Sculptures Ntawm Micron Nplai: Yuav ua li cas 5-axis CNC Thiab Micro Hluav Taws Xob Hluav Taws Xob Ua Haujlwm Ua Haujlwm Ua Haujlwm Ua Ke Kom Tau Txais Kev Tsim Khoom Ntawm Qhov Kawg Cap Ntawm Ib Qhov Endoscope

Nyob rau hauv kev tsim ntawm qhov kawg npog ntawm lub endoscope, complex geometries thiab micrometer - theem kam rau ua tau teev tseg nyob rau hauv lub tsim blueprint thawb tsoos manufacturing txuj ci rau lawv cov kev txwv. Thaum nws yog qhov tsim nyog kom haum rau square CMOS sensors, ntau cov khoom siv fiber ntau, thiab cov dej tsis sib xws, nrog rau phab ntsa tuab li 0.05 millimeters, ib txoj kev ua haujlwm ib leeg tsis txaus. Lub niaj hnub precision manufacturing muab cov lus teb: kev koom ua ke ntawm 5-axis CNC micro-milling thiab micro- hluav taws xob tawm machining (Micro-EDM) txheej txheem. Qhov no tsis yog ib qho yooj yim stacking ntawm cov txheej txheem, tab sis ib tug meej thiab kev sib ntaus sib tua ntawm lub micrometer scale raws li complementary khoom tshem tawm cov hauv paus ntsiab lus. Kab lus no yuav tshawb xyuas tob npaum li cas ob qhov kev txiav{11}}ntug thev naus laus zis txhua qhov qhia txog lawv qhov muaj zog thiab sib txuas sib txuas, hloov pauv cov khoom siv hlau rau hauv ib qho nyuaj- qauv, meej- loj, thiab flawlessly-surfaced me me ua haujlwm nqa khoom.
I. Kev Pom Kev Sawv Cev ntawm Kev Ua Lag Luam Kev Sib Tw: Vim li cas Cov Txheej Txheem Kev Cai Lij Choj ua tsis tiav?
Ua ntej delving rau hauv cov ntsiab lus kev, nws yog ib qho tsim nyog yuav tsum tau qhia meej txog kev tsim cov kev cov nyom ntawm cov chaw nyob deb nroog, vim tias cov kev cov nyom no sawv cev rau qhov txwv ntawm cov txheej txheem ua ib txwm:
Qhov "tsis tuaj yeem" geometric duab: Niaj hnub nimno endoscopes siv zog rau qib siab tshaj plaws ntawm kev ua haujlwm ceev. Tus ntoo khaub lig- ntu ntawm lub tsev nyob deb yuav yog ib qho asymmetrical "Swiss cheese", uas muaj D- zoo li cov kab noj hniav, ntau lub voj voog lossis elliptical channel, thiab cov grooves me me tshwj xeeb rau cov xov hlau. Kev sib raug zoo ntawm cov yam ntxwv no yuav tsum muaj qhov tseeb qhov tseeb (± 5 μm).
Lub "tshuab-thiab-kov-breakable" nyias- cov qauv phab ntsa: Kom haum rau txhua txoj haujlwm nyob rau hauv qhov tsawg kawg nkaus txoj kab uas hla (xws li Ø2.0mm), cov hlau "fab phab ntsa" ntawm cov kab uas nyob ib sab yuav tsum yog nyias li cicada's tis (0.05-0.0mm). Qhov no yog nyias dua li daim ntawv luam ib txwm. Ib qho me me txiav quab yuam lossis clamping kev ntxhov siab tuaj yeem ua rau nws deform lossis tawg.
Cov kev xav tau sab hauv rau "lub kaum sab xis tiag": Qhov chaw teeb tsa ntawm cov duab sensor yuav tsum tiaj tus kiag li, thiab cov ces kaum ntawm cov kab noj hniav yuav tsum yog cov kaum sab xis zoo meej (ntse sab hauv cov ces kaum). Txhua lub kaum sab xis yuav ua rau lub sensor qaij thiab ua rau cov duab distortion. Tsoos milling pob qhov ntswg cutters los yog kawg mills yuav inevitably tsim cov cuab yeej vojvoog rounded fab.
"Daim iav-zoo li" thiab du sab hauv qhov chaw tsis muaj burrs: Txhua qhov chaw sab hauv, tshwj xeeb tshaj yog cov uas dhau los ntawm cov fibers optical thiab cov xov hlau hla, yuav tsum du zoo li daim iav (nrog rau tus nqi Ra tsawg heev) thiab tsis muaj burrs kiag li. Txhua qhov microscopic protrusions los yog burrs tuaj yeem txiav los ntawm cov fibers nyias dua li cov plaub hau, ua rau cov cuab yeej ua tsis tiav.
"Sticky" nyuaj-rau- cov khoom siv tshuab: Txawm hais tias nws yog 316L stainless hlau lossis Ti-6Al-4V titanium alloy, lawv ob leeg tam sim no muaj kev sib tw hauv micro-processing. Stainless hlau yog nquag ua hauj lwm hardening, thaum titanium alloy muaj tsis zoo tshav kub conductivity thiab yog nquag ua raws li cov cuab yeej txiav, posing ib tug loj kev ntsuam xyuas rau lub cuab tam lub neej thiab ua stability.
II. 5-axis CNC Micro-milling: Lub Macro Shaper ntawm Complex Peb-dimensional Forms
Tsib -axis CNC micro-milling yog lub zog tseem ceeb rau kev tsim lub ntsiab contour thiab feem ntau cov yam ntxwv ntawm ib feem. Lo lus "tsib-axis" yog hais txog peb txoj kab axis (X, Y, Z) thiab ob lub axis tig (feem ntau yog A-axis thiab C-axis), uas muab cov cuab yeej tsis muaj kev sib piv ntawm kev ywj pheej ntawm kev ywj pheej.
Cov txiaj ntsig tseem ceeb: Ib qho kev teeb tsa, ntau yam kev ua haujlwm nyuaj. Qhov no yog qhov loj tshaj leap ntawm 5-axis piv rau 3-axis. Cov cuab yeej tuaj yeem tig mus rau ntawm lub kaum sab xis, txav mus rau qhov chaw ua haujlwm los ntawm sab lossis hauv qab, yog li ua rau kev ua haujlwm ntawm qhov chaw nrog cov nkhaus nkhaus, qhov inclined, thiab cov kab noj hniav sib sib zog nqus hauv ib qho kev teeb tsa. Rau lub plhaub tej thaj chaw deb, qhov no txhais tau hais tias sab nraud streamlined nkhaus nto, inclined flushing channel qhov hluav taws xob, thiab ntau qhov sib txawv ntawm qhov chaw teeb tsa tuaj yeem ua tiav tsis tu ncua, zam qhov yuam kev tshwm sim los ntawm ntau qhov teeb tsa thiab ua kom ntseeg tau qhov tseeb ntawm qhov tseeb ntawm txhua qhov chaw.
Lub pob txha technical rau kev ua tiav "micro" milling:
Ultra-siab-ceev spindle thiab micro- txoj kab uas hla tej cuab yeej: Lub spindle ceev feem ntau yog ntau kaum txhiab mus rau ntau pua txhiab revolutions ib feeb (RPM). Ua ke nrog cov khoom siv tawv tawv lossis pob zeb diamond-coated milling cutters nrog diameters me me li 0.1mm lossis txawm me me, tsis tshua muaj siab txiav kab nrawm tuaj yeem ua tiav, thaum txiav ntim ib tus hniav me me, yog li txo qis txiav quab yuam thiab cua sov, uas yog ib qho tseem ceeb rau kev ua nyias- phab ntsa nta tsis ua deformation.
Nanometer-theem servo thiab dynamic raug: Cov kab thiab kev sib hloov axes ntawm lub tshuab cuab yeej yuav tsum muaj nanometer- theem kev daws teeb meem thiab cov yam ntxwv zoo heev dynamic teb. Thaum ua cov txheej txheem nkhaus, tag nrho cov axes yuav tsum tau txav mus rau synchronously, smoothly, thiab ntawm kev kub ceev. Ib qho kev lag luam me me los yog kev vibration yuav tawm cov cim ntawm qhov chaw ua haujlwm.
Cov cuab yeej ntse txoj kev thiab kev vibration suppression: CAM software yuav tsum tsim kom muaj cov cuab yeej ua tau zoo kom tsis txhob muaj kev hloov pauv thiab hloov pauv tam sim ntawd. Cov tshuab siab heev kuj tau nruab nrog kev vibration suppression systems uas tuaj yeem saib xyuas thiab tiv thaiv kev vibrations tsim thaum lub sijhawm ua haujlwm, uas yog qhov tseem ceeb rau kev ua tiav qib siab - qhov chaw zoo thiab txuas ntxiv lub neej ntawm cov cuab yeej.
Qhov tshwm sim ntawm cov txheej txheem txwv: Txawm hais tias 5-axis micro-milling yog qhov muaj zog, nws yog ib qho "force" ua. Thaum cov xwm txheej hauv qab no tshwm sim, nws cov kev txwv lub cev raug nthuav tawm:
Qhov tseeb sab hauv ntse ntse: tsuav yog siv lub milling cutter, puag ncig cov ces kaum tshwm sim los ntawm lub cuab tam lub vojvoog yuav tsis raug zam.
Microscopic qhov lossis grooves nrog qhov tob loj heev - mus rau - txoj kab uas hla: Cov cuab yeej txiav slender tsis muaj kev nruj thiab nws yooj yim rau khoov deformation, ua rau lub qhov sib txawv los yog qhov sib txawv ntawm qhov dav.
Ua hauj lwm hardening thiab cov cuab yeej hnav: Thaum ua cov hlau tsis muaj steel thiab titanium alloys, lub cuab yeej hnav tawm sai heev. Cov cuab yeej hnav -tawm yuav ua rau cov txheej txheem ua haujlwm hnyav thiab cuam tshuam rau qhov raug qhov tseeb.
III. Micro-EDM (Micro Electrical Discharge Machining): Tsis yog-hu rau Microscopic Etching Art
Thaum milling ncav cuag nws lub cev txwv, micro- hluav taws xob tawm machining los ua si. Qhov no yog ib qho uas tsis yog -txoj kev sib cuag uas siv qhov kub thiab txias uas tsim los ntawm cov pa tawm mus rau yaj thiab vaporize cov ntaub ntawv hauv zos. Nws feem ntau suav nrog xaim hluav taws xob tawm machining (Wire EDM) thiab sinker discharge machining (Sinker EDM).
Lub hauv paus ntsiab lus ua haujlwm: Lub tshuab hluav taws xob yog siv los ntawm cov cuab yeej electrode (tooj liab, tungsten, thiab lwm yam) thiab cov khoom ua haujlwm (cov hlau conductive). Thaum ob qho tib si coj los ze rau ib leeg hauv qhov ntau ntawm ob peb micrometers mus rau ntau kaum micrometers, cov kua dej ua haujlwm insulating (feem ntau deionized dej los yog roj) tawg, ua rau muaj hluav taws xob tam sim ntawd. Qhov nruab nrab kub ntawm qhov tso tawm channel tuaj yeem ncav cuag 10,000 degree, ua rau cov khoom siv hlau hauv zos yaj lossis txawm vaporize. Lub zog tawg pov tseg cov khoom molten rau hauv cov dej ua haujlwm thiab tom qab ntawd ntxuav nws tawm.
Cov "special rog" uas tau kov yeej cov kev cov nyom ntawm milling:
Ua kom tiav cov ces kaum ntse ntse thiab cov npoo huv: Los ntawm kev siv cov khoom siv electrodes (lub thawv dab dej EDM), txhua cov duab tuaj yeem ua tau raws li qhov tseeb, suav nrog cov kaum sab xis, cov kaum sab xis, thiab ob qho tib si - qhov sib txawv. Nws yog feem ntau siv los tshem tawm sab hauv cov ces kaum sab laug los ntawm milling, tsim txoj cai zoo meej - lub kaum sab xis mounting rooj rau sensors.
Kev ntxhov siab -kev ua haujlwm pub dawb ntawm ultra- cov yam ntxwv nyias: Vim tsis muaj cov cuab yeej txiav quab yuam, kev siv hluav taws xob tawm tuaj yeem ua rau cov tav, phab ntsa thiab cov grooves nqaim li nyias li 0.05mm lossis txawm thinner yam tsis ua rau deformation ntawm lub workpiece. Qhov no yog qhov tseem ceeb heev rau kev ua cov txheej txheem ultra-thin metal partitions uas cais cov chav sib txawv.
Kev ua haujlwm siab -hardness thiab nyuaj- rau- cov khoom siv tshuab: Lub peev xwm ntawm hluav taws xob tawm tshuab tsuas yog nyob ntawm qhov kev coj ua ntawm cov khoom, thiab tsis muaj dab tsi cuam tshuam nrog nws qhov hardness, lub zog, los yog toughness. Yog li ntawd, nws tuaj yeem yooj yim tshuab cov ntaub ntawv hardened tom qab quenching, tsis tau qhia txhua yam kev ntxhov siab lossis ua rau cov khoom tawv.
Ua kom tiav qhov zoo tshaj plaws: Los ntawm kev siv cov machining siab heev (tsis tshua muaj tam sim no, siab zaus), ib tug nto nrog ib tug tsis tshua muaj nqi Ra (<0.1μm) can be obtained, without any directional tool marks. The recast layer (white layer) generated by the discharge is very thin and can be removed through subsequent electrolytic polishing.
Tus kheej- txwv: Cov khoom tshem tawm tus nqi kuj qeeb; nws tsuas tuaj yeem ua cov khoom siv hluav taws xob; cov electrodes yog nquag hnav thiab yuav tsum tau them nyiaj; rau loj - teev cov khoom tshem tawm, qhov ua tau zoo yog qis dua li ntawm milling.
IV. Txoj Kev Txawj Ntse ntawm Cov Txheej Txheem Kev Sib Koom Tes: Ib Txoj Haujlwm Sib Koom Tes ntawm 1 + 1 > 2
Cov tuam ntxhab saum toj kawg nkaus tsis siv ob txoj kev no ntawm nws tus kheej. Hloov chaw, lawv ua cov txheej txheem kev txawj ntse raws li cov qauv tsim ntawm cov khoom kom ua tiav cov txiaj ntsig zoo. Cov txheej txheem kev tsim vaj tsev nyob deb li cas yog raws li hauv qab no:
5-axis CNC micro-milling (rau kev ua haujlwm ntxhib thiab lub ntsiab lub cev tiav):
Kev pib ua haujlwm: Siv cov cuab yeej loj loj- cov cuab yeej txiav kom sai sai tshem tawm feem ntau ntawm cov khoom siv ntau dhau, yog li tsim cov qauv txheej txheem ntawm ntu.
Semi-ua tiav: Siv cov cuab yeej txiav me me kom tso cov nyiaj sib xws rau cov txheej txheem ua tiav tom ntej.
Cov txheej txheem tiav: Siv ultra-zoo micro- txoj kab uas hla milling cutters thiab siab rotational speeds, nrog me me txiav qhov tob, qhov kawg contours thiab feem ntau ntawm cov npoo nkhaus yog ua tiav kom tau raws li cov kev cai tseem ceeb rau qhov ntev thiab qhov chaw tiav. Qhov kev sib txuas 5-axis tuaj rau hauv kev ua si ntawm theem no kom ua tiav kev ua haujlwm du ntawm txoj kev nkhaus.
Micro hluav taws xob tawm machining (rau toughening thiab ntug xov):
Hlau txiav EDM: Nws tuaj yeem siv rau kev txiav cov ntaub ntawv, lossis rau kev ua haujlwm tsis tu ncua sab nraud uas tsis tuaj yeem ncav cuag los ntawm milling cutter.
Lub thawv EDM: Qhov no yog ib kauj ruam tseem ceeb rau kev ua tiav cov kaum ntse ntse sab hauv thiab cov yam ntxwv ultra- nyias.
Electrode fabrication: Ua ntej, raws li tus qauv 3D, kev ua haujlwm meej (txawm tias micro- hluav taws xob tawm machining) yog siv los tsim cov electrodes uas ua los ntawm tooj liab lossis graphite. Qhov tseeb ntawm cov electrodes ncaj qha txiav txim siab qhov tseeb ntawm lub workpiece.
Hluav taws xob tso tawm Machining: Precisely position lub electrode ntawm qhov chaw ntawm lub workpiece uas yuav tsum tau machined (xws li lub ces kaum ntawm lub sensor kab noj hniav), thiab ua hluav taws xob tawm etching. Los ntawm kev siv ntau yam electrodes (txiav ntxhib, txiav npluav) lossis hloov cov hluav taws xob tsis zoo, maj mam ua cov ces kaum zoo meej thiab ua tiav cov txheej txheem saum npoo tiav.
Ua cov phab ntsa nyias nyias: Rau cov phab ntsa nyias li 0.05mm, nyias nyias nyias electrodes yog siv. Fine tawm yog nqa tawm ib txhij los yog ua ntu zus los ntawm ob sab, precisely tswj tus nqi ntawm etching los ua tus kawg nyias phab ntsa qauv.
Tshaj tawm - ua tiav thiab ua kom huv huv qhov kawg:
Deburring thiab polishing: Txawm hais tias EDM tsim tsis muaj burrs, cov npoo machined tseem yuav muaj cov kab mob me me. Kev ua tiav kawg tuaj yeem ua tiav los ntawm kev siv lub tshuab ua kom zoo nkauj, sib nqus polishing, lossis tshuaj polishing.
Electrolytic polishing: Lub workpiece yog immersed nyob rau hauv electrolyte raws li lub anode. Los ntawm electrochemical dissolution, lub microscopic protrusions nyob rau saum npoo yog xaiv tshem tawm, ua rau ib daim iav -zoo li du nto. Tib lub sijhawm, txheej nyias ntawm re- txheej txheej tshuab tsim los ntawm EDM kuj raug tshem tawm.
Multi-theem ultrasonic tu: Cov khoom raug ntxuav hauv ntau lub tso tsheb hlau luam ultrasonic nrog ntau zaus thiab cov kuab tshuaj, tshem tawm tag nrho cov micrometer thiab sub-micrometer hlau hais, roj stains thiab ua kua dej seem, ua tiav kev kho mob - qib huv.
Micron- ntsuas ntsuas ntsuas:
Siv lub tshuab ntsuas kev sib koom tes (CMM) nruab nrog ultra- kev sojntsuam zoo, qhov loj me, qhov tseeb ntawm qhov chaw thiab daim ntawv thiab txoj haujlwm kam rau ua yog ntsuas.
Siv lub siab - daws teeb meem kho qhov muag pom kev los yog lub teeb dawb interferometers, lub ntsej muag roughness, contours, thiab microscopic defects uas tsis pom ntawm qhov muag liab qab tuaj yeem kuaj pom.
Tag nrho cov ntaub ntawv tau muab piv nrog CAD qauv, thiab tag nrho - daim ntawv ntsuam xyuas qhov loj tau tsim los xyuas kom meej tias txhua qhov ua tau raws li qhov kam rau ua ntawm ± 5 μm.
V. Lub luag haujlwm ntawm tus neeg tsim khoom: Los ntawm cov tswv cuab rau cov txheej txheem kev sib koom ua ke
Muaj cov cuab yeej siv tshuab 5-axis siab heev thiab cov tshuab hluav taws xob tawm tsuas yog daim pib. Qhov tseem ceeb ntawm kev sib tw yog nyob rau hauv:
Cov txheej txheem kev npaj thiab simulation muaj peev xwm: Ua ntej qhov tseeb machining, los ntawm CAM thiab machining simulation software, tag nrho cov txheej txheem machining yog simulated ua ntej los txhim kho txoj hauv kev, xaiv cov tswv yim electrode, thiab kwv yees muaj peev xwm cuam tshuam lossis overcuts, ua tiav "tau txais nws thawj zaug".
Kev tswj cov cua sov thiab cov txheej txheem tswj kev ruaj ntseg: Tag nrho cov kev ua haujlwm ib puag ncig yuav tsum tau tswj qhov kub thiab av noo. Rau micro-metric processing, thermal expansion ntawm lub tshuab cuab yeej nws tus kheej, nrog rau kev cuam tshuam ntawm tus neeg teb xov tooj lub cev kub, yuav tsum tau muab rau hauv tus account. Cov qauv kev teeb tsa muaj xws li qhov tsis tu ncua -rhiav kub, tshuab cuab yeej preheating, thiab ntawm - kab kub them nyiaj.
Hla - txheej txheem benchmarking uniformity: Xyuas kom meej tias los ntawm milling mus rau EDM thiab thaum kawg mus rau qhov kawg kev soj ntsuam, lub workpiece muaj ib tug sib koom ua ke thiab meej system nyob rau hauv tag nrho cov txheej txheem. Qhov no tso siab rau qhov tseeb fixture tsim thiab raug tshuab cuab yeej sib dhos tshuab.
Xaus: Kev tsim khoom ntawm lub hau kawg ntawm lub endoscope yog lub pinnacle ntawm precision processing technology. Kev sib xyaw ua ke ntawm 5-axis CNC micro-milling thiab micro- hluav taws xob tawm machining sawv cev rau qib siab tshaj plaws ntawm kev tsim tawm tam sim no ntawm micrometer nplai. Cov yav tas los precisely shapes macroscopic daim ntawv los ntawm "force" tswj, thaum lub tom kawg overcomes huab nta los ntawm "hluav taws xob" micro-etching. Cov txheej txheem kev koom ua ke no tsis tsuas yog daws qhov tsis sib xws ntawm cov duab geometric nyuaj thiab qhov kawg precision, tab sis kuj ua kom muaj peev xwm ua tau zoo ntawm -kev ua haujlwm nyuaj rau cov khoom siv tshuab. Rau cov tuam txhab lag luam uas muaj peev xwm ua tau zoo thiab siv tau qhov kev sib koom tes tsim kev lag luam, qhov uas lawv xa tsis yog ib feem xwb, tab sis ib qho me me engineering platform uas integrates optics, fluidics, thiab mechanics zoo kawg nkaus. Nws yog qhov kev lees paub tseem ceeb rau kev txhawb nqa cov cuab yeej phais mob me me kom txuas ntxiv hloov mus rau cov lus qhia me me, ntse dua, thiab muaj zog dua.