Ubunjineli beNdawo yokuHlala yeGearbox yeCrosskart: Ukuntywila nzulu kwiMishini ye-CNC ye-5-Axis yeMidlalo yeeMoto ezingaphandle kwendlela
Ubunjineli bobuGcisa obuPhambili Indlu yeGearbox yeCrosskart: Ukungena nzulu kwi-5-Axis CNC Machining ye-Off-Road Motorsport
Kwibala le-octane ephezulu ye-FIA European Autocross Championship, iiCrosskarts kunye nee-2WD autocross buggies zinyamezela iimeko zokusebenza ezinobungozi. Ziqhutywa ziimpembelelo ezithe nkqo ezinobundlobongela, ukuqhushumba kwelitye elinqabileyo, kunye nemithwalo ye-torque ekhawulezileyo evela kwiinjini ezijikelezayo ezidityaniswe neebhokisi zegiya zomdyarho ezilandelelanayo, yonke into kufuneka ilinganisele ngendlela ethambileyo: kufuneka ibe lula kakhulu kodwa ingabi nakwenzeka.
Iindlu ze-aluminium zemveli ezifakwe kwi-cast aluminium zibangela uxanduva olukhulu phantsi kwezi meko zinzima zokubaleka ngendlela yokungcola, ngokuyintloko ngenxa ye-intransity porosity (iipokotho zomoya ezincinci ezisebenza njengeendawo zoxinzelelo) kunye nokuphambuka kwesakhiwo phantsi komthwalo. Xa imoto ifika kwindawo enkulu, amandla amakhulu akhawulezileyo anokubangela ukuba indlu iguqe kancinci, ilungelelanise kakuhle amaziko e-shaft yangaphakathi kwaye ibangele ukuwohloka kwegiya ngokukhawuleza okanye ukucheba amazinyo. Ukuphelisa ezi ndlela zokungaphumeleli, sisebenzisa iibhloko ze-billet ze-Aluminium 7075-T6 eziqinileyo ezidityaniswe ne-5-axis CNC machining ephucukileyo, ukulungiswa kobunjineli, kunye nolawulo lomgangatho oluqinileyo oluvaliweyo.
Ngaphambi kokuba siqalise iindlela zezixhobo kwibhloko yezinto ezingacwangciswanga, iqela lethu lobunjineli lenza uphononongo olupheleleyo ukuze kuvalwe umsantsa phakathi kweengcamango ze-CAD zethiyori kunye neenyani zokwenziwa kwezinto ezithengiswayo.
- Imephu yeTensor yoXinzelelo: Sisebenzisa isoftware ye-CAE ephucukileyo, silingisa ukusasazwa koxinzelelo oluguquguqukayo phantsi kwee-torque spikes eziphezulu ezifikelela kwi-400 Nm ngexesha lokutshintsha kwegiya ngamandla kunye nokujika kwe-chassis okuqatha.
- Ukuhluba Izinto: Ii-algorithms zokuphucula i-Topology zikhetha ukususa izinto kwiindawo ezinoxinzelelo oluphantsi (zinciphisa ubukhulu bodonga lwangaphandle olungelulo ulwakhiwo ukusuka kwi-6 mm ukuya kwi-3.5 mm ngelixa zisenza zibe nkulu iimbambo zesakhiwo ezijikeleze ii-bearing bores eziphambili kunye nee-chassis mounting tabs. Oku kufezekisa ukwehla okukhulu kobunzima ngama-22% ngaphandle kokunciphisa ukhuseleko lwesakhiwo.
- Ukususa iiSharp Junctions: Iimodeli zoyilo oluqhelekileyo zihlala zibonisa iikona zangaphakathi ezibukhali okanye imida eqinileyo ye-R1mm ngaphakathi kweepokotho ezinzulu. Phantsi kokungcangcazela okuqhubekayo kwe-frequency ephezulu, ezi zidibaniso ezibukhali zisebenza njengezinto ezibangela uxinzelelo oluyingozi apho ii-micro-cracks zesakhiwo zisasazeka khona.
- Ukulungiswa kweToolpath: Silungisa yonke imida yangaphakathi yeepokotho ukuya kuthi ga kwi-radius encinci ye-R3 mm. Olu tshintsho lwejometri lususa ngokupheleleyo uxinzelelo, luthintele ukuxokozela kwezixhobo ngexesha lokusila, kwaye luqinisekisa ukugqitywa komphezulu we-Ra 0.4um ococekileyo kakhulu ngelixa luhambelana ngokugqibeleleyo nee-carbide ball-nose end mills eziqhelekileyo.
- Iibhokisi zegiya ezilandelelanayo zeCrosskart zihlala zihlaselwa kukwahlulwa rhoqo ecaleni kwendlela kunye nokulungiswa komlinganiselo wegiya. Ukucofa imisonto ngqo kwi-aluminium ethambileyo kudla ngokukhokelela ekuwohlokeni kwemisonto ngokukhawuleza okanye ukukrazulwa kwemisonto phantsi kwezibhamu ezinefuthe eliphezulu.
- Isisombululo: Zonke iimbobo zokufaka ii-casing split-lines kunye nee-oil pan zenzelwe ukufumana i-stainless steel wire thread inserts ezinzima (Iihelikoli), ukuqinisekisa ukuqina kokubopha ukusuka kwisinyithi ukuya kwisinyithi kwimijikelo emininzi yokwakha ngokutsha.
Indlu yebhokisi yegiya elandelelanayo ibonakaliswa ziitshaneli zeoyile zangaphakathi ezintsonkothileyo, iipokotho ezisezantsi zokunciphisa ubunzima, kunye neebhorethi ezibalulekileyo ezifuna ulungelelwaniso oluchanekileyo lwejometri. Ukuseta okuqhelekileyo kwe-3-axis okanye i-4-axis kufuna imisebenzi emininzi kunye nokubekwa kweenkcukacha okuntsonkothileyo.
Iingenelo zeMishini eziDibeneyo ze-5-Axis
- Ukuchaneka kokuseta okukodwa: Ngokujikelezisa nokuthambekisa umsebenzi ngaxeshanye kwi-axes ze-A kunye ne-B ngelixa sisebenzisa iintshukumo zezixhobo kwi-X, Y, kunye ne-Z, iziko zethu zoomatshini ze-5-axis zifikelela kumacala amahlanu endlu kwiseti enye yokusebenza. Oku kususa iimpazamo zokubeka izinto kunye nokuqinisekisa ukuba i-mainshaft bore, i-countershaft bore, kunye ne-shift drum geometry zihlala zixinene ngokugqibeleleyo ngaphakathi kwe-0.01 mm.
- Ukuqina kwesixhobo esilungisiweyo: Ukusika okune-axis ezi-5 kuvumela i-spindle yomatshini ukuba ithambeke xa ithelekiswa nenxalenye. Oku kwenza ukuba oomatshini bethu basebenzise ii-carbide end mills ezimfutshane neziqinileyo kakhulu ukuze basuse imingxunya yangaphakathi enzulu eyi-120 mm. Izixhobo ezimfutshane zinciphisa ukuphambuka kunye nokuxokozela, okusivumela ukuba sigcine ulawulo olungenasiphako kunye nokuchaneka komphezulu kwisiseko semingxunya.
Imveliso ngaphakathi kwesixhobo sethu sokuchaneka esingama-2,568m² ilandela ulandelelwano oluqinileyo nolulandelekayo olunezinyathelo ezintandathu ukuqinisekisa ukuhambelana okuyingxenye ukuya kwenye kwamaqela omdyarho wehlabathi:
[Inyathelo lesi-6: Ukudizayina Okuqinileyo] ── [Inyathelo lesi-5: 100% CMM Metrology] ── [Inyathelo lesi-4: Ukudiza okuchanekileyo kwe-5-Axis]
Ukucubungula kuqala ngebhloko eqinileyo ye-Aluminium 7075-T6. Sisebenzisa I-Optical Emission Spectrometry ukuqinisekisa ukwakheka kweekhemikhali (i-Zn 5.1%-6.1%, i-Mg 2.1%-2.9%) ihambelana nemigangatho yeenqwelo-moya.
Ukususwa ngokukhawuleza kwesitokhwe se-volumetric kusetyenziswa izixhobo ze-trochoidal carbide ezingama-20mm. Isibonelelo somatshini wokugaya esingu-5 mm ukuqwalasela ukugoba kwezinto ngexesha lokukhululwa koxinzelelo.
Indlu efakwe umatshini omncinci ibhakwa kwi-oven elawulwa yikhompyutha ukuze ilungise ulwakhiwo lwayo lwengqolowa kwaye iqinisekise uzinzo olupheleleyo ngaphambi kokuba kugqitywe ukusika kokugqibela.
Iibhari zokubhoboza ezichanekileyo zitshixa kwii-final diameter tolerances (+0.005mm ukuya ku-+0.015mm). Iprofayili yesantya esiphezulu isusa amaphiko okupholisa kunye namanqaku e-aerodynamic.
Uhlolo olulawulwa yimozulu olusebenzisa Oomatshini bokulinganisa abaQokelelweyo (i-CMM) ngeeprobe ezineencam zerubhi ukuya kwiikhoordinathi zetshathi ngokuchasene nemodeli ye-3D CAD ephambili.
Inkqubo ye-electrochemical edala umaleko ofana ne-ceramic oyi-50um (Al2O3). Iphakamisa ubunzima bomphezulu ukuya 450 HP ukuze ikwazi ukumelana nokuguguleka okuphezulu.
| Isigaba soMgangatho | Iprotokholi ePhambili kunye neeMetriki | Izixhobo zokuhlola ezisetyenzisiweyo | Iikhrayitheriya zokuPhumela ekuJolisweni |
| I-IQC (Engenayo) | Ukuqinisekiswa kweBanga lezinto eziluhlaza | I-Optical Emission Spectrometer / iBrinell Hardness Tester | Uqinisekiso lwesiginitsha yesiseko se-7075-T6; Ubunzima be-150 HB |
| I-IPQC (Ekwinkqubo) | Ukulandelela iDynamic Tool-Wear kunye neDatum | Iiprobe ze-infrared zeRenishaw ezikwi-Machine | Imbuyekezo yokunciphisa izixhobo ngexesha langempela; jonga ukuphambuka kwendlela ngaphakathi kwendawo yokunyamezelana |
| I-FQC (Uvavanyo lokugqibela) | Ukuqinisekiswa koQinisekiso lweJiyomethri kunye nokuGqitywa komphezulu | Umatshini wokulinganisa we-3D Coordinate (CMM) / iProfilometer | Ulungelelwaniso lwembobo yeebheringi 0.01mm; Ukugqitywa komphezulu wokutywina iRa 0.4um |
Ngokudibanisa ngokuqinileyo umatshini wokugaya i-CNC we-axis ezi-5 okumgangatho ophezulu, ukuphuculwa koyilo lwe-topology oluphambili, kunye neenkqubo eziqinileyo ze-metrology, i-CREATINGTEC ibonelela ngesiseko sokuvelisa esichanekileyo esifunekayo ukugcina iibhokisi zegiya zemoto ezisebenza ngaphandle kwendlela zisebenza kakuhle phantsi koxinzelelo olukhulu lokhuphiswano.