntutha imiphetho ebukhali. Inqubo yokwenza imishini ye-Electrochemical iyashesha futhi ivamise ukuba lula kakhulu kunezindlela ezijwayelekile zokususa ngesandla noma ngezinqubo zokuzenzela okungezona ezendabuko.

I-SHAPED-TUBE ELECTROLYTIC MACHINING (STEM) inguqulo yenqubo ye-electrochemical machining esiyisebenzisela ukumba izimbobo ezincane ezinobubanzi obujulile. Ishubhu le-titanium lisetshenziswa njengethuluzi elimbozwe nge-resin evalela ugesi ukuze kuvinjelwe ukukhishwa kwezinto kwezinye izifunda njengobuso obuseceleni bembobo neshubhu. Singakwazi ukubhoboza osayizi bembobo ongu-0.5 mm ngokujula kuya kububanzi obuyi-300:1

I-PULSED ELECTROCHEMICAL MACHINING (PECM): Sisebenzisa ukuminyana kwamanje okuphezulu kakhulu ngohlelo lwe-100 A/cm2. Ngokusebenzisa ama-pulsed currents siqeda isidingo samazinga aphezulu okugeleza kwe-electrolyte okubeka imikhawulo yendlela ye-ECM ekwenziweni kwesikhunta kanye nokufa. Umshini womshini we-electrochemical oshayelayo uthuthukisa impilo yokukhathala futhi uqede isendlalelo sokusakaza kabusha esishiywe yinqubo ye-electrical discharge machining (EDM) endaweni yesikhunta neyokufa.

In ELECTROCHEMICAL GINDING (ECG) we sihlanganisa ukusebenza okujwayelekile kokugaya nge-electrochemical machining. Isondo lokugaya i-cathode ejikelezayo enezinhlayiya ezihuquzelayo zedayimane noma i-aluminium oxide eziboshwe ngensimbi. Ukuminyana kwamanje kuphakathi kuka-1 no-3 A/mm2. Ngokufanayo ne-ECM, i-electrolyte efana nokugeleza kwe-nitrate ye-sodium kanye nokukhishwa kwensimbi ekugayeni kwe-electrochemical kubuswa isenzo se-electrolytic. Ngaphansi kuka-5% wokukhishwa kwensimbi kwenziwa ngokuhuzuka kwesondo. Inqubo ye-ECG ifaneleka kahle kuma-carbides nama-alloys anamandla amakhulu, kodwa ayifaneleki kangako ukucwila noma ukwenza isikhunta ngoba umshini wokugaya ungase ungafinyeleli kalula emigodini ejulile. Izinga lokususwa kwezinto ekugayeni kwe-electrochemical lingavezwa kanje:

 

MRR = GI / d F

 

Lapha i-MRR iku-mm3/min, u-G uyisisindo ngamagremu, i-amperes yamanje, u-d ukuminyana ku-g/mm3 kanti u-F uyi-Faraday's constant (96,485 Coulombs/mole). Ijubane lokungena kwesondo lokugaya libe yi-workpiece lingavezwa kanje:

 

Vs = (G / d F) x (E / g Kp) x K

 

Lapha i-Vs iku-mm3/min, u-E iyi-voltage yeseli ngamavolthi, u-g iyisikhala sesondo ukuya kucezu lokusebenza ngo-mm, i-Kp iyi-coefficient yokulahlekelwa kanti u-K iyi-electrolyte conductivity. Inzuzo yendlela yokugaya i-electrochemical ngaphezu kokugaya okuvamile ukugqokwa kwamasondo okuncane ngoba ngaphansi kuka-5% wokukhishwa kwensimbi kungenxa yesenzo sokuhuzuka kwesondo.

 

Kukhona ukufana phakathi kwe-EDM ne-ECM:

 

1. Ithuluzi kanye ne-workpiece kuhlukaniswa igebe elincane kakhulu ngaphandle kokuxhumana phakathi kwabo.

 

2. Kokubili ithuluzi kanye nempahla kumele kube amakhondatha kagesi.

 

3. Womabili amasu adinga ukutshalwa kwezimali okuphezulu. Kusetshenziswa imishini yesimanje ye-CNC

 

4. Zombili izindlela zisebenzisa amandla kagesi amaningi.

 

5. I-conductive fluid isetshenziswa njengento ephakathi kwethuluzi kanye nomsebenzi we-ECM kanye noketshezi lwe-dielectric lwe-EDM.

 

6. Ithuluzi liphakelwa ngokuqhubekayo ku-workpiece ukuze kugcinwe igebe elihlala njalo phakathi kwabo (i-EDM ingase ihlanganise ukuhoxiswa kwethuluzi okuphakathi noma okujikelezayo, okuyingxenye, okuyingxenye).

IZINQUBO ZOKUSHIYA IHYBRID: Sivamise ukusizakala ngezinzuzo zezinqubo zemishini eyingxube lapho izinqubo ezimbili noma ngaphezulu ezihlukene njenge-ECM, EDM….etc. zisetshenziswa ngokuhlanganiswa. Lokhu kusinika ithuba lokunqoba ukushiyeka kwenqubo eyodwa ngenye, futhi sizuze ezinhlelweni zenqubo ngayinye.

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