{ "slug": "deburring-methods", "title": "CNC 零件去毛刺方法：15 种工艺对比", "description": "按棱边类型、毛刺尺寸、棱边半径、Ra 影响、适用材料和成本等级对比十五种去毛刺工艺，附工艺选择逻辑、节拍计算实例、质量检查要点与交叉孔处理指导。", "lang": "zh", "tables": [ { "caption": "去毛刺与倒棱方法对比（15 种工艺）", "columns": [ "方法", "棱边类型", "材料", "最大毛刺尺寸", "倒棱量 / R", "Ra 影响", "成本等级", "设备门槛", "来源" ], "rows": [ { "方法": "Manual (file / scraper / blade)", "棱边类型": "外棱边、定角度倒角；不适用于薄壁 / 内部交叉孔 / 关键半径", "材料": "所有金属", "最大毛刺尺寸": "no unified limit (gap)", "倒棱量 / R": "edge break 0.2–0.5 mm; skilled ±0.05 mm", "Ra 影响": "手工抛光倒棱 ≤ 0.01 mm；Ra 视工具而定", "成本等级": "2", "设备门槛": "低；手工工具 €10–50", "来源": "S1, S19" }, { "方法": "CNC in-machine chamfer / edge tool", "棱边类型": "外棱边、孔口、刀具可触及的棱边", "材料": "所有金属", "最大毛刺尺寸": "not specified (gap)", "倒棱量 / R": "90° chamfer 0.1–2.0 mm; ball end mill R 0.1–0.5 mm", "Ra 影响": "视刀具而定；Ra 变化极小", "成本等级": "2", "设备门槛": "中等；需 CNC 设备 + 编程", "来源": "S19" }, { "方法": "Rotary brush (incl. in-machine)", "棱边类型": "外棱边、螺纹、狭窄转角、轻微内部结构", "材料": "所有金属", "最大毛刺尺寸": "light burrs only (gap)", "倒棱量 / R": "fine brush edge break 0.01–0.02 mm", "Ra 影响": "改善 Ra；微细刷 1,000–3,000 rpm", "成本等级": "2", "设备门槛": "低–中；可装入 CNC 刀库", "来源": "S1" }, { "方法": "Barrel tumbling", "棱边类型": "小型件的外棱边", "材料": "金属，部分塑料", "最大毛刺尺寸": "small burrs (gap)", "倒棱量 / R": "larger edge radius; numeric R not given", "Ra 影响": "比振动光饰更粗；未给出 Ra 范围", "成本等级": "3", "设备门槛": "中等；滚筒转速 20–45 rpm", "来源": "S10" }, { "方法": "Vibratory finishing", "棱边类型": "外棱边 + 磨料可到达的内部、槽、交叉孔", "材料": "所有金属", "最大毛刺尺寸": "stainless burr ≈ 75–80 µm (retrieval-index transcription)", "倒棱量 / R": "controlled edge R 0.05–0.3 mm", "Ra 影响": "Ra 3.2 → 0.8 µm；范围 0.4–1.6 µm", "成本等级": "3", "设备门槛": "中等；节拍 20–120 min", "来源": "S9, S10, S42" }, { "方法": "Centrifugal barrel", "棱边类型": "小型精密件，外棱边", "材料": "金属", "最大毛刺尺寸": "small–medium burrs", "倒棱量 / R": "numeric R not given", "Ra 影响": "Ra 0.2–0.8 µm", "成本等级": "3", "设备门槛": "中–高；去毛刺 15–45 min", "来源": "S10, S13" }, { "方法": "Centrifugal disc", "棱边类型": "小型件，大批量", "材料": "金属", "最大毛刺尺寸": "small burrs", "倒棱量 / R": "numeric R not given", "Ra 影响": "Ra 0.2–0.8 µm；低 Ra 光整", "成本等级": "3", "设备门槛": "中–高；去毛刺约 2 h，自动卸料", "来源": "S14, S15" }, { "方法": "Drag finishing", "棱边类型": "刀具、回转体零件的外棱边", "材料": "硬质合金、淬硬钢", "最大毛刺尺寸": "micro edge burrs", "倒棱量 / R": "60 min: Ø6 mm tool R ≈ 18 µm; Ø8 mm ≈ 20 µm", "Ra 影响": "已报告粗糙度改善率", "成本等级": "3", "设备门槛": "中–高；装夹后拖曳通过磨料", "来源": "S16" }, { "方法": "Abrasive flow machining (AFM)", "棱边类型": "内部流道、交叉孔、深腔", "材料": "所有金属", "最大毛刺尺寸": "thin burrs (gap)", "倒棱量 / R": "uniform edge R 0.02–0.05 mm", "Ra 影响": "内部 Ra 精细；挤压压力 10–200 bar", "成本等级": "5", "设备门槛": "高；专用设备 + 工装", "来源": "S1, S17, S23" }, { "方法": "Electrochemical deburring (ECD)", "棱边类型": "内部交叉孔、难以触及的相交处", "材料": "仅导电金属", "最大毛刺尺寸": "up to 0.5 mm", "倒棱量 / R": "edge R 0.05–0.2 mm (single secondary source); control ±0.05 mm", "Ra 影响": "Ra 2–4 µm；无机械力", "成本等级": "4", "设备门槛": "高；电源 + 专用阴极", "来源": "S6, S7, S21" }, { "方法": "Thermal energy method (TEM)", "棱边类型": "同时处理全部内外棱边", "材料": "钢、不锈钢、铸铁最佳；不适用铝 / 大多数塑料", "最大毛刺尺寸": "thin burrs / flash", "倒棱量 / R": "edge break 0.02–0.05 mm", "Ra 影响": "氧化残留需后道清洗", "成本等级": "5", "设备门槛": "高；腔体设备 €300k–800k", "来源": "S1, S3, S19" }, { "方法": "Laser deburring (SLD)", "棱边类型": "钣金外棱边、指定半径", "材料": "金属", "最大毛刺尺寸": "thin burrs remelted", "倒棱量 / R": "minimum achievable R ≈ 0.55 mm", "Ra 影响": "棱边重熔；无刀具磨损", "成本等级": "4", "设备门槛": "高；激光源 + 光学系统 + 工装", "来源": "S33, S34" }, { "方法": "High-pressure water jet (HPW)", "棱边类型": "交叉孔、深孔、螺纹孔（需视线可达）", "材料": "所有金属；对韧性毛刺效果有限", "最大毛刺尺寸": "loose / light-adhering only", "倒棱量 / R": "no R value; firm burrs remain", "Ra 影响": "无热 / 化学应力；可与清洗合并", "成本等级": "4", "设备门槛": "高；高压泵 + NC 多轴喷嘴", "来源": "S19, S24, S26" }, { "方法": "Chemical deburring (electroless)", "棱边类型": "复杂小型件、难以触及的区域", "材料": "钢、铝、不锈钢（视槽液而定）", "最大毛刺尺寸": "up to a few tenths of mm", "倒棱量 / R": "leveling; no fixed R", "Ra 影响": "借助峰谷电位差实现表面整平", "成本等级": "3", "设备门槛": "中等；槽体 + 槽液管理", "来源": "S36, S37, S38" }, { "方法": "Cryogenic + shot blast", "棱边类型": "外部飞边 / 毛刺", "材料": "橡胶、塑料、压铸金属", "最大毛刺尺寸": "thin flash; precision to 0.01 mm", "倒棱量 / R": "clean flash break; part dimensions retained", "Ra 影响": "基面粗糙度几乎不受影响", "成本等级": "4", "设备门槛": "高；保温腔体 + 抛丸轮", "来源": "S28, S30, S31, S52" } ] }, { "caption": "熟练的手工去毛刺工人能稳定控制多大的倒棱量？", "columns": [ "毛刺尺寸等级", "毛刺高度", "典型场景", "来源" ], "rows": [ { "毛刺尺寸等级": "Precision burr", "毛刺高度": "< 0.02 mm", "典型场景": "航空 / 医疗关键棱边", "来源": "S2" }, { "毛刺尺寸等级": "Minor burr", "毛刺高度": "0.02–0.05 mm", "典型场景": "一般精密加工", "来源": "S2" }, { "毛刺尺寸等级": "Moderate burr", "毛刺高度": "0.05–0.15 mm", "典型场景": "常规铣削 / 钻孔棱边", "来源": "S2" }, { "毛刺尺寸等级": "Heavy burr", "毛刺高度": "> 0.15 mm", "典型场景": "刀具磨钝 / 韧性材料 / 大切深", "来源": "S2" } ] }, { "caption": "螺纹和狭窄转角要做出最小的倒棱量，该用哪种去毛刺方法？", "columns": [ "棱边位置", "首选", "备选", "不建议", "来源" ], "rows": [ { "棱边位置": "External straight edge / fixed chamfer", "首选": "CNC in-machine chamfer tool", "备选": "manual, rotary brush", "不建议": "TEM for a simple edge (over-cost)", "来源": "S19" }, { "棱边位置": "External 3D freeform edge", "首选": "ball end mill / disc brush", "备选": "robotic compliant spindle", "不建议": "rigid chamfer tool", "来源": "S19" }, { "棱边位置": "Bore entrance / bore internal surface", "首选": "Flex-Hone (Ø4–960 mm)", "备选": "rotary brush", "不建议": "rigid tool (cannot follow bore)", "来源": "S19" }, { "棱边位置": "Cross-hole / intersection", "首选": "ECD or Flex-Hone", "备选": "TEM, AFM, HPW", "不建议": "manual (inconsistent), rigid tool", "来源": "S19, S21" }, { "棱边位置": "Deep cavity / internal passage", "首选": "AFM", "备选": "TEM, ECD", "不建议": "brush / belt (cannot reach)", "来源": "S1, S17" }, { "棱边位置": "Hidden / inaccessible burr", "首选": "TEM", "备选": "ECD", "不建议": "line-of-sight methods", "来源": "S3, S19" }, { "棱边位置": "Screw / thread edge", "首选": "fine rotary brush", "备选": "ECD", "不建议": "aggressive belt (damages thread)", "来源": "S1" } ] }, { "caption": "振动光饰会怎样改变棱边半径和表面粗糙度？", "columns": [ "参数", "数值", "来源" ], "rows": [ { "参数": "Ceramic media standard cycle", "数值": "40–60 min, edge R 0.05–0.15 mm", "来源": "S9" }, { "参数": "Extended cycle for R up to 0.3 mm", "数值": "90–120 min", "来源": "S9" }, { "参数": "Aluminium edge break 0.10–0.20 mm, 10 mm ceramic", "数值": "30–60 min", "来源": "S11" }, { "参数": "Deburring cycle range", "数值": "20–60 min", "来源": "S12" }, { "参数": "Radiusing cycle range", "数值": "30–90 min", "来源": "S12" }, { "参数": "Material removal, ceramic", "数值": "0.01–0.05 mm per surface", "来源": "S9" }, { "参数": "Material removal, plastic media", "数值": "0.002–0.01 mm per surface", "来源": "S9" }, { "参数": "Media-to-part volume ratio", "数值": "3:1–5:1 (precision up to 6:1+)", "来源": "S9, S10" }, { "参数": "Bowl load fill", "数值": "60%–70%", "来源": "S9" }, { "参数": "Stainless burr the process is sized for", "数值": "≈ 75–80 µm (retrieval-index transcription, not directly verified)", "来源": "S42" }, { "参数": "Removal from part diameter or thickness", "数值": "7–25 µm", "来源": "S42" }, { "参数": "Rotary brush, aluminium", "数值": "1,000–1,500 rpm, 15–30 µm compound", "来源": "S1" }, { "参数": "Rotary brush, hardened steel", "数值": "2,000–3,000 rpm, 3–9 µm diamond", "来源": "S1" } ] }, { "caption": "振动光饰选型通常以多厚的不锈钢毛刺为对象？", "columns": [ "选型参数", "数值", "来源" ], "rows": [ { "选型参数": "Typical stainless burr", "数值": "≈ 75–80 µm (76 µm in the retrieval index; not directly verified)", "来源": "S42" }, { "选型参数": "Removal per cycle", "数值": "7–25 µm", "来源": "S42" }, { "选型参数": "Centrifugal barrel vs vibratory, same work", "数值": "15–45 min vs 4–24 h", "来源": "S13" }, { "选型参数": "Centrifugal disc deburr", "数值": "about 2 h, auto-unload", "来源": "S14, S15" } ] }, { "caption": "电化学去毛刺能去除多少毛刺，会留下多大半径？", "columns": [ "参数", "常规 ECD", "交叉孔研究", "来源" ], "rows": [ { "参数": "Applied voltage", "常规 ECD": "12–24 V (DC supply 8–30 V)", "交叉孔研究": "50–100 V", "来源": "S6" }, { "参数": "Current density", "常规 ECD": "5–10 A/cm²", "交叉孔研究": "30–200 A/cm²", "来源": "S6" }, { "参数": "Interelectrode gap", "常规 ECD": "0.1–0.3 mm", "交叉孔研究": "0.1–0.7 mm", "来源": "S6" }, { "参数": "Time", "常规 ECD": "5–100 s", "交叉孔研究": "—", "来源": "S6" }, { "参数": "Typical cycle", "常规 ECD": "30–45 s; about 20 s multi-hole", "交叉孔研究": "—", "来源": "S6, S21" }, { "参数": "Electrolyte pressure", "常规 ECD": "0.3–0.5 MPa", "交叉孔研究": "—", "来源": "S6" }, { "参数": "Burr height removed", "常规 ECD": "up to 0.5 mm", "交叉孔研究": "—", "来源": "S6" }, { "参数": "Edge radius left", "常规 ECD": "R 0.05–0.2 mm (single secondary source — see note above)", "交叉孔研究": "—", "来源": "S6" } ] }, { "caption": "电化学去毛刺的典型电压和电流密度是多少？", "columns": [ "工件材料", "电解液", "来源" ], "rows": [ { "工件材料": "Carbon / low-carbon steel", "电解液": "5%–15% or 2%–2.5% NaNO3", "来源": "S6" }, { "工件材料": "Copper alloys", "电解液": "5%–15% NaNO3", "来源": "S6" }, { "工件材料": "Aluminium alloys", "电解液": "5%–20% NaNO3", "来源": "S6" }, { "工件材料": "Stainless steels", "电解液": "5% NaNO3 + 0.5% NaCl", "来源": "S6" }, { "工件材料": "Electrolyte supply pressure", "电解液": "0.3–0.5 MPa; tool gap 0.1–0.3 mm; tip overlap 1.5–2 mm", "来源": "S6" } ] }, { "caption": "热能法（TEM）的节拍有多快？", "columns": [ "参数", "数值", "来源" ], "rows": [ { "参数": "Combustion temperature", "数值": "2,500–3,500 °C, milliseconds", "来源": "S3" }, { "参数": "Fuel gas", "数值": "methane + oxygen, pressurized chamber", "来源": "S3, S4" }, { "参数": "Cycle excluding load/unload", "数值": "less than 1 minute; active burn < 1 s", "来源": "S3, S1" }, { "参数": "Edge break", "数值": "0.02–0.05 mm; over-burn can round to 0.05 mm", "来源": "S1" }, { "参数": "Removed burr amount set by", "数值": "gas volume, burr thickness, material heat-transfer rate, fuel-oxygen ratio", "来源": "S3" } ] }, { "caption": "哪些材料不适合热能去毛刺？", "columns": [ "材料", "首选方法", "注意事项 / 限制", "来源" ], "rows": [ { "材料": "Carbon / low-carbon steel", "首选方法": "CNC tool, vibratory, ECD, TEM, chemical", "注意事项 / 限制": "化学槽液需预留材料损耗余量", "来源": "S6, S36" }, { "材料": "Stainless steel", "首选方法": "vibratory, ECD, TEM, AFM", "注意事项 / 限制": "化学法使用硝酸；TEM 会留下氧化物需清洗", "来源": "S3, S38" }, { "材料": "Aluminium", "首选方法": "plastic media, rotary brush, Flex-Hone, chemical (NaOH)", "注意事项 / 限制": "TEM 一般不适合；硬质陶瓷磨料会压伤软表面", "来源": "S1, S38" }, { "材料": "Copper / brass", "首选方法": "plastic / steel media, ECD, vibratory", "注意事项 / 限制": "软黄铜上避免使用强力陶瓷磨料", "来源": "S6, S10" }, { "材料": "Hardened steel / carbide", "首选方法": "diamond brush, drag finishing, AFM, ECD", "注意事项 / 限制": "需细粒度磨料（3–9 µm 金刚石）", "来源": "S1, S16" }, { "材料": "Titanium", "首选方法": "AFM, ECD, fine media", "注意事项 / 限制": "导电性 / 反应活性偏低，需针对性调配电解液", "来源": "S17" }, { "材料": "Rubber / elastomer", "首选方法": "cryogenic + shot", "注意事项 / 限制": "温度须降到材料 Tg 以下", "来源": "S31" }, { "材料": "Plastic / nylon", "首选方法": "cryogenic, fine brush, HPW", "注意事项 / 限制": "TEM 会烧蚀塑料；ECD 不可行（不导电）", "来源": "S19, S30" }, { "材料": "Die-cast metal", "首选方法": "cryogenic (warm range), plastic media", "注意事项 / 限制": "电镀前须保护多孔铸造表皮", "来源": "S29, S51" } ] }, { "caption": "高压水去毛刺通常用多高的压力？", "columns": [ "来源 / 设备", "压力范围", "备注" ], "rows": [ { "来源 / 设备": "HPWD typical (S26)", "压力范围": "5,000–7,500 psi (34–52 MPa), up to 15,000 psi (103 MPa)", "备注": "检索索引转录，未直接核实；报告 BDX-613-2421（1980）经 DOI 引用" }, { "来源 / 设备": "Sugino JCC (S24)", "压力范围": "up to 50 MPa", "备注": "CNC 喷嘴，交叉孔 / 深孔 / 螺纹孔" }, { "来源 / 设备": "Sugino JDM (S25)", "压力范围": "up to 70 MPa", "备注": "交叉孔、齿轮" }, { "来源 / 设备": "PrecisionPro (S19)", "压力范围": "300–2,500 bar (30–250 MPa)", "备注": "去毛刺层级——仅去除松散或附着轻微的毛刺；牢固毛刺仍会残留" }, { "来源 / 设备": "Sinobakr (S27)", "压力范围": "5–50 MPa stepless", "备注": "去除率 99%；过滤精度 1–5 µm；汽车零件" }, { "来源 / 设备": "WOMA UHP (S55)", "压力范围": "up to 4,000 bar (400 MPa; 58,000 psi)", "备注": "超高压泵上限——切割 / 重清洗层级，不是去毛刺常规参数" } ] }, { "caption": "激光去毛刺能达到的最小棱边半径是多少？", "columns": [ "参数", "数值", "来源" ], "rows": [ { "参数": "Laser source", "数值": "5 kW diode / 5 kW Nd:YAG", "来源": "S33, S35" }, { "参数": "Feed rate", "数值": "up to 9 m/min", "来源": "S33" }, { "参数": "Minimum achievable edge radius", "数值": "about 0.55 mm (PDF not re-verified online)", "来源": "S34" }, { "参数": "Edge forming capacity, high-strength steel", "数值": "increased by more than 240%", "来源": "S33" } ] }, { "caption": "化学去毛刺与电化学去毛刺有什么区别？", "columns": [ "工艺", "驱动力", "典型节拍", "适用位置" ], "rows": [ { "工艺": "Chemical deburring (electroless)", "驱动力": "bath chemistry, no power", "典型节拍": "about 60 s", "适用位置": "" }, { "工艺": "Electrochemical deburring (ECD)", "驱动力": "DC supply + targeted cathodes + electrolyte", "典型节拍": "20–45 s per cycle", "适用位置": "" }, { "工艺": "Terminology conflict", "驱动力": "some pages call ECD chemical deburring", "典型节拍": "—", "适用位置": "" }, { "工艺": "Chemical solutions", "驱动力": "acid or alkali per alloy", "典型节拍": "—", "适用位置": "" } ] }, { "caption": "去毛刺应在阳极氧化前还是后进行？", "columns": [ "步骤", "操作" ], "rows": [ { "步骤": "1", "操作": "CNC machine to drawing dimensions" }, { "步骤": "2", "操作": "Deburr and clean" }, { "步骤": "3", "操作": "Pre-treatment (etch, de-smut)" }, { "步骤": "4", "操作": "Anodize to specified type and thickness" }, { "步骤": "5", "操作": "Dye (optional)" }, { "步骤": "6", "操作": "Seal" }, { "步骤": "7", "操作": "Inspect" } ] }, { "caption": "去毛刺会占零件总成本的多少？", "columns": [ "来源", "占比", "适用范围" ], "rows": [ { "来源": "SpecForge / IQS (S39)", "占比": "about 30%", "适用范围": "precision aerospace" }, { "来源": "SpecForge (S39)", "占比": "15%–20%", "适用范围": "automotive" }, { "来源": "Ramachandran survey (S41, JMPT 44(1–2) 1994, DOI 10.1016/0924-0136(94)90033-7)", "占比": "5%–15%", "适用范围": "average edge/surface finishing" }, { "来源": "Dingzhu / AFS (S43)", "占比": "5%–12%", "适用范围": "castings" } ] }, { "caption": "产量做到多少时，CNC 集成刷或 Flex-Hone 去毛刺比手工更划算？", "columns": [ "产量", "推荐方案", "平衡逻辑", "来源" ], "rows": [ { "产量": "Prototype / one-off (< 50 pcs)", "推荐方案": "manual blade / file", "平衡逻辑": "无需投资，灵活", "来源": "S19" }, { "产量": "Small batch (about 50 pcs/month up)", "推荐方案": "CNC-integrated Flex-Hone / brush", "平衡逻辑": "约 50 件/月时与手工持平", "来源": "S19" }, { "产量": "Medium batch (hundreds)", "推荐方案": "vibratory / centrifugal batch finishing", "平衡逻辑": "批量超过约 20 件/批后单件人工成本下降", "来源": "S9" }, { "产量": "High volume (>10,000/day)", "推荐方案": "TEM or dedicated deburring system", "平衡逻辑": "一次循环覆盖全部棱边；产能高", "来源": "S19" }, { "产量": "Continuous flow (e.g. crankshafts)", "推荐方案": "linear continuous vibrator", "平衡逻辑": "单件不到 1 min，60+ 件/h", "来源": "S44" } ] }, { "caption": "深冷去飞边对零件尺寸和表面有什么影响？", "columns": [ "参数", "数值", "来源" ], "rows": [ { "参数": "Machine cooling range", "数值": "−130 °C to +50 °C; operating down to about −150 °C", "来源": "S29, S30" }, { "参数": "Liquid nitrogen boiling point", "数值": "about −196 °C", "来源": "S30" }, { "参数": "EPDM glass-transition Tg", "数值": "−55 °C", "来源": "S31" }, { "参数": "SBR Tg", "数值": "−40 °C", "来源": "S31" }, { "参数": "NBR Tg", "数值": "−30 °C", "来源": "S31" }, { "参数": "Example batch", "数值": "7 kg, −70 °C, 8 min, wheel 6,500 rpm, basket 20 rpm, 1.0 mm media", "来源": "S28" } ] }, { "caption": "月产 20,000 件铝外壳时，去毛刺自动化能省多少？", "columns": [ "项目", "计算依据", "数值" ], "rows": [ { "项目": "Monthly volume", "计算依据": "case input (S2)", "数值": "20,000 pcs" }, { "项目": "Manual cycle", "计算依据": "case input (S2)", "数值": "90 s/pc" }, { "项目": "Automated rotary brush cycle", "计算依据": "case input (S2)", "数值": "22 s/pc" }, { "项目": "Original monthly machine time", "计算依据": "20,000 × 90 s ÷ 3,600", "数值": "500 h" }, { "项目": "New monthly machine time", "计算依据": "20,000 × 22 s ÷ 3,600", "数值": "122.2 h" }, { "项目": "Theoretical cycle-time saving", "计算依据": "500 − 122.2", "数值": "377.8 h" }, { "项目": "Cycle reduction ratio", "计算依据": "(90 − 22) ÷ 90", "数值": "75.6%" }, { "项目": "Defective pcs", "计算依据": "20,000 × 3.0% → × 0.2%", "数值": "600 → 40 pcs" }, { "项目": "Reported labour saving / cost change", "计算依据": "source-reported (S2)", "数值": "60 h/month; −8%" } ] }, { "caption": "月产 15,000 件不锈钢阀体时，交叉孔去毛刺能省多少？", "columns": [ "项目", "计算依据", "数值" ], "rows": [ { "项目": "Monthly volume", "计算依据": "case input (S2)", "数值": "15,000 pcs" }, { "项目": "Manual / new cycle", "计算依据": "case input (S2)", "数值": "4.8 / 1.2 min per pc" }, { "项目": "Original monthly time", "计算依据": "15,000 × 4.8 min = 72,000 min; ÷ 60", "数值": "1,200 h" }, { "项目": "New monthly time", "计算依据": "15,000 × 1.2 min = 18,000 min; ÷ 60", "数值": "300 h" }, { "项目": "Labour time saving (theoretical, full load)", "计算依据": "1,200 − 300", "数值": "900 h" }, { "项目": "Caliber note", "计算依据": "theoretical machine time vs reported capacity", "数值": "reported +18% includes bottleneck/scheduling — not interconvertible" }, { "项目": "Cycle reduction ratio", "计算依据": "(4.8 − 1.2) ÷ 4.8", "数值": "75%" }, { "项目": "Leak-failure pcs", "计算依据": "15,000 × 2.6% → × 0.3%", "数值": "390 → 45 pcs" }, { "项目": "Failure reduction", "计算依据": "390 − 45", "数值": "345 pcs (−88.5%)" }, { "项目": "Complaints", "计算依据": "source-reported (S2)", "数值": "11 → 2 per quarter" } ] }, { "caption": "交叉孔去毛刺的各种方法对比如何？", "columns": [ "方法", "可达机制", "节拍", "棱边控制", "副作用", "最适用", "来源" ], "rows": [ { "方法": "Flex-Hone", "可达机制": "柔性磨球顺着孔壁进入相交处", "节拍": "short, CNC-integrable", "棱边控制": "plateau finish + radius", "副作用": "成本最低；对极小或坚硬毛刺效果有限", "最适用": "大多数通用交叉孔", "来源": "S19" }, { "方法": "ECD", "可达机制": "专用阴极溶解毛刺", "节拍": "about 20 s, dozens of holes at once", "棱边控制": "R 0.05–0.2 mm, ±0.05 mm (single secondary source)", "副作用": "仅适用导电零件；需零件专用阴极", "最适用": "液压阀体、多处相交", "来源": "S6, S21" }, { "方法": "TEM", "可达机制": "混合气充满每条通道并烧除全部毛刺", "节拍": "< 1 s active, all locations", "棱边控制": "edge break 0.02–0.05 mm", "副作用": "氧化层；薄壁风险；不适用铝", "最适用": "复杂隐蔽相交处，钢 / 不锈钢", "来源": "S3, S19" }, { "方法": "AFM", "可达机制": "磨料介质被强制挤过通道", "节拍": "3–10 min per batch", "棱边控制": "uniform R 0.02–0.05 mm", "副作用": "速度慢、成本高、需磨料装夹", "最适用": "要求锐洁的关键相交处、高价值零件", "来源": "S17, S23" }, { "方法": "HPW", "可达机制": "CNC 喷嘴对准交叉孔", "节拍": "seconds per feature", "棱边控制": "removes loose burrs", "副作用": "牢固毛刺仍残留；需烘干", "最适用": "切屑 + 松散毛刺、深孔 / 螺纹孔", "来源": "S24, S19" }, { "方法": "Abrasive micro-blast", "可达机制": "喷砂嘴伸入小孔；可达小至 0.056 in 的孔", "节拍": "manual / automated", "棱边控制": "fine blasted texture", "副作用": "—", "最适用": "薄而脆的毛刺", "来源": "S21" } ] } ] }