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Gio trnh: Cng ngh ch to my
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Chng 1
cc khi nim c bn
1.1- M u Ngnh Ch to my ng vai tr quan trng trong vic sn xut ra cc thit b, cng c cho mi ngnh trong nn kinh t quc dn, to tin cn thit cc ngnh ny pht trin mnh hn. V vy, vic pht trin KH - KT trong lnh vc Cng ngh ch to my c ngha hng u nhm thit k, hon thin v vn dng cc phng php ch to, t chc v iu khin qu trnh sn xut t hiu qu kinh t cao nht. Cng ngh ch to my l mt lnh vc khoa hc k thut c nhim v nghin cu, thit k v t chc thc hin qu trnh ch to sn phm c kh t cc ch tiu kinh t k thut nht nh trong iu kin quy m sn xut c th. Mt mt Cng ngh ch to my l l thuyt phc v cho cng vic chun b sn xut v t chc sn xut c hiu qu nht. Mt khc, n l mn hc nghin cu cc qu trnh hnh thnh cc b mt chi tit v lp rp chng thnh sn phm. Cng ngh ch to my l mt mn hc lin h cht ch gia l thuyt v thc tin sn xut. N c tng kt t thc t sn xut tri qua nhiu ln kim nghim khng ngng nng cao trnh k thut, ri c em ng dng vo sn xut gii quyt nhng vn thc t phc tp hn, kh khn hn. V th, phng php nghin cu Cng ngh ch to my phi lun lin h cht ch vi iu kin sn xut thc t. Ngy nay, khuynh hng tt yu ca Ch to my l t ng ha v iu khin qu trnh thng qua vic in t ha v s dng my tnh t khu chun b sn xut ti khi sn phm ra xng. i tng nghin cu ca Cng ngh ch to my l chi tit gia cng khi nhn theo kha cnh hnh thnh cc b mt ca chng v quan h lp ghp chng li thnh sn phm hon chnh. lm cng ngh c tt cn c s hiu bit su rng v cc mn khoa hc c s nh: Sc bn vt liu, Nguyn l my, Chi tit my, My cng c, Nguyn l ct, Dng c ct v.v... Cc mn hc Tnh ton v thit k g, Thit k nh my c kh, T ng ha qu trnh cng ngh s h tr tt cho mn hc Cng ngh ch to my v l nhng vn c quan h khng kht vi mn hc ny. Mn hc Cng ngh ch to my khng nhng gip cho ngi hc nm vng cc phng php gia cng cc chi tit c hnh dng, chnh xc, vt liu khc nhau v cng ngh lp rp chng thnh sn phm, m cn gip cho ngi hc kh nng phn tch so snh u, khuyt im ca tng phng php chn ra phng php gia cng thch hp nht, bit chn qu trnh cng ngh hon thin nht, vn dng c k thut mi v nhng bin php t chc sn xut ti u nng cao nng sut lao ng. Mc ch cui cng ca Cng ngh ch to my l nhm t c: cht lng sn phm, nng sut lao ng v hiu qu kinh t cao.
Khoa C kh - Trng i hc Bch khoa
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1.2- qu trnh sn xut v qu trnh cng ngh

1.2.1- Qu trnh sn xut
Ni mt cch tng qut, qu trnh sn xut l qu trnh con ngi tc ng vo ti nguyn thin nhin bin n thnh sn phm phc v cho li ch ca con ngi. nh ngha ny rt rng, c th bao gm nhiu giai on. V d, c mt sn phm c kh th phi qua cc giai on: Khai thc qung, luyn kim, gia cng c kh, gia cng nhit, lp rp v.v... Nu ni hp hn trong mt nh my c kh, qu trnh sn xut l qu trnh tng hp cc hot ng c ch bin nguyn liu v bn thnh phm thnh sn phm c gi tr s dng nht nh, bao gm cc qu trnh chnh nh: Ch to phi, gia cng ct gt, gia cng nhit, kim tra, lp rp v cc qu trnh ph nh: vn chuyn, ch to dng c, sa cha my, bo qun trong kho, chy th, iu chnh, sn lt, bao b, ng gi v.v... Tt c cc qu trnh trn c t chc thc hin mt cch ng b nhp nhng cho qu trnh sn xut c lin tc. S nh hng ca cc qu trnh nu trn n nng sut, cht lng ca qu trnh sn xut c mc khc nhau. nh hng nhiu nht n cht lng, nng sut ca qu trnh sn xut l nhng qu trnh c tc ng lm thay i v trng thi, tnh cht ca i tng sn xut, chnh l cc qu trnh cng ngh.
1.2.2- Qu trnh cng ngh
Qu trnh cng ngh l mt phn ca qu trnh sn xut, trc tip lm thay i trng thi v tnh cht ca i tng sn xut. i vi sn xut c kh, s thay i trng thi v tnh cht bao gm: - Thay i trng thi hnh hc (kch thc, hnh dng, v tr tng quan gia cc b phn ca chi tit...) - Thay i tnh cht (tnh cht c l nh cng, bn, ng sut d...) * Qu trnh cng ngh bao gm: - Qu trnh cng ngh to phi: hnh thnh kch thc ca phi t vt liu bng cc phng php nh c, hn, gia cng p lc ... - Qu trnh cng ngh gia cng c: lm thay i trng thi hnh hc v c l tnh lp b mt. - Qu trnh cng ngh nhit luyn: lm thay i tnh cht c l ca vt liu chi tit c th tng cng, bn. - Qu trnh cng ngh lp rp: to ra mt v tr tng quan xc nh gia cc chi tit thng qua cc mi lp ghp gia chng to thnh sn phm hon thin. Qu trnh cng ngh cho mt i tng sn xut (chi tit) phi c xc nh ph hp vi cc yu cu v cht lng v nng sut ca i tng. Xc nh qu trnh cng ngh hp l ri ghi thnh vn kin cng ngh th cc vn kin cng ngh gi l quy trnh cng ngh.
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1.3- cc thnh phn ca quy trnh cng ngh

1.3.1- Nguyn cng
Nguyn cng l mt phn ca qu trnh cng ngh, c hon thnh mt cch lin tc ti mt ch lm vic do mt hay mt nhm cng nhn thc hin. y, nguyn cng c c trng bi 3 iu kin c bn, l hon thnh v tnh lin tc trn i tng sn xut v v tr lm vic. Trong qu trnh thc hin quy trnh cng ngh nu chng ta thay i 1 trong 3 iu kin trn th ta chuyn sang mt nguyn cng khc. V d: Tin trc c hnh nh sau: Nu ta tin u A ri A B tr u tin u B (hoc ngc li) th vn thuc mt nguyn cng v vn m bo tnh cht lin tc v v tr lm vic. Nhng nu tin u A cho c lot xong ri mi tr li tin u B cng cho c lot th thnh hai nguyn cng v khng m bo c tnh lin tc, c s gin on khi tin cc b mt khc nhau trn chi tit. Hoc tin u A my ny, u B tin my khc th r rng hai nguyn cng v v tr lm vic thay i. Nguyn cng l n v c bn ca qu trnh cng ngh. Vic chn s lng nguyn cng s nh hng ln n cht lng v gi thnh sn phm, vic phn chia qu trnh cng ngh ra thnh cc nguyn cng c ngha k thut v kinh t. * ngha k thut: Mi mt phng php ct gt c mt kh nng cng ngh nht nh (kh nng v to hnh b mt cng nh cht lng t c). V vy, xut pht t yu cu k thut v dng b mt cn to hnh m ta phi chn phng php gia cng tng ng hay ni cch khc chn nguyn cng ph hp. V d: Ta khng th thc hin c vic tin cc c trc v phay rnh then cng mt ch lm vic. Tin cc c trc c thc hin trn my tin, phay rnh then thc hin trn my phay. * ngha kinh t: Khi thc hin cng vic, ty thuc mc phc tp ca hnh dng b mt, ty thuc s lng chi tit cn gia cng, chnh xc, cht lng b mt yu cu m ta phn tn hoc tp trung nguyn cng nhm mc ch m bo s cn bng cho nhp sn xut, t hiu qa kinh t nht. V d: Trn mt my, khng nn gia cng c th v tinh m nn chia gia cng th v tinh trn hai my. V khi gia cng th cn my c cng sut ln, nng sut cao, khng cn chnh xc cao t hiu qu kinh t (ly phn ln lng d); khi gia cng tinh th cn my c chnh xc cao m bo cc yu cu k thut ca chi tit.
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1.3.2- G
Trc khi gia cng, ta phi xc nh v tr tng quan gia chi tit so vi my, dng c ct v tc dng ln chi tit mt lc chng li s x dch do lc ct v cc yu t khc gy ra khi gia cng nhm m bo chnh xc v tr tng quan . Qu trnh ny ta gi l qu trnh g t chi tit. G l mt phn ca nguyn cng, c hon thnh trong mt ln g t chi tit. Trong mt nguyn cng c th c mt hoc nhiu ln g. V d: tin cc mt tr bc A, B, C ta thc hin 2 ln g: C A B - Ln g 1: G ln 2 mi chng tm v truyn mmen quay bng tc gia cng cc b mt C v B. - Ln g 2: i u gia cng b mt B (v mt ny cha c gia cng ln g trc do phi lp vi tc).
1.3.3- V tr
V tr l mt phn ca nguyn cng, c xc nh bi mt v tr tng quan gia chi tit vi my hoc gia chi tit vi dng c ct. Mt ln g c th c mt hoc nhiu v tr. V d: Khi phay bnh rng bng dao phay nh hnh, mi ln phay mt rng, hoc khoan mt l trn chi tit c nhiu l c gi l mt v tr (mt ln g c nhiu v tr). Cn khi phay bnh rng bng dao phay ln rng, mi ln phay l mt v tr (nhng do tt c cc rng u c gia cng nn ln g ny c mt v tr).
1.3.4- Bc
Bc cng l mt phn ca nguyn cng khi thc hin gia cng mt b mt (hoc mt tp hp b mt) s dng mt dng c ct (hoc mt b dng c) vi ch cng ngh (v, s, t) khng i. Mt nguyn cng c th c mt hoc nhiu bc.
V d: Cng l gia cng hai on trc nhng nu gia cng ng thi bng hai dao l mt bc; cn gia cng bng mt dao trn tng on trc l hai bc. * Khi c s trng bc (nh tin bng 3 dao cho 3 b mt cng mt lc), thi gian gia cng ch cn tnh cho mt b mt gia cng c chiu di ln nht.
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1.3.5- ng chuyn dao
ng chuyn dao l mt phn ca bc ht i mt lp vt liu c cng ch ct v bng cng mt dao. Mi bc c th c mt hoc nhiu ng chuyn dao. V d: tin ngoi mt mt tr c th dng cng mt ch ct, cng mt dao ht lm nhiu ln; mi ln l mt ng chuyn dao.
1.3.6- ng tc
ng tc l mt hnh ng ca cng nhn iu khin my thc hin vic gia cng hoc lp rp. V d: Bm nt, quay dao, y ng ... ng tc l n v nh nht ca qu trnh cng ngh. Vic phn chia thnh ng tc rt cn thit nh mc thi gian, nghin cu nng sut lao ng v t ng ha nguyn cng. 1.4- cc dng sn xut v cc hnh thc t chc sn xut Dng sn xut l mt khi nim cho ta hnh dung v quy m sn xut mt sn phm no . N gip cho vic nh hng hp l cch t chc k thut - cng ngh cng nh t chc ton b qu trnh sn xut. Cc yu t c trng ca dng sn xut: - Sn lng. - Tnh n nh ca sn phm. - Tnh lp li ca qu trnh sn xut. - Mc chuyn mn ha trong sn xut. Ty theo cc yu t trn m ngi ta chia ra 3 dng sn xut: - n chic - Hng lot - Hng khi.
1.4.1- Dng sn xut n chic
Dng sn xut n chic c c im l: - Sn lng hng nm t, thng t mt n vi chc chic. - Sn phm khng n nh do chng loi nhiu. - Chu k ch to khng c xc nh. i vi dng sn xut ny ta phi t chc k thut v cng ngh nh sau: - S dng cc trang thit b, dng c cng ngh vn nng p ng tnh a dng ca sn phm. - Yu cu trnh th cao, thc hin c nhiu cng vic khc nhau. - Ti liu hng dn cng ngh ch l nhng nt c bn, thng l di dng phiu tin trnh cng ngh.
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1.4.2- Dng sn xut hng lot
Dng sn xut hng lot c c im l: - Sn lng hng nm khng qu t. - Sn phm tng i n nh. - Chu k ch to c xc nh. Ty theo sn lng v mc n nh sn phm m ta chia ra dng sn xut lot nh, lot va, lot ln. Sn xut lot nh rt gn v ging vi sn xut n chic, cn sn xut lot ln rt gn v ging sn xut hng khi.
1.4.3- Dng sn xut hng khi
Dng sn xut hng khi c c im l: - Sn lng hng nm rt ln. - Sn phm rt n nh. - Trnh chuyn mn ha sn xut cao. i vi dng sn xut ny ta phi t chc k thut v cng ngh nh sau: - Trang thit b, dng c cng ngh thng l chuyn dng. - Qu trnh cng ngh c thit k v tnh ton chnh xc, ghi thnh cc ti liu cng ngh c ni dung c th v t m. - Trnh th ng my khng cn cao nhng i hi phi c th iu chnh my gii. - T chc sn xut theo dy chuyn. Dng sn xut hng khi cho php p dng cc phng php cng ngh tin tin, c iu kin c kh ha v t ng ha sn xut, to iu kin t chc cc ng dy gia cng chuyn mn ha. Cc my dng sn xut ny thng c b tr theo theo th t nguyn cng ca qu trnh cng ngh. Ch l vic phn chia thnh ba dng sn xut nh trn ch mang tnh tng i. Trong thc t, ngi ta cn chia cc dng sn xut nh sau: - Sn xut n chic v lot nh. - Sn xut hng lot. - Sn xut lot ln v hng khi. Ngoi ra, cn phi nm vng cc hnh thc t chc sn xut s dng thch hp cho cc dng sn xut khc nhau. Trong qu trnh ch to sn phm c kh thng c thc hin theo hai hnh thc t chc sn xut l: sn xut theo dy chuyn v khng theo dy chuyn. 1-4-4. Hnh thc t chc sn xut 1 Hnh thc sn xut theo dy chuyn thng c p dng quy m sn xut hng lot ln v hng khi. c im: - My c b tr theo th t cc nguyn cng ca qu trnh cng ngh, ngha
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l mi nguyn cng c hon thnh ti mt v tr nht nh. - S lng ch lm vic v nng sut lao ng ti mt ch lm vic phi c xc nh hp l m bo tnh ng b v thi gian gia cc nguyn cng trn c s nhp sn xut ca dy chuyn. Nhp sn xut l khong thi gian lp li chu k gia cng hoc lp rp, ngha l trong khong thi gian ny tng nguyn cng ca qu trnh cng ngh c thc hin ng b v sau khong thi gian y mt i tng sn xut c hon thin v c chuyn ra khi dy chuyn sn xut. 2 Hnh thc sn xut khng theo dy chuyn thng c p dng quy m sn xut lot nh. c im: - Cc nguyn cng ca qa trnh cng ngh c thc hin khng c s rng buc ln nhau v thi gian v a im. My c b tr theo kiu, loi v khng ph thuc vo th t cc nguyn cng. - Nng sut v hiu qu kinh t thp hn hnh thc sn xut theo dy chuyn. Ngy nay, nh ng dng cc thnh tu v in t, tin hc, x l in ton v k thut iu khin t ng, cng ngh ca qu trnh sn xut c thc hin bi cc my c iu khin t ng nh my tnh in t, c kh nng lp trnh a dng thch nghi vi sn phm mi. Dng sn xut nh vy c gi l sn xut linh hot v cng l dng sn xut c trng v ngy cng ph bin trong x hi.
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Chng 2
Cht lng b mt chi tit my

Cht lng sn phm trong ngnh ch to my bao gm cht lng ch to cc chi tit my v cht lng lp rp chng thnh sn phm hon chnh. nh gi cht lng ch to cc chi tit my, ngi ta dng 4 thng s c bn sau: - chnh xc v kch thc ca cc b mt. - chnh xc v hnh dng ca cc b mt. - chnh xc v v tr tng quan gia cc b mt. - Cht lng b mt. Chng ny chng ta nghin cu cc yu t c trng ca cht lng b mt, nh hng ca cht lng b mt ti kh nng lm vic ca chi tit my, cc yu t nh hng n cht lng b mt v cc phng php m bo cht lng b mt trong qu trnh ch to chi tit my. 2.1- cc yu t c trng cho cht lng b mt Kh nng lm vic ca chi tit my ph thuc rt nhiu vo cht lng ca lp b mt. Cht lng b mt l ch tiu tp hp nhiu tnh cht quan trng ca lp b mt: - Hnh dng lp b mt ( sng, nhm...) - Trng thi v tnh cht c l ca lp b mt ( cng, chiu su bin cng, ng sut d...) - Phn ng ca lp b mt i vi mi trng lm vic (tnh chng mn, kh nng chng xm thc ha hc, bn mi...)
2.1.1- Tnh cht hnh hc ca b mt gia cng
Tnh cht hnh hc ca b mt gia cng c nh gi bng nhm b mt v sng b mt. a) nhm b mt (hnh hc t vi, bng) Trong qu trnh ct, li ct ca dng c ct v s hnh thnh phoi kim loi to ra nhng vt xc cc nh trn b mt gia cng. Nh vy, b mt c nhm. nhm ca b mt gia cng c o bng chiu cao nhp nh Rz v sai lch profin trung bnh cng Ra ca lp b mt. 1 Chiu cao nhp nh Rz : l tr s trung bnh ca tng cc gi tr tuyt i ca chiu cao 5 nh cao nht v chiu su 5 y thp nht ca profin tnh trong phm vi chiu di chun o l. Tr s Rz c xc nh nh sau:
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Rz =
y
(h1 + h 3 .. + h 9 ) + (h 2 + h 4 .. + h 10 )
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l ng nh Rmax
h5 h6 h10 h9 yn
y1 h2
h1 h4
h3
ng y Hnh 2.1- nhm b mt chi tit.
Chiu di chun l l chiu di ca phn b mt c chn o nhm b mt, khng tnh n nhng dng mp m khc c bc ln hn l (sng b mt chng hn).
2 Sai lch profin trung bnh cng Ra: l trung bnh s hc cc gi tr tuyt i ca khong cch t cc im trn profin n ng trung bnh, o theo phng php tuyn vi ng trung bnh.
Ra = 1 n 11 y x dx y i n i =1 l 0
nhm b mt c nh hng ln n cht lng lm vic ca chi tit my. V d: i vi nhng chi tit trong mi ghp ng ( trt, sng dn, con trt...), b mt lm vic trt tng i vi nhau nn khi nhm cng ln cng kh m bo hnh thnh mng du bi trn b mt trt. Di tc dng ca ti trng, cc nh nhm tip xc vi nhau gy ra hin tng ma st na t, thm ch c ma st kh, do gim thp hiu sut lm vc, tng nhit lm vic ca mi ghp. Mt khc, ti cc nh tip xc, lc tp trung ln, ng sut ln vt qu ng sut cho php pht sinh bin dng do ph hng b mt tip xc, lm b mt b mn nhanh, nht l thi k mn ban u. Thi k mn ban u cng ngn th thi gian phc v ca chi tit cng gim. i vi cc mi ghp c di ln, khi p hai chi tit vo nhau to mi ghp th cc nhp nh b san phng, nhm cng ln th lng san phng cng ln, di ca mi ghp cng gim nhiu, lm gim bn chc ca mi ghp. Nhm cng nh th b mt cng nhn, kh nng chng li s n mn cng tt: b mt cng nhn bng th cng lu b g. nhm b mt l c s nh gi nhn b mt trong phm vi chiu di chun rt ngn l. Theo tiu chun Nh nc th nhn b mt c chia lm 14 cp ng vi gi tr ca Ra, Rz (cp 14 l cp nhn nht, cp 1 l cp nhm nht). Trong thc t sn xut, ngi ta nh gi nhm b mt chi tit my theo cc mc : th (cp 1 4), bn tinh (cp 5 7), tinh (cp 8 11), siu tinh (cp 12 14). Trong thc t, thng nh gi nhm b mt bng mt trong hai ch tiu trn. Vic chn ch tiu no l ty thuc vo cht lng yu cu v c tnh kt cu ca b mt. Ch tiu Ra c s dng ph bin nht v n cho php ta nh gi chnh xc hn v thun li hn nhng b mt c yu cu nhm trung bnh. Vi nhng b mt qu
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nhm hoc qu bng th ch tiu Rz li cho ta kh nng nh gi chnh xc hn l dng ch tiu Ra. Ch tiu Rz cn c s dng i vi nhng b mt khng th kim tra trc tip thng s Ra, nh nhng b mt kch thc nh hoc c profin phc tp. b) sng b mt sng b mt l chu k khng bng phng ca b mt chi tit my c quan st trong phm vi ln hn nhm b mt. Ngi ta da vo t l gn ng L gia chiu cao nhp nh v bc l h sng phn bit nhm b mt H v sng ca b mt chi tit my. nhm b mt ng vi t l: l/h = 0 50 Hnh 2.2- Tng qut v nhm v sng sng b mt ng vi t l: b mt chi tit my L/H = 50 1000 trong , L: khong cch 2 nh sng. l: khong cch 2 nh nhp nh t vi. H l chiu cao ca sng. h: chiu cao nhp nh t vi.
2.1.2- Tnh cht c l ca b mt gia cng
a) Hin tng bin cng ca lp b mt Trong qu trnh gia cng, tc dng ca lc ct lm x lch mng tinh th lp kim loi b mt v gy bin dng do vng trc v vng sau li ct. Phoi kim loi c to ra do bin dng do ca cc ht kim loi trong vng trt. Gia cc ht tinh th kim loi xut hin ng sut. Th tch ring tng v mt kim loi gim vng ct. Gii hn bn, cng, gin ca lp b mt c nng cao; ngc li tnh do dai ca lp b mt li gim. Tnh dn t cng nh nhiu tnh cht khc ca lp b mt cng thay i. Kt qu tng hp l lp b mt kim loi b cng ngui, chc li v c cng t vi cao. C 2 ch tiu nh gi bin cng: - cng t vi. - Chiu su ca lp bin cng. Mc bin cng v chiu su lp bin cng b mt ph thuc vo tc dng ca lc ct, mc bin dng do ca kim loi v nh hng nhit trong vng ct. Lc ct (cng , thi gian tc dng) tng lm cho mc bin dng do ca vt liu tng; qua lm tng mc bin cng v chiu su lp bin cng b mt. Nhit sinh ra vng ct (nhit , thi gian tc dng) s hn ch hin tng bin cng b mt. b) ng sut d trong lp b mt
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Nguyn nhn gy ra ng sut d trong lp b mt chi tit my: su xa nht vn l do bin dng do. - Khi ct mt lp mng vt liu, trng lc xut hin gy ra bin dng do khng u tng khu vc trong lp b mt. Khi trng lc mt i, bin dng do khng ng u ny s gy ra ng sut d trong lp b mt. - Bin dng do sinh ra khi ct lm chc lp vt liu b mt, lm tng th tch ring ca lp kim loi mng ngoi cng. Lp kim loi bn trong do khng b bin dng do nn vn gi th tch ring bnh thng. Lp kim loi ngoi cng c xu hng tng th tch, gy ra ng sut d nn; v c lin h vi nhau nn lp kim loi bn trong phi sinh ra ng sut d ko cn bng. - Nhit sinh ra vng ct c tc dng nung nng cc b cc lp mng b mt lm gim mun n hi ca vt liu, c khi lm gim ti tr s nh nht. Sau khi ct, lp vt liu b mt vng ct b ngui nhanh co li, sinh ra ng sut d ko; cn bng th lp kim loi bn trong phi sinh ra ng sut d nn. - Kim loi b chuyn pha trong qu trnh ct v nhit sinh ra vng ct lm thay i cu trc vt liu, dn n s thay i v th tch kim loi. Lp kim loi no hnh thnh cu trc c th tch ring ln s sinh ra ng sut d nn; lp kim loi c cu trc vi th tch ring b phi sinh ra ng sut d ko cn bng. c) Phng php xc nh cht lng b mt Trong thc t c nhiu phng php xc nh cht lng b mt chi tit my. Sau y l mt s phng php chnh: 1 o nhm b mt: - Dng mi d: o cc b mt c nhm ln. - Dng my o quang hc: dng khi nhm nh. - Dng cht do p ln chi tit, o nhm thng qua b mt cht do : dng khi o nhm cc b mt l. - Xc nh nhm bng cch so snh (bng mt) vt cn o vi mu c sn. 2 o ng sut d: - Dng tia Rnghen: chiu tia ri kho st phn tch biu Rnghen. - Dng cu trc in t: 3 o bin cng: - cng: dng my o cng. - Chiu su bin cng: ct mu, em mi bng ri cho xm thc ha hc nghin cu cu trc lp b mt. 2.2- nh hng ca cht lng b mt ti kh nng lm vic ca chi tit my Kh nng lm vic ca chi tit my c quyt nh bi: tnh chng mn, bn mi, tnh chng n mn ha hc, chnh xc cc mi lp ghp.
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Cht lng b mt nh hng ng k n kh nng lm vic ca chi tit my. C th k ra cc yu t b nh hng bi cht lng b mt nh: H s ma st, tnh chng mn, cng vng tip xc, tnh dn in, dn nhit, bn mi, bn va p, tnh chng n mn... Sau y ta ni n cc nh hng thng gp:
2.2.1- nh hng n tnh chng mn
a) nh hng n nhm b mt Do b mt hai chi tit tip xc nhau c nhp nh t vi nn trong giai on u ca qu trnh lm vic, hai b mt ny ch tip xc nhau mt s nh cao nhp nh; din tch tip xc thc ch bng mt phn ca din tch tnh ton. Ti cc nh tip xc , p sut rt ln, thng vt qu gii hn chy, c khi vt qu c gii hn bn ca vt liu. p sut lm cho cc im tip xc b nn n hi v lm bin dng do cc nhp nh, l bin dng tip xc. Khi hai b mt c chuyn ng tng i vi nhau Hnh 2.3- M hnh 2 b mt tip xc s xy ra hin tng trt do cc nh nhp nh; cc nh nhp nh b mn nhanh lm khe h lp ghp tng ln. l hin tng mn ban u. Trong iu kin lm vic nh v va, mn ban u c th lm cho chiu cao nhp nh gim 65 75%; lc din tch tip xc thc tng ln v p sut tip xc gim i. Sau giai on mn ban u (chy r) ny, qu trnh mi mn tr nn bnh thng v chm, l giai on mn bnh thng (giai on ny, chi tit my lm vic tt nht). Cui cng l giai on mn kch lit, khi b mt tip xc b trc ra, ngha l cu trc b mt chi tit my b ph hng. Mi quan h gia lng mn v thi gian s dng ca mt cp chi tit ma st vi nhau ty theo nhm b mt ban u c biu th nh sau:
mn [u] c b a
t3 t2 t1
T3
T2
T1
Hnh 2.4- Qu trnh mi mn ca mt cp chi tit.
Cc ng c trng a, b, c ng vi ba nhm ban u khc nhau ca cc b mt tip xc. ng c trng c, cp chi tit c nhn bng b mt ban u km nht nn giai on mn ban u xy ra nhanh nht, cng mn ln nht giai
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Lu c bnh
on mn ban u. Thc nghim chng t rng, nu gim hoc tng nhm ti tr s ti u, ng vi iu kin lm vic ca chi tit my th s t c lng mn ban u t nht, qua , ko di tui th ca chi tit my. mn (ng 1 ng vi iu kin ban u u lm vic nh. ng 2 ng vi 2 iu kin lm vic nng). Lng mn ban u t nht ng vi gi tr ca Ra ti cc im u2 Ra1, Ra2; l gi tr ti u ca Ra. Nu gi tr ca Ra nh hn tr 1 s ti u Ra1, Ra2 th s b mn u1 kch lit v cc phn t kim loi d khuch tn. Ngc li, gi tr Ra2 Ra1 0 ca Ra ln hn tr s ti u Ra1, Ra Ra2 th lng mn tng ln v cc Hnh 2.5- Quan h gia lng mn ban u u v sai lch profin trung bnh cng Ra nhp nh b ph v v ct t. b) nh hng ca lp bin cng b mt Lp bin cng b mt ca chi tit my c tc dng nng cao tnh chng mn. Bin cng b mt lm hn ch s khuch tn xy trong khng kh vo b mt chi tit my to thnh cc xyt kim loi gy ra n mn kim loi. Ngoi ra, bin cng cn hn ch qu trnh bin dng do ton phn ca chi tit my, qua hn ch hin tng chy v hin tng mi mn. Ngoi phng php gia cng ct gt, ngi ta dng cc phng php gia cng bin dng do bin cng b mt: phun bi, ln bi, nong p ... c) nh hng ca ng sut d trong lp b mt ng sut d lp b mt chi tit my ni chung khng c nh hng ng k ti tnh chng mn nu chi tit my lm vic trong iu kin ma st bnh thng.
2.2.2- nh hng n bn mi ca chi tit my
a) nh hng ca nhm b mt nhm b mt c nh hng n bn mi ca chi tit my, nht l khi chi tit my chu ti trng chu k c i du, ti trng va p v y cc nhp nh t vi c ng sut tp trung ln, ng sut ny s gy ra cc vt nt t vi v pht trin y cc nhp nh, l ngun gc ph hng chi tit my do mi. Nu nhm thp th bn, gii hn mi ca vt liu s cao, v ngc li. b) nh hng ca lp bin cng b mt
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Lu c bnh
B mt b bin cng c th lm tng bn mi khong 20%. Chiu su v mc bin cng ca lp b mt u c nh hng n bn mi ca chi tit my; c th l hn ch kh nng gy ra cc vt nt t vi lm ph hng chi tit, nht l khi b mt chi tit c ng sut nn. c) nh hng ca ng sut d trong lp b mt ng sut d nn trn lp b mt c tc dng nng cao bn mi, cn ng sut d ko li h thp bn mi ca chi tit my. V th, khi ch to ngi ta c gng lm cho chi tit c c ng sut nn trn b mt. Bng thc nghim ta c cng thc:
1 = 1 . 0 tt bd
trong : tt-1: gii hn mi khi c ng sut d (thc t). bd-1: gii hn mi khi khng c ng sut d (ban u). 0: ng sut d ln nht, dng nu ng sut ko, m nu ng sut nn. : l h s ph thuc vt liu, c cho trong cc s tay.
2.2.3- nh hng ti tnh chng n mn ha hc ca lp b mt chi tit my
a) nh hng ca nhm b mt Cc ch lm trn b mt do nhm to ra l ni cha cc tp cht nh axit, mui... Cc tp cht ny c tc dng n mn ha hc i vi kim loi. Qu trnh n mn ha hc trn lp b mt chi tit theo sn ca nhp nh v hnh thnh cc nhp nh mi Nh vy, b mt chi tit my cng t nhm th s cng t b n mn ha hc (v kh nng cha cc tp cht t), bn knh y cc nhp nh cng ln kh nng chng n mn ha hc ca lp b mt cng cao. C th chng n mn ha hc bng cch ph ln b mt chi tit my mt lp bo v bng phng php m hoc bng phng php c kh lm chc lp b mt. b) nh hng ca lp bin cng b mt Bin cng tng th tnh chng n mn gim v bin cng tng th s thay i ca cc ht khng ng u. Ht ferrit bin dng nhiu hn ht peclit, iu lm cho nng lng nng cao khng u v th nng in tch ca cc ht thay i khc nhau. Ht ferrit bin cng nhiu hn s tr thnh ant. Ht peclit b bin cng t hn s tr thnh catt. Lc ny, to ra cc pin n mn nn n mn s tng. c) nh hng ca ng sut d trong lp b mt ng sut d hu nh khng nh hng n tnh chng mn khi lm vic nhit bnh thng. Cn nhit cao th s c nh hng.
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2.2.4- nh hng n chnh xc cc mi lp ghp
Trong giai on mn ban u, chiu cao nhp nh t vi Rz, i vi mi ghp lng c th gim i 65 75% lm khe h lp ghp tng ln v chnh xc lp ghp gim i. m bo n nh ca mi lp lng trong thi gian s dng, phi gim nhp nh t vi. Gi tr Rz hp l c xc nh theo chnh xc ca mi lp ty theo tr s ca dung sai kch thc lp ghp. - Nu ng knh lp ghp > 50mm th Rz = (0.1 0.15)T - Nu ng knh lp ghp 18 < < 50mm th Rz = (0.15 0.2)T - Nu ng knh lp ghp < 18mm th Rz = (0.2 0.25)T Vi cc mi ghp c di ln khi p hai chi tit vo nhau to mi ghp th nhm b san phng, nhm cng ln th lng san phng cng ln, di ca mi ghp cng gim, bn mi ghp gim. Rz tng th bn ca mi ghp cht gim. V d: bn mi lp cht gia vnh bnh xe la v trc ng vi chiu cao nhp nh t vi Rz l 36.5 m s thp hn khong 40% so vi bn cng ca mi lp ng vi Rz l 18 m, v di mi lp ghp sau nh hn mi lp ghp trc c 15%. Tm li, chnh xc cc mi lp ghp trong kt cu c kh ph thuc vo cht lng cc b mt lp ghp. bn cc mi lp ghp, trong n nh ca ch lp ghp gia cc chi tit, ph thuc vo nhm ca cc b mt lp ghp. 2.3- cc yu t nh hng n cht lng b mt chi tit Trng thi v tnh cht ca lp b mt chi tit my trong qu trnh gia cng do nhiu yu t cng ngh quyt nh nh tnh cht vt liu, thng s cng ngh, vt liu dao, s rung ng trong qu trnh gia cng, dung dch trn ngui ... Ngi ta chia cc yu t nh hng n cht lng b mt thnh 3 nhm: - Cc yu t nh hng mang tnh in dp hnh hc ca dng c ct v ca thng s cng ngh ln b mt gia cng. - Cc yu t nh hng ph thuc vo bin dng do ca lp b mt. - Cc yu t nh hng do rung ng my, dng c, chi tit gia cng.
2.3.1- nh hng n nhm b mt
a) Cc yu t mang tnh in dp hnh hc ca dng c ct v ch ct nghin cu, ta xt phng php tin. Qua thc ngim, ngi ta xc nh mi quan h gia cc thng s: nhp nh t vi Rz, lng tin dao S, bn knh mi dao r, chiu dy phoi nh nht c th ct c hmin. Ty theo gi tr thc t ca lng chy dao S m ta c th xc nh mi quan h trn nh sau:
S2 - Khi S > 0.15 mm/vg th R z = 8.r
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Lu c bnh
- Khi S < 0.1 mm/vg th R z =
r. h min S 2 h min + 1 + 8.r 2 S2
y, hmin ph thuc bn knh r ca mi dao: + Nu mi li ct bng kim cng mn, lc r = 10 m th hmin = 4 m. + Mi dao hp kim cng bng thng nu r = 40 m th hmin > 20 m. - Khi S qu nh (< 0,03 mm/vg) th tr s ca Rz li tng, tc l khi gia cng tinh vi S qu nh s khng c ngha i vi vic ci thin cht lng b mt chi tit v xy ra hin tng trt m khng to thnh phoi. Chiu su ct t cng c nh hng tng t nh lng chy dao i vi chiu cao nhp nh t vi, nu b qua o ca trc chnh my. Cc thng s hnh hc ca li ct, c bit l gc trc v mn c nh hng n Rz. Khi gc tng th Rz gim, mn dng c tng th Rz tng. Ngoi nh hng n nhm b mt, hnh dng hnh hc ca dng c ct v ch ct cng nh hng n lp bin cng b mt v c tnh n qua h s hiu chnh.
V d: Xt s nh hng ca hnh dng hnh hc ca dng c ct v ch ct n cht lng b mt chi tit khi tin. S1 m Rz 1 2 a) S1 1 2 b) S1 Rz 1 2 1 Rz r1 1 1 S2 Rz
c) S1
2 t Rz
d) S1
Rz 1
r2
2 e)
f)
Hnh 2.6- nh hng ca hnh dng hnh hc ca dng c ct v ch ct n nhm b mt khi tin
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Lu c bnh
Sau mt vng quay ca phi, dao tin s dch chuyn mt on l S1 t v tr 1 n v tr 2 (hnh 2.6a). Trn b mt gia cng s b cha li phn kim loi m khng c ht i bi dao. Chiu cao nhp nh Rz xc nh bi S1 v hnh dng hnh hc ca dao ct. Nu gim lng chy dao th chiu cao nhp nh cng gim (hnh 2.6b). Thay i gi tr gc v 1 khng nhng lm thay i chiu cao nhp nh m cn lm thay i c hnh dng nhp nh (hnh 2.6c). Nu bn knh mi dao c dng trn r1 th nhp nh cng c y lm trn (hnh 2.6d). Nu tng bn knh mi dao ln r2 th chiu cao nhp nh Rz s gim (hnh 2.6e). Khi bn knh nh r nh v lng chy dao S ln, ngoi phn cong ca li ct, phn thng cng tham gia vo vic nh hng n hnh dng v chiu cao nhp nh (hnh 2.6f)
b) Cc yu t ph thuc bin dng do ca lp b mt Khi gia cng vt liu do, b mt ngoi s bin dng rt nhiu lm cho cu trc ca n thay i. Khi , hnh dng hnh hc v nhp nh u thay i. Khi gia cng vt liu gin, c mt s phn nh li ph v, lm tng nhp nh b mt. 1 Tc ct V l yu t c bn nht, nh hng ti s pht trin ca bin dng do khi tin: - Khi ct thp Cacbon vn tc thp, nhit ct khng cao, phoi kim loi tch d, bin dng ca lp b mt khng nhiu, v vy nhm b mt thp. Khi tng vn tc ct n khong V = 20 40 m/ph th nhit ct, lc ct u tng v c gi tr ln, gy ra bin dng do mnh, mt trc v mt sau dao kim loi b chy do. Khi lp kim loi b nn cht mt trc dao v nhit cao lm tng h s ma st vng ct s hnh thnh lo dao. Lo dao lm tng nhm b mt gia cng. Nu tip tc tng vn tc ct, lo dao b nung nng nhanh hn, vng kim loi bin dng b ph hy, lc dnh ca lo dao khng thng ni lc ma st ca dng phoi v lo dao b cun i (lo dao bin mt khi vn tc ct khong V = 30 60 m/ph). Vi vn tc ct V > 60 m/ph th lo dao khng hnh thnh c nn nhm b mt gia cng gim, nhn tng.
Rz
b V(m/ph) 0 20 100 200
Hnh 2.7- nh hng ca vn tc ct n nhp nh t vi Rz
- Khi gia cng kim loi gin (gang), cc mnh kim loi b trt v v ra khng c th t lm tng nhp nh t vi b mt. Tng vn tc ct s gim c hin tng
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Lu c bnh
v vn ca kim loi, lm tng nhn bng ca b mt gia cng. 2 Lng chy dao S l thnh phn th hai ca ch ct nh hng nhiu Rz n chiu cao nhp nh Rz. iu khng C nhng do lin quan v hnh hc ca dao m B cn do bin dng do v bin dng n hi A ca lp b mt. Khi gia cng thp Carbon, vi gi tr V(m/ph) lng chy dao S = 0,02 0,15 mm/vg th b mt gia cng c nhp nh t vi thp nht. 0,02 0,15 0 Nu gim S < 0,02 mm/vg th nhp nh t Hnh 2.8- nh hng ca lng chy dao n nhp nh t vi Rz. b mt gim v nh hng ca bin dng do ln hn nh vi s tng ln, nhn bng hng ca cc yu t hnh hc. Nu lng chy dao S > 0,15 mm/vg th bin dng n hi s nh hng n s hnh thnh cc nhp nh t vi, kt hp vi nh hng ca cc yu t hnh hc lm cho nhm b mt tng ln nhiu. Nh vy, m bo t nhn bng b mt v nng sut cao nn chn gi tr lng chy dao S = 0,05 0,12 mm/vg i vi thp Carbon. 3 Chiu su ct t cng c nh hng tng t nh lng chy dao S n nhm b mt gia cng, nhng trong thc t, ngi ta thng b qua nh hng ny. V vy, trong qu trnh gia cng ngi ta chn trc chiu su ct t. Ni chung, khng nn chn gi tr chiu su ct qu nh v khi li ct s b trt v ct khng lin tc. Gi tr chiu su ct t 0,02 0,03 (mm). 4 Tnh cht vt liu cng c nh hng n nhm b mt ch yu l do kh nng bin dng do. Vt liu do v dai (thp t Cacbon) d bin dng do s cho nhm b mt ln hn vt liu cng v gin. Khi gia cng thp Carbon, t nhm b mt thp, ngi ta thng tin hnh thng ha nhit 850 8700C (hoc ti thp) trc khi gia cng. ci thin iu kin ct v nng cao tui th dng c ct ngi ta thng tin hnh 9000C trong 5 gi cu trc kim loi c ht nh v ng u. c) nh hng do rung ng ca h thng cng ngh n cht lng b mt Qu trnh rung ng trong h thng cng ngh to ra chuyn ng tng i c chu k gia dng c ct v chi tit gia cng, lm thay i iu kin ma st, gy nn sng v nhp nh t vi trn b mt gia cng. Sai lch ca cc b phn my lm cho chuyn ng ca my khng n nh, h thng cng ngh s c dao ng cng bc, ngha l cc b phn my khi lm vic s c rung ng vi nhng tn s khc nhau, gy ra sng dc v sng ngang trn b mt gia cng vi bc sng khc nhau. Khi h thng cng ngh c rung ng, sng v nhp nh t vi dc s tng nu lc ct tng, chiu su ct ln v tc ct cao. Tnh trng my c nh hng quyt nh n nhm ca b mt gia cng.
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Lu c bnh
Mun t nhm b mt gia cng thp, trc ht phi m bo cng vng, phi iu chnh my tt v gim nh hng ca cc my khc xung quanh.
2.3.2- nh hng n bin cng b mt
Khi tng lc ct, nhit ct v mc bin dng do th mc bin cng b mt tng. Nu ko di tc dng ca lc ct, nhit ct trn b mt kim loi s lm tng chiu su lp bin cng b mt. Nu gc trc tng t gi tr m n gi tr dng th mc v chiu su bin cng b mt chi tit gim. Vn tc ct tng lm gim thi gian tc ng ca lc gy ra bin dng kim loi, do lm gim chiu su bin cng v mc bin cng b mt. Qua thc nghim, ngi ta c kt lun: - V < 20 m/ph: chiu su lp bin cng tng theo gi tr ca vn tc ct - V > 20 m/ph: chiu su lp bin cng gim theo gi tr ca lng chy dao Ngoi ra, bin cng b mt cng tng nu dng c ct b mn, b cn.
2.3.3- nh hng n ng sut d b mt
Qu trnh hnh thnh ng sut d b mt khi gia cng ph thuc vo s bin dng n hi, bin dng do, bin i nhit v hin tng chuyn pha trong cu trc kim loi. Qu trnh ny rt phc tp. * i vi dng c ht mi: Cc chi tit gia cng bng ht mi t do (mi nghin) thng c ng sut d ko, cn nu mi bng ai mi hoc mi th c ng sut d nn. * i vi dng c c li ct: Ta xt qu trnh bo: Lc ct R c phn y thnh lc php tuyn N v lc tip tuyn P. v Lc ct R lm cho lp b mt gia cng b bin dng r n do v bin dng n hi. z Lc php tuyn N gy ra p ng sut nn. Lc tip tuyn P gy ra ng sut ct (trt v ko). Hnh 2.9- Quan h gia lc v gc khi bo Nh vy, iu kin to ra ng sut nn (ng sut nn c li cho bn mi ca chi tit my) trn b mt gia cng s l: P . N > P > = cot g = cot g + 90 0 = cot g( ) N vi: l h s poatxng.
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Lu c bnh
l gc ma st gia dao v b mt gia cng. l gc ct ca dao. y, nu = (1 0.5) th: (1 0.5) > cotg( - ) ngha l: (450 720) < ( - ) M thng th = 500 700, nh vy rt kh t c ng sut d nn trong iu kin gc trc c gi tr dng ( > 0), m ch t c ng sut d nn nu gc trc c gi tr m ( < 0).
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Lu c bnh
Chng 3
chnh xc gia cng

3.1- khi nim v nh ngha chnh xc gia cng ca chi tit my l mc ging nhau v hnh hc, v tnh cht c l lp b mt ca chi tit my c gia cng so vi chi tit my l tng trn bn v thit k. Ni chung, chnh xc ca chi tit my c gia cng l ch tiu kh t v gy tn km nht k c trong qu trnh xc lp ra n cng nh trong qu trnh ch to. Trong thc t, khng th ch to c chi tit my tuyt i chnh xc, ngha l hon ton ph hp v mt hnh hc, kch thc cng nh tnh cht c l vi cc gi tr ghi trong bn v thit k. Gi tr sai lch gia chi tit gia cng v chi tit thit k c dng nh gi chnh xc gia cng. * Cc ch tiu nh gi chnh xc gia cng: - chnh xc kch thc: c nh gi bng sai s kch thc tht so vi kch thc l tng cn c v c th hin bng dung sai ca kch thc . - chnh xc hnh dng hnh hc: l mc ph hp ln nht ca chng vi hnh dng hnh hc l tng ca n v c nh gi bng cn, van, khng tr, khng trn... (b mt tr), phng, thng (b mt phng). - chnh xc v tr tng quan: c nh gi theo sai s v gc xoay hoc s dch chuyn gia v tr b mt ny vi b mt kia (dng lm mt chun) trong hai mt phng ta vung gc vi nhau v c ghi thnh iu kin k thut ring trn bn v thit k nh song song, vung gc, ng tm, i xng.... - chnh xc hnh dng hnh hc t vi v tnh cht c l lp b mt: nhm b mt, cng b mt... Khi gia cng mt lot chi tit trong cng mt iu kin, mc d nhng nguyn nhn sinh ra tng sai s ca mi chi tit l ging nhau nhng xut hin gi tr sai s tng cng trn tng chi tit li khc nhau. S d c hin tng nh vy l do tnh cht khc nhau ca cc sai s thnh phn. Mt s sai s xut hin trn tng chi tit ca c lot u c gi tr khng i hoc thay i nhng theo mt quy nh nht nh, nhng sai s ny gi l sai s h thng khng i hoc sai s h thng thay i. C mt sai s khc m gi tr ca chng xut hin trn mi chi tit khng theo mt quy lut no c, nhng sai s ny gi l sai s ngu nhin. 3.2- cc phng php t chnh xc gia cng trn my i vi cc dng sn xut khc nhau th s c phng hng cng ngh v t chc sn xut khc nhau. t c chnh xc gia cng theo yu cu ta thng dng hai phng php sau:
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Lu c bnh
3.2.1- Phng php ct th tng kch thc ring bit
Sau khi g chi tit ln my, cho my ct i mt lp phoi trn mt phn rt ngn ca mt cn gia cng, sau dng my, o th kch thc va gia cng. Nu cha t kch thc yu cu th iu chnh dao n su thm na da vo du xch trn my, ri li ct th tip mt phn nh ca mt cn gia cng, li o th v.v... v c th tip tc cho n khi t n kch thc yu cu th mi tin hnh ct ton b chiu di ca mt gia cng. Khi gia cng chi tit tip theo th li lm nh qu trnh ni trn. Trc khi ct th thng phi ly du ngi th c th r chuyn ng ca li ct trng vi du vch v trnh sinh ra ph phm do qu tay m dao n vo qu su ngay ln ct u tin. * u im: - Trn my khng chnh xc vn c th t c chnh xc nh tay ngh cng nhn. - C th loi tr c nh hng ca dao mn n chnh xc gia cng, v khi r g, ngi cng nhn b li cc sai s h thng thay i trn tng chi tit. - i vi phi khng chnh xc, ngi th c th phn b lng d u n nh vo qu trnh vch du hoc r trc tip. - Khng cn n g phc tp. * Khuyt im: - chnh xc gia cng ca phng php ny b gii hn bi b dy lp phoi b nht c th ct c. Vi dao tin hp kim cng mi bng li ct, b dy b nht ct c khong 0,005 mm. Vi dao mn, b dy b nht khong 0,02 0,05 mm. Ngi th khng th no iu chnh c dng c li ct ht i mt kch thc b hn chiu dy ca lp phoi ni trn v do khng th bo m c sai s b hn chiu dy lp phoi . - Ngi th phi tp trung khi gia cng nn d mt, do d sinh ra ph phm. - Do phi ct th nhiu ln nn nng sut thp. - Trnh tay ngh ca ngi th yu cu cao. - Do nng sut thp, tay ngh ca th yu cu cao nn gi thnh gia cng cao. Phng php ny thng ch dng trong sn xut n chic, lot nh, trong cng ngh sa cha, ch th. Ngoi ra, khi gia cng tinh nh mi vn dng phng php ct th ngay trong sn xut hng lot loi tr nh hng do mn mi.
3.2.2- Phng php t ng t kch thc
Trong sn xut hng lot ln, hng khi, t chnh xc gia cng yu cu, ch yu l dng phng php t ng t kch thc trn cc my cng c c iu chnh sn. phng php ny, dng c ct c v tr chnh xc so vi chi tit gia cng. Hay ni cch khc, chi tit gia cng cng phi c v tr xc nh so vi dng c ct, v tr ny c m bo nh cc c cu nh v ca g, cn g li c v tr xc nh
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Lu c bnh
trn bn my cng nh cc nh v ring. Khi gia cng theo phng php ny, my v dao c iu chnh sn. Chi tit gia cng c nh v nh c cu nh v tip xc vi mt y v mt b bn. Dao phay a ba mt c iu chnh trc sao cho mt bn tri ca dao cch mt bn ca nh v mt khong K = const 2 cch b c nh v ng sinh thp nht ca dao cch mt trn ca phin nh v pha a di mt khong bng a. Do vy, khi gia cng c lot phi, nu khng k n Hnh 3.1- Phng php t ng mn ca dao (coi nh dao khng mn) th t kch thc trn my phay. cc kch thc a v b nhn c trn chi tit gia cng ca c lot u bng nhau. * u im: - m bo chnh xc gia cng, gim bt ph phm. chnh xc t c khi gia cng hu nh khng ph thuc vo trnh tay ngh cng nhn ng my v chiu dy lp phoi b nht c th ct c bi v lng d gia cng theo phng php ny s ln hn b dy lp phoi b nht c th ct c. (Khng cn cng nhn c tay ngh cao nhng cn th iu chnh my gii). - Ch cn ct mt ln l t kch thc yu cu, do nng sut cao. - Nng cao hiu qu kinh t. * Khuyt im: (nu quy m sn xut qu b) - Ph tn v vic thit k, ch to g cng nh ph tn v cng, thi gian iu chnh my v dao ln c th vt qu hiu qu m phng php ny mang li. - Ph tn v vic ch to phi chnh xc khng b li c nu s chi tit gia cng qu t khi t ng t kch thc nguyn cng u tin. - Nu cht lng dng c km, mau mn th kch thc iu chnh s b ph v nhanh chng. Do li phi iu chnh khi phc li kch thc iu chnh ban u. iu ny gy tn km v kh phin phc. 3.3- cc nguyn nhn sinh ra sai s gia cng Trong qu trnh gia cng, c rt nhiu nguyn nhn sinh ra sai s gia cng. Sai s gia cng gm c sai s h thng v sai s ngu nhin. Sai s xut hin trn tng chi tit ca c lot u c gi tr khng i gi l sai s h thng khng i. Hoc sai s xut hin trn tng chi tit ca c lot c gi tr thay i nhng theo mt quy lut nht nh, sai s ny gi l sai s h thng thay i. C mt sai s khc m gi tr ca chng xut hin trn mi chi tit khng theo mt quy lut no c, nhng sai s ny gi l sai s ngu nhin.
22
Lu c bnh
Cc nguyn nhn sinh ra sai s h thng khng i: - Sai s l thuyt ca phng php ct. - Sai s ch to ca dng c ct, chnh xc v mn ca my, g,. - bin dng ca chi tit gia cng. Cc nguyn nhn sinh ra sai s h thng thay i: - Dng c ct b mn theo thi gian. - Bin dng v nhit ca my, g, dng c ct. Cc nguyn nhn sinh ra sai s ngu nhin: - Tnh cht vt liu ( cng) khng ng nht. - Lng d gia cng khng u (do sai s ca phi). - V tr ca phi trong g thay i (sai s g t) - S thay i ca ng sut d. - Do g dao nhiu ln. - Do mi dao nhiu ln - Do thay i nhiu my gia cng mt lot chi tit. - Do dao ng nhit ca ch ct gt.
3.3.1- nh hng do bin dng n hi ca h thng cng ngh
H thng cng ngh MGDC (my, g, dao, chi tit) khng phi l mt h thng tuyt i cng vng m ngc li khi chu tc dng ca ngoi lc n s b bin dng n hi v bin dng tip xc. Trong qa trnh ct gt, cc bin dng ny gy ra sai s kch thc v sai s hnh dng hnh hc ca chi tit gia cng. Lc ct tc dng ln chi tit gia cng, sau thng qua g truyn n bn my, thn my. Mt khc, lc ct cng tc dng ln dao v thng qua cn dao, bn dao truyn n thn my. Bt k mt chi tit no ca cc c cu my, g, dng c hoc chi tit gia cng khi chu tc dng ca lc ct t nhiu u b bin dng. V tr xut hin bin dng tuy khng ging nhau nhng cc bin dng u trc tip hoc gin tip lm cho dao ri khi v tr tng i so vi mt cn gia cng, gy ra sai s. Gi l lng chuyn v tng i gia dao v chi tit gia cng do tc dng ca lc ct ln h thng cng ngh. Lng chuyn v c th c phn tch thnh ba lng chuyn v x, y, z theo ba trc ta X, Y, Z. Khi tin, di tc dng ca lc R ct, dao tin b dch chuyn mt lng Pz R l . Lc , bn knh ca chi tit gia cng s tng t (R) n (R + R). z Ta c: Rtt Py
y Hnh 3.2- nh hng ca lng chuyn v n kch thc gia cng khi tin.
R tt = R + R =
(R + y )2 + z 2
2
z = (R + y ) 1 + R+y
23

2
Lu c bnh
z v z l rt nh so vi R nn R + y l i lng nh khng ng k, gn ng ta c:
Rtt R + y v R y. Do , i vi dao mt li ct, lng chuyn v y (chuyn v theo phng php tuyn ca b mt gia cng) c nh hng ti kch thc gia cng nhiu nht, cn chuyn v z (chuyn v theo phng tip tuyn ca b mt gia cng) khng nh hng nhiu n kch thc gia cng. i vi dao nhiu li ct hoc dao nh hnh th c trng hp c ba chuyn v x, y, z u c nh hng n chnh xc gia cng. xc nh nh hng ny, ngi ta phi dng phng php thc nghim. Phn lc ct tc dng ln h thng cng ngh MGDC thnh ba thnh phn lc Px, Py, Pz, sau o bin dng ca h thng theo ba phng X, Y, Z. Trong tnh ton, ngi ta ch quan tm n lc php tuyn Py, trng hp yu cu chnh xc cao, th phi tnh n nh hng ca Px, Pz bng cch nhn thm h s. Py l thnh phn lc php tuyn thng gc vi mt gia cng v y l lng P chuyn v tng i gia dao v chi tit gia cng. T s y c gi l cng vng y ca h thng cng ngh v k hiu l JHT : Py J HT = MN / mm (kG / mm ) y Nh vy, tr s bin dng y c quan h vi lc tc dng theo hng v vi cng vng ca h thng cng ngh. nh ngha v cng vng: cng vng ca h thng cng ngh l kh nng chng li bin dng ca n khi c ngoi lc tc dng vo. Lng chuyn v ca h thng cng ngh khng phi l chuyn v ca mt chi tit m l chuyn v ca c mt h thng gm nhiu chi tit lp ghp vi nhau. Do , theo nguyn l cng c lp tc dng ta c: y = ym + yg + yd + yp 1 Mt khc, theo nh ngha ta c: y = Py . J T , suy ra:
1 1 1 1 1 1 = + + + = J Jm Jg Jd Jp Ji
iu ny cho thy rng, h thng cng c nhiu thnh phn th cng km cng vng. Vi mt chi tit c cng vng l J, nu ta chia chi tit ny thnh nhiu chi tit nh khc ri ghp li th chi tit mi s c cng vng km hn trc. Tuy nhin, i khi ta phi chia nh chi tit ra cho d gia cng, lc ny cn phi chn phng php ph hp vn m bo vic gia cng v cng vng.
24
Lu c bnh
1 l mm do, th ta c: HT = m + g + d + p J Ta c nh ngha mm do: " mm do ca h thng l kh nng bin dng n hi ca h thng cng ngh di tc dng ca ngoi lc".
Gi =
a) nh hng ca cng vng h thng cng ngh thy r hn nh hng ca cng vng h thng cng ngh n chnh xc gia cng, ta kho st qu trnh tin mt trc trn. Chi tit c g trn hai mi tm, v tr tng i gia dao v chi tit ph thuc vo v tr tng i ca trc, sau v bn dao. Do vy, ta kho st chuyn v ca tng b phn ni trn, ri tng hp li s c chuyn v ca c h thng cng ngh, t bit c sai s gia cng. Sai s do chuyn v ca hai mi tm gy ra Gi s, xt ti v tr m dao ct cch mi tm sau mt khong l x. Lc ct php tuyn ti im B C ang ct l Py. Lc ny, do km A cng vng nn mi tm sau b ys r1 dch chuyn mt on ys t D Ps yt Pt im B n B, cn mi tm A C B trc b dch chuyn mt on x Py yt t im A n A. Nu xem L chi tit gia cng cng tuyt i th ng tm ca chi tit s Hnh 3.3- S tin trc trn trn hai mi tm dch chuyn t AB n AB. Gi L l chiu di trc cn gia cng, lc ny lc tc dng ln mi tm sau l: (L x ) m A = 0 Ps . L Py . (L x ) = 0 Ps = Py . L Lc tc dng ln mi tm trc s l: x Pt + Ps = Py Pt = Py . L Lng chuyn v ca mi tm sau theo phng lc tc dng Py: Py (L x ) P (1) ys = s = . L Js Js Lng chuyn v ca mi tm trc theo phng lc tc dng Py: P Py x yt = t = . Jt Jt L
(2)
Vy, v tr tng i ca mi dao so vi tm quay ca chi tit s dch chuyn i (L x ) (3) mt khong t C n C: CC' = CD + CD' = y t + (y s y t ). L
25
Lu c bnh
Nh vy, nu cha k n bin dng ca chi tit gia cng th i lng CC chnh l lng tng bn knh r1 ca chi tit gia cng ti mt ct ang xt. Thay (1), (2) vo (3) ta c:
r1 =
Py (L x )2 Py x 2 + . 2 . Jt L Js L2
T phng trnh ny ta thy, khi ta thc hin chuyn ng n dao dc ct ht chiu di chi tit (tc l khi x thay i) th lng tng bn knh r1 l mt ng cong parabol. T , ta thy r nh hng ca cng vng ca hai mi tm khng nhng gy ra sai s kch thc m cn c sai s hnh dng, n lm cho trc tin c dng lm gia v loe hai u. Sai s do bin dng ca chi tit gia cng Chi tit gia cng c cng vng khng phi l tuyt i nh khi ta xt trn, m n cng s b bin dng khi chu tc dng ca lc ct. Ngay ti im m lc ct tc dng, chi tit gia cng s b vng. vng chnh l lng tng bn knh r2 v cng l mt thnh phn ca sai s gia cng. Lng tng bn knh r2 ny hon ton c th xc nh c nh cc bi ton c bn v bin dng n hi ca mt h di tc dng ca ngoi lc. Sau y l vi kt qu cho cc trng hp in hnh: - Trng hp chi tit g trn 2 mi tm P x 2 (L x )2 y r2 = . L 3EI vi: E: mun n hi ca vt liu chi tit gia cng. x I: mmen qun tnh ca mt ct gia cng (vi trc trn I = 0,05d4). L Khi dao chnh gia chi tit th r2 l ln nht: r2 max =
Py L3 48EI
- Trng hp chi tit g trn mm cp (cngxn) Khi gia cng nhng chi tit ngn L c < 5 , phi ch cn g trn mm cp. d d x Lng chuyn v cc i ca phi:
L3 y =P . max y 3EI Trong trng hp ny cng 3EI vng ca phi s l: J = p L3
ymax L
26
Lu c bnh
- Trng hp phi c g trn mm cp v c chng mi tm sau Khi phi c g nh bn th vic xc nh lng chuyn v cc i ca phi phi gii bng bi ton siu tnh. P .L3
x L
Ta c: ti v tr:
ymax
max
102.E.I
v:
Py
NB
x = 2 1 = 0,414 L 102.E.I J = p L3
- Trng hp gia cng trc trn c thm luynet Khi gia cng trc trn di L c t s > 10 , cn thit phi d c thm luynet. Nu l luynet c nh th x lng chuyn v cc i ca L phi theo phng Py c xc nh bng cng thc:
y
Py R1 Py
max
0,089.Py .L3 48.E.I
x = 0,2343 , cng L 48.E.I vng ca phi: J = p 0,089.L3
ti v tr:
Sai s do bin dng ca dao v g dao: Dao ct v g dao khi chu tc dng ca ngoi lc cng b bin dng n hi P v lm cho bn knh chi tit gia cng tng ln mt lng r3 vi: r3 = y . Jd cng vng Jd ca dao ct v g dao l hng s. dao s mang dao ct di chuyn dc theo trc ca chi tit ct ht chiu di. V vy, v tr bt k khi coi ch ct l khng i th Py lun l hng s. V th, r3 cng l hng s. iu ny chng t rng r3 ch c th gy ra sai s kch thc ng knh ca chi tit gia cng m khng gy ra sai s hnh dng. Do , bng cch ct th, o v iu chnh li chiu su ct hon ton c th kh c r3.
27
Lu c bnh
b) nh hng do dao mn Khi dao mn s lm cho li ct b cn i, vic lm cho kch thc gia cng thay i, lc ct cng thay i mt lng Py t l thun vi din tch mn Um. Ngoi ra, cc thng s hnh hc ca dao cng c nh hng n lng thay i lc php tuyn Py. Do vy, khi xc nh Py ngoi mn dao cn phi nhn thm cc h s iu chnh. Ta c: Py = Kdm. K. K. Kr. Um (cc h s t l c tra theo bng) Khi gia cng trn cc my iu chnh sn (theo phng php t ng t kch thc), mn dao s gy ra sai s h thng thay i. c) nh hng do sai s ca phi Tng qut th sai s ng knh ca chi tit gia cng do nh hng ca Py cng vng l: D = 2(y m + y d + y p ) = 2.y = 2 , vi Py = CPy. Sy. tx. HBn = Cy. Sy. tx. J Do sai s v hnh dng hnh hc ca phi trong qu trnh ch to m trong qu trnh ct lng d gia cng thay i, lm cho chiu su ct cng thay i v lc ct thay i theo, gy nn sai s hnh dng cng loi trn chi tit. Nu gi p l sai s ca Kch thc phi th khi gia cng s xut khi iu chnh hin sai s ca chi tit l ct. Ta c: ph = 2Rph = 2(Rph max - Rph min) = 2(t0 max - t0 min) v ct = 2ct t min = 2(ymax - ymin) ymin vi, t0 l chiu su ct tnh ton Dct min khi iu chnh my; nu gi t l chiu ct thc t th: Dph min t = t0 - y Do : tmax = t0 max - ymax Hnh 3.4- nh hng sai s hnh dng ca phi n sai s hnh dng ca chi tit khi tin. tmin = t0 min - ymin ph Gi = l h s chnh xc ha, K = ct l h s gim sai (h s in dp). ct ph
Dct max t max
Dph max
K=
y max y min y max y min y max y min = = t 0 max t 0 min (t max + y max ) (t min + y min ) (t max t min ) + (y max y min ) = t t 1 = 1 + max min > 1 . K y max y min
Vy,
ymax
28
Lu c bnh
Hay ph > ct , iu ny ni ln rng sau mi bc gia cng, sai s s gim i. Nu cng ln th sai s ca phi nh hng n sai s ca chi tit cng gim. T phi ban u c sai s ph, sau khi gia cng ln 1 s c chi tit c sai s D1 l D1. Sau gia cng ln 2, sai s chi tit s l D2, suy ra = . D 2 C nh vy, n ln ct th i, sai s ca chi tit sau ln ct i l Di, h s chnh xc l:
= D i 1 . D i
Nhn cc h s chnh xc sau i ln ct, ta c:

ph ln D ph i i = D i = ln . i
Ch rng, vic tnh s bc cng ngh ch ng n s bc th i no m sai s gia cng Di ca chi tit ln hn sai s do nh hng ca h thng cng ngh. Tm li, khng th sau mt ln gia cng m ta c chi tit c chnh xc theo yu cu, v cc ln gia cng v sau th nh hng ca sai s do phi cng t.
3.3.2- nh hng do chnh xc v tnh trng mn ca my, g v dao ct
a) nh hng ca my Vic hnh thnh cc b mt gia cng l do cc chuyn ng ct ca nhng b phn chnh ca my nh trc chnh, bn xe dao, bn my... Nu cc chuyn ng ny c sai s, tt nhin n s phn nh ln b mt gia cng ca chi tit my. * Nu ng tm trc chnh my tin L khng song song vi sng trt ca thn a my trong mt phng nm ngang th khi tin rmax chi tit gia cng s c hnh cn. Ta c, rmax - r = a, vi a l khng song song trong mt phng nm ngang trn Sng trt chiu di L. * Nu ng tm trc chnh my tin L khng song song vi sng trt ca thn my trong mt phng thng ng th khi tin rmax chi tit gia cng s c hnh hypecblit. Ta c, rmax2 = r2 + b2, vi b l khng song song trong mt phng thng ng trn Sng trt chiu di L.
29
Lu c bnh
* Nu sng trt khng thng trn mt phng nm ngang s lm cho qu o chuyn ng ca mi dao khng thng, lm cho ng knh chi tit gia cng ch to, ch nh. ng knh Di ti mt mt ct no s Sng trt l: Di = D 2 vi: D l ng knh ti mt ct nu sng trt thng; l lng dch chuyn ln nht ca sng trt trn mt phng nm ngang so vi v tr tnh ton. * lch tm ca mi tm A-A A trc so vi tm quay ca trc e1 chnh s lm cho ng tm ca e chi tit gia cng khng trng vi ng tm ca hai l tm Tm quay c gia cng trc g t. (tm trc chnh my) Chi tit vn c tit din trn nhng tm ca n lch vi ng ni hai l tm l e1. Tm quay khi Tm quay khi * Nu chi tit gia cng trong gia cng phn B gia cng phn A mt ln g th ng tm ca chi B A tit l ng thng nhng hp vi ng ni hai l tm mt ng ni hai l tm gc . Nhng nu gia cng vi hai ln g (i u) th mi on ct c mt ng tm ring. * Nu trc chnh my phay ng khng thng gc vi mt phng ca bn my theo phng ngang th mt phng phay c s khng song song vi mt phng y ca chi tit c S nh v trn bn my. khng song song ny chnh bng Bn my khng vung gc ca ng tm trc chnh trn c chiu rng ca chi tit gia cng. * Nu trc chnh my phay ng khng thng gc vi mt phng ca bn my theo phng dc ca bn my th b mt gia S Bn my cng s b lm.
30
Lu c bnh
My d c ch to nh th no th sau mt thi gian s dng cng b mn. Hin tng mn trong qu trnh s dng l do ma st gia cc mt c chuyn ng tng i vi nhau. Nht l khi c bi phoi trn ln vi du bi trn th hin tng mi mn cng nhanh. Ngoi ra, du bi trn v dung dch trn ngui cn gy nn hin tng n mn ha hc nhng b phn n tc dng vo v lm mn thm nhanh. Trng thi mn ca my s gy ra sai s mang tnh cht h thng. b) nh hng ca g Sai s ch to, lp rp g cng nh hng n chnh xc ca chi tit gia cng. Nu g ch to c sai s hoc b mn sau mt thi gian s dng s lm thay i v tr tng quan gia my, dao v chi tit gia cng, do , gy ra sai s gia cng. m bo chnh xc gia cng (b li nhng sai s do ch to, lp rp, mn cc chi tit chnh ca g), chnh xc ca g c ch to ra phi cao hn t nht mt cp so vi chnh xc ca kch thc cn t c s gia cng trn g . iu ny khng d dng t c khi gia cng nhng chi tit c chnh xc cao. c) nh hng ca dng c ct chnh xc ch to dng c ct, mc mi mn ca n v sai s g t dng c trn my u nh hng n chnh xc gia cng. Khi gia cng bng cc dng c nh kch thc (mi khoan, khot, doa, chut...) th sai s ch to dng c nh hng trc tip n chnh xc gia cng. Dao phay ngn, phay a dng gia cng rnh then th sai s ng knh v chiu rng ca dao cng nh hng trc tip n chnh xc chiu rng rnh then. Sai s bc ren, gc nng ca ren, gc nh ren, ng knh trung bnh ca cc loi tar, bn ren u phn nh trc tip ln ren gia cng. Khi gia cng bng cc loi dao nh hnh, nu prfin ca li ct c sai s s lm sai b mt gia cng. Ngoi sai s ch to, trong qu trnh ct, dao s b mn v nh hng rt ln n chnh xc gia cng. Ty theo mc mn, dao c th thay i c hnh dng ln kch thc v sinh ra sai s trn chi tit gia cng di dng sai s h thng thay i. Ngoi ra, vic g t dao khng chnh xc cng gy nn sai s kch thc v hnh dng hnh hc ca chi tit gia cng. V d, khi tin ren, nu dao g khng vung gc vi ng tm chi tit th gc ren ct ra bn phi v bn tri khng bng nhau Hay khi tin trc trn, nu dao g cao hn hoc thp hn tm quay ca chi tit th s lm cho ng knh chi tit gia cng tng ln mt lng.
3.3.3- nh hng do bin dng nhit ca my, dao v chi tit
a) nh hng do bin dng nhit ca my Khi my lm vic, nhit cc b phn khc nhau c th chnh lch khong 10 150C, sinh ra bin dng khng u v my s mt chnh xc.
31
Lu c bnh
nh hng n chnh xc gia cng nhiu nht l bin dng nhit ca trc chnh. Nhit tng lm cho tm trc chnh x dch theo hng ngang v hng ng v cc im trn n c nhit khc nhau. Thng thng, nhit tng nhiu nht trc chnh, nhit y c th cao hn cc ni khc ca trc chnh t 30 40%. X dch theo hng ngang lm thay i kch thc v hnh dng ca chi tit gia cng, gy ra sai s h thng thay i. Khi s vng quay trc chnh n cng ln th s x dch cng nhiu v t l thun vi n . Thi gian t nng trc chnh khong 3 5 gi, sau nhit t nng cng nh v tr tm s n nh. Nu tt my s xy ra qu trnh lm ngui chm v tm ca trc chnh s x dch theo hng ngc li. khc phc sai s gia cng do bin dng nhit gy ra c th cho my chy khng ti chng 2 3 gi ri mi tin hnh iu chnh my. Ngoi ra, i vi cc my cng c chnh xc cao, nh nng mt tri chiu vo cng lm cho my mt chnh xc. b) nh hng do bin dng nhit ca dao ct Ti vng ct, hu ht cng c hc cn thit cho qa trnh ct u chuyn thnh nhit. Ty theo ch ct, vt liu lm dao, vt liu gia cng m t l phn nhit phn b vo phoi, chi tit gia cng, dng c ct v mt phn ta ra mi trng xung quanh s khc nhau. Khi nhit ct truyn vo dao, dao b n di, mi dao vn thm v pha trc lm cho ng knh ngoi gim i, ng knh l tng ln. Cho n khi dao trng thi cn bng nhit th dao khng n di thm na v nu khng c s mn dao th kch thc gia cng s khng i. c) nh hng do bin dng nhit ca chi tit gia cng Mt phn nhit vng ct truyn vo chi tit gia cng, lm n bin dng v gy ra sai s gia cng. Nu chi tit c nung nng ton b th ch gy ra sai s kch thc, cn nu b nng khng u th cn gy ra c sai s hnh dng. Nhit ca chi tit gia cng trong qu trnh ct ph thuc vo ch ct. Khi tin, nu tng vn tc ct v lng chy dao, tc l rt ngn thi gian nung nng lin tc chi tit gia cng th nhit ca n s nh. Cn chiu su ct tng th nhit chi tit gia cng cng tng theo.
3.3.4- Sai s do rung ng pht sinh ra trong qu trnh ct
Rung ng ca h thng cng ngh trong qu trnh ct khng nhng lm tng nhm b mt v sng, lm cho dao nhanh mn m cn lm cho lp kim loi mt b cng ngui, hn ch kh nng ct gt. Rung ng lm cho v tr tng i gia dao ct v vt gia cng thay i theo
32
Lu c bnh
chu k, nu tn s thp, bin ln s sinh ra sng b mt; nu tn s cao, bin thp s sinh ra nhm b mt. Ngoi ra, rung ng lm cho chiu su ct, tit din phoi v lc ct s tng, gim theo chu k, lm nh hng ti sai s gia cng.
3.3.5- Sai s do chn chun v g t chi tit gia cng gy ra
c th gia cng c phi g t chi tit ln my. Bn thn vic g t ny cng c sai s v nh hng trc tip n chnh xc gia cng. Khi g t khng hp l, sai s do g t ln v nh hng n chnh xc gia cng.
3.3.6- Sai s do phng php o v dng c o gy ra
Trong qu trnh ch to, vic kim tra, o lng cng gy ra sai s v nh hng n chnh xc gia cng. Nhng sai s do o lng bao gm: - Sai s do dng c o: tuy l dng c nh gi chnh xc gia cng nhng bn thn n khi ch to, lp rp cng b sai s. - Sai s do phng php o nh chn chun , cch c, lc o khng u.... - Sai s do mn ca dng c sau mt thi gian s dng, gim bt nh hng ca o lng n chnh xc gia cng, khi o lng phi chn dng c o v phng php o ph hp vi chnh xc theo yu cu. 3.4- cc phng php xc nh chnh xc gia cng
3.4.1- Phng php thng k kinh nghim
y l phng php n gin nht, cn c vo chnh xc bnh qun kinh t nh gi. chnh xc bnh qun kinh t l chnh xc c th t c mt cch kinh t trong iu kin sn xut bnh thng, l iu kin sn xut c c im sau: - Thit b gia cng hon chnh. - Trang b cng ngh t c yu cu v cht lng. - S dng bc th trung bnh. - Ch ct theo tiu chun v nh mc thi gian cng theo tiu chun. Cch tin hnh: Cho gia cng trn mt loi my, mt ch cng ngh, bc th trong iu kin tiu chun v xem th t c chnh xc gia cng ra sao. Lm nhiu ln nh th, thng k li kt qu t c v lp thnh bng. chnh xc bnh qun kinh t khng phi l chnh xc cao nht c th t c ca mt phng php gia cng v cng khng phi l chnh xc c th t c trong bt k iu kin no. Phng php ny nn dng lm tham kho v khi vn dng phi cn c thm iu kin sn xut c th xc nh cho thch hp.
3.4.2- Phng php xc sut thng k
Phng php ny c s dng trong sn xut hng lot v hng khi. Cch tin hnh: Ct th mt lot chi tit c s lng thu c nhng
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Lu c bnh
c tnh phn b ca kch thc t c. Thng thng, s lng chi tit ct th t 60 n 100 chi tit trong mt ln iu chnh my. o kch thc thc ca tng chi tit trong c lot. Tm kch thc gii hn ln nht, nh nht ca c lot. Chia khong gii hn t ln nht n nh nht thnh mt s khong (thng ln hn 6 khong). Xc nh s lng chi tit c kch thc nm trong mi khong v xy dng ng cong phn b kch thc thc nghim. ng cong thc nghim c trc honh l kch thc t c, cn trc tung l tn sut ca cc kch thc xut hin trong mi mt khong. Trn ng cong thc nghim ta thy rng: kch thc phn b ca c lot chi tit ct th tp trung khong gia. S chi tit ct th trong mt ln iu chnh my cng ln th ng cong cng c dng tim cn n ng cong phn b chun Gauss.
y
0 Hnh 3.5- ng cong phn b kch thc thc nghim. Hnh 3.6- ng cong phn b kch thc chun Gauss.
Phng trnh ng cong phn b chun c vit di dng:

1 y= .e . 2
(L L )
i
vi,
: phng sai ca ng cong phn b. Li: kch thc thc t c ca chi tit ct th th i
L : kch thc trung bnh cng ca lot chi tit ct th.
i =1
; trong , n l s lng chi tit ct th ca mt lot trong n mt ln iu chnh my. Phng sai ca ng cong phn b tc thi xc nh theo cng thc:
=
L=
Li
(L i L )
n i =1
Trong khong 3, cc nhnh ca ng cong gn st vi trc honh v gii hn ti 99,73% ton b din tch ca n. Nh vy, trong phm vi 3 ng cong phn b chun cha ti 99,73% s chi tit trong c lot ct th.
34
Lu c bnh
y2
min
y1
max
ngha: Gi s c hai ng cong phn b kch thc y1 v y2 vi khong phn tn tng ng l 61 v 62. Dung
sai ca kch thc cn gia cng l T. Ta thy rng, y2 c cp chnh xc cao hn 62 y1 (v 2 < 1) v y2 c 62 < T nn s 61 khng c ph phm, cn y1 c 61 > T T nn s c ph phm. Tuy nhin, ng cong phn b chun mi ch th hin tnh cht phn b ca cc sai s ngu nhin. Trong qu trnh gia cng, cc sai s ngu nhin, sai s h thng thay i, sai s h thng khng i cng ng thi xut hin. V vy, sau khi xc nh c phng sai ca sai s ngu nhin cn phi xc nh quy lut bin i ca sai s h thng thay i B(t). Ring sai s h thng khng i A s khng nh hng n s phn tn kch thc gia cng v c th trit tiu c n khi iu chnh my. Nh vy, trong qu trnh B gia cng, phn b kch thc B =0 =3 B thc phi l t hp ca quy 3 3 = 0,67 lut phn b chun v quy 3 B B lut bin i sai s h thng = = 1,1 3 thay i l quy lut ng xc 3 L sut. Lc ny, ng cong phn b kch thc s ph 0 -3 3 B Hnh 3.7- ng cong phn b kch thc thc. . thuc vo t l 3 Nu sai s h thng thay i khng tuyn tnh vi thi gian th ng cong phn b kch thc s khng i xng. Hnh 3.8- ng cong phn b khng i xng. Lc , d m bo 6 T nhng c th vn c ph phm. Nu khi gia cng mt lot chi tit m c hai hay nhiu nhm chi tit c sai s h thng khc nhau th ng Hnh 3.9- ng cong phn b kch thc cong phn b s c hai hoc ca 2 nhm chi tit trn 2 my khc nhau. nhiu nh. V d nh mt lot chi tit nhng c gia cng trn hai my khc nhau th ng cong phn b s c 2 nh.
35
Lu c bnh
Ngoi ra, c th t hp cc sai s ngu nhin v cc sai s h thng thay i bng cch x dch ng cong phn b chun i mt lng bng sai s h thng nhng vn gi nguyn hnh dng ng cong phn b (hnh 3.10). Trong trng hp ny, khong phn tn tng cng cc kch thc c lot chi tit ct th c xc nh Hnh 3.10- ng cong phn theo cng thc: b c tnh ti cc sai s ngu nhin v sai s h thng. = 6 + B Phng php ny tuy n gin nhng tn km v phi ct th c lot chi tit. gim bt chi ph ng thi rt ngn thi gian xc nh quy lut phn b kch thc, ngi ta dng cc s liu c sn tham kho khi gia cng cc kch thc c tnh cht tng t trong iu kin gia cng tng t.
3.4.3- Phng php tnh ton phn tch (dng trong nghin cu)
Theo phng php ny, ta phn tch nguyn nhn sinh ra sai s gia cng, tnh cc sai s , ri tng hp chng li thnh sai s gia cng tng. T , v quy lut phn b v cn c vo nh gi chnh xc gia cng. Trong mi trng hp, sai s gia cng tng phi nh hn dung sai cho php ca chi tit cn ch to. * Phn tch nguyn nhn: (xem trang 22; 23) * Tng hp cc sai s: - Tng cc sai s h thng khng i A l mt sai s h thng khng i v c tng hp theo nguyn tc tng i s:
A = Ai .
i =1 p
- Tng cc sai s h thng thay i B(t) l mt sai s h thng thay i v c tng hp theo nguyn tc tng i s:
B (t ) = B j (t ) .
j =1 q
- Tng cc sai s ngu nhin l mt sai s ngu nhin v c tng hp theo nguyn tc cng xc sut, c phng sai l:
=
z =1
(K z . z )2 .
- Sai s h thng v sai s ngu nhin tng hp theo nguyn tc tng s hc. * V quy lut phn b: Lc bt u gia cng, trung tm phn b l C0, khong phn tn l D0E0 vi C0D0 = C0E0 = 3.
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Lu c bnh
Kch thc Ek 3
Ck B(t) Thi gian (pht) ti tk S lng (chic) Dk E0 C0 A D0 L0 t0 Bi(t) Ai
Hnh 3.11- ng cong phn b thc kch thc gia cng.
Sau , theo thi gian sai s h thng thay i s lm cho trung tm phn b di ng theo ng C0Ck, gii hn phn b n cng bin i theo ng D0Dk v E0Ek. Nh vy, trong qu trnh gia cng kch thc cc chi tit t c theo thi gian s thay i trong hai ng gii hn D0Dk v E0Ek. T , ng phn b kch thc gia cng s c dng nh trn, l ng cong tng hp ca sai s h thng thay i B(t) v sai s ngu nhin. Khi khong phn tn ca ng cong kch thc thc bng vi dung sai ca chi tit cn Lmax gia cng: = T, th ta phi iu chnh li my, a tm phn b v li v tr ban u. Khong thi gian gia hai ln iu chnh my, ngi ta gi l chu k iu chnh li my. Tck Ch rng, chu k iu chnh Lmin my phi nh hn hoc bng tui bn dao v nu khng th dao s h Hnh 3.12- Chu k iu chnh li my. khi cha kp iu chnh li my. 3.5- iu chnh my iu chnh my nhm m bo chnh xc ca tng nguyn cng. y l qu trnh chun b, g t dng c ct, g v cc trang b cng ngh khc ln my; xc nh v tr tng i gia dng c ct v mt cn gia cng nhm gim bt cc sai s gia cng, t c cc yu cu cho trn bn v. Trong sn xut n chic v lot nh, chnh xc gia cng yu cu c th
37
Lu c bnh
t c bng phng php ct th. Trong sn xut hng lot ln v hng khi, chnh xc gia cng nhn c bng phng php t ng t kch thc trn my iu chnh sn. Lc ny, iu chnh my c nhim v: - G t g v dng c ct vo v tr c li nht cho iu kin ct gt. - Xc nh ch lm vic ca my v chu k iu chnh li my. - m bo v tr tng i ca dng c ct, g, c t, mu chp hnh... xc nh chnh xc qu tch v lng dch chuyn ca dao so vi chi tit gia cng. y l vn phc tp nht ng thi n cng c ngha quyt nh n chnh xc gia cng. Hin nay c ba phng php iu chnh hay dng nht l: iu chnh tnh, iu chnh theo chi tit ct th bng calip th v iu chnh theo chi tit ct th bng dng c o vn nng.
3.5.1- iu chnh tnh
iu chnh tnh l g dao theo calip hay mu khi my ang ng yn (cha ct). Tin hnh: - Lp calip (hoc mu) vo v tr ca chi tit gia cng, sau dch chuyn dng c ct t st vo b mt ca calip (hoc mu) ri kp cht dng c li. - Cc c t cng theo calip m iu chnh mt cch tng t. - Xc nh ch ct v chu k iu chnh li my. - G phi vo v tr v gia cng. c im: - Phng php ny nhanh, n gin. - Tuy nhin, khng t c chnh xc gia cng cao v trong qu trnh gia cng, h thng cng ngh b bin dng n hi do nhit ct v lc ct gy ra (khi my ang ng yn th cha c). Ngoi ra, do cha tnh n o trc chnh (do c khe h trc), nhm b mt ca calip hay mu chp hnh. Do , kch thc thc gia cng s ln hn (mt ngoi) hoc nh hn (mt trong) so vi kch thc yu cu. hn ch sai s, ngi ta phi b li lng thay i kch thc thc ca chi tit gia cng so vi kch thc iu chnh bng cch thm hoc bt i mt lng b sung bs (thm vo khi gia cng mt trong, bt i khi gia cng mt ngoi). Lctt = Lcct bs Trong , Lctt: kch thc iu chnh tnh ton. Lcct: kch thc thc ca chi tit gia cng cn nhn c sau khi iu chnh my; nu iu chnh ban u tm phn b nm gia trng dung sai th: (L + L max ) , L , L : kch thc nh nht, ln nht trn bn v. L dc tt = min min max 2 bs: lng b sung cho bin dng n hi ca h thng cng ngh, khe h trc chnh, nhm b mt ca chi tit gia cng.
38
Lu c bnh
i vi b mt khng i xng: bs = 1 + 2 + 3 i vi b mt i xng: bs = 2(1 + 2 + 3) Py vi, 1: lng bin dng n hi ca h thng cng ngh, 1 = . J 2: chiu cao nhp nh, 2 = Rz. 3: khe h bn knh ca trc chnh my, thng thng 3 = 0,02 0,04 mm. Du (+) ly khi gia cng mt tron v du (-) khi gia cng mt ngoi Theo kinh nghim, sai s ca lng b sung c th ti 50% gi tr bn thn n cng thm cc sai s khc nn phng php iu chnh tnh khng cho php t chnh xc cao hn cp 7. Vy, iu chnh tnh ch dng sn xut n chic, lot nh.
3.5.2- iu chnh theo chi tit ct th nh calip th
Phng php ny dng calip lm vic ca ngi th tin hnh iu chnh. Calip l dng c kim tra xem kch thc thc ca chi tit c nm trong phm vi dung sai hay khng m khng cn bit gi tr thc ca chi tit. Kt cu ca calip nt c hai u: mt u c kch thc danh ngha bng kch thc gii hn nh nht ca l, gi l u qua; mt u c kch thc danh ngha bng kch thc gii hn ln nht ca l, gi l u khng qua. Tin hnh: - Xc nh v tr tng i ca dao vi phi, sau c nh cc vu, c chn... - Tin hnh ct th khong 3 5 chi tit. - Dng calip kim tra cc chi tit trn, nu t th gia cng cho c lot chi tit. c im: - iu chnh my theo phng php ny chc chn c ph phm bi v lot chi tit c gia cng l n chic, c khong phn tn l 6: + Nu 6 > T, th chc chn c ph phm. + Nu 6 T, s khng c ph phm khi tm ca ng cong phn b kch thc trng tm min dung sai chi tit, tuy nhin do ta khng xc nh c tm ca ng cong phn b kch thc do vy vn c ph phm. - Nu s lng chi tit ct th cng nhiu th ph phm cng gim nhng cng khng th loi tr ht ph phm. iu chnh my l phng php ph bin, c dng trong cc nh my c kh.
3.5.3- iu chnh theo chi tit ct th nh dng c o vn nng
Tin hnh: - G t dao v cc c hnh trnh cn c vo kch thc iu chnh Lc. - Ct th m chi tit. - o kch thc m chi tit , xc nh c tm phn b v phng sai - So snh tm phn b kch thc v tm dung sai, t iu chnh my theo dung sai thu hp.
39
Lu c bnh
Phng php ny do gio s A. B. Iakhin xut da trn c s l thuyt xc sut l: Nu c mt lot chi tit m kch thc ca n phn b theo quy lut chun vi phng sai l . Nu phn loi s chi tit trn thnh nhiu nhm, mi nhm m chi tit th kch thc trung bnh ca cc nhm phn cng phn b theo quy lut chun vi phng sai l 1 =
Tdc
Hnh 3.13 ch ra cc v tr bin ca ng cong phn b lot phi trong min dung sai T v cc ng cong phn b ca nhm. Nu kch thc trung bnh cng ca m chi tit ct th ri vo khong M N MN th s khng c ph phm. 3 31 31 3 Khong MN c gi l dung sai iu chnh Tdc v n c xc nh T nh sau: Tdc = T - 6( + 1) Hnh 3.13- ng cong phn b kch thc ca c lot () v ng cong phn b theo T T s = c gi l h s an kch thc trung bnh ca tng nhm (1). 6 ton v cng ln th kh nng gim ph phm cng tng. Nh vy, dung sai iu chnh Tdc c quan h vi dung sai chi tit ch to T, h s an ton v s chi tit ct th m. Nu tng s chi tit ct th m, dung sai iu chnh Tdc s tng v d iu chnh hn nhng thi gian ct th ko di. S chi tit ct th m c xc nh nh sau:
6 m> (thng ly m = 2 8 chi tit) T 6 Nu c tnh n sai s h thng th dung sai iu chnh s gim xung. Lc , dung sai iu chnh s l: Tdc = T - 6( + 1) - HT = T - 6( + 1) - [A + B(t)] vi: A l sai s h thng c nh (c th loi tr c nn khng cn quan tm). B(t) l sai s h thng thay i. * Nu khng tnh n sai s h thng thay i B(t): trng hp ny ch nn ng dng khi gia cng i m dng c ct c tc mi mn nh nh dao kim cng...; dng khi yu cu chnh xc gia cng cao bi v chnh xc gia cng cao th cn T nh, lc yu cu Tdc nh. * Nu tnh n sai s h thng thay i B(t): trng hp ny c s dng rng ri hn v cc dao c mi mn nh nh dao kim cng th rt t. Khi lng mn ca dao lm cho kch thc gia cng sp vt ra khi dung sai cho php th phi iu chnh li ng cong phn b li li, nm trong phm vi dung sai v khng sinh ra ph phm.
2
m 1 = m
40
Lu c bnh
Chng 4
Chun trong ch to my
4.1- nh ngha v phn loi
4.1.1- nh ngha
Mi chi tit khi c gia cng c thng c cc dng b mt sau: b mt gia cng, b mt dng nh v, b mt dng kp cht, b mt dng o lng, b mt khng gia cng. Trong thc t, c th c mt b mt lm nhiu nhim v khc nhau nh va dng nh v, va dng kp cht hay kim tra. xc nh v tr tng quan gia cc b mt ca mt chi tit hay gia cc chi tit khc nhau, ngi ta a ra khi nim v chun v nh ngha nh sau: Chun l tp hp ca nhng b mt, ng hoc im ca mt chi tit m cn c vo ngi ta xc nh v tr ca cc b mt, ng hoc im khc ca bn thn chi tit hoc ca chi tit khc. Nh vy, chun c th l mt hay nhiu b mt, ng hoc im. V tr tng quan ca cc b mt, ng hoc im c xc nh trong qu trnh thit k hoc gia cng c, lp rp hoc o lng. Vic xc nh chun mt nguyn cng gia cng c chnh l vic xc nh v tr tng quan gia dng c ct v b mt cn gia cng ca chi tit m bo nhng yu cu k thut v kinh t ca nguyn cng .
4.1.2- Phn loi
Mt cch tng qut, ta c th phn loi chun trong Ch to my thnh cc loi nh sau: Chun Chun thit k Chun gia cng Chun tinh Chun tinh chnh Chun tinh ph Chun cng ngh Chun lp rp Chun th Chun kim tra
41
Lu c bnh
a) Chun thit k Chun thit k l chun c dng trong qu trnh thit k. Chun ny c hnh thnh khi lp cc chui kch thc trong qu trnh thit k. Chun thit k c th l chun thc hay chun o. Chun thc nh mt A (hnh 4.1a) dng O xc nh kch thc cc A A1 bc ca trc. Chun o A2 nh im O (hnh 4.2b) A3 l nh hnh nn ca mt b) a) ln bnh rng cn dng xc nh gc cn . Hnh 4.1- Chun thit k. b) Chun cng ngh Chun cng ngh c chia ra thnh: Chun gia cng, chun lp rp v chun kim tra. Chun gia cng dng xc nh v tr ca nhng b mt, ng hoc im ca chi tit trong qu trnh gia cng c. Chun ny bao gi cng l chun thc.
B H A a) Hnh 4.2- Chun gia cng. - Nu g t gia cng theo phng php t ng t kch thc cho c lot chi tit my th mt A lm c hai nhim v t v nh v (hnh 4.2a). - Nu r g tng chi tit theo ng vch du B th mt A ch lm nhim v t, cn chun nh v l ng vch du B (hnh 4.2b). Nh vy, chun gia cng c th trng hoc khng trng vi mt t ca chi tit ln g hoc ln bn my. Chun gia cng cn c chia ra thnh chun th v chun tinh. Chun th l nhng b mt dng lm chun cha qua gia cng. Hu ht cc trng hp th chun th l nhng yu t hnh hc thc ca phi cha gia cng; ch trong trng hp phi a vo xng dng gia cng s b th chun th mi l nhng b mt gia cng, trng hp ny thng gp trong sn xut my hng nng. Chun tinh l nhng b mt dng lm chun qua gia cng. Nu chun tinh
A b)
42
Lu c bnh
cn c dng trong qu trnh lp rp th gi l chun tinh chnh, cn chun tinh khng c dng trong qu trnh lp rp th gi l chun tinh ph.
a)
b)
Hnh 4.3- Chun tinh chnh v chun tinh ph. V d: - Khi gia cng bnh rng, ngi ta thng dng mt l A nh v. Mt l ny sau s c dng lp ghp vi trc. Vy, l A c gi l chun tinh chnh (hnh 4.3a). - Cc chi tit trc thng c 2 l tm hai u. Hai l tm ny c dng lm chun gia cng trc, nhng v sau s khng tham gia vo lp ghp, do vy y l chun tinh ph (hnh 4.3b). Chun lp rp l chun dng xc nh v tr tng quan ca cc chi tit khc nhau ca mt b phn my trong qu trnh lp rp. Chun lp rp c th trng vi mt t lp rp v cng c th khng. Chun kim tra (hay chun o lng) l chun cn c vo tin hnh o hay kim tra kch thc v v tr gia cc yu t hnh hc ca chi tit my. V d: Khi kim tra khng ng tm ca cc bc trn mt trc, ngi ta thng dng hai l tm ca trc lm chun, chun ny c gi l chun kim tra. Ch : Trong thc t, chun thit k, chun cng ngh (chun gia cng, chun kim tra, chun lp rp) c th trng hoc khng trng nhau. Do vy, trong qu trnh thit k, vic chn chun thit k trng chun cng ngh l ti u v lc mi s dng c ton b min dung sai; nu khng tha mn iu trn th ta ch s dng c mt phn ca trng dung sai. V d: Khi gia cng piston, yu cu M phi m bo kch thc H1 m bo t s nn cho ng c. Chun thit k l mt M. Ta phi chn chun gia cng l M, lc H1 H mi s dng c ht dung sai ca H1; cn nu chn chun gia cng l N th phi H2 gia cng H2 t c H1 thng qua kch thc H. Nh vy th H1 s l khu khp N kn, dung sai n s l tng dung sai cc khu thnh phn H v H2, v th gia cng H2 s rt kh m bo dung sai ca H1.
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Lu c bnh
4.2- qu trnh g t chi tit trong gia cng G t chi tit bao gm hai qu trnh: nh v chi tit v kp cht chi tit. nh v l s xc nh chnh xc v tr tng i ca chi tit so vi dng c ct trc khi gia cng. Kp cht l qu trnh c nh v tr ca chi tit sau khi nh v chng li tc dng ca ngoi lc (ch yu l lc ct) trong qu trnh gia cng lm cho chi tit khng c x dch v ri khi v tr c nh v. V d: Khi g t chi tit trn mm cp ba chu t nh tm. Sau khi a chi tit ln mm cp, vn cho cc chu cp tin vo tip xc vi chi tit sao cho tm ca chi tit trng vi tm ca trc chnh my, l qu trnh nh v. Tip tc vn cho ba chu cp to nn lc kp chi tit chi tit s khng b dch chuyn trong qu trnh gia cng, l qu trnh kp cht. Ch rng, trong qu trnh g t, bao gi qu trnh nh v cng xy ra trc, ch khi no qu trnh nh v kt thc th mi bt u qu trnh kp cht. Khng bao gi hai qu trnh ny xy ra ng thi hay qu trnh kp cht xy ra trc qu trnh nh v. 4.3- Nguyn tc nh v 6 im Bc t do theo mt phng no ca mt vt rn tuyt i l kh nng di chuyn ca vt rn theo phng m khng b bi bt k mt cn tr no trong phm vi ta ang xt. Mt vt rn tuyt i trong khng gian c 6 bc t do chuyn ng. Khi ta t n vo trong h ta cc, 6 bc t do l: 3 bc tnh tin dc trc T(Ox), T(Oy), T(Oz) v 3 bc quay quanh trc Q(Ox), Q(Oy), Q(Oz). Hnh bn l s xc nh v tr ca mt vt rn tuyt i trong h to cc. - im 1 khng ch bc tnh tin theo Oz - im 2 khng ch bc quay quanh Oy. - im 3 khng ch bc quay quanh Ox. - im 4 khng ch bc tnh tin theo Ox - im 5 khng ch bc quay quanh Oz. - im 6 khng ch bc tnh tin theo Oy Ngi ta dng nguyn tc 6 im ny nh v cc chi tit khi gia cng.
Hnh 4.4- Nguyn tc nh v 6 im.
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Lu c bnh
Ch : - Mi mt mt phng bt k u c kh nng khng ch 3 bc t do nhng khng th s dng trong mt chi tit c 2 mt phng cng khng ch 3 bc t do. - Trong qu trnh gia cng, chi tit c nh v khng cn thit phi lun 6 bc t do m ch cn nhng bc t do cn thit theo yu cu ca nguyn cng . - S bc t do khng ch khng ln hn 6, nu c 1 bc t do no c khng ch qu 1 ln th gi l siu nh v. Siu nh v s lm cho phi gia cng b knh hoc lch, khng m bo c v tr chnh xc, gy ra sai s g t phi, nh hng n chnh xc gia cng. Do , trong qu trnh gia cng khng c xy ra hin tng siu nh v. - Khng c khng ch thiu bc t do cn thit, nhng cho php khng ch ln hn s bc t do cn thit c th d dng hn cho qu trnh nh v g t. - S bc t do cn hn ch ph thuc vo yu cu gia cng tng bc cng ngh, vo kch thc b mt chun, vo mi lp ghp gia b mt chun ca phi vi b mt lm vic ca c cu nh v phi.
a)
b)
a)
b)
a)
b)
Hnh 4.5- Mt s trng hp nh v thng gp. a) Siu nh v. b) nh v ng.

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Lu c bnh
V d minh ha v kh nng khng ch ca cc chi tit nh v thng gp:
L>D
L<D
Khi V di khng ch 4 bc t do.
Khi V ngn khng ch 4 bc t do.
Cht tr di nh v 4 bc t do.
Cht tr ngn nh v 2 bc t do. Cht trm nh v 1 bc t do.
L>D
L Hai mi tm nh v 5 bc t do. Mm cp ba chu nh v 4 bc t do.
Phin t kt hp vi mt cht tr ngn, mt cht trm nh v 6 bc t do.
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Lu c bnh
4.4- tnh sai s g t Sai s g t ca mt chi tit trong qu trnh gia cng c c xc nh bng cng thc sau:
gd = kc + dg + c
4.4.1- Sai s kp cht kc
Sai s kp cht l lng chuyn v ca gc kch thc do lc kp thay i chiu theo phng kch thc thc hin gy ra: kc = (ymax - ymin). cos Trong , : gc gia phng kch thc thc hin v phng dch chuyn y ca gc kch thc. ymax, ymin: lng chuyn v ln nht v nh nht ca gc kch thc khi lc kp thay i. S dch chuyn ca gc kch thc l do tc dng ca lc kp, lm bin dng b mt ca chi tit dng nh v vi nhng thnh phn nh v ca g. Gio s A. P. Xclpxki bng thc nghim a ra cng thc xc nh bin dng ch tip xc gia mt chi tit vi vu t ca g: W W y = C.qn vi, C: h s ph thuc vo vt liu v tnh trng tip xc; q: p lc ring trn b mt tip xc (N/mm2); Hnh 4.6- Sai s do lc kp gy ra. n: ch s (n<1). Khi lc kp thay i t Wmin n Wmax th phi cng chuyn v t ymin n ymax v do , kch thc gia cng thay i t Hmin n Hmax.
Hmax Hmin ymin 4.4.2- Sai s ca g dg ymax
Sai s ca g sinh ra do ch to g khng chnh xc, do mn ca n v do g t g trn my khng chnh xc:

dg = ct + m + d
Trong , ct: sai s do ch to g, khi ch to g thng ly chnh xc ca n cao hn so vi chi tit gia cng trn g . m: sai s do mn ca g, sai s ny ph thuc vo vt liu, trng lng phi, tnh trng b mt tip xc gia phi vi g v iu kin g t phi. d: sai s do g t g trn my, sai s ny khng ln lm. Ni chung, sai s g l rt nh nn cho php c b qua. Ch khi yu cu chnh xc cao th lc ly sai s g bng (0,2 0,3) sai s gia cng.
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Lu c bnh
4.4.3- Sai s chun c
Chun thit k v chun cng ngh c th trng hoc khng trng nhau. Nu chng trng nhau tc l th hin tt quan im cng ngh ca cng tc thit k. Khi thit k, cc kch thc l v hng, c ngha l kch thc gia mt A v mt B c to thnh m khng cn quan tm l kch thc l mt A n mt B hay t mt B n mt A. V mt cng ngh m ni th cc kch thc ghi trong bn v ch to khng cn l kch thc tnh v v hng na. A Xt kch thc 100 0,1 gia hai b mt A v B. Khi thit k, ngi ta cho kch thc l 100mm vi sai lch l 0,1mm. Cn trn quan im cng B ngh th ta ch n s hnh thnh ca kch thc trong qu trnh cng ngh nh th no? Mt A hay mt B s c gia cng trc; s hnh thnh kch thc ra sao trnh bt ph phm? Hnh 4.7- S hnh thnh kch Gi s, mt A c gia cng nguyn cng st thc cng ngh. trc, mt B ang c gia cng th kch thc 100 c gc A v hng v mt B. Nh vy, kch thc cng ngh c hng r rt, hng i t gc kch thc ti mt gia cng. Khi nim v gc kch thc ch dng trong phm vi cng ngh, n c th trng hoc khng trng vi chun thit k. V mt cng ngh, iu quan trng cn bit l gc kch thc khi gia cng v chun nh v nguyn cng c trng nhau khng? Nu khng trng s sinh ra sai s chun, nh hng n chnh xc gia cng.
100 0,1 H
M N
A
M
B
N
A
hnh b, nu gc kch thc khi gia cng mt N l Hnh 4.8- S hnh thnh sai s chun. M v chun nh v l K th khi gia cng mt N, kch thc B chu nh hng ca s bin ng ca gc kch thc l H (chun nh v khng trng vi gc kch thc). Khi , sai s chun ca kch thc B l cA = H. nh ngha: Sai s chun pht sinh khi chun nh v khng trng vi gc kch thc v c tr s bng lng bin ng ca gc kch thc chiu ln phng kch thc thc hin.
a) b)
hnh a, khi gia cng mt N, gc kch thc v chun nh v u nm trn mt K, nn khi gia cng mt N hnh thnh kch thc A th sai s chun ca kch thc A l cA = 0.
HH
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Lu c bnh
Phng php tnh sai s chun: Phng php cc i - cc tiu Lp chui kch thc cng ngh cho kch thc cn tnh sai s chun L sao cho L l khu khp kn. Khi , L ng vai tr l mt hm s m cc bin s l cc khu thnh phn ca chui kch thc cng ngh (c th l khu c kch thc thay i xi hoc khu c kch thc khng i aj ). L = (x1, x2, ... xn; a1, a2, ...an) Khi tnh sai s chun cho mt kch thc L no tc l tm lng bin ng L ca n khi nhng kch thc lin quan thay i (cc khu c kch thc thay i). c (L ) = L = .x 1 + .x 2 + ... + .x n x 1 x 2 x n
c (L ) = L = x i x i i =1
n
Khi lp chui kch thc cng ngh cn tun theo nguyn tc sau: chui kch thc cng ngh c bt u t mt gia cng, ti mt chun nh v, n chun o lng (gc kch thc) ri cui cng tr v mt gia cng. Phng php ny c dng khi chnh xc khng cao trong iu kin sn xut n chic, lot nh. Phng php xc sut Phng php ny c dng khi yu cu chnh xc gia cng chi tit cao v trong sn xut hng lot hay hng khi bi v n c tin cy cao hn phng php cc i - cc tiu. Sai s chun ca kch thc L no tnh theo phng php xc sut l:
2 2 K . c (L ) = x .K i .x i i i =1 trong , Ki l h s ph thuc vo quy lut phn b ca cc kch thc trong chui kch thc cng ngh, thng ly Ki = 1 1,5. Khi phn b theo ng cong phn b chun Gauss th Ki = 1. Nh vy, nhn thy rng khi mun tnh sai s chun cho mt kch thc L no , trc tin ta phi xc nh c chui kch thc lin quan ca n, ri sau dng cc cng thc trn tnh.
n 2
v d v tnh sai s chun theo phng php cc i - cc tiu:
V d 1: Tnh sai s chun ca cc kch thc M, K v H trong trng hp khoan l d trn mt tr c ng knh D D theo phng php t ng t kch thc. Chi tit c nh v trn khi V di vi gc v then bng, kp cht bng lc W (s nh v nh hnh v).
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Lu c bnh
W M D D d K O H
R I Dmax Dmin O O1 I
* Kch thc M v K: Kch thc M c gc kch thc l mt phng i xng ca khi V hay l im O. Kch thc H c gc kch thc l Ox hay l im O. Chi tit tr c dung sai D khi g ln khi V s c ng tm x dch theo mt phng i xng ca khi V hay ti mt ct ang v l on OO1. Ta c: OO1 = IO1 IO vi, IO1 =
D max 2. sin 2 D IO = min 2. sin 2 Do vy, D min D 1 = . D OO1 = max 2. sin 2. sin 2 2
Sai s chun ca kch thc M l lng dch chuyn ca gc kch thc OO1 chiu theo phng Ox:
Ox Sai s chun ca kch thc K l lng dch chuyn ca gc kch thc OO1 c (M ) = ch OO1 = OO1 . cos 90 0 = 0
chiu theo phng Oy:

c (K ) = ch OO1 Oy = OO1 . cos 0 0 = 1 2 . sin 2 .D
* Kch thc H:
Od Const H R I
Ta lp chui kch thc cng ngh, bt u t mt gia cng (tm l Od) n chun nh v (I); t chun nh v n gc kch thc (R) ri tr v mt gia cng. Ta c: H = O d I IR Mt khc, IR = OI OR D D = 2 2. sin 2
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Lu c bnh
D 1 IR = . 1 2 sin 2 D 1 Do vy, H = Const . 1 2 sin 2 Vy, sai s chun ca kch thc H l:
D 1 D 1 1 1 = c (H ) = 0 2 2 sin sin 2 2
V d 2: Tnh sai s chun ca cc kch thc A, B, d khi gia cng trc trn my tin. Chi tit c g trn 2 mi tm. Ta thy, kch thc d c gc kch d thc (ng ni 2 mi tm) khng i. Do vy, kch thc d c sai s A chun bng 0. B V ng knh D ca l tm trc khi gia cng c dung sai l D, do vy khi ta g chi tit ln 2 mi tm gia cng th cc kch thc A, B s c gc kch thc (mt u chi tit) b dch chuyn mt on theo phng ngang. D D D Ta c: = max min = 2. tg 2. tg 2. tg 2 2 2 Nh vy, sai s chun ca cc kch Bmax thc A v B s l: Dmax Bmin D c (A ) = c (B ) = = 2. tg 2 Amin * Nu mi tm trc m l mi tm Dmin mm th cc kch thc A v B s c Amax sai s chun c = 0 bi v mi tm mm s t iu chnh sai lch chiu su l tm ng vi tng chi tit, do v tr ca mt u bn tri chi tit khng thay i so vi dng c ct chnh.
D D
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Lu c bnh
V d 3: Tnh sai s chun ca cc kch thc C, A theo s phay rnh c kch thc B nh hnh di. Gia cng theo phng php t ng t kch thc. * Kch thc C: W B A Ta thy khu G l khu c nh C C (v gia cng theo J X H phng php t G ng t kch G thc); khu H l K khu bin ng. Do vy, sai s chun ca kch thc C l: C=H-G
L L
H H
c =
C .H = H H
* Kch thc A: Ta lp chui kch thc A: Ta thy rng, khu J l khu c nh (v gia cng theo phng php t ng t kch X J thc); khu X l khu bin ng. Ta c: A = J + X = J + (H - K).cotg (trong , K = const v khong cch gia g) Vy, sai s chun ca kch thc A l: c (A ) = H. cot g A V d 4: Phay rnh b trn chi tit hnh tr theo phng php gia cng t ng t kch thc. Chi tit c nh v trn mt mt phng ngang v mt phng nghing mt gc ; kp cht bng lc W c phng l ng phn gic ca gc . Tnh sai s chun cc kch thc H1, H2, H3 v khng i xng ca rnh b v ng knh D. * Kch thc H1: y Ta nhn thy, H1 c gc kch thc l O. b H3 Cng ging nh trng hp khi nh v trn W khi V, gc kch thc O cng dch chuyn H1 D nhng phng mt on l OO1 = H2 2. sin O 2 D D dch chuyn l phng theo ng phn gic ca gc . Vy, ta c c sai s chun ca kch thc H1 l: D c (H1 ) = ch OO1 = OO1 . sin = Oy 2 2
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Lu c bnh
* Kch thc H2: Ta nhn thy, kch thc H2 c gc kch thc trng vi chun nh v nn sai s chun ca n l bng 0: c (H2) = 0. * Kch thc H3: Ta lp chui kch thc ca H3. Ta thy rng, khu D l khu bin ng, khu H2 l khu H3 c nh (v c gia cng theo phng php t ng t kch thc). Do vy, ta c sai s chun ca kch thc H3 l: D D H2 H3 = D H2 c (H3) = D * khng i xng ca rnh b v ng knh D: Ta thy rng, v gia cng bng phng php t ng dt kch thc do , ng tm ca rnh b s khng i. ng knh D c dung sai l D, do vy, khi kch thc D thay i trong phm vi dung sai th lc g chi tit gia cng th ng tm ng ca n s b dch chuyn i mt on theo phng ngang: D = OO1 . cos = . cot g 2 2 2 D Vy, khng i xng l: e = = . cot g 2 4 2 4.5- cc nguyn tc chn chun Khi chn chun gia cng, ta phi xc nh chun cho nguyn cng u tin v chun cho nguyn cng tip theo. Thng thng, chun dng cho nguyn cng u tin l chun th, cn chun dng trong cc nguyn cng tip theo l chun tinh. Mc ch ca vic chn chun l bo m : - Cht lng ca chi tit trong qu trnh gia cng. - Nng cao nng sut v gim gi thnh.
4.5.1- Nguyn tc chn chun th
Chun th thng c dng trong nguyn cng u tin trong qu trnh gia cng c. Vic chn chun th c ngha quyt nh i vi qu trnh cng ngh, n c nh hng n cc nguyn cng tip theo v chnh xc gia cng ca chi tit. Khi chn chun th phi ch hai yu cu: - Phn phi lng d cho cc b mt gia cng. - Bo m chnh xc cn thit v v tr tng quan gia cc b mt khng gia cng v cc b mt sp gia cng. Da vo cc yu cu trn, ngi ta a ra 5 nguyn tc khi chn chun th: Nu chi tit gia cng c mt b mt khng gia cng th nn chn b mt lm chun th, v nh vy s lm cho s thay i v tr tng quan gia b mt gia cng v b mt khng gia cng l nh nht.
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Lu c bnh
V d: Hnh bn l chi tit c cc b mt B, C, D c gia cng, duy nht ch c b mt A l khng gia cng. Ta chn b mt A lm chun th gia cng cc mt B, C, D m bo ng tm vi A.
C
A D
Nu c mt s b mt khng gia cng th nn chn b mt khng gia cng no c yu cu chnh xc v v tr tng quan cao nht i vi cc b mt gia cng lm chun th. V d: Khi gia A cng l bin, nn ly B mt A lm chun th m bo l c b dy u nhau v yu cu v v tr tng quan gia tm l vi mt A cao hn i vi mt B. Nu tt c cc b mt phi gia cng, nn chn mt no c lng d nh, u lm chun th. C gng chn b mt lm chun th tng i bng phng, khng c bavia,u ngt, u rt hoc qu g gh. Chun th ch nn dng mt ln trong c qu trnh gia cng. M V d: T phi thp cn ban u, gia cng c DA, DB, DC ta c th chn chun th nh sau: - Nguyn cng 1: G phi ln mm cp my tin bng mt M, gia cng DC. DC DA DB - Nguyn cng 2: Tr u, g phi ln mm cp bng mt M, gia cng DA. Lc ny trc gia cng ra s c khng ng tm gia DC v DA v dng chun th cho hai nguyn cng. m bo gia cng chnh xc, ta phi lm nh sau: - Nguyn cng 1: G phi ln mm cp my tin bng mt M, tin mt on ngn trn mt ngoi, kho u, khoan tm u C, gia cng DC. - Nguyn cng 2: Chn chun tinh l mt on b mt ngoi va tin nguyn cng 1, kho u, khoan tm u A, gia cng DA. - Nguyn cng 3: G u DA (hoc DC) ln mm cp, u kia chng tm gia cng tip mt DB.
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Lu c bnh
4.5.2- Nguyn tc chn chun tinh
Khi chn chun tinh, ngi ta cng a ra 5 nguyn tc sau: C gng chn chun tinh l chun tinh chnh, khi chi tit lc gia cng s c v tr tng t lc lm vic. Vn ny rt quan trng khi gia cng tinh. V d: Khi gia cng rng ca bnh rng, chun tinh c chn l b mt l ca bnh rng, chun tinh ny cng l chun tinh chnh v sau ny n s c lp vi trc. C gng chn chun nh v trng vi gc kch thc sai s chn chun bng 0. Chn chun sao cho khi gia cng, chi tit khng b bin dng do lc ct, lc kp. Mt chun phi din tch nh v. Chn chun sao cho kt cu g n gin v thun tin khi s dng. C gng chn chun thng nht, tc l trong nhiu ln cng ch dng mt chun thc hin cc nguyn cng ca c qu trnh cng ngh, v khi thay i chun s sinh ra sai s tch ly nhng ln g sau.
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Lu c bnh
Chng 5
Cc phng php gia cng chun b

5.1- chn phi Mun ch to mt chi tit my t yu cu k thut v ch tiu kinh t, ta phi xc nh c kch thc ca phi v chn loi phi thch hp. Kch thc ca phi c tnh ton theo lng d gia cng, cn chn loi phi th phi cn c vo cc yu t sau: - Vt liu v c tnh ca vt liu m chi tit cn c theo yu cu thit k. - Kch thc, hnh dng v kt cu ca chi tit. - s lng chi tit cn c hoc dng sn xut. - C s vt cht k thut c th ca ni sn xut. Chn phi hp l khng nhng m bo tt nhng tnh nng k thut ca chi tit m cn c nh hng tt n nng sut v gi thnh sn phm. Chn phi tt s lm cho qu trnh cng ngh n gin i nhiu v ph tn v vt liu cng nh chi ph gia cng gim i. Chi ph kim loi khi gia cng c nh gi bng h s s dng vt liu K: G K = ct G ph trong , Gct: khi lng chi tit hon thin (kg) Gph: khi lng phi (kg) Trong gia cng c kh, cc dng phi c th l: Phi c, phi rn, phi dp, phi cn v cc loi vt liu phi kim loi nh g, php, nha... 5.2- cc phng php gia cng chun b Gia cng chun b phi l nhng nguyn cng chun b phi cho qu trnh gia cng c, bao gm lm sch, nn thng phi, gia cng ph, gia cng l tm. Phi sau khi c ch to xong thng c cht lng b mt xu nh x x, r, nt, chai cng...; hnh dng hnh hc c nhiu sai lch nh mo, van, cn, cong vnh... Nu ta a phi sau khi ch to xong vo gia cng chi tit ngay th sai s in dp ca phi ln chi tit gia cng s ln, phi gia cng nhiu ln th mi m bo yu cu ca chi tit. Nh vy s mt thi gian, chi ph gia cng ln, gi thnh sn xut s tng. i vi cc loi phi thanh cn phi nn thng trc khi a ln my gia cng; phi thanh thp cn li phi ct thnh tng on cho ph hp vi chiu di ca chi tit v d g t. Ngoi ra, nguyn cng u tin phi dng chun th, m chun th th phi tng i bng phng. Do vy, vic gia cng chun b phi l mt vic lm rt cn thit v khng th thiu. N l nhng nguyn cng m u cho qu trnh cng ngh gia cng c (sn xut n chic, lot nh). Thm ch, i vi sn xut c sn lng ln th gia cng
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Lu c bnh
chun b phi c tch hn ra khi quy trnh cng ngh gia cng c, khi c mt b phn ring m nhim vic chun b phi vi y thit b ring.
5.2.1- Lm sch phi
Hu ht cc loi phi cn phi lm sch, c bit l phi c hoc rn dp bi v lm nh vy s gip: - Loi tr lp ct b chy bm trn b mt phi c hoc cc vy kim loi b chy trn b mt phi rn, phi c. - Loi tr cc ra, mp ca phi rn, dp hoc cc lp kim loi h hng trn b mt trc khigia cng. - To nn cc b mt sch s gia cng c d dng, m bo v sinh. Trong sn xut nh thng dng phng php th cng bng nhng dng c n gin nh chi st, bn chi st, gia, ba... t nng sut thp. Trong sn xut hng lot v hng khi, ngi ta lm sch nh cc thit b chuyn dng c kh ho. i vi nhng chi tit nh c th cho vo mt thng quay, cc chi tit s va p vo nhau lm cho vt ct, bn, g ri ra. Hoc dng mi, ngn la loi tr cc vt bn, g, ch kim loi b h hng, Ngoi ra, cn c th lm sch vt rn trong hn hp ct v nc hoc trong dung dch axit.
5.2.2- Nn thng phi
i vi phi thanh, phi cn cn phi nn thng trc khi a vo gia cng; ngoi ra i vi cc phi di khng nhng phi nn trc khi gia cng c m sau khi tin (trc khi mi) cn phi nn thng li. Phi sau khi nn thng s c lng d u, gim c sai s gia cng, m bo phi y d, kp cht tt. Nn bng ba tay i vi cc chi tit tr ngn, ng knh khng ln th dng mt ngm, xem xt thng ri dng ba nn trn e. y l phng php th cng nht, khng i hi thit b phc tp nhng nng sut rt thp, chnh xc khng cao v ph thuc vo kinh nghim, tay ngh ca ngi th. Nn p i vi chi tit tr ngn, ng knh ln th dng g trn thn my tin c hoc dng g trn my p. Ngoi ra, ngi ta cn dng nn p trn hai khi V. Trong 2 mi tm c mt c nh, mt iu chnh c theo hng chiu trc. Khi nn p, chi tit v hai mi tm u b x dch xung, sau khi nn xong l xo li y v v tr ban u. Hnh 5.1- Nn thng trn hai mi tm.
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Lu c bnh
nng cao chnh xc, dng ng h so ch th. Ngun sinh lc c th dng c cu vt me-ai c, c cu du p hay kh nn. Nn thng trn my chuyn dng i vi chi tit tr di, ng knh ln (25 150mm) th vic nn thng s c thc hin trn my nn thng chuyn dng.
H bnh kha truyn chuyn ng ti thng Vnh g ng bt mi lm nhn
Hnh 5.2- My nn thng chuyn dng.
My nn thng chuyn dng gm c thng quay, trong thng c nhng b con ln c dng hypecblit trn xoay c t nghing mt gc sao cho ng sinh l ng thng. Nhng b con ln ny tng cp mt c t cho nhau, va quay theo thng va quay quanh tm ca n lm nhim v nn thng v dn phi i. Phi c t vo gia cc b con ln nh hai xe nh hai u. Khong cch gia hai con ln c th iu chnh c ph hp vi cc loi ng knh khc nhau. Nng sut ca my nn thng chuyn dng rt cao, nhng do kch thc cng knh nn ch dng trong sn xut hng lot ln v hng khi. Nn thng trn my cn ren i vi phi c kch thc ngn th c th nn thng trn my cn ren phng nu thay bn cn ren bng bn phng. Phng php ny c th nn c nhng on ngn, chnh xc t t 0,05 0,15 m vi mi mm ng knh trn chiu Hnh 5.3- S nn thng di 1m. trn my cn ren. Phng php ny c nng sut rt cao.
5.2.3- Gia cng ph
Mc ch ca gia cng ph l bc i lp v ngoi ca cc loi phi c b mt qu xu (r, dnh ct, bin cng...) v c sai lch qu ln, pht hin cc khuyt tt. My dng gia cng ph cn c cng sut ln, cng vng cao t nng sut cao, cn chnh xc th khng cn cao lm. Khi sn lng nh, vic gia cng ph c th tch ring gia cng trn mt vi my c trong phn xng c kh.
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Lu c bnh
Khi sn lng ln, vic gia cng ph c thc hin trn cc my chuyn dng t phn xng gia cng chun b phi.
5.2.4- Ct t phi
Ct t phi thng dng vi cc loi phi thanh, phi cn cn ct t thnh tng on tng ng theo chiu di trc hoc ct cc u ngt, u rt ca cc phi c. Khi chn phng php ct t phi phi xt n mt s yu t sau y: - chnh xc ct t nh chnh xc chiu di phi, phng v thng gc ca mt ct vi ng tm ca phi. - B rng ming ct ln hay b c lin quan n chi ph vt liu nhiu hay t, c bit l i vi nhng kim loi qu. - Nng sut ct. Ty theo loi phi, sn lng v iu kin v c s vt cht k thut ca ni sn xut m chn phng php ct sao cho m bo nng sut cao, t c cc yu cu k thut ca phi v tit kim nguyn vt liu, gim chi ph ch to. Ct t bng ca tay Ct t phi bng ca tay c nng sut thp, tn nhiu cng sc, ming ca kh thng, nhng c th tit kim c vt liu v ming ca hp, thit b n gin. C th ct c cc loi phi thp cn, c ng, thp hnh nh... Ct t trn my ca cn My ca cn c kt cu n gin, d s dng, ming ca tng i hp, so vi ca tay th nng sut hn nhiu, gim cng lao ng ca cng nhn. Tuy nhin, khi so vi cc phng php ca khc th n li khng nng sut bng v c hnh trnh chy khng ca li ca. C th ct c cc loi phi thp cn, c ng, thp hnh nh..., thng dng trong cc x nghip quy m nh v vn u t t, d s dng, chim din tch nh. Ct t bng ca a Khi ct t bng dao ca a c th c nng sut cao, cht lng mt ct tt song ming ct rng. Loi ca a ny c th ct t c phi thp trn, phi nh hnh. i vi phi c kch thc nh c th g ct mt ln nhiu phi. Ct t bng bnh mi Ct t bng phng php ny c th t chnh xc cao, cht lng mt ct cao, sau khi ct khng cn gia cng li. Nu so vi ca a th nng sut khng bng nhng cht lng mt ct li tt hn v tit kim c vt liu v ming ct nh. Phng php ny c th ct c phi trn nh, nh hnh nh, c bit l cc thp cng, thp ti...
59
Lu c bnh
Ct t bng bnh ma st Dng c ct l mt a phng c chiu dy khong 1,5 3 mm, ng knh khong 300 1500 mm. Mt trn ca a c kha, khi quay n tip xc vi phi, pht ra nhit lng ln lm cho kim loi b nng chy v b ct t, trong khi a c lm ngui bng cch ngm trong nc hoc ti dung dch lm ngui lin tc (nhng khng ti vo v tr ct), do vy, c th ct c phi cng hn dng c ct. Phng php ny c nng sut kh cao, khng cn li ca t tin nn gi thnh thp, tuy nhin, chnh xc thp, gy n v khng an ton. Ct t trn my tin Vic ct t trn my tin c thun li l c th thc hin chung trn mt ln g vi cc bc cng ngh khc nh gia cng l tm, tin ngoi... Ct t trn my tin ct c phi trn, ng knh c th ct ln n 3200 mm (i vi my tin rvnve ln). Ct t trn my chuyn dng Cc loi phi thanh, phi tm c th c ct t trn my ct chuyn dng nh my ct tm, my ct t... Phng php ny c nng sut rt cao, nhng ming ct khng chnh xc. Ct t bng ngn la O2 - C2H2 Phng php ny c th ct c nhiu phi c hnh dng khc nhau nh trn, thanh, tm, nh hnh, to c chi tit nh hnh t vic ct thp tm... Phng php ny c nng sut rt cao, thun li, tin dng mi ni, nhng nhc im chnh ca n l cht lng mt ct thp, chnh xc khng cao, hay b cong vnh... Ct t bng in cc Phng php ny ch s dng khi ct cc phi lm bng vt liu c cng cao v cc hp kim cng. Ct t bng tia Laser Phng php ny l mt thnh tu mi ca th gii, n c th ct cc phi c chiu dy nh, c bit l vt liu cng v dn nh kim cng, thu tinh, s... Phng php ny c chnh xc cao, rnh ct nh, p, nng sut rt cao...
5.2.5- Gia cng l tm
L tm l loi chun tinh ph thng nht, dng nh v chi tit dng trc trong nhiu ln g hoc nhiu nguyn cng khc nhau. N khng nhng lm chun trong qu trnh gia cng m cn dng c trong qu trnh kim tra v sa cha sau ny. L tm c nhiu loi, nhng thng dng cc loi sau y:
60
Lu c bnh
1200
1200
600
600
600
d l L a)
d l L b)
D c)
Hnh 5.3- Cc loi l tm.
Kiu (a) l kiu n gin nht, gc cn ca mt t thng l 600, ch trong trng hp chi tit ln mi dng loi c gc cn ln hn (750 hoc 900). L c ng knh d cho u mi tm thot, cn phn cn ca mi tm t st vo l cn. Kiu (b) c thm phn cn vt 1200 bo v l tm khi b st mp ngoi, ng thi cn c th cho php gia cng sut c mt u ca trc. Kiu (c) cn c thm phn ren l tm khi s dng xong l tm, dng mt nt c ren vn vo nhm bo v l tm khng b h hng. Hai loi (b) v (c) p dng trong nhng trng hp m l tm c dng trong thi gian di. L tm c yu cu k thut khi gia cng kh cao: - L tm phi l mt ta vng chc ca chi tit, din tch tip xc phi , gc cn phi chnh xc, su l tm phi m bo. - L tm phi nhn bng (phn cn 600) gim ma st, chng mn v gim bt bin dng tip xc, tng cng cng vng. - Hai l tm phi nm trn mt ng tm trnh tnh trng mi tm tip xc khng u nn chng mn v lm cho mt tr s gia cng khng thng gc vi mt u. Trong sn xut nh, ngi ta c th gia cng l tm trn cc my vn nng nh my tin, my khoan; bng cch dng mi khoan nh khoan trc phn tr, sau dng mi khoan ln khot thm phn cn (nu khng c mi khoan tm).
d 118
0
600 L1 L
Hnh 5.4- Mi khoan tm.

61
Lu c bnh
Trong sn xut hng lot v hng khi, vic gia cng l tm c thc hin trn my chuyn dng, chi tit c g t trn hai khi V t nh tm, khi gia cng tin hnh theo hai bc: th nht phay hai mt u trc ng thi bng hai dao phay mt u; bc th hai tin hnh gia cng cng lc hai l tm bng mi khoan tm chuyn dng.
Hnh 5.5- Gia cng l tm trn my chuyn dng.
Trong qu trnh cng ngh, nu chi tit gia cng nhit luyn th chc chn l tm s c sai s d cho l tm c c gia cng bng cch no i na. Lc , nu mun s dng tip l tm th phi sa li l tm m bo ng hnh dng v cc yu cu khc. Mun sa li l tm phi dng mi hnh cn c gc cn bng 600 hoc nghin bng bt mi.
62
Lu c bnh
Chng 6
gia cng b mt Chi tit my

Chi tit my c hnh dng, chng loi, kch thc rt phong ph. Tuy nhin, nu xt mt cch tng qut th chi tit my l tng hp ca cc b mt c bn nh: trn xoay (trong, ngoi), mt phng, mt xon vt, mt nh hnh. Chng ny, chng ta nghin cu phng php gia cng cc b mt (gia cng ct gt). 6.1- gia cng b mt tr ngoi B mt tr ngoi c nhiu dng khc nhau v kt cu nh: trc (trc trn, trc bc, trc ngn, trc di, trc c, trc rng); ng (dy, mng); a (dy, mng); cn. Do vy, ty theo tng loi kt cu m ta c cch g t cng nh chn phng php gia cng thch hp. m bo tnh nng s dng, khi ch to trc cn m bo nhng yu cu k thut ch yu sau: - chnh xc kch thc ng knh cc c trc lp ghp t cp chnh xc 7 8, c th ti cp 6; cc sai s hnh dng hnh hc nh cn, van... nm trong gii hn dung sai ng knh. - chnh xc kch thc chiu di mi bc trc khong 0,05 2mm. - chnh xc v v tr tng quan nh o cc c trc, khng thng gc gia ng tm v mt u vai trc sai lch gii hn trong khong 0,01 0,05mm - nhm b mt cc c trc lp ghp Ra = 1,25 0,16 ty theo yu cu lm vic c th. Phi ch to trc c th l phi cn theo tiu chun (gia cng cc trc trn, trc bc c chnh lch ng knh cc bc khng ln); phi rn khun, dp khun dng cho cc trc c yu cu c tnh cao nh trc lch tm, trc khuu, trong sn xut hng lot ln, hng khi; phi c bng gang c bn cao dng cho cc trc ln gim nh trng lng, gim lng d v thi gian gia cng.
6.1.1- Gia cng trc nhit luyn
a) Tin mt tr ngoi
Phng php g t chi tit:
B mt tr ngoi ch yu c gia cng bng phng php tin. Chun cng ngh khi tin b mt tr ngoi c th l mt ngoi, mt trong, hai l tm, hoc kt hp mt trong (mt ngoi) vi l tm. Ty theo vic chn chun m khi gia cng mt ngoi ta c nhiu cch g t chi tit khc nhau: - G trn mm cp ba chu t nh tm (chun l mt trong, mt ngoi). - G trn mm cp bn chu (chun l mt trong, mt ngoi). - G trn mm cp v chng tm [chun l mt trong (ngoi) v l tm].
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Lu c bnh
- G trn hai mi tm (chun l hai l tm). - G bng ng kp n hi (chun l mt trong, mt ngoi). - G trn cc loi trc g (chun l mt trong). - G trn cc g chuyn dng. Ngoi ra, i vi cc chi tit trc di (l/D > 10 12) th ngi ta phi dng thm luynet. Luynet l trang b cng ngh khng tham gia vo nh v m ch tng thm cng vng cho chi tit gia cng. Luynet tnh l loi luynet c g c nh trn bng my. Loi ny c cng vng cao nhng i hi phi iu chnh cc vu luynet cn thn. B mt ca chi tit gia cng tip xc vi cc vu phi c gia cng trc sao cho tm ca n trng vi ng tm hai l tm hay ng tm quay ca my. Luynet ng l loi luynet c g c nh vi bn dao, n lun lun nm gn v tr ca dao ct, do vy n c tc dng tt hn luynet tnh. Luynet ng c cng vng km hn luynet tnh v thng c dng khi gia cng trc trn. Vu ca luynet ng c th chy trc hoc sau v tr ca dao ct. Khi gia cng tinh th vu ca luynet ng chy trc v tr dao ct v nu chy sau th n s lm xc b mt va gia cng, cn cc trng hp khc th vu ca luynet ng chy sau v tr dao ct.
a)
b)
Hnh 6.1- Tin trc dng luynet. a) Dng luynet c nh; b) Dng luynet di ng.
Phng php ct v bin php nng cao nng sut:
* Phng php ct: Khi tin th ta c th dng cc phng php ct sau y: - Ct theo lp: 1 Ct tng lp l phng php ct m vic 2 ct gt s thc hin theo tng lp. 3 Phng php ny c cng vng tt, lc ct nh nn c th t chnh xc cao
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Lu c bnh
nhng nng sut khng cao. - Ct tng on: Ct tng on l phng php ct t kch thc yu cu theo tng on. on u trc c lng d ln nn phi chia thnh 2 lp ct cho ht lng d, tip theo ct tip on gia v cui cng l on cui. Phng php ny c nng sut cao nhng lng d ln v khng u nhau, lc ct ln v cng vng b gim xung. - Ct phi hp: y l phng php ct phi hp ca 1 hai phng php trn, n c th iu ha 2 c nhc im ca hai phng php . Lc u ta ct lp ngoi 1, sau ct cc on 2. Khi tin tinh, vic chn phng php ct no cn ph thuc vo cch ghi kch thc, cch chn chun v chnh xc yu cu.
1 2
* Bin php nng cao nng sut: Nng cao c nng sut lao ng, gim gi thnh sn phm l mc tiu hng u ca tt c cc x nghip sn xut. C nhiu cch nng cao nng sut sn xut nh c kh ha v t ng ho cc quy trnh cng ngh, s dng my t ng, my iu khin theo chng trnh s, dng cc g chuyn dng, c cu kp nhanh bng kh nn... y, ta xt n ta xt n bin php nng cao nng sut bng cch rt ngn thi gian gia cng trc tip T0: L. i T0 = n. s trong , L: l chiu di tin dao, L = L0 + lav + lvq vi: L0 l chiu di tin dao thc. lav l khong cha dao n vo. lvq l khong cha dao vt qu. Z i: l s ln ct ht lng d, i = t vi; Z l lng d. t l chiu su ct. n: l s vng quay trc chnh. s: l lng chy dao dc. Nh vy, rt ngn thi gian gia cng trc tip, ta phi gim chiu ng
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Lu c bnh
ct L, gim s ln ct, hoc tng s vng quay, lng chy dao. Sau y l cc bin php nng cao nng sut dng cho phng php tin. - S dng nhiu dao ct mt lc: Thay dao ct thng thng bng t hp gm nhiu dao. Khi gia cng, mi dao ch ct mt phn ca chiu di chi tit do vy t c nng sut cao. - S dng my c hai bn dao (my bn t ng): Ngi ta thng s dng phng php ny trong sn xut ln khi lng d gia cng kh ln.
Ss
St Dng my tin bn t ng.
Nhiu dao ct mt lc.
- Tng ch ct: Nu iu kin k thut cho php nh my cng sut, g kp chi tit tt, dao c m bo... c th tng ch ct ln cao nng cao nng sut. Ngoi ra, khi gia cng nn ti dung dch trn ngui ko di tui th ca dao v gim thi gian ph. b) Phay th mt tr ngoi Mt tr ngoi cn c th gia cng bng dao phay tr trn my phay chuyn dng v c nng sut rt cao. My loi ny c hai trc dao lp cc dao phay v mt trc g lp chi tit. Khi gia cng c th thc hin theo hai cch: - Khi gia cng cc trc c kt cu n gin, mi bc trc c gia cng cng lc bi hai dao phay lp trn hai trc dao (hnh 6.2a). Chi tit sau khi tin vo vng gia cng phi quay quay i mt gc 1850 gia cng ht ton b chu vi b mt. - Cch hai dng khi gia cng trc c kt cu phc tp hn, mi b mt c gia cng bi mt dao ring v chi tit phi quay i 3700 ct ht chu vi b mt.
a)
b)
Hnh 6.2- Phay trc trn my phay chuyn dng.

66
Lu c bnh
6.1.2- Gia cng ln cui v gia cng sau nhit luyn a) Tin mng gia cng ln cui, dng phng php tin mng bng dao hp kim cng hoc dao kim cng c li ct c mi cn thn thng v bng li ct cao. Ch ct khi tin mng c lng chy dao v chiu su ct kh nh cn vn tc ct th kh ln. Khi gia cng hp kim nhm, tc ct c th t 1000 1500 m/ph; vi hp kim ng V = 300 450 m/ph; kim loi khc V = 200 250 m/ph. Khi tin mng bng dao kim cng c th khng cn dung dch trn ngui nhng nu dng dao hp kim cng th cn thit phi c v kh nng chu nhit ca n km hn. My v trang b cng ngh tin mng phi c chnh xc v cng vng cao. Tin mng c th cho php to ra b mt c cp chnh xc 6, nhm Ra = 0,1 0,4m; khng c ht mi bm vo b mt gia cng, nng sut cao. y c th l phng php gia cng duy nht i vi vt liu l hp kim mu v vi vt liu ny khng th mi c do phoi mi s dnh bt vo b mt lm vic ca mi v do lm mt kh nng ct gt ca chng. b) Mi Sau khi nhit luyn, chi tit lun b bin dng so vi trc khi nhit luyn nh cong vnh, l tm b hng... gia cng sau khi nhit luyn, ngi ta dng phng php mi. Ht mi c th dng lin kt cng ( mi), t do (mi nghin), lin kt n hi (dng t trng lin kt). Khi gia cng th, chn cng vi cht dnh kt l gm, ht ln; gia cng tinh, chn mm, cht dnh kt hu c, ht nh. Khi gia cng thp cng, chn mm hn so vi khi gia cng thp mm. Mi bng mi: * Phng php mi c tm: Chi tit khi mi c tm thng c g bng hai l tm hoc mm cp kt hp l tm. Do , trc khi mi ta phi sa li l tm v nn thng li chi tit (nu cong).
nd Sn z
nct
Sd
Hnh 6.3- Mi c tm.

67
Lu c bnh
Chuyn ng ct do chuyn ng quay ca mi to nn, vn tc ct thng khong v = 25 50 (m/s). Chi tit cng quay vi chiu ngc li vi mi nhng vn tc quay nh, khong: vct = (1 3%)v. Khi mi c tm, thng dng hai phng php n dao: dc v ngang. - Mi n dao dc: Phng php chy dao dc thng dng khi mi cc b mt c chiu di ln hn so vi chiu rng mi. Sau mi hnh trnh chy dao dc, mi mi tin su vo mt Sd nd lng chy dao ngang. Phng php ny rt thng dng, t chnh xc cao, su ct nh (ct nct th t = 0,1 0,4 mm; ct tinh t = Hnh 6.4- Chy dao dc. 0,01 0,04 mm) nn lc mi b. Lng tin dao dc c chn theo chiu rng B, khi mi th thng ly Sd = (0,3 0,7)B; khi mi tinh ly Sd = (0,2 0,3)B. Khi mi tinh, nhng ln chy dao cui ta khng cho tin su vo na m vn cho tip tc mi n khi tt hoa la mi thi. - Mi n dao ngang: Thng dng phng php ny khi mi chi tit c ng knh ln, chiu di b mt cn mi ngn hn chiu rng mi, sn lng ln. Cch mi ny i hi cng vng chi tit tt, myc cng sut ln, nd Sn rng bn v sa tht tt. u im ca cch mi ny l t nng sut cao, c th kt hp mi mt bc v ngng trc ng thi hoc mi cc b mt nh hnh. Tuy nhin nct chnh xc t c khng cao v ph Hnh 6.5- Chy dao ngang thuc vo ch sa .
Tnh thi gian c bn:
+ Khi mi n dao dc: T0 =
L a K ( ph) n ct .S d S n
trong : L: chiu di hnh trnh dc: L = L0 - (0,4 0,6)B; vi B l chiu rng mi; L0 l chiu di ca b mt cn mi. nct: S vng quay chi tit trong mt pht, v/ph. Sd: L lng chy dao dc, mm/ vng chi tit. c xc nh bng .B/ vng
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Lu c bnh
chi tit. Khi mi th, = 0,5 0,8; khi mi tinh, = 0,2 0,5. K : H s lin quan vi chnh xc khi mi (mi tt hoa la). Khi yu cu t chnh xc n 0,02 0,03 mm, K = 1,7; khi t chnh xc n 0,04 0,06mm, K = 1,4; khi t chnh xc n 0,07 0,09 mm, K = 1,25; khi t chnh xc n 0,1 0,15 mm, K = 1,1. a :lng d mi tnh cho mt pha, mm. Sn :lng n dao ngang, mm/htk a K (ph ) + Khi mi n dao ngang: T0 = n ct .S n Cc gi tr a, nct, K c xc nh nh trn. Sn: l lng tin dao ngang, mm/ vng chi tit. * Phng php mi khng tm: Mi khng tm c c im l chun nh v ca chi tit gia cng chnh l b mt gia cng. Chi tit mi c t t do ln cn m khng cn nh v, kp cht. i vi cc chi tit ngn, c th t ni tip nhau trn mng dn. Do vy nng sut gia cng cao, thch hp vi dng sn xut lot ln hoc hng khi. Chi tit nm gia hai mi, mt ct v mt dn. dn dng to ra chuyn ng quay (ngc chiu vi ct) v tnh tin dc trc cho chi tit. Tc ct ca mi khong v = 30 50 m/s, tc ca dn nh hn tc ca ct khong 75 80 ln, v th ma st gia vt mi vi dn ln hn nhiu so vi ct.
v vct vdn
h dn mi Dao Chi tit Hnh 6.6- Mi khng tm
g chnh ca chi tit khi mi khng tm l cn . Mt ca cn phi t song song vi trc ca mi. Gc nghing ca cn l 300 (khi chi tit c kch thc ln d > 30 mm th gc nghing khong 20 250). Mt vt ca cn phi hng vo pha dn v cng vi dn hnh thnh nn khi V nh v chi tit. Chiu cao g t ca chi tit khi mi khng tm c nh hng n cht lng gia cng rt nhiu. Thng thng, ngi ta phi t cn lm sao cho tm ca chi
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Lu c bnh
tit cao hn tm ca mi v dn ( khng b mo) mt khong (0,5 1) bn knh chi tit nhng nh hn 14 mm. Mi khng tm c u im l nng sut gia cng cao, thch hp cho dng sn xut hng lot, khi, c th mi c cc chi tit m khng th mi c tm nh chi tit nh, ngn nh cht xch, vin bi kim... v khi khng th to nn l tm g t hoc mi s ct vo cc mi tm hoc g ca my. Tuy nhin li c nhc im l khng m bo ng tm gia cc c trc, khng gia cng c cc b mt khng lin tc (nh c rnh then) nn ch yu l gia cng trc trn. C 2 phng php mi v tm: Mi n dao dc v mi n dao ngang. - Mi n dao dc: Mi khng tm chy dao dc v Bnh mi Bnh dn tnh cht cc chuyn ng ging nh mi c tm nhng khc ch l dn lm nhim v cung cp cho chi tit chuyn ng quay v tnh tin. dn c dng hypecblit trn xoay v c t nghing i mt gc = (1 40). Tc quay Vct v tc chy Cn dc Sd ca chi tit ph thuc vo tc Hnh 6.7- Chy dao dc. dn V.dn v . Vct = V.dn. cos. (m/ph) Sd = V.dn. sin./ 1000 (mm/ph) trong , l h s trt gia chi tit v dn, =0,95 0,98. Khi bit ng knh Dd.dn v tc quay n.dn ca dn, c th xc nh Vct v Sd theo cng thc sau:
.D d.dan .n d.dan cos . (m / ph ) 1000 S d = .D d.dan .n d.dan sin . (mm / ph ) Vct =
Khi mi tinh, thng chn t 1 20 ; khi mi th chn t 2030 40. Phng php ny cho php t chnh xc hnh dng hnh hc b mt rt cao. - Mi n dao ngang: Mi khng tm n dao ngang tng t nh mi c tm n dao ngang. N c th gia cng c trc bc, nu sa chnh xc c th mi c mt cn, mt nh hnh nhng yu cu cng vng ca chi tit phi tt v mt gia cng phi ngn. Bnh dn khng cn c dng hypecblit m l hnh tr v trc ca n t song song vi trc mi ( = 0). Trong trng hp , ta thy Sd s bng 0. Vic n dao ngang Sn c thc hin bng cch tin dn hng vo pha mi. Thng thng Sn = 0,003 - 0,01mm/vng chi tit.
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Lu c bnh
Trng hp mi b mt cn, trc dn s c quay i 1 gc so vi trc mi bng gc cn ca chi tit cn mi. Khi cn thm mt cht t chng vo mt u cn ln trnh trng hp chi tit b y li khi mi, lm mt chnh xc.
Tnh thi gian c bn:
+ Khi mi n dao dc: T0 =
l 0 .m + B K Sd m
(ph )
trong : lo: chiu di chi tit c mi, mm. m: s lng chi tit trong lot c mi lin tc theo dy chuyn. B: chiu rng mi, mm. Sd: lng tin dao dc, c xc nh nh trn (mm/ph). K: h s tnh n chnh xc khi mi. a K (ph ) + Khi mi n dao ngang: T0 = n Sn trong : a: lng d mt pha, mm. n: s vng quay chi tit trong 1 pht, v/ph. Sn: lng n dao ngang ca dn, mm/vng chi tit. K: h s chnh xc ho. Mi nghin: Mi nghin l qu trnh s dng cc ht mi c ht nh dng t do, trn vi cc loi dung dch (du nhn, m b, paraphin v mt s axit hu c), sau ph ln b mt lm vic ca dng c nghin. Khi a dng c nghin vo tip xc vi b mt chi tit gia cng phi to cho n mt p lc cn thit (khng ln lm), nh p lc ny v cc chuyn ng tng i, cc ht mi s ct i mt lp t vi trn b mt chi tit gia cng lm tng bng b mt. chnh xc v kch thc c th t c cp 6 - 7 v nhm b mt t n Rz = 0,04 0,63. Tuy nhin, phi trc khi mi nghin phi c gia cng chnh xc (n cp 7 v nhm b mt phi t Ra = 0,63 2,5) v mi nghin khng sa c sai lch v tr tng quan do lng d khi mi nghin khng ln hn 0,02 mm. Dng c nghin c ch to bng vt liu mm hn so vi cc chi tit c nghin, thng thng c ch to bng gang Peclit, Ferit, ng... Ty theo b mt gia cng m dng c nghin l bc ch C hay tm phng nhng phi m bo rng c th iu chnh c p sut nghin theo gi tr yu cu cn thit. p sut khi nghin thng chn trong khong t 2 8 Kg/cm2; gi tr ln dng cho nghin th, gi tr nh cho nghin tinh. Tc ct thng c chn thp, t 10 12 m/ph. ht khi nghin thng chn t M3 n M20, ht M3 dng khi nghin ln cui hay chy r, M20 dng khi nghin th.
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Lu c bnh
Cc chuyn ng ct khi nghin gm: Tnh tin kh hi v quay trn. Tu theo trng hp c th m cc chuyn ng ny c th do chi tit hay dng c thc hin. Nguyn l lm vic ca mi a chi tit nghin vi dng c nghin l tm phng: Mt a nghin c chuyn ng quay trn, a nghin khc c th ng yn hoc quay trn (ngc chiu vi a kia). Chi tit c t gia hai a a nghin Chi tit nghin v trong a cch (khng hng Hnh 6.8- Mi nghin mt tr ngoi tm vo a cch). a cch c tm quay lch so vi tm quay ca hai a nghin v c x rnh, do vy chi tit gia cng s quay quanh tm a nghin, quay quanh tm ca n v chuyn ng qua li theo phng dc trc ca n (chy trong rnh ca a cch). Mi nghin ni chung c nng sut thp v ht mi c kch thc nh, vn tc nghin v p lc nghin thp. B mt sau mi nghin c th t chnh xc cp 6, nhm b mt Ra = 0,2 0,01, cht lng b mt tt v lp kim loi c ct rt mng, lc ct khng ln, nhit ct khng cao. Mi siu tinh: Mi siu tinh l phng php gia cng ln cui, c th t cp chnh xc 6 v Rz = 0,05 0,8. Dng c mi l u mang cc thi . Chi tit c chuyn ng quay vi vn tc v = 6 30 m/ph, cn mi tnh tin theo phng dc trc ca chi tit vi tc 0,1 mm/vg. c bit, u mi cn c thm chuyn ng lc ngn dc trc vi tn s cao (500 2000 hnh trnh kp/pht), nhng hnh trnh rt ngn (2 6 mm).
Sd
Hnh 6.9- Mi siu tinh.
Khi mi siu tinh, p lc ca mi rt nh, tc ct tng i thp. Do c chuyn ng ct phc tp nn cc vt ct mi xa u ln nhau lm cho nhn bng cao (Rz = 0,05 0,1 m) v thi gian mi ngn. Tuy nhin, cng nh mi nghin, mi siu tinh khng sa c sai lch hnh dng v v tr tng quan nn lng d gia cng rt nh (5 7 m). Do vy, trc khi mi siu tinh phi gia cng trc t c kch thc gii hn trn trong bn v.
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Lu c bnh
nh bng: nh bng l phng php lm tng bng b mt, thng dng cho trc khi m v cc chi tit trang tr vi lng d khi gia cng khng ln hn 5m. nh bng dng ht mi rt nh trn vi du nhn c bi ln bnh nh bng n hi (bng g, vi, da p, dy ai) quay vi tc rt cao (20 40 m/s). Trc khi nh bng, chi tit phi qua mi v cc phng php gia cng tinh khc. Khi nh bng, c th p chi tit vo bnh mi bng tay hoc bng my. nh bng c th t Rz = 0,05 0,1, nhng khng th sa c sai lch hnh dng, v tr tng quan, cc khuyt tt li trn b mt (r, lm). 6.2- gia cng b mt tr trong Cng ging nh b mt tr ngoi, b mt tr trong (l) cng c nhiu loi nh l trn, l bc, l cn, l nh hnh. Ty thuc vo tng loi m ta c cc bin php cng ngh khc nhau gia cng cc b mt . thun tin trong vic xc nh gii php cng ngh khi gia cng l, ngi ta tin hnh phn loi l theo t l gia chiu su l l v ng knh l d nh sau: - L ngn: l/d < 0,5. - L thng: 0,5 < l/d < 3. - L di: 3 < l/d < 10. - L su: l/d > 10
a- Khoan l Khoan l mt trong nhng phng php ph bin v c bn nht gia cng l trn vt liu c. Khoan khng nhng c thc hin trn my khoan m cn thc hin kh rng ri v thng xuyn trn cc my tin, my phay, my doa... Khoan c th gia cng c cc loi l thng v khng thng vi ng knh t 0,25 80 mm; chnh xc gia cng thp, ch t cp 10, 11 (cao nht ch l 7 i vi khoan nng sng); nhm b mt Ra = 20 40 m. Do vy, khoan ch dng gia cng cc l bt bulng, l lm ren, cc l c yu cu khng cao v nguyn cng th cho cc nguyn cng tinh sau n. Kch thc l gia cng bng phng php khoan ph thuc vo kch thc mi khoan. i vi l thng nh, trung bnh thng dng mi khoan rut g; l ln, chiu dy nh v thng th dng mi khoan vnh; cn i vi l su (l/d > 10 12) th dng mi khoan nng sng. S d khoan ch t chnh xc thp l v: - Kt cu mi khoan cha hon thin. Lun phi tn ti li ct ngang (v khng th ch to mi khoan c ng knh li bng khng), ti li ct ngang gc trc < 0, cho nn li ct ngang cng di th lc dc trc cng ln, mi khoan cng nhanh mn. Ngy nay, ngi ta c gng ch to mi khoan sao cho li ct ngang cng ngn cng tt.
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Lu c bnh
- Cc sai s do ch to v mi mi khoan sinh ra ( khng ng tm gia phn ct v chui cn) s lm cho l khoan b lay rng ra. Trn mi khoan, phn ct c cn ngc, khi mi khoan mi li cng nhiu th kch thc l s nh i.
2 = 116 1200 a)
b)
c)
Hnh 6.10- Cc loi mi khoan. a) Mi khoan rut g; b) Mi khoan vnh; c) Mi khoan nng sng.
* Cc sai s xy ra khi khoan:
L khoan b cong
L khoan b lay rng
L khoan b tp, loe
Hnh 6.11- Cc loi sai s khi khoan.
- L khoan b cong: sai s ny do mi hai li ct khng u, lc dc trc ca mi khoan khng u lm cho l khoan b cong, loi ny hay gp khi khoan trn my khoan hay my phay (chi tit ng yn). Ngoi ra, khi khoan cc vt liu m l khoan gp phi cc r kh hay pha cng cng b sai s ny. - L khoan b lay rng: khi tm quay v tm phn ct ca mi khoan khng trng nhau s lm cho l khoan b rng ra. - L khoan b tp, loe: do khi n dao khng ng tm, cng vng mi khoan km s lm cho tm quay v tm mi khoan b lch i mt gc. - L b thu hp: Trn mi khoan, phn ct c cn ngc, khi mn th ta s mi li, nu mi khoan mi li cng nhiu th kch thc mi khoan s cng nh so vi ban u, do l gia cng s nh i. * Bin php khc phc: Ngoi nhng bin php m bo cng vng v chnh xc ca h thng cng ngh nh chnh xc ca my, dao, g; kt cu hp l ca chi tit; cn phi ch n cc bin php cng ngh sau y: - Gim bt lc chiu trc v mmen ct bng cch gim bt chiu di li ct ngang khi mi sc mi khoan.
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Lu c bnh
- Khi khoan l su, nn cho chi tit quay to chuyn ng ct, cn mi khoan thc hin chuyn ng tnh tin, chn lng chy dao nh lc ct b, khng nh hng n qu trnh ct gt (v do mi khoan km cng vng nn nu n va quay, va tnh tin th s d b nghing hoc lch). - Dng bc dn hng m bo chnh xc. - Khoan l nh phi khoan mi trc nh tm bng mi khoan ngn. - Dng pointu ly du trc khi khoan. - S dng dung dch trn ngui ng v . b) Khot Khot l nguyn cng m rng l, nng cao chnh xc sau khi khoan v ch c th thc hin vi cc l c sn (l c, dp, khoan). Khot cn l nguyn cng chun b cho nguyn cng doa, mi. Khot c th t chnh xc cp 8, 9; nhm b mt Ra = 2,5 1,25. Mi khot c c im l c 3 4 li ct, cng vng ln hn nhiu so vi mi khoan, do vy d thc hin vic gia cng vi lng d ln, c th sa c cc sai lch v hnh dng hnh hc v v tr tng quan m khoan khng th lm c, ng thi nng cao c bng, chnh xc, nng sut. Khot thng dng gia cng l tr, nu dng mi khot nh hnh c th vt ming loe, gia cng l cn, l bc, gia cng mt phng ming l ... nng cao chnh xc ca l v gim bt thi gian ph, nng cao nng sut, c th dng bc dn hng mt pha hoc hai pha khi khot.
Bc dn Chi tit
Bc dn Chi tit
Hnh 6.12- Dng bc dn hng cho nguyn cng khot.
c) Doa Doa l phng php gia cng tinh hoc bn tinh cc l sau khi khoan, khot hoc sau khi khoan vi cc kch thc nh. Doa c th thc hin trn cc loi my doa, my tin hay my khoan hoc c th doa tay. Doa c th t chnh xc cp 9 7, c th t cp 6; nhm b mt Ra = 6,3 1,25 m, c khi t 0,63 m.
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Lu c bnh
Hnh 6.13- Dao doa.
Dao doa c cng vng cao, s li ct nhiu (6 18) nhng phn b khng i xng trnh rung ng v sai s in dp. Li ct ca dao doa c th l li thng hay li xon c; rng c th l nguyn hay rng chp (c th thay i c ng knh gia cng). Doa c nng sut cao do c nhiu li ct, d cho tc ct khi doa thp (8 10 m/ph) nhng lng chy dao ln, khong 0,5 3,5 mm/v. Gi thnh ca dao doa cao, hn na dao doa thng i theo b vi mi khoan v khot cho nn ch t hiu qu kinh t khi sn xut lot ln i vi cc l tiu chun. Cn trong sn xut n chic, c th thay doa bng tin. Lng d khi doa nh v yu cu ng u kh kht khe. Khi doa th, lng d khong 0,25 0,5 mm; khi doa tinh khong 0,05 0,15 mm. Khi lng d qu nh s c hin tng b trt, bng km; nhng nu lng d qu ln, dao chu ti cao, nhanh mn v co ln b mt chi tit lm bin cng gy kh khn cho nguyn cng doa tinh (v th khng nn dng dao tinh mn doa th). Doa cng c th gia cng c l nh, to, ngn, di theo tiu chun hoc khng tiu chun; l thng hay khng thng. Tuy nhin, khi doa cc l khng tiu chun th phi ch to cc loi dao chuyn dng, lc gi thnh s cao. Bn cnh , mc d c th nhng khng nn doa cc l ngn, l khng thng, l c rnh dc bi v l ngn s khng c kh nng nh hng dao doa v l gia cng d b lay rng; l khng thng th s khng gia cng n y l c. Cn l c rnh dc th khng c kh nng nh hng ng dao vi tm l nn l gia cng s b mo. trnh hin tng lay rng l, c th dng cc bin php sau: - Dng trc doa ty ng: Trc dao doa khng ni cng vi trc chnh m ni lc l. Dao doa lc ny c nh hng chnh bng l gia cng, do khng chu nh hng sai lch ca trc chnh hoc sai lch v ng tm gia trc chnh v trc dao. - Dng dao doa ty ng: y l loi dao doa n gin, ch c hai li ct. Li ct c kh nng x dch t nhiu theo phng hng knh t la theo ng tm l gia cng. Loi ny thng dng khi gia cng cc l phi tiu chun c ng knh t 75 150 mm, u im l gn, nh, n gin, m bo chnh xc gia cng. - nng cao chnh xc th ngoi vic to iu kin cho lng d ng u th nn khoan, khot, doa hoc t nht l khot, doa thc hin trn cng mt ln g.
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Lu c bnh
Tnh thi gian c bn khi khoan, khot, doa:
T0 =
l.i n.S
(ph )
Trong : i: s bc gia cng. n: s vng quay ca dao (hoc chi tit khi khoan trn my tin). S: lng tin dao vng, mm/vng chi tit. l: chiu di tin dao, mm. l = l0 + lav + lvq, vi l0 l chiu su ca l gia cng; - lav l lng n vo: Dd cot g + (1 3) (mm ) + Khi khoan l t vt liu c: l av = 2 vi, D: ng knh mi khoan, mm; d: chiu rng li ct ngang, mm; : gc nghing chnh ca mi khoan, rad. + Khi khoan rng l: lav = t.cotg + (1 3) (mm) vi, t: chiu su ct, t = Db - Da trong , Da: kch thc l trc khi khoan (hay khot, doa) rng. Db: kch thc l sau khi gia cng. - lvq l lng vt qu, mm. + Khi khoan l thng: Khoan l t vt liu c: lvq = 1 3 mm. Khoan rng l: lvq = (0,2 0,5)K, vi K l chiu di phn sa ng + Khi khoan l khng thng: lav = 0. d) Tin l Tin l tuy c nng sut thp hn khoan hoc khot nhng li c kh nng bo m yu cu k thut cao hn. Ngoi ra, tin cn c th gia cng c cc loi l ln, l phi tiu chun, l c to bng c, rn, dp sn, l cn, l bc, l c rnh, l khng thng hoc l nh hnh...
Hnh 6.14- Tin l.
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Lu c bnh
Tuy nhin, cc chi tit c tin l thng phi c kt cu thch hp nh c dng trn xoay, khng qu cng knh hay qu ln v khi lng, hoc khi tm phn b khng qu xa vi tm l gia cng trnh tnh trng gy ra lc qun tnh ly tm ln; l khng qu su v nh v hn ch ca kch thc v cng vng dao. Chun nh v khi tin trong ch c th l mt ngoi hoc mt ngoi kt hp vi mt u. Dao tin l phi c gc sau ln hn so vi gc sau ca dao tin ngoi v thng g dao cao hn tm ca chi tit tng gc sau khi ct, hn ch s c st mt sau ca dao vo b mt gia cng, mt khc cn c kh nng chng rung. Tin l c th gia cng trn cc loi my tin, my phay, my doa... Khi tin l trn my tin th thng ch gia cng cc l nh, ngn hnh tr hoc cn. Cn cc l ca cc chi tit dng hp thng c gia cng trn my doa. Trong sn xut n chic, khi gia cng nhng chi tit dng hp nh, c th gia cng trn my tin vn nng (hoc my phay), lc chi tit c g trn bn dao v c chuyn ng dc, cn dao s thc hin chuyn ng ct V theo cch gia cng trn my doa. e) Chut l Chut l l phng php gia cng l c nng sut cao do nhiu li ct cng tham gia ct gt v khng mt thi gian cho vic o, iu chnh dao nh nhiu phng php khc. V th, phng php ny c nng sut rt cao, v thng dng khi sn xut hng lot ln, khi. Chut c th gia cng t chnh xc b mt cp 7, nhm b mt Ra = 0,8 0,6; cht lng b mt tt v vn tc ct thp nn bin dng do khng nhiu. Khi chut l, chuyn ng ct chnh l chuyn ng tnh tin ca dao, chi tit ng yn. Qu trnh chut khng c chuyn ng chy dao. C th chia thnh hai loi: chut y v chut ko. Chut c th thay th gia cng mt ln cc nguyn cng th, bn tinh v tinh; thay th cho c khoan rng, khot v doa; kt hp chut l vi rnh then hay rnh then hoa.
Hnh 6.15- S chut l. a) Chut ko; b) Chut y

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Lu c bnh
Chut c th gia cng c cc loi l trn, vung, nh hnh nhng phi l l thng, thng v tit din khng i; cc l c ng knh n 320 mm, then hoa ng knh n 420 mm, rnh rng 100 mm, chiu di l n 10 m. Tuy nhin, dao chut rt t tin, kh ch to. Lc chut ln nn my phi c cng sut ln; chi tit, dao, my phi c cng vng ln. Chut khng sa c sai lch v v tr tng quan do trc khi chut, l cn phi gia cng chnh xc v v tr tng quan. Sai s hay gp nht khi chut l thnh mng hoc thnh dy khng u l l gia cng rt d b bin dng. Bi v khi chut, p lc hng knh ln nn i vi l c thnh mng th sau khi chut ng knh b nh i; cn l c thnh dy khng u th hnh dng l b mo (do bin dng n hi).
6.2.2- Gia cng ln cui v gia cng sau nhit luyn
a) Tin mng Phng php ny cng tng t nh khi gia cng mt tr ngoi. Dao tin lc ny l dao c gn mnh hp kim cng hoc kim cng c mi nghin cn thn vi nhm li ct Rz = 0,04 0,32, s dng my c cng vng cao, chnh xc cao, my c tc ct cao (khi tin hp kim nhm: v = 1500 m/p; tin hp kim ng: v = 450 m/p; tin thp: v = 200 250 m/p). chnh xc t c khi tin mng c th l cp 6 7; Ra = 0,63 1,25 m; nng sut gia cng cao v l phng php gia cng ch yu i vi cc hp kim mu. b) Mi l Mi l l phng php gia cng tinh l, cc l sau khi mi c th t cp chnh xc 6 7; Ra = 3,2 0,2m. Mi l thng dng trong cc trng hp sau: - Mi cc l c cng cao ( qua ti). - Mi cc l ln, l phi tiu chun, l c kt cu khng thun tin cho cc phng php khc v c yu cu chnh xc cao. - Mi cc l cn sa li sai lch v v tr tng quan ca l do cc nguyn cng trc li. V chuyn ng ct v bn cht ca qu trnh gia cng khi mi mt tr trong cng hon ton ging nh khi mi b mt tr ngoi. Tuy nhin, khi mi l, ng knh b hn ch bi kch thc l gia cng ( 0,8ct). V th, khng th t c tc mi bng cch tng ng knh m phi tng s vng quay ca trc mang , nhng lc ny s gp nhiu tr ngi nh lc qun tnh ly tm s rt ln, rung ng v khng an ton. Tc ca khng c vt qu 35 m/s. Do vy, b mt ca l gia cng t bng khng cao (so vi mi mt ngoi).
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Lu c bnh
Mi bng mi: * Phng php mi c tm: Mi l c tm c th gia cng c cc l tr, l cn; c thc hin trn cc my mi trong, my mi trn ngoi vn nng... Vic chn my no l tu thuc vo dng sn xut v phng php mi. Khi mi l c tm c th thc hin theo hai cch: chi tit quay, v chi tit ng yn.
Hnh 6.16- Mi trong c tm.
Cch 1: Chi tit c kp cht trong mm cp v quay trn, cn trc cng quay trn (ngc chiu vi chi tit) v thc hin chuyn ng chy dao dc hoc chay dao ngang. Cch mi ny thng c s dng trn my mi trn trong. Cch ny thng dng gia cng nct nhng chi tit nh, cc vt th trn xoay hay d g trn mm cp v c th thc hin trn my tin vn nng vi g chuyn dng nh ng, a. n im lu l ng knh mi: d Hnh 6. 17- Mi l trn 0,8.dl, vn tc quay ca trc khong 20 my mi trn trong. 30 m/s. Cch 2: Chi tit c g c nh trn bn my, trc mang thc hin tt c cc chuyn ng: Chuyn ng quay trn ca ct, cc chuyn ng chy dao v chuyn ng hnh tinh ca xung quanh l gia cng. Kiu mi ny c dng trn my mi hnh tinh, thng gia cng cc chi tit loi ln, cng knh nh lc my, thn, b, tm... bi v nu dng cch th nht th vic g t ln mm cp khng th thc hin c hoc rt l kh khn, hn na s xut hin lc ly tm, i hi Sn my phi c kch thc rt ln v cng sut rt ln, Sd n cng vng cao. Cc my mi hnh tinh thng c ch to theo kiu di ng c v c th g trc tip ln chi tit gia cng. iu to kh nng rt thun
Hnh 6. 18- Mi l trn my mi hnh tinh.
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Lu c bnh
li cho cc cng vic sa cha hoc trong dng sn xut n chic hay lot nh. N thng c s dng i vi cc nh my ch to my hng nng. * Phng php mi khng tm: Phng php mi ny c kh nng t chnh xc v ng tm rt cao. Thng dng gia cng cc chi tit c yu cu ng tm cao gia l v mt tr ngoi trong sn xut hng lot ln v hng khi, cc chi tit khng th g trn my mi trn trong nh chi tit c thnh mng, chiu di ngn (nh segment).
Con ln t Chi tit nct n dn
Con ln ta
mi
dn
Hnh 6.19- Mi l khng tm
Chi tit gia cng quay nh dn (c h s ma st ln) v cc con ln t v ta. mi ngoi chuyn ng ct khi quay cn thc hin cc chuyn ng chy dao dc v ngang. Phng php ny c chun cng ngh l mt ngoi, nn trc khi mi phi gia cng bn tinh hoc tinh mt ngoi. Mi nghin: Mi nghin l v c bn cng ging nh mi nghin mt tr ngoi, n ht i mt lp rt mng kim loi t chnh xc v bng b mt cao. Nghin l c th t chnh xc cp 6, Ra = 0,3 0,01 m ( c iu ny th trc khi nghin chi tit phi t chnh xc cp 7, Ra = 1,6 0,4 m).
Chi tit
Hnh 6.20- Mi nghin l bng bc ch C.
Khi nghin l, chuyn ng ct l chuyn ng quay trn v tnh tin kh hi ca cc dng c nghin.
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Lu c bnh
Mi khn: Mi khn l s pht trin cao hn ca mi nghin. y l phng php gia cng tinh, t cht lng b mt tt, nng sut cao hn so vi cc phng php gia cng khc. C th t c cp chnh xc 6, nhm b mt Ra = 0,16 0,32 m. So vi mi nghin th mi khn c nhng thay i sau: - Thay dng c mi nghin v bt mi bng dng c khc mang cc thi gi l u khn. - Chuyn ng ct c xc nh r rng, gm chuyn ng quay v chuyn ng tnh tin kh hi dc trc ca u khn. - p lc mi, di ca th ra hai u l sau mi hnh trnh kp v nhng thng s khc c quy nh cht ch. Khi gia cng, chi tit ng yn v Trc chnh c kp cht bng g trn bn my. u khn c ni vi trc chnh qua cc khp (khp cu hay khp cc ng) v thanh dn. u khn mang nhiu thi n S , cc thi c b tr theo phng mi song song hay nghing vi trc quay 1 u khn gc v c th di chuyn c theo phng hng knh. Chi tit mi, sau khi a u khn vo trong chi tit, trc chnh quay, lc ny s cung cp mt p lc nht nh cho p ln b mt gia cng. Vic cung cp p lc cho l ty vo kt cu u khn, Hnh 6.21- S mi khn l. c th bng tay thng qua ren vt rt hai u cn hoc tt nht l dng du p tc ng vo trc du khn tm. Sau khi gia cng xong, ta tin hnh ngc li nh trn ly u khn ra. Hnh 6.22 l kt cu ca u khn Trc thay i n gin. mi c lp trn cc tm p lc ln Cnh mang kp, tm kp c lp trn cnh mang . tng p lc tc dng ln , ngi ta iu chnh bng ren trc c phn cn i xung lm bung cc cnh ra L xo tc dng vo b mt mi. phng cc cnh mi b vng ra khi rt u mi ra khi l, u v cui cc tm kp c hai l xo vng chng vo rnh. Ngoi ra, cn nhiu loi u khn Hnh 6.22- Kt cu ca u khn. khc.
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Lu c bnh
Khi gia cng, do u khn c chuyn ng quay v tnh tin ng thi nn to ra vt ct gt ca ht mi l nhng Chiu 2 su l ng xin v an cho nhau thnh li u n, L chnh nh c im ny m cc vt ct sau s l2 d xo vt ct trc, lm cho b mt chi tit gia Hnh 6.23- Vt gia cng khi mi khn. cng c nhn bng. Sau mi hnh trnh kp th phi iu chnh kch thc u khn (tng p lc ln ), lng iu chnh ny tng ng vi lng n dao ngang khi mi l (mm/htk). Sau khi gia cng ht lng d th khng iu chnh na, m cho thc hin lm vic tip trong mt thi gian xo ht cc vt gia cng.
l1
Hnh 6.24- Sai lch khi mi khn.
chnh xc khi mi khn ph thuc vo vt qu l1, l2 ca thi . Nu l1, l2 ln th b mt gia cng s b loe; nu l1, l2 nh th b tp. Thng thng, ly chiu di vt qu ny khong: l1, l2 = (0,25 0,5).l u im: - Nng sut cao, nh c nhiu thi lm vic. - C th sa c sai s hnh dng. - Vn tc ct thp nn nhit ct thp, t thay i tnh cht c l ca lp b mt. - cng vng ca u khn tt, khng bin dng trc nn m bo l trn. Nhc im: - Sau khi gia cng c ht mi cm vo b mt gia cng, lm cho chi tit b mi mn nhanh. khc phc, sau gia cng nn ra sch chi tit bng dung dch Keroxt. - Khng sa c sai lch v v tr tng quan. - Khng gia cng c kim loi mu v phoi ca kim loi mu l phoi vn, do n s lp kn cc l trn mi, lm cho khng th mi tip c.
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Lu c bnh
6.3- gia cng mt phng Trong cc b mt hnh thnh nn chi tit my th mt phng l b mt ph bin nht. gia cng mt phng, ngi ta c th dng nhiu phng php nh phay, bo, xc, tin, mi... Sau y, ta s nghin cu cc phng php gia cng ny.
a) Bo v xc Bo v xc l nhng phng php gia cng mt phng c tnh vn nng cao, c s dng rng ri trong sn xut n chic v hng lot. Bo v xc c th gia cng mt phng t chnh xc cp 9, 10, nhm b mt Rz = 20 40m; v th thng dng gia cng th nhm bc i phn ln lng d. Chuyn ng ct ca bo v xc n gin. Bo c chuyn ng ct l tnh tin ca dao bo theo phng ngang, cn xc th theo phng thng ng. Ring vi my bo ging th chi tit c g ln bn my v thc hin chuyn ng ct. Dao bo c kt cu khng khc g dao tin v hnh dng hnh hc phn ct, cn dao xc tuy b phn ct hi khc nhng cc gc ca phn ct th tng t dao tin C hai phng php ny u c nng sut thp bi v: - Tn thi gian cho hnh trnh chy khng. - Vn tc ct thp (vi bo: v = 12 22 m/p; vi xc: v < 12 m/p) v c chuyn ng tnh tin kh hi nn nu vn tc ct cao th lc qun tnh s rt ln.
t s
s Hnh 6.25- Bo v xc.
Bo thng c s dng gia cng cc mt phng ngoi. c bit vi cc mt phng di v hp th bo t c nng sut rt cao. Chi tit thng c g trn t hay cc c chn, v tr c kim tra bng mi r hoc ng h so, do vy m chnh xc ph thuc vo tay ngh cng nhn. Xc c s dng khi gia cng cc mt phng rnh, hp bn trong (nh rnh then trong l). Dao xc c cc gc ct tng t nh bo, hnh dng th c ch to thch ng vi chuyn ng theo phng thng ng. Khi gia cng mt phng bng phng php bo, xc th u tin chn chiu su ct ln trc, sau mi chn n tc ct.
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Lu c bnh
Tnh thi gian c bn khi bo v xc:
B.i (ph ) n.S Vi: B l chiu rng tnh theo phng chy dao, mm. B = b0 +b1 +b2; b0 l chiu rng ca b mt gia cng; b1, b2 l lng n vo v vt qu. i: s bc gia cng. S: lng tin dao sau mt hnh trnh kp, mm/htk. n: s hnh trnh kp trn mt pht, htk/ph V .1000 n= c ; L(1 + m) Vc l tc ct khi bo (xc); L l chiu di hnh trnh bo (xc) tnh theo phng vn tc ct, L = l0+l1+l2; l0:chiu di b mt gia cng; l1, l2: lng cha trc v thot dao khi bo m l t s gia tc ct v tc chy khng khi dao bo (xc) li v: m = Vc / Vck. Ngoi ra, c th tnh theo cng thc: (b + b 1 + b 2 ).(l 0 + l 1 + l 2 ).(1 + m) T0 = 0 i (ph ) Vc .1000.S To =
b) Phay Phay l phng php gia cng mt phng c s dng rng ri nht. Trong sn xut ln, phay hu nh thay th hon ton bo bi v phay c nhiu li ct, tc ct cao hn nn nng sut cao hn.
Hnh 6.26- Cc s phay cc mt phng.

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Lu c bnh
Khi phay, chnh xc c th t c cp 8, 9; nhm b mt Rz = 10 20. Khi phay tinh c th t chnh xc cp 7, Ra = 1,25. Phay mt phng c th c s dng trn cc my phay vn nng nm ngang hay ng, my chuyn dng. Ngoi ra, cn c th dng my phay ging. Dao gia cng mt phng c th l dao phay hnh tr, dao phay mt u, dao phay ngn hay dao phay a. Khi phay mt phng bng dao phay tr c th thc hin bng hai cch: - Phay nghch: l cch phay m vct tc ct v hng tin dao ngc chiu trong vng ct. Phay nghch thng c dng v chiu dy lp ct t nh n ln nn t va p, nn bo qun my, dao d dng v c th dng my c gia cng. Do vy, khi gia cng th hay gia cng vt liu cng th nn phay nghch. Tuy nhin, v lp ct bt u c chiu dy l 0 do , ti y vt liu b nn xung, khi dao i qua, ti nhng ni b nn s b li lm do bin dng n hi. - Phay thun: l cch phay m vct tc ct v hng tin dao cng chiu trong vng ct. u im ca phay thun l khng gy nn hin tng trt trn b mt khi n dao, do nhm b mt nh, ng thi nng cao nng sut (vi cng iu kin ct th cao hn 50% so vi phay nghch) nn phay thun c dng khi gia cng tinh hay vt liu mm, my chnh xc v c cng vng cao. Tuy nhin, phay thun c chiu dy ct t ln xung nh, do vy gy va p, v th ch dng phay thun khi my mi hay my c b phn kh r gia ai c v vitme bn my (v lc ct c phng trng vi phng lc y ca vitme - ai c).
a)
b)
Hnh 6.27- S phay mt phng bng dao phay tr. a) Phay nghch; b) Phay thun
G t chi tit khi phay mt phng: - Ly du, ct th: Chi tit c th c g trc tip ln bn my, r theo du v k lt xc nh v tr. Sau kp cht bng ren vt hay m kp hoc g chi tit ln t ri ct th v iu chnh dn. Phng php ny dng khi sn lng t. - Dng g c c so dao: Vi g ph hp vi chi tit cn gia cng, ch cn a dao vo ng c so dao v gia cng. Cch ny dng cho sn lng ln.
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Lu c bnh
nng cao nng sut khi phay, ngy nay ngi ta dng cc cch sau: - G nhiu dao ln mt trc gia cng ng thi nhiu b mt: Phng php ny nhm tn dng cng sut ca my, dng nhiu dao ct cng mt lc, gim bt cng g t nhiu ln v c bit l lm cho thi gian my trng nhau. Ngoi ra, cn c th g nhiu dao ln nhiu trc, cch ny dng khi my phay c nhiu trc chnh. - Phay nhiu chi tit trn mt ln g: G nhiu chi tit ct cng mt lc s rt ngn c thi gian ph g t, kp cht chi tit; ng thi tn dng rt ngn c thi gian my v s gim lng n vo v vt qu. Nu chi tit c kt cu b mt khng lin tc th c th cho chy dao nhanh qua cc ch trng gim bt thi gian. - Dng bn quay: rt ngn thi gian ph, ng thi kt hp s dng nhiu dao cng mt lc, ngi ta dng g c bn quay khng lin tc. Vi dao phay a 3 mt, ch sau mt ln chy dao l c th gia cng c 4 b mt song song, quay i 900 l c mt chi tit c hon thnh.
Bn quay Bn quay Dao phay Chi tit
Chi tit S phay trn bn quay khng lin tc. S phay trn bn quay lin tc.
Tuy nhin, bn quay lin tc vn c thi gian khng gia cng quay bn, do tn dng lun thi gian ny, ngi ta dng bn quay lin tc. Phi c xp st nhau, bn quay ng thi dao cng quay gia cng. Khi ct bng bn quay lin tc, yu cu tc ca bn quay phi nh hn hay bng lng chy dao cn thit v sao cho cng nhn c kh nng tho lp xong trong tm tay ca h.
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Lu c bnh
- Dng bn chuyn ng tnh tin kh hi: Trn g c th lp c nhiu chi tit, khi ang Vng gia cng gia cng chi tit th nht, th ngi cng nhn lp chi tit Vng lp Vng tho th hai vo u kia ca g. Khi gia cng xong chi tit th nht th bn my s chy n dao ct tip chi tit th hai, trong lc th ngi cng nhn tho chi tit th nht ra v lp vo phi th ba. Khi gia cng xong chi tit th hai th bn my chy ngc li gia cng chi tit th ba v c tip tc nh th.
Tnh thi gian c bn:
Khi phay bng dao phay tr v mt u: L.i T0 = (ph ) SM trong : SM: lng tin dao pht, mm/ph SM = Sz.Z.n, Sz l lng tin dao rng (mm/rng); Z l s rng ca dao phay; n l s vng quay ca dao (v/ph). l: chiu di hnh trnh chy dao, mm l =l0 +lav +lvq l0 l chiu di b mt gia cng (mm); lav l lng n vo, n c xc nh: + Vi dao phay tr: l av = R 2 (R t ) 2 R l bn knh dao phay tr (mm); t l chiu su ct (mm). + Vi dao phay mt u: l av = D.t t 2 D l ng knh dao phay, t l chiu su ct (mm). lvq l lng vt qu, thng c chn t 2 5mm v ph thuc vo ng knh dao. c) Chut mt phng Chut mt phng l phng php gia cng mt phng c chnh xc, nng sut cao (gia cng th, tinh ch trong mt ln chut) nhng gi thnh cng cao (ch to dao kh tn km) do vy ch dng trong sn xut hng lot. Chut mt phng c th gia cng mt phng t chnh xc cp 7, nhm b mt Ra = 0,32 0,16. Khi chut mt phng, ngoi yu cu v cng sut my, cng vng ca my, dao; vic kp cht chi tit phi ht sc chc chn. Chut mt phng c th dng nhiu kiu dao khc nhau.
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Lu c bnh
Chut lp l phng php chut m lng d c chia thnh cc phn c chiu dy bng nhau. Cch ny thng c dng gia cng b mt qua gia cng v t chnh xc tt. Chut mnh l phng php chut m lng d c chia thnh cc phn c chiu dy khc nhau. Cch ny thng dng gia cng b mt cha qua gia cng, yu cu Chut mnh Chut lp rng ca dao c cao nh nhau v chiu rng ca rng s c m dn Hnh 6.28- S chut mt phng. ra v mt pha hoc t gia m rng ra hai pha hoc t hai pha m vo gia, lc ny dao chut lm vic tng t nh bo c nhiu dao. tng nng sut khi chut mt phng, ngi ta cn thay chuyn ng tnh tin ca dao bng chuyn ng quay lin tc ca bn my trn c g chi tit hoc bng chuyn ng quay lin tc ca hai bnh truyn lm cho bng ti chy lin tc.
6.3.2- Gia cng ln cui v gia cng sau nhit luyn
a) Bo tinh mng Bo tinh mng l phng php gia cng tinh mt phng cc chi tit khng qua nhit luyn hoc bng hp kim mu c kh nng t chnh xc v cht lng b mt cao. Ngoi ra, y l phng php gia cng tinh mt phng c nng sut rt cao. Bo tinh mng c th gia cng mt phng t chnh xc cp 7; nhm b mt Ra = 0,32 0,16. Tuy nhin, trc chi tit phi c gia cng t chnh xc cp 8, 9; nhm b mt dao cao Ra = 0,16; my bo chnh xc, cng vng cao, khng c r, li ct c ch to chnh xc (qua mi nghin), g dao chnh xc (kim tra bng khe h nh sng). Bn cht ca bo tinh mng vi dao rng bn l dng dao c li ct rng (40 120 mm); ct vi chiu su ct rt b (0,05 0,08 mm) nhng lng chy dao li kh ln ( 0,5 chiu rng li ct); tc Hnh 6.29- Bo tinh mng. ct cng tng i ln, i vi dao thp gi th v = 6 12 m/ph, cn i vi dao hp kim th v = 15 20 m/ph.
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Lu c bnh
b) Mi Mi trn my mi phng: Mi trn my mi phng l mt phng php c bn gia cng tinh mt phng, hoc gia cng ln cui cc mt qua ti sau khi phay hay bo. Mi phng c th gia cng c mt phng t chnh xc cp 7, nhm b mt Ra = 1,6 m. Tuy nhin, do nhit pht sinh ra trong qu trnh mi phng ln nn rt d gy ra bin dng nhit trong qu trnh mi, c bit ch vi cc chi tit mng. * Mi phng bng mi hnh tr: Phng php mi phng V ny c kh nng t c chnh xc v nhn bng b mt cao bi v phng php ny c th thot phoi, thot nhit v ti dung dch trn S ngui vo khu vc gia cng d. Tuy nhin, do din tch Vbm tip xc vi chi tit khng ln nn nng sut thp, khc Hnh 6.30- Mi phng bng mi hnh tr. phc th dng rng bn. * Mi phng bng mi mt u: Phng php mi ny c nng sut cao, tit kim c mi. Tuy nhin, do kh thot phoi v kh a c dung dch trn ngui vo vng gia cng do m vic thot nhit chm, v vy chnh xc v nhn bng thp hn so Hnh 6.31- Mi phng bng vi mi bng mi hnh tr. Mun c mi mt u. c chnh xc v nhn bng cao th phi chn ch ct thp, lc th nng sut li khng cao. Nu nghing i mt gc nh th c th gii quyt c vn thot nhit, thot phoi v a dung dch trn ngui, nhng khi cc vt mi s khng xa ln nhau nn nhn bng b mt thp v mt gia cng cn b lm xung. Mi nghin: Mi nghin mt phng thng c gia cng trn my nghin trc thng ng hoc dng cc g trn my khoan hay my phay ng. a nghin c ch to theo dng tm hoc dng a trn. B mt ca a nghin c th phng hoc c cc rnh; vi a phng th qu trnh cp bt nghin rt kh khn nn chi tit s c profin li, cn a c rnh cho php bt nghin i ti tt c cc phn ca b mt gia cng nn chi tit c chnh xc v nng sut cao hn.
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Lu c bnh
Khi nghin th, a nghin thng lm bng ng hay hp kim mu (v chng c kh nng gi c ht mi ln); cn khi nghin tinh th a nghin c lm bng gang peclit (v loi ny d gi ht mi mn nh). Bt nghin l Al2O3 hay Cr2O3. Nghin phng c thc hin bng cc phng php: bc tnh tin i li (a); bc vng (b) v phng php phi hp (ca bc tnh tin v bc vng):
1 2 3 1 2
a) Hnh 6.32- Cc phng php nghin mt phng. 1- Dng c nghin; 2- Vng cch; 3- Chi tit
b)
- Theo phng php bc tnh tin i li, chuyn ng ca chi tit gia cng bao gm chuyn ng tnh tin i li song song hoc cc chuyn ng tnh tin i li vung gc vi nhau. - Theo phng php bc vng th a nghin quay, chi tit c nh hoc a nghin c nh, chi tit quay. - Cn phng php phi hp th a nghin quay, chi tit th tnh tin i li. c) Co Co l phng php gia cng tinh vi dng c l dao co (thp dng c) v c thc hin bng tay hay bn c kh. Co c th gia cng c nhiu b mt khc nhau nh mt phng, rnh mang c, rnh then...; c th t chnh xc cao v phng (c th t 0,01/ 1000 mm) v v tr tng quan gia chng bng cc dng c n gin. Tuy vy, co li tn nhiu cng sc, nng sut khng cao v khng gia cng c vt liu qu cng nn thng dng sn xut nh. Bn cht ca co l dng bn mu (m bn) c phng cao, trt ln mt lp sn rt mng ri p ln b mt cn co kim tra phng, sau tm nhng im cao c dnh sn co. B mt phng c nh gi qua s im dnh sn phn b trn mt phng. - Co th: 12 18 im trn din tch 25x25 mm2. - Co tinh: 20 25 im trn din tch 25x25 mm2. B mt sau khi co c th gi c lp du bo m bi trn tt trong qu trnh lm vic, v nh c th gip cho mt phng lu mn.
Mn t nht Mn ln nht
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Lu c bnh
6.4- gia cng b mt ren Ren l loi b mt c to thnh trn c s ng xon c tr (hoc cn). B mt ren c s dng rt ph bin trong c kh ni ring v cng nghip ni chung. Ren c nhiu loi khc nhau nh ren kp cht (bulng, ai c c tit din tam gic); ren truyn ng (vitme - ai c c tit din hnh thang, ch nht, trn); ren lp kn (ren ng nc c tit din trn u). Nhng yu cu khi gia cng ren l: chnh xc bc ren; chiu dy ren trn ng knh trung bnh; chnh xc bin dng v tit din ren; bng sn ren...
a) Tar, bn ren Ct ren bng tar v bn ren c tin hnh bng tay hay bng my. Tar v bn ren l hai dng c ct ren c tiu chun ha. Tar dng ct ren trong, bn ren dng ct ren ngoi. Tar Ty theo cng dng v kt cu m ngi ta chia tar thnh cc loi sau: l1 l2 l4 - Tar tay: gm 2, 3 chic trong mt b. - Tar my: dng trn my khoan. - Tar ai c: dng gia cng ai c. Tar ch yu dng ct ren trong tiu chun c ng knh trung bnh v nh. l l3 Tar c th gia cng c ren tr, ren cn, Hnh 6.33- Tar tay. thng hoc khng thng. Gc nghing chnh ty theo loi tar v iu kin ct m c gi tr khong 3030 250. Rnh tar dng cha phoi, ty theo ng knh m s rnh c th t 3 6 rnh, thng thng l rnh thng, i vi l su th l rnh xon. Tc ct khi gia cng bng tar thp (5 15 m/p) bi v tar c nhiu li ct cng lm vic mt lc, do nhit to ra ln, rt d gy chy nh ren. chnh xc khi ct ren ty thuc vo vt liu lm tar, chnh xc ch to n v phng php thc hin khi gia cng. Nu phn ct c mi th chnh xc c th t cp 7, nu khng ch t cp 8. L ren c gia cng bng tar d b nghing, lc s rt d gy tar. khc phc hin tng ny, khi tar my phi thc hin khoan v tar trn mt ln g; nu hai ln g th khi tar phi dng u t la d nh v tar theo l khoan. Nng sut ct ren bng tar rt thp v tc ct thp v hnh trnh chy khng. nng cao nng sut, ngi ta dng loi tar t bp li sau khi ct ren xong c th rt thng ra khi l; hay dng mi tar my u cong trn my khoan hay tin gia cng ai c lin tc, loi b c hnh trnh chy khng.
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Lu c bnh
Bn ren: Nu trng hnh dng bn ngoi, khng k cc l thot phoi th bn ren c hnh ca mt ai c. Trn vnh ngoi ca bn ren c 4 l cn 900 bt vt kp bn ren trong tay quay. Hai trong 4 l c ng tm lch i so vi phng hng knh mt lng l c dng iu chnh kch thc khi bn ren b mn. c im v tc ct, chnh xc v nng sut cng ging nh l tar. nng cao nng sut, ngi ta cng dng loi bn ren t m, tc l sau khi ct ren xong, cc li ct ca bn ren t m ra c ng knh trong ln hn ng knh nh ren v c th rt hn ra ngoi.
Hnh 6.34- Bn ren.
b) Tin ren Tin ren bng dao tin ren y l phng php gia cng ren ph bin nht c tin hnh trn my tin ren va vn nng, ph hp vi sn xut n chic v lot nh. p ng yu cu lm vic ca ren phi bo m gc tit din , bin dng ren v ng knh trung bnh. iu ny ch c th thc hin c khi g dao chnh xc, tc l li ct phi nm trong mt Hnh 6.35- Tin ren. phng nm ngang vi ng tm ca chi tit gia cng, ng i xng ca mi dao thng gc vi ng tm chi tit v cch n mt on bng bn knh chn ren. Ngy nay, c hai phng php tin ren nh sau: - Tin dao hng knh: a) b) Phng php ny c th ct ren t nhn b mt ren cao nhng kh thot phoi nn ch c th p dng ch S S ct thp, do nng sut Hnh 6.36- S ct khi tin ren. ct thp.
a) Tin dao hng knh; b) Tin dao nghing.
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Lu c bnh
- Tin dao nghing: Kiu ny d thot phoi, iu kin ct tt hn nhng nhn mt ren li khng cao. Do , thng thng ln ct cui cng tin hnh chy dao hng knh tng nhn bng b mt ren. Khi tin ren nhiu u mi, lc chuyn sang u mi khc cn iu chnh dao vo ng v tr, khi chi tit c tch khi xch tin ren v quay mt gc tng ng so vi s u mi ren. nng cao nng sut tin ren, c th nng cao ch ct trong ch yu l tng vn tc ct v chiu su ct. Tuy nhin, cch ny s gp kh khn khi gia cng ren c bc ln, chiu di on ct ren ngn v rt d b va p. khc phc th ngi ta dng c cu rt dao nhanh, sau khi gia cng ht chiu di ren th s c tc ng lm cho dao li ra hay tin vo (ph thuc vo ren trong hay ngoi), tip l rt dao ra nhanh cho n khi chm c chn th dao li tr v v tr ban u. Tin ren bng dao rng lc Dao rng lc c coi nh gm nhiu dao tin ren n c chiu cao tng dn trong mt ln chy ren c th gia cng chiu su ren, m bo nng sut gia cng . Ct ren bng dao rng lc thng c tin hnh trn my tin rvnve t ng v bn t ng. Gia cng ren bng dao rng lc ch dng khi ct ren thng sut.
Hnh 6.37- Dao tin rng lc.
Gia cng ren bng u ct ren Dng u ct ren c th ct ren trong v ren ngoi trn my chuyn dng hoc trn my tin ren vn nng. Trn thn ca u ct ren c lp cc dao ct ren rng lc. cui hnh trnh ct, cc dao c ni nhanh ra khi vng tip xc vi chi tit, do vic li dao c tin hnh nhanh hn v gim thi gian ph. Gia cng ren bng u ct ren thng dng trong sn xut hng lot, tc ct tng i ln 15 20 m/ph. Phng php ny cho nng sut rt cao, cao hn hn cc phng php gia cng ren trc.
Hnh 6.38- u ct ren.
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Lu c bnh
Tin ren gi lc tin ren cao tc, ngi ta dng mt u tin ren cao tc lp trn my tin vn nng hoc my chuyn dng. Phng php ny c th gia cng c c ren trong v ren ngoi. u tin ren cao tc thng lp 4 6 dao v lp lch tm so vi tm chi tit. Khi quay mi li dao ht i mt lng hnh li lim. u tin ren cao tc ngoi chuyn ng quay sinh ra vn tc ct, cn c chuyn ng tnh tin ct ht chiu di ren.
Hnh 6.39- S tin ren cao tc. a) Tin ren cao tc bao ngoi; b) Tin ren gi lc khng bao
u ren cao tc c th dng vn tc ct ln (v cc dao ct khng lin tc nn thot phoi, thot nhit tt), nu dng dao thp gi v = 80 100 m/ph; cn dng dao gn mnh hp kim cng th vn tc ct c th n 300 m/ph. V vy, nng sut rt cao. c) Phay ren Phay ren l phng php gia cng ren trong v ren ngoi t chnh xc v nng sut cao. Thng dng trong sn xut hng lot trn my phay chuyn dng. Phay on ren di on ren di khi chiu di on ren gia cng ln hn 2 3 ln ng knh ren, khi dng dao phay a gia cng.
Hnh 6.40- S phay on ren di bng dao phay a.

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Lu c bnh
Khi dng dao phay a th trc dao phi nghing vi trc mt gc ng bng gc nng ca ren. Tuy nhin, dng cch ny s c sai s dng ren bi v ch ng knh trung bnh ca ren mi yu cu gc nghing ca trc dao bng gc nng ca ren, trong khi dao lun xoay mt gc c nh. Hn th na, li ct khng nm trong mt phng qua tm, do ren c bin dng ng th dao phi c li ct dng ng cong, m nu th th qu phc tp. V vy, ngi ta dng dao c li ct thng v chp nhn sai s dng ren. Cho nn, cch ny ch dng gia cng ren c yu cu chnh xc khng cao hoc gia cng th mc d c nng sut kh cao. Phay on ren ngn on ren ngn khi chiu di on ren gia cng khng vt qu 2 3 ln ng knh ren, khi dng dao phay rng lc gia cng.
Hnh 6.41- S phay on ren ngn bng dao rng lc.
Khi lm vic, chi tit quay chm, dao va quay va tnh tin dc trc. Trc dao khng cn phi g nghing i mt gc so vi trc chi tit, iu ny c ngha nh tin, do nu g dao ng tm ca n v ca chi tit cng nm trong mt phng nm ngang v song song vi nhau th dng li ct l ng thng, dao d ch to v chnh xc dng ren cao hn. d) Cn ren Cn ren l mt trong nhng phng php gia cng ren t nng sut cao nht, nn thng dng trong sn xut hng khi v hng lot ln. V bn cht, cn ren khc hn vi cc phng php gia cng ren m ta ni trn, ch n to ren khng phi bng cch ct ra phoi m bng bin dng do. Chnh c im ny gip cho ren c c sc bn rt tt do khng lm ct t cc th dc ca kim loi nh cc phng php gia cng ct gt. Dng c cn ren c th l bn cn phng, bn cn hnh cung hay con ln ren (l cn ren). Bn cn ren phng (a) lp trn g c th lm vic trn u my bo hoc
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my chuyn dng cn ren; trn bn cn c to ra cc rnh vi gc nghing ren tng ng vi ren cn gia cng. Cch ny dng cn ren nhng chi tit c ren vi kch thc nh.
Hnh 6.42- S gia cng ren bng phng php cn.
Cn bng hai l cn ren (b) lm vic trn my cn ren chuyn dng, c nng sut cao hn v chuyn ng lin tc (khng gin on nh dng bn cn ren). Khi cn, chi tit c trn thanh sao cho tm chi tit thp hn tm l cn khong 0,2 mm. L cn A quay trn trn trc c nh, l B c dn ng quay v c th ra vo iu chnh khi gia cng. Cn ren bng bn cn hnh cung (c) thng dng khi cn ren t ng c nng sut rt cao (20.000 25.000 bulng/h), song chnh xc ren khng cao. Cn bng ba l cn (d) cho chnh xc v nng sut cao.
6.4.2- Gia cng sau nhit luyn
Mi ren dng gia cng tinh nhng ren c yu cu chnh xc cao nh ren trn cc calip ren, tar, con ln ren, bn cn ren, ren trong cc my chnh xc... v cc loi ren qua nhit luyn. Mi ren c thc hin trn my mi ren chuyn dng, c cng ngh gia cng chnh xc v tng i phc tp. Tuy vy, ngy nay do yu cu nng cao cht lng sn phm, cng ngh ny pht trin mnh m v c nhiu thit b mi ren chnh xc ra i.
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Ch ct khi mi ren c th tnh ton theo cng thc cho trong s tay. Tuy vy, khi chn ch mi cn phi ch n vt liu gia cng, s ln mi, cng vt mi m iu chnh cho ph hp. Cn v lng d khi mi, vi nhng loi ren bc nh th ngi ta khng ct s b m mi to ren ngay trn phi; ren c bc ln v gia cng s b th lng d mi cn li c th tnh theo cng thc: (K: h s) = K.D0,25.S0,25 vi: D: ng knh ren mi (mm) S: bc ren (mm) a) Mi bng mi mt u mi ( mi n) Phng php ny c dng ph bin, prfin ca tng ng vi prfin ren. mi c chuyn ng quay v tnh tin hng knh c th gia cng c nhng loi n ren c kch thc khc nhau v mi c ht chiu su ca n. Bn my mang chi tit quay v c chuyn ng tnh tin dc trc vi tc nct dch chuyn bng mt vng quay ca n. Khi g t, trc ca mi v trc ca chi Sct tit nm trong mt phng nhng lch nhau mt gc ng bng gc nng ca ren. Hnh 6.43- S mi ren Phng php ny t chnh xc gia bng mi mt u mi. cng cao, cu to ca n gin, d sa . b) Mi bng mi nhiu u mi nng cao nng sut, ngi ta dng phng php mi ren vi mi nhiu u mi. Thc ra, nhiu u mi gm nhiu mt u mi ghp li nn nng sut cao hn n mt u mi. Phng php ny, mi khng cn t nghing so vi chi tit mt gc m t c ng tm song song vi ng tm chi tit. nct Tuy nhin, cng v iu ny m chnh xc Sct thp hn mi vi mt u mi. Phng php ny ch mi c cc loi ren Hnh 6.44- S mi ren c bc ln hn 0,6 mm bi v nu bc ren bng mi nhiu u mi. nh hn th khng m bo bn ca mi, d lm v cc ng ren ca mi. Mi ren bng mi nhiu u mi i hi my phi c c cu sa chnh xc, thng thng dng c cu tin bng mi kim cng.
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6.5- gia cng b mt then B mt then l loi b mt dng truyn mmen xon hoc dn hng, c dng rng ri v cu to n gin v chc chn, d tho lp, gi thnh r... Then l chi tit c tiu chun ha gm nhiu loi khc nhau nh then bng, then vt, then bn nguyt, then hoa.
6.5.1- Gia cng then trn trc
Then trn trc c gia cng bng phng php phay sau khi trc tin tinh. Nu then c yu cu i xng cao, trc khi phay then phi mi hai c trc lm chun (g ln hai khi V ngn) khi gia cng. a) Gia cng then bng Then bng l loi then c tit din hnh ch nht, hai u thng hoc trn, mt lm vic l hai mt bn. Rnh then bng c nhiu loi nh: khng thng, thng mt u v thng hai u.
Loi khng thng
Loi thng mt u Hnh 6.45- Cc loi rnh then trn trc.
Loi thng hai u
gia cng rnh then bng trn trc, ngi ta s dng dao phay ngn, c th l dao phay ngn thng thng hay dao phay ngn chuyn dng. Dng dao phay ngn thng thng Do dao phay ngn thng thng khng c li ct mt u, cho nn khi gia cng rnh then bng loi khng thng th phi khoan mi mt (hoc hai) l c ng knh bng chiu rng rnh then, sau , mi cho dao phay ngn vo v thc hin chy dao dc trc ct ht chiu di rnh then. ng chuyn dao theo s (6.48a) i vi khoan mi mt l v theo s Hnh 6.46- Phay rnh then bng vi dao phay ngn thng thng. (6.48b) i vi khoan mi hai l. Khi gia cng rnh then bng loi thng mt hoc hai u th khng cn phi khoan mi. ng chuyn dao khi phay rnh then bng thng mt u theo s (a)
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v thng hai u theo s (b) hnh 6.48. Dng dao phay ngn chuyn dng Dao phay ngn chuyn dng khc vi loi dao phay ngn thng thng, ch n c thm li ct mt u, do vy khi ct rnh khng cn phi khoan mi. ng chuyn dao theo s (b) hnh 6.48.
Li dao nhanh Chy dao nhanh
Hnh 6.47- Phay rnh then bng vi dao phay ngn chuyn dng.
Gia cng Gia cng a) b) Hnh 6.48- S ng chuyn dao.
b) Gia cng then vt Then vt l loi then lm vic cc mt trn v mt di, cn mt bn c khe h. Then c vt mt mt c dc 1 / 100. Loi then ny truyn c mmen xon ln lc dc trc, c th chu c va p; tuy nhin n gy ra rung ng nn ngy cng t c s dng. gia cng rnh then vt trn trc, ngi ta dng dao phay a ba mt. Tuy dng dao phay a ba mt gia cng s c chnh xc km v rnh then d b rng ra (do bin dng n hi ca trc g dao, dao mi khng ng, kh bo m c mt bn dao thng gc vi ng tm trc g dao), Hnh 6.49- Then vt nhng do then vt c mt bn h, cho nn vn dng v loi ny c nng sut rt cao. c) Gia cng then bn nguyt Then bn nguyt cng ging nh then bng c mt lm vic l hai mt bn, n c u im l c th t ng thch ng vi cc nghing ca rnh may, nhng nhc im l trc b yu do phay rnh (c su hn cc loi then kia). gia cng rnh then bn nguyt trn trc, dng dao phay a ba mt. Lc ny, dao quay v ch c chuyn ng hng knh. Bn knh ca dao bng bn knh then v thng l b ( rnh su) nn ch ct b hn ch, do vy, nng sut thp.
Hnh 6.50- Then bn nguyt
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d) Gia cng then hoa Do cng ngh phay rnh then cha hon thin, mun gia cng chnh xc th rt phc tp v tn km. Do , nu cn chnh xc th thay rnh then bng rnh then hoa.
a)
b) Hnh 6.51- S phay trc then hoa.
c)
Then hoa c th coi l gm nhiu then v cc then c lm lin vi trc, thng c khong 5, 6, 8, 10 rnh. Phay rnh then hoa trn trc c th c thc hin bng mt hoc hai ln ty theo sn lng. Trong sn xut hng lot, phay rnh then hoa c thc hin hai ln: phay hai mt bn trc, sau phay phn mt tr (a); hoc phay mt ln bng dao nh hnh (b). Trong sn xut ln, hay dng dao phay ln then hoa dng trc vt trn my phay ln chuyn dng (c).
6.5.2- Gia cng then trn l
a) Gia cng then bng Then bng trn l thng gp cc bnh rng, bnh ai, a xch, tay quay... gia cng rnh then trn l, ngi ta thng dng phng php xc trn my xc. Vi phng php ny, vic iu chnh my c thc hin theo kiu ly du v c dng rt nhiu trong mi dng sn xut. Ngoi ra, trong sn xut nh, khi gia cng rnh then trn l, thng dng phng php bo trn my bo ngang. Cn trong sn xut lot ln v hng khi, th Hnh 6.52- Xc rnh then.
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hay dng phng php chut, c th l gia cng l xong, sau mi chut rnh then hoc l kt hp chut rnh then v l ng thi. Vi cch ny, then c gia cng chnh xc, nng sut rt cao nhng ch to dao kh tn km. b) Gia cng then hoa Vi sn xut dng nh, vic gia cng then hoa trn l c thc hin bng cch xc trn my xc tng rnh mt, ri phn gia cng n ht. Khi sn xut hng lot ln, hng khi th dng phng php chut gia cng then hoa trn l. Lc ny l gia cng then hoa c gia cng sn, dao chut ch ct phn rnh then hoa. Ngoi ra, c th dng phng php bin dng do gia cng l then hoa, l t l then hoa.
6.5.3- Mi rnh then hoa
Then hoa l mi ghp cn c chnh xc, v vy, sau khi gia cng cn phi mi then hoa c trc ln l. Khi lp ghp then hoa, s c 3 phng php nh tm mi ghp:
nh tm theo ng knh trong.
nh tm theo ng knh ngoi.
nh tm theo hai cnh bn.
Hnh 6.53- Cc phng php nh tm then hoa.
- Lp theo ng knh trong t c ng tm cao nht. Thng thng l dng kiu lp ny v n chnh xc. - Lp theo ng knh ngoi t c ng tm thp hn, nhng khi mi s d hn so vi nh tm theo ng knh trong. Kiu lp ny thng dng trong tt c cc mi ghp then khng dch chuyn dc trc. - Lp theo hai cnh bn c ng tm km nht nhng n truyn c mmen xon cao nht v ti trng phn b u trn cc rng. Mi ghp ny thng dng khi yu cu quay hai chiu, truyn mmen xon ln, khng yu cu cao v ng tm. a) Mi rnh then hoa trn trc Khi mi rnh then hoa trn trc, ngi ta thng dng cc phng php mi sau: Khi nh tm theo ng knh trong mi rnh then hoa trn trc khi nh tm theo ng knh trong, ngi ta thng dng phng php mi nh hnh.
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Phng php mi nh hnh ny, g lp n gin, m bo chnh xc v tr tng quan ca cc b mt. Tuy nhin, do mi ng thi c ba mt cho nn, rt nhanh mn, trong qu trnh gia cng phi sa lin tc. Nu mun ko di tui th ca th phi dng c cng cao hn cng chi tit, do vy s Hnh 6.54- Mi nh hnh lm cho cht lng b mt mi xu. khc phc rnh then hoa trn trc. nhc im ny, ngi ta tin hnh mi na tinh bng c c tnh k thut ph hp, sau mi tinh bng cng hn. Tuy nhin, nh th th nng sut s gim. Ngoi ra, ngi ta cn dng cc kiu mi khc nh: mi hai cnh bn ring, mi ng knh trong ring. Khi nh tm theo ng knh ngoi: Khi nh tm theo ng knh ngoi th vic mi rnh then hoa trn trc s c tin hnh trn my mi trn ngoi ging nh mi cc b mt tr trn. Khi nh tm theo hai cnh bn: Khi nh tm theo hai cnh bn, vic mi hai cnh bn s c tin hnh trn my mi phng bng a, c dng thm c cu phn mi ht cc mt bn. Kh khn ca cch ny l vic g lp v iu chnh phc tp v trn cng mt trc lp hai nn khong trc th ra lp cc mt bch p s di, d gy ra rung ng.
Hnh 6.55- Mi cnh bn rnh then hoa trn trc.
b) Mi rnh then hoa trn l Vic mi rnh then hoa trn l kh thc hin hn so vi mi trn trc. Khi nh tm theo ng knh trong Mi rnh then hoa trn l, nh tm theo ng knh trong cng c thc hin ging nh mi l b mt tr trong, c tin hnh trn my mi trn trong. Khi nh tm theo ng knh ngoi: Trng hp ny, ngi ta thng dng phng php mi khn. Kt cu ca u khn rnh then hoa khc vi u khn l thng. Khi nh tm theo hai cnh bn: Khi nh tm theo hai cnh bn, thng dng phng php mi nghin mi hai cnh bn.
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6.6- gia cng b mt nh hnh B mt cc chi tit my, ngoi cc mt c bn nh mt phng, mt tr... cn c cc mt cong, mt thn khai, mt hypecboit... Tp hp cc loi b mt ny ta c mt nh hnh.
6.6.1- Gia cng bng phng php chp hnh
a) Dng dao nh hnh Tin Tin bng dao nh hnh to nn cc b mt chi tit bi mt ng sinh l mt ng bt k do li dao to thnh, quay quanh ng chun trn. Tin nh hnh c th dng dao tin nh hnh hnh tr hoc hnh trn. C li ct ca dao l mt ng sinh nn cn mi dao chnh xc, qu trnh ch to dao phc tp, gi thnh cao nn ch dng trong sn xut ln. S Do ch cn thc hin chy dao ngang l c th hnh thnh c chi tit nn nng Hnh 6.56- Tin nh hnh. sut rt cao. Tuy nhin, do qu trnh ct thc hin trn ton b chiu di li ct nn lc ct rt ln, i hi my phi c cng sut ln, cng vng ca h thng cng ngh rt cao. chnh xc ca chi tit s khng t c cao, do ph thuc vo vic ch to dao v bin dng ng cong. Phay Phay vi dao nh hnh c th phay c mt s loi mt nh hnh nh mt cong, rnh, mt tng hp... vi nng sut cao. Phng php ny thng ch dng gia cng cc b mt nh hnh ngn trong sn xut ln v dao phi ch to ring cho tng loi sn phm, c hnh dng ging nh hnh dng b mt chi tit, chnh xc tng i nn qu trnh ch to dao rt phc tp, gi cao. Khi gia cng, lc ct s ln, phi hn ch v ch ct. Chiu Hnh 6.57- Phay nh hnh. su ct v ng knh dao s thay i trong qu trnh ct, chnh xc ca sn phm ph thuc vo chnh xc ca dao, cch g t chi tit v chnh xc ca b mt chun.
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b) Chp hnh theo dng Tin Tin chp hnh theo dng s dng dao tin thng, dng c lm ring c th ging hnh dng chi tit (nh gia cng piston) hoc khc hnh dng chi tit (nh ch l rnh cho bn dao c con ln chy bn trong). Phng php ny khng nhng ch gia cng c mt nh hnh trn xoay m cn c th gia cng c nhng mt lch tm, mt lm vic ca Sd cam, mt van ca pittng... Khi gia cng theo phng php ny th dng c lp c nh trn bn my, vitme - ai c bn dao ngang ca my tin c tho i, my Hnh 6.58- Tin chp hnh theo dng. ch c chuyn ng chy dao dc, cn chuyn ng chy dao ngang c thc hin theo dng. Phay Phng php ny gii quyt c kh khn m dao phay nh hnh gp phi nh chiu di mt nh hnh ln, nu dng dao phay nh hnh th vic thit k v ch to dao rt kh khn, mt khc li ct di nn lc ct ln, ch ct s b hn ch . Thc cht ca qu trnh phay chp hnh l mt trong hai chuyn ng vung gc vi nhau c thc hin da theo profin ca dng ch to trc. lm c vic phi tho vitme ai c chy dao ca bn my theo phng , cn mi d lun p st vi dng chp hnh do tc dng ca l xo hay i trng tng ng. Chuyn ng chy dao theo phng cn li c gi nguyn nh c. chnh xc ca phay chp hnh Hnh 6.59- Phay chp hnh. ph thuc rt nhiu vo chnh xc ca dng, truyn ng ca my, c cu ph, ng thi ph thuc vo chnh xc iu chnh. Hnh dng dng c to nn bng phng php v v hon ton cn c vo dng chi tit gia cng. gim nh hng sai s ca dng, ngi ta lm dng c kch thc ln hn nhiu so vi chi tit thc. Tuy nhin, nh th th kt cu s rt cng knh, phc tp.
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c) Chp hnh theo c cu Chp hnh theo c cu l dng gia cng chp hnh, nhng phi da vo dng m da vo cc c cu c bit.
Tin chm cu ngoi bng mm quay.
Tin chm cu ngoi bng thanh c.
Hnh 6.60- Tin chm cu ngoi.
Khi cn tin chm cu, mun m bo chnh xc v nng sut cao, ta s dng thm g chuyn dng gia cng, c th l mm quay hoc thanh c. Mm quay l mt b phn c g thm ln bn xe dao thng qua mt ci ke vung gc. Trn mm quay l dao gia cng. Khi quay tay quay, nh b truyn trc vt - bnh vt m mm quay s mang dao, quay quanh tm ca mm quay (lc ny c iu chnh trng vi tm ca chm cu cn tin). Ngoi ra, cn c th dng thanh c tin chm cu. Dng mt thanh c t mt du vo l khuyt trn mt c chuyn dng, u kia ca thanh c c gn vi bn trt ngang. Khi cho tin dao ngang t ng, thanh c s quay quanh l khuyt trn c chuyn dng, y bn trt xe dao sang pha bn phi, lc dao s ct c mt mt cong c bn knh bng chiu di thanh c.
6.6.2- Gia cng bng phng php bao hnh
Mt nh hnh c gia cng theo phng php bao hnh l bnh rng dng thn khai. Lc ny, li ct c dng thng nn d mi chnh xc. Hn na, phng php ny c nguyn l gia cng tt nn m bo chnh xc cao. Phng php ny ta s nghin cu k Chng 9 - Gia cng bnh rng.
6.6.3- Gia cng bng my iu khin theo chng trnh s CNC
y l lnh vc gia cng mi, xem k gio trnh Lp trnh trn my CNC.
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Chng 7
Thit k quy trnh cng ngh gia cng chi tit my

7.1- ngha ca cng vic chun b sn xut Bt c mt sn phm no trc khi a vo sn xut u phi qua giai on chun b sn xut. Mt trong nhng cng vic chnh ca cng tc chun b sn xut l thit lp quy trnh cng ngh gia cng c. Thit k quy trnh cng ngh gia cng c l lp nn nhng vn kin, ti liu phc v v hng dn cho vic gia cng cc chi tit trn my, bao gm c vic thit k nhng trang b cn thit. Mc ch l nhm hng dn cng ngh, lp cc ch tiu kinh t k thut, k hoch sn xut v iu hnh sn xut. Mc phc tp ca QTCN ph thuc vo dng sn xut. Trong sn xut lot nh, n chic quy trnh cng ngh ch bao gm trnh t cc nguyn cng vi mt s thng s cn thit nh ch r my, dao, thi gian gia cng, bc th... Cn sn xut lot ln, hng khi th quy trnh rt quy m, t m, bao gm nhiu ti liu khc nhau. mt quy trnh cng ngh thit k ra c tt th phi c cc iu kin sau: - Phi m bo cht lng sn phm. - Phng php gia cng phi kinh t nht. - p dng c nhng thnh tu mi nht trong khoa hc k thut. - Phi thch hp vi iu kin c th ca nh my, kh nng v lc lng cn b, cng nhn, thit b... - Phi tranh th s dng cc sng kin kinh nghim hp l ha sn xut. - ng dng nhng hnh thc t chc sn xut tin tin. C hai trng hp lp quy trnh cng ngh, mt l khi thit k mt nh my mi, hai l trong nhng iu kin ca mt nh my ang hot ng. Lp quy trnh cng ngh theo n c dng khi thit k nhng nh my mi, phn xng mi. Lc u ta thit k mt quy trnh cng ngh theo cc ti liu ban u ca vt phm ch to trong nh my cho. Sau tnh ph ti ca my, ng thi trn c s quy trnh thit k ta phi nh trc vic phn nhm lot thit b ny theo tng phn xng ring v b tr chng. Trng hp ny, iu kin la chn trang thit b rng ri hn, quy trnh cng ngh phi linh hot c th sa i theo yu cu. Lp quy trnh cng ngh theo iu kin sn xut ang tn ti c dng khi phn xng, nh my c phi ch to nhng sn phm mi. Khi lp quy trnh cng ngh theo cch ny th quy trnh cng ngh chu nhng hn ch cht ch hn v thit b, din tch, ti trng my, k hoch sn xut... nhng li c tha k nhng kinh nghim sn xut.
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7.2- phng php thit k qtcn gia cng chi tit my

7.2.1- Nhng ti liu ban u thit k quy trnh cng ngh
Mun thit k mt quy trnh cng ngh tt, trc ht chng ta phi c cc ti liu ban u sau: - Bn v ch to ca chi tit vi y : + Mt ct, hnh chiu din t r rng. + Ghi y kch thc, dung sai v cc iu kin k thut khc. + Ghi r nhng ch cn gia cng c bit (v d: gia cng khi lp). + Ghi r vt liu, phng php nhit luyn, cng yu cu. - Sn lng chi tit k c thnh phn d tr. - Hnh v b phn ca sn phm trong c chi tit gia cng. - Nhng ti liu v thit b: thuyt minh my, cc tiu chun dao, g... Ngoi ra, cn cn c cc ti liu, s tay khc nh: tiu chun xc nh lng d, dung sai, vt liu, s tay v g, tiu chun v ch ct, nh mc kinh t - k thut...
7.2.2- Trnh t thit k mt quy trnh cng ngh
Thit k quy trnh cng ngh nn theo trnh t nh sau: - Nghin cu bn v chi tit, kim tra li tnh cng ngh ca n. - Phn loi chi tit, sp t vo cc nhm. - Xc nh dng sn xut. - Chn phi v phng php ch to phi. - Xc nh chun v chn cch nh v, kp cht cho mi nguyn cng. - Lp th t cc nguyn cng. - Chn my cho mi nguyn cng. - Tnh lng d gia cc nguyn cng v dung sai nguyn cng. - Chn dng c ct v dng c o lng. - Chn g, nu cn th thit k g. - Xc nh ch ct. - nh bc th. - nh mc thi gian v nng sut, tnh ton kinh t, so snh phng n. - Ghi vo phiu cng ngh, v cc s nguyn cng. 7.3- Mt s bc c bn khi thit k quy trnh cng ngh
7.3.1- Tnh cng ngh trong kt cu
Tnh cng ngh trong kt cu l mt tnh cht quan trng ca sn phm hoc chi tit c kh nhm m bo lng tiu hao kim loi t nht, khi lng gia cng v lp rp t nht, gi thnh ch to thp nht trong iu kin v quy m sn xut nht nh.
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Khi nghin cu nng cao tnh cng ngh ca kt cu c kh, ta phi da vo mt s c s sau y: Tnh cng ngh ca kt cu ph thuc rt nhiu vo quy m sn xut, tnh cht hng lot ca sn phm. V quy m sn xut v tnh hng lot quyt nh rt nhiu mc hp l ca vic s dng phng php cng ngh ny hay phng php cng ngh khc trong vic ch to sn phm. Vic ng dng vo thc t mt phng hng cng ngh no i hi phi tin hnh hng lot cng vic v chi ph trang b my mc, g, dng c... Do , khi thit k phi lu n tnh cng ngh ca kt cu. Tnh cng ngh ca kt cu cn phi c nghin cu i vi ton b sn phm. Nu ch tch ring tng chi tit ring l ra nghin cu tnh cng ngh th c th dn n s thay i rt nhiu, c khi xt ton b sn phm th tnh cng ngh trong kt cu li km i. Nghin cu tnh cng ngh ca kt cu phi c t ra v gii quyt trit trong tng giai on ca qu trnh sn xut. V qu trnh sn xut mt mt hng rt phc tp nn phi c xem xt tng bc v kt cu tm cch gii quyt hp l cc vn nhm a li hiu qu kinh t ln nht. Nghin cu tnh cng ngh ca kt cu phi tnh n c im ca ni s sn xut ra sn phm y. Nhng im trn ni ln tnh tng i v tnh cng ngh ca kt cu trong gia cng v lp rp. Mt kt cu c tnh cng ngh cao x nghip ny nhng cha hn l cao x nghip khc. nh gi c tnh cng ngh cao hay thp th ch tiu bao trm nht v c th dng trong mi trng hp l gi thnh ch to sn phm. Trong thc t, thng dng hai ch tiu chnh l khi lng lao ng v khi lng vt liu tiu tn ch to ra sn phm. * i vi qu trnh gia cng ct gt, tnh cng ngh ca kt cu chi tit my c xt trn c s cc yu cu c th nh sau: - Gim lng vt liu ct gt bng cch thit k phi v cc b mt gia cng hp l, xc nh chnh xc lng d gia cng, gii hn khi lng ct gt ch nhng b mt quan trng. - Gim qung ng chy dao khi ct. - n gin ha kt cu, m bo gia cng kinh t (tch chi tit phc tp thnh cc chi tit n gin, d gia cng, g c nhiu chi tit khi gia cng). - To iu kin s dng dng c tiu chun, thng nht. - m bo dng c ct lm vic thun tin, khng b va p khi ct. - m bo chi tit cng vng, to iu kin ct gt vi ch ct ln. - Gp phn gim ph tn iu chnh thit b, trang b cng ngh, gim s ln g t chi tit khi gia cng. - Phn bit r rng gia b mt gia cng v b mt khng gia cng.
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7.3.2- Xc nh lng d gia cng
a) Khi nim v lng d gia cng Lng d gia cng c l lp kim loi c ly i trong qu trnh gia cng c kh. Ta phi xc nh lng d gia cng hp l l v: - Lng d qu ln s tn nguyn vt liu, tiu hao lao ng gia cng nhiu, tn nng lng, dng c ct, vn chuyn nng... dn n gi thnh tng. - Nu lng d qu nh s khng ht i cc sai lch ca phi do sai s in dp ca phi li, c th xy ra hin tng trt gia dao v chi tit. Lng d trung gian c xc nh bng hiu s kch thc do bc hay nguyn cng st trc (a) li v kch thc do bc hay nguyn cng ang thc hin (b) to nn, k hiu l Zb. - i vi mt ngoi: Zb Zb = a - b a b - i vi mt trong: b a Zb = b - a Zb
Mt ngoi. Mt trong.
Lng d tng cng l lp kim loi cn phi ht i trong tt c cc bc hoc nguyn cng tc l trong sut c qu trnh gia cng trn b mt bin t phi th thnh chi tit hon thin, k hiu Z0. Lng d tng cng c xc nh bng hiu s kch thc phi th v kch thc chi tit ch to xong. - i vi mt ngoi: Z0 = aph - act - i vi mt trong: Z0 = act - aph Nh vy, r rng l lng d tng cng s bng tng cc lng d trung gian trong tt c cc bc ca qu trnh cng ngh: Z 0 = Z i , n l s bc cng ngh.
i =1 n
Lng d i xng, n tn ti khi gia cng cc b mt trn xoay ngoi hoc trn xoay trong, hoc khi gia cng song song cc b mt phng i din nhau. - i vi mt ngoi: 2 Z b = da db - i vi mt trong: 2 Z b = db da
Zb
db da Mt ngoi.
Zb
Zb
da db Mt trong.
Zb
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b) Phng php xc nh lng d gia cng hp l Trong Ch to my c hai phng php xc nh lng d: * Phng php thng k kinh nghim Vi phng php ny lng d c xc nh da trn tng s lng d cc bc gia cng theo kinh nghim. Lng d phi c thng ly theo kinh nghim m khng tnh ti cc bc gia cng. Trong cc s tay thng cho loi lng d ny. Song theo phng php ny th ta xc nh lng d gia cng mt cch my mc, khng da trn cc bc gia cng, khng tnh ti s nh v, kp cht, cc iu kin khc khi ct... nn lng d thng ln hn yu cu, dn n khng kinh t. * Phng php tnh ton phn tch Phng php ny do GS. Kvan xut, da trn vic phn tch v tng hp cc yu t to nn lp kim loi cn phi ht i c mt chi tit hon thin. Phng php ny tnh lng d cho hai trng hp: - Trng hp dao c iu chnh sn trn my. - Trng hp g t chi tit theo kiu r g. Cc vn trnh by sau y ch yu thuc trng hp dao c iu chnh sn trn my, nu p dng vo trng hp r g th ch cn b sung mt t m thi. i vi mt ngoi Khi gia cng mt lot phi cng loi trn my iu chnh sn, v kch thc phi dao ng trong gii hn dung sai nn lng d gia cng cng s dao ng. nhng phi c kch thc nh nht amin khi gia cng xong s c kch thc bmin, lng d gia cng s l Zb min; cn nhng phi c kch thc ln nht amax khi gia cng xong s c kch thc bmax, lng d gia cng s l Zb max. Lng d thc khi gia cng s nm trong khong Zb min Zb max.
Zb max Zb min ymax amin CH bmin ymin
amax
bmax
Hnh 7.1- Gi tr lng d gia cng i vi mt lot phi trn my iu chnh sn.
Ta thy rng, nu iu chnh dao theo kch thc CH ct lot phi th khi gp phi c kch thc amin n s ct lp chiu su ct nh nht, lc ct s nh nht v bin dng s nh nht ymin, ta s c lng d nh nht Zb min. Kch thc hnh thnh sau khi ct l CH + ymin. Ngc li, khi gp phi c kch thc amax th s ct lp chiu su ct ln nht, lc ct ln nht, bin dng s ln nht ymax, ta c lng d ln nht Zb max. Kch thc hnh thnh sau khi ct l CH + ymax.
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Zb min = amin - (CH + ymin) = amin - bmin Zb max = amax - (CH + ymax) = amax - bmax Nu thay tr s v dung sai ca cc kch thc a, b l a, b: amax = amin + a bmax = bmin + b ta s c: Zb max = (amin + a) - (bmin + b) = amin - bmin + a - b Zb max = Zb min + a - b Lng d danh ngha (lng chnh lch gia hai kch thc danh ngha adn, amax Zb dn = and - bdn bdn): Ba = (amin + Ha) - (bmin + Hb) adn = amin - bmin + Ha - Hb Ha amin Zb dn = Zb min + Ha - Hb i vi mt trong Lm tng t nh vi mt ngoi, ta c c: Zb min = bmax - amax Zb max = bmin - amin Thay: amin = amax - a; bmin = bmax - b vo Zb max ta c: Zb max = Zb min + a - b Zb dn = bnd - adn = (bmax - Bb) - (amax - Ba) = bmax - amax + Ba - Bb Zb dn = Zb min + Ba - Bb i vi b mt i xng Lng d ca b mt i xng c xc nh tng t nh trn, ta c: - Mt ngoi i xng: 2Zb min = Da min - Db min 2Zb max = Da max - Db max = 2Zb min + D a - D b 2Zb dn = 2Zb min + HD a - HD b - Mt trong i xng: 2Zb min = Db max - Da max 2Zb max = Db min - Da min = 2Zb min + D a - D b 2Zb dn = 2Zb min + BD a - BD b Dung sai ca lng d l hiu s gia lng d ln nht v nh nht: - B mt khng i xng: z = Zb max - Zb min = a - b - B mt i xng: z = 2Zb max - 2Zb min = D a - D b Ly tng cc lng d trung gian ta s c lng d tng cng Z0.
Vy ta c:
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c) Cc yu t to thnh lng d trung gian Phn kim loi cn phi ht i qua mt bc hay mt nguyn cng tc l lng d trung gian, bao gm cc yu t sau y: Rz a - Chiu cao trung bnh ca lp nhp nh b mt do bc cng ngh st trc li. Ta - Chiu su lp h hng b mt do bc cng ngh st trc li. a - Sai lch v v tr khng gian ca chi tit do bc cng ngh st trc li ( khng song song, cong vnh, lch tm...). a - Sai s g t do nguyn cng ang thc hin gy ra. Nh vy, gi tr nh nht ca lng d gia cng b mt khng i xng tnh cho bc cng ngh ang thc hin c xc nh nh sau: Zb min = Rza + Ta + a + b W W i vi b mt i xng, th phng ca a v b c th khc nhau nn ta phi tnh theo php cng vect:
Rza + Ta Zb min amin b a b bmin Hnh 7.2- Cc yu t to thnh lng d gia cng.
2 Z b min = 2 Rz a + Ta + a + b
Khi bit r phng ca a v b th ta cng hai vect theo cng thc:

a + b = a + b + 2 a . b . cos a , b
2 2
tuy nhin, trong thc t th phng ca hai vect rt kh xc nh. V vy, ta ly tr s trung bnh theo xc sut:
a + b = a + b
2 2
Nh vy, cng thc tnh lng d cho b mt i xng l:

2 2 2 Z b min = 2 Rz a + Ta + a + b Cc cng thc trn cho ta cch tnh lng d t cc yu t hp thnh vi trng hp tng qut. Cn trong mt s trng hp c th, biu thc tnh lng d khng cn y cc yu t . V d: - Sau nguyn cng th nht, i vi cc chi tit lm bng gang hoc kim loi mu th khng cn Ta trong biu thc tnh lng d na. S d nh vy, v lp kim loi hng to nn l do bin dng do, m i vi kim loi c ht to nh gang hay kim loi mu th hin tng khng ng k. - Khi chun nh v trng vi mt gia cng (nh mi khng tm, doa ty ng, chut l, mi nghin) th sai s chun ca kch thc thc hin bng 0, v nu b qua sai s do kp cht v sai s g, lc trong biu thc tnh khng c b.
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- i vi nhng nguyn cng cui nhm nng cao bng b mt (nh nghin, mi siu tinh) th Ta, a, b = 0, lc trong biu thc ch cn Rza. - Cc b mt qua nhit luyn, sau qua mi th trong biu thc tnh lng d s khng c Ta bi v khi mi phi gi li lp b mt x l nhit.
Trnh t tnh lng d trung gian v kch thc gii hn cho tng bc cng ngh
1. Lp quy trnh cng ngh v phng n g t phi cho cc nguyn cng. 2. Xc nh cc b mt gia cng v th t cc bc cng ngh cho tng b mt. 3. Xc nh gi tr cc i lng Rza, Ta, a, b. 4. Xc nh tr s tnh ton Zb min cho tt c cc bc cng ngh. Mt ngoi Mt trong 5. Ghi kch thc tnh ton ca bc 5. Ghi kch thc tnh ton ca bc cng ngh cui cng theo bn v (kch cng ngh cui cng theo bn v (kch thc gii hn ln nht). thc gii hn nh nht). 6. Xc nh kch thc cho bc st 6. Xc nh kch thc cho bc st trc bng cch cng Zb min vi kch trc bng cch ly kch thc gii hn ln nht theo bn v tr i Zb min. thc gii hn nh nht theo bn v. 7. Xc nh kch thc cho tng bc 7. Xc nh kch thc cho tng bc cng ngh cn li bng cch cng gi cng ngh cn li bng cch ly kch tr Zb min tng ng vi kch thc tnh thc tnh ton ca bc cng ngh tip ton ca bc cng ngh tip theo. theo tr i gi tr Zb min tng ng. 8. Ghi kch thc gii hn nh nht ng 8. Ghi kch thc gii hn nh nht ng vi tng bc cng ngh trn c s quy vi tng bc cng ngh trn c s quy trn gi tr kch thc tnh ton theo trn gi tr kch thc tnh ton theo hng s c ngha ca dung sai tng hng s c ngha ca dung sai tng bc cng ngh. bc cng ngh. 9. Xc nh kch thc gii hn ln 9. Xc nh kch thc gii hn nh nht cho tng bc cng ngh bng nht cho tng bc cng ngh bng cch cng thm dung sai tng bc cch tr tng kch thc gii hn ln cng ngh vi kch thc gii hn nh nht quy trn theo dung sai, mt lng bng dung sai ca mi bc. nht quy trn theo dung sai. 10. Xc nh gi tr ca lng d theo 10. Xc nh gi tr ca lng d theo tng cp bc cng ngh ni tip nhau: tng cp bc cng ngh ni tip nhau: Zb max = hiu hai kch thc nh nht. Zb max = hiu hai kch thc ln nht. Zb min = hiu hai kch thc nh nht. Zb min = hiu hai kch thc ln nht. 11. Xc nh lng d tng cng cho tng b mt gia cng Z0 max v Z0 min bng cch cng tt c cc gi tr lng d trung gian tng ng. 12. Kim tra cc kt qu tnh ton bng cch tm hiu s lng d v hiu s dung sai, ri em so snh kt qu vi nhau: z = Zb max - Zb min = a - b ; hoc z 0 = Z0 max - Z0 min = ph - ct
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Kt qu tnh ton s c ghi vo bng sau y: Cc yu t to Th t cc Kch thc Lng d Gi tr tnh ton Dung thnh lng d bc hoc gii hn gii hn sai nguyn cng (mm) (m). (m) T gia cng b Zb min K.thc (m) Max Min Max Min Rza Ta mt. b (m) (mm) a (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) I (phi) x X x x X II x X x x x x X III x X x x x x X ... ... ... ... ... ... ... ... ... ... ... ... IX x X x x x x X X x X x x x x B/v B/v B/v Ct 1: Ghi trnh t cc bc cng ngh hoc nguyn cng gia cng b mt. hng u tin l phi, hng cui l nguyn cng phi t chnh xc, Rz yu cu. Ct 2, 3, 4, 5: Tra v tnh ton theo cc s tay, ti liu. Ring I(5) th trng v bn thn phi th lm sao c g t. Ct 6: I(6) trng, cc khc ca ct 6 c tnh theo cng thc tnh lng d trung gian (ty theo b mt m dng cng thc cho hp l). Ct 7: Ghi cc kch thc tnh ton vo ct 7 theo cch sau: - i vi mt ngoi: nguyn cng cui cng [tc X(7)] ghi kch thc nh nht theo bn v [tc X(10)]. Cng kch thc ny vi lng d tnh ton ct 6 s c kch thc tnh ton ca nguyn cng st trc. Tip tc cho n ht. - i vi mt trong: nguyn cng cui cng [tc X(7)] ghi kch thc ln nht theo bn v [tc IX(10)]. Ly kch thc ny tr i lng d tnh ton ct 6 s c kch thc tnh ton ca nguyn cng st trc. Tip tc cho n ht. Ct 8: Hng cui cng [tc X(8)] ghi theo dung sai ca bn v, tt c cc cn li ca ct c tra theo s tay. Ct 9, 10: Hng cui cng [tc X(9), X(10)] ghi theo cc kch thc gii hn ca bn v. Cn cc cn li th c ghi theo cch sau: - i vi mt ngoi: Ly kch thc tnh ton ct 7 em quy trn (ty theo hng s c ngha ca dung sai) ri ghi vo ct 10. Sau , ly kch thc gii hn ct 10 cng vi dung sai s c kch thc ct 9. - i vi mt ngoi: Ly kch thc tnh ton ct 7 em quy trn (ly gim i mt n v) ri ghi vo ct 9. Sau , ly kch thc gii hn ct 9 tr i dung sai s c kch thc ct 10. Ct 11, 12: Ghi kt qu vo cc theo cng thc: - i vi mt ngoi: Zb min = amin - bmin; Zb max = amax - bmax - i vi mt trong: Zb min = bmax - amax; Zb max = bmin - bmin
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Cng tt c lng d ct 11 ta c c lng d tng cng ln nht Z0 max [tc I(11)], cng tt c lng d ct 12 ta c c lng d tng cng ln nht Z0 min [tc I(12)]. Kim tra li kt qu tnh bng cng thc: z = Zb max - Zb min = a - b V d: Cn gia cng trc t phi liu ban u l phi cn, kch thc t c sau khi gia cng s l D = 350 - 0,215. Cc bc gia cng, gi tr tnh ton lng d gia cng c cho bng sau. Hy b sung nhng s liu cn thiu (in m).
Th t gia cng Cc yu t to thnh lng d (m). Dung Kch thc sai gii hn Gi tr tnh T (mm) ton Zb min K.thc (m) (m) (mm) Max Min (6) (7) (8) (9) (10) 367,495 20000 388 368 17300 410 350,195 1350 349,785 215 351,55 350 350,2 349,785
Lng d gii hn (m) Max (11) 36450 1550
Rz (1) Phi Tin th Tin tinh
(2) (3) 3000 50 50 -
(4) (5) 5500 105 1000 -
Min (12) 17800 415
Ch : - V l mt i xng nn lng d tnh ton s l 2Zb min ch khng cn l Zb min, khng c chia 2. - Vic quy trn gi tr lng d tnh ton l theo hng s c ngha ca dung sai. Nu l mt ngoi th ly ln mt n v; nu l mt trong th ly gim i mt n v.
7.3.3- Chn phi v phng php ch to phi
Trong thc t sn xut, phi thng c chn theo hai hng sau: - Theo hnh dng chi tit gia cng, vi cch ny phi c hnh dng v kch thc gn nh chi tit hon chnh. Lc , chi ph gia cng s c gim xung nhng c th chi ph sn xut phi s ln, c bit l vi sn xut n chic v lot nh (v d nh phi ca trc khuu). - Theo cc phi liu c sn xut sn, s dng rng ri (phi cn). Trng hp ny th c th lng d gia cng s kh ln, dn n chi ph gia cng cao nhng c u im l chi ph cho vic ch to phi thp. Vic chn loi v phng php ch to phi l mt vn tng hp nhm mc ch m bo hiu qu kinh t - k thut. Phng n phi hp l nht l phng n c tng ph tn t nht. La chn phng php ch to phi c th cn c vo cc yu t sau: - Cn c vo vt liu ch to chi tit. V d nh chi tit bng gang th dng phng php c; bng thp th dng phng php cn, rn, dp, c... - Cn c vo hnh dng chi tit v yu cu k thut. Chi tit c hnh dng phc tp th dng phng php c; chi tit n gin, kch thc ln th dng cn...
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- Cn c vo dng sn xut. Nu sn xut n chic, lot nh th dng c trong khun ct, c th cng, hn, rn; sn xut lot ln, hng khi th dng c p lc, c trong khun kim loi... - Cn c vo iu kin c th. Xem xt iu kin k thut nh my sn xut c cho php gia cng c cc loi phi no, t tm hng la chn phng php ch to phi. 7.4- Xc nh trnh t gia cng hp l Khi thit k QTCN gia cng chi tit my phi ch xc nh hp l tin trnh cng ngh ng vi cc b mt ca chi tit, sao cho chu k gia cng hon chnh mt chi tit l ngn nht, gp phn hn ch chi ph gia cng, m bo hiu qu sn xut. C s ca vic xc nh trnh t gia cng hp l l tin trnh cng ngh gia cng cc chi tit in hnh: cng, hp, trc, bc, bnh rng v iu kin c th. * Cc nguyn tc khi xc nh trnh t gia cng hp l: - Chn chun th v cch thc hin nguyn cng th nht tht cn thn. - Tip xc nh trnh t cc nguyn cng sau v chn chun tinh. - Cn c vo yu cu chnh xc v nhm b mt m chn phng php gia cng ln cui ca cc b mt quan trng. V d: Ta cn gia cng mt l c yu yu cu t cp chnh xc 7, Ra = 1,25. Khi , vi sn xut lot nh ta c th dng trnh t: Khoan - Khot - Doa; hay Khoan - Tin - Mi. Nu sn xut lot ln th c th dng: Khoan - Chut. - C gng bo m tnh thng nht v chun tinh. - Ch ti cc nguyn cng c th sinh ra ph phm. Nhng nguyn cng ny nn t trc trnh lng ph hoc b tr thm vic kim tra trung gian. - Ch ti nhng nguyn cng d sinh ra bin dng (nh gia cng th, nhit luyn). Tch nhng nguyn cng ny khi nguyn cng gia cng tinh hoc thm vo quy tnh nhng nguyn cng chnh sa nh nn thng... - C gng gim s ln g, tng s v tr trong mi ln g. 7.5- thit k nguyn cng
7.5.1- Chn my
Khi gia cng ct gt, my ct c xc nh theo cc nguyn tc sau: - My c chn phi m bo thc hin c phng php gia cng xc nh, ng vi chi tit gia cng. - My c chn phi m bo t yu cu cht lng gia cng. Thng thng chn my c cp chnh xc ln hn cp chnh xc cn thc hin t 1 2 cp. - Cng sut v phm vi iu chnh thng s cng ngh ca my phi to iu kin gia cng tt, ngha l t cht lng v nng sut gia cng tt. - Ty thuc vo dng sn xut m chn my cho hp l. Vi sn xut lot nh, ta s dng my vn nng; vi sn xut ln ta dng cc my chuyn dng.
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7.5.2- Chn chun, phng n g t phi v trang b cng ngh
Chn chun cng ngh nhm m bo g t phi t hiu qu k thut v kinh t cao. Phi c g t vi trang b cng ngh tiu chun, trang b cng ngh t hp t cc b phn tiu chun hay trang b cng ngh chuyn dng.
7.5.3- Xc nh cc thng s cng ngh
Thng s cng ngh c bn ca qu trnh ct gt i vi chi tit my l: vn tc ct, s vng quay, lng chy dao, chiu su ct, s ln ct. Gi tr ca cc thng s cng ngh ph thuc tng phng php gia cng, tng loi my, tng kiu trang b cng ngh v tnh cht ca vt liu gia cng. Vic xc nh thng s cng ngh trong thc t ch yu bng th hoc tra trong s tay, ri i chiu vi phm vi gi tr thc trn my, kt hp vi vic kim tra li cng sut v nng sut gia cng. m bo cht lng gia cng v hiu qu kinh t, cn xc nh gi tr ti u ca thng s cng ngh. Ni chung, khi gia cng th th mc tiu ch yu l t nng sut gia cng cao; ngc li khi gia cng tinh th mc tiu li l cht lng gia cng.
7.5.4- Xc nh thi gian gia cng
Thi gian gia cng c xc nh m bo nguyn tc tn dng vi hiu qu cao nht vn thi gian lm vic ca trang thit b, dng c cng ngh v sc lao ng. Trong thc t, thng xc nh thi gian gia cng theo hai phng php l bm gi v da vo nh mc tiu chun. Ni chung, phng php bm gi st thc t hn nn t hiu qu tt hn v thi gian cn thit thc hin cc cng vic trong qu trnh gia cng c xc nh trn c s quan st, phn tch tng ng tc.
7.5.5- Xc nh s lng my v cng nhn
S lng my cn thit cho mt nguyn cng c xc nh theo tng khi lng ca nguyn cng, tnh ra tng gi my cn thit, i vi sn lng quy nh v vn thi gian lm vic thc t hng nm ca mt my ty theo ch lm vic hng ngy (my ca/ngy). T .k M= m TM . m vi, + Tm l tng gi my cn thit gia cng sn lng chi tit (gi/nm). + k l h s xt n kh nng vt nh mc, tng nng sut (k = 0,9 0,95). + TM l vn thi gian lm vic thc t ca mt my theo ch mt ca sn xut hng ngy (TM = 2200 gi/nm). + m l s ca sn xut hng ngy (m = 1 3). + M l s my tnh ton cn thit cho nguyn cng. S lng cng nhn cn thit cho nguyn cng cng c xc nh trn c s tng khi lng lao ng ca nguyn cng hng nm v vn thi gian lm vic thc
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Lu c bnh
t ca mt cng nhn hng nm theo ch mt ca sn xut hng ngy. T .k R= n TC vi, + Tn l tng gi ngi cn thit cho c sn lng (gi/nm). + TC l vn thi gian lm vic thc t ca mt cng nhn theo ch mt ca sn xut hng ngy (TC = 2000 gi/nm). 7.6- nh mc tnh cht kinh t - k thut Mt phng n cng ngh bao gi cng c so snh, phn tch v mt kinh t. Mun chn ng phng hng, bin php tng nng sut v h gi thnh trong phi c nhng ch tiu kinh t - k thut nh gi.
7.6.1- Ch tiu kinh t - k thut
Ch tiu kinh t - k thut bao gm: Ch tiu v thi gian T Ch tiu k thut v thi gian l thi gian cn hon thnh mt cng vic nht nh trong iu kin sn xut bnh thng ca nh my (phn xng) c tnh n kinh nghim v nhng thnh tu mi v k thut cng nh v t chc sn xut. * Thi gian gia cng tng chic: Ttc = T0 + Tph + Tpv + T tn trong , + T0: thi gian c bn. Thi gian ny cn thit bin i trc tip hnh dng, kch thc v tnh cht c l ca chi tit gia cng v c th thc hin bng tay hay my, c cng thc tnh cho tng nguyn cng. + Tph: thi gian ph, l thi gian cng nhn thao tc c th hon thnh cng vic c bn v c lp li sau mt chi tit hay mt nhm chi tit m khi khng tc ng n hnh dng, kch thc v tnh cht ca chi tit nh: thi gian g, tho chi tit, o lng... Tnc = T0 + Tph, l thi gian nguyn cng. + Tpv: thi gian phc v trng nom cho my lm vic, c th phc v v k thut nh: i dng c, sa , mi dao... hay phc v v t chc nh: tra du, bn a+b . Tnc , vi a, b l cc h s t l thi gian (tra s tay). giao ca, qut dn... Tpv = 100 + Ttn: l thi gian ngh ngi t nhin theo nhu cu cn thit ca con ngi. c Tpv = . Tnc 100
a+b+c Vy, thi gian gia cng tng chic l: Ttc = 1 + Tnc 100 * Nu gia cng hng lot chi tit, cn c th iu chnh th ta c thm thi gian chun b kt thc, bao gm nhng vic c lin quan n vic chun b gia cng mt lot chi tit v thu dn khi kt thc nh: iu chnh my, dng c ct, g lp...
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Lu c bnh
Ttc lot = Ttc +
Tcbkt , vi n l s chi tit trong lot. n
Ch tiu v nng sut Q i vi mt nguyn cng hoc c sn phm. Ch tiu k thut v nng sut Q l nng sut lao ng xc nh bng s lng sn phm c ch to ra trong mt n v thi gian. m m Q= . k (tng chic), hoc Q = . k (hng lot) Ttc Ttc lo t vi, m l thi gian (mt ca, gi hay pht).
7.6.2- Gi thnh sn phm
Mt phng n cng ngh phi c nh gi v mt kinh t, ngha l chn phng n cng ngh kinh t nht s dn n gi thnh h. nh gi ta phi tnh gi thnh sn phm chi tit: G = A.n + B = f(nhiu yu t). vi, + A: l ph tn thng xuyn cho mi chi tit nh vt liu, khu hao, lng cng nhn..., d sn lng nhiu hay t th ph tn ny vn khng i. + B: l ph tn c nh nh lng cng nhn iu chnh my, g, thit b chuyn dng... tnh cho tng chi tit, ph tn ny cng nh khi x cng ln. T , ta c gi thnh mt sn phm: g = G/n, da vo y m ta nh gi v chn phng n cng ngh c gi thnh thp nht. Gi s, ta c hai phng n G cng ngh vi gi thnh sn phm c biu din bi cc ng G1 v G2. R rng, nu s lng chi tit cn gia cng n < n1, ta chn G2 phng n G1. Cn nu n > n1 B2 th chn phng n G2. B1 G1 Tuy nhin, do chi ph c n nh B ph thuc vo n nn n n1 n'2 n2 n3 mt gi t no th cc ng Hnh 7.3- Gi thnh sn phm. G1 v G2 phi tng ln mt lng no (lng tng ny bng vi chi ph c nh tng thm). n lc , ta li phi xt tip phng n no c gi thnh thp hn th chn.
7.6.3- Bin php tng nng sut, h gi thnh sn phm
Ni n nng sut v h gi thnh l mt phm tr rt rng, c th phm vi k thut, phm vi t chc hoc kt hp c hai mt li. Trong thc t c th p dng nhiu phng php tng nng sut v h gi thnh
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Lu c bnh
gia cng qua cch gim i lng thi gian c bn T0 v thi gian ph Tph. L. z . D. L. i L. i T0 = = = Ta c: 1000. v. S n. S n. S. t trong , L: chiu di ct (mm). v: tc ct (m/ph). S: lng chy dao (mm/v). n: s vng quay ca trc chnh (v/ph). i: s ln chy dao. t: chiu su ct (mm). z: lng d gia cng c (mm). Bin php gim thi gian c bn T0 - Nng cao chnh xc ca phi v phi ch to c lng d u, chnh xc th i gim. Phi c x l nhit (ram, , thng ha) to iu kin ct gt d dng. - Rt ngn chiu di chy dao bng cch: dng nhiu dao, chn lng n ti v thot ra ca dao mt cch hp l. - Tng ch ct (chn tmax, Smax m bo bng b mt, tng vn tc ct nhng vn m bo tui bn kinh t ca dng c ct, m bo cht lng gia cng). - Gia cng nhiu b mt cng mt lc bng dao nh hnh hoc bng nhiu dao thc hin trn cc my t ng v bn t ng nhiu trc. Bin php gim thi gian ph Tph - Gim thi gian g t chi tit gia cng bng cch dng cc c cu kp nhanh (kh nn, du p), g t t ng t kch thc, dng g vn nng iu chnh. - Lm cho thi gian ph trng vi thi gian my nh dng g bn quay, g phay kiu i v cng ct, phay lin tc, kim tra t ng, cp phi t ng. - C kh ha, t ng ha qu trnh cng ngh, gim thi gian vn chuyn chi tit, gim thi gian dng my o, dng my iu khin theo chng trnh... - Dng dao chuyn dng gia cng c nhiu b mt, gim thi gian thay dao, iu chnh dao... - T chc lm vic hp l.
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Chng 8
Quy trnh cng ngh ch to Cc chi tit in hnh

Trong ngnh Ch to my, chi tit gia cng c hnh dng hnh hc rt phong ph v vi mi chi tit th s mt c quy trnh cng ngh ch to. Tuy nhin, chng ta c th tp hp mt s rt ln cc chi tit v nhm my thnh mt s loi c hn, bo m c kh nng chuyn t qu trnh cng ngh n chic thnh qu trnh cng ngh hng lot mang du hiu in hnh c trng cho tng loi. Nhng chi tit c xp cng mt loi hay nhm khi chng c chc nng v quy trnh cng ngh tng t nhau. Trong iu kin sn xut hng lot, quy trnh cng ngh in hnh c tc dng lm gim bt cng vic chun b sn xut, khng cn lp mt hoc mt vi phng n cng ngh cho ring tng chi tit, khng cn thit k v ch to trang b cng ngh ring cho tng chi tit... Hin nay, cc chi tit c kh c phn loi thnh cc chi tit dng hp, dng cng, dng bc, dng trc, dng a. Chng ny s trnh by quy trnh cng ngh gia cng cho tng dng chi tit in hnh ny. Khi lm cng tc chun b sn xut mt chi tit no , trc ht cn xem xt n thuc dng chi tit no trong cc dng trn nh hng v tham kho quy trnh cng ngh in hnh ca chi tit tng ng, trn c s b sung nhng ni dung cn thit c c quy trnh cng ngh gia cng cho chi tit cn sn xut. 8.1- quy trnh cng ngh ch to chi tit dng hp Trong tt c cc loi my mc u c chi tit dng hp. Hp bao gm nhng chi tit c hnh khi rng (xung quanh c thnh vch) thng lm nhim v ca chi tit c s lp cc n v lp (nhm, cm, b phn) ca nhng chi tit khc ln n to thnh mt b phn my nhm thc hin mt nhim v ng hc no ca my. Hp c rt nhiu kiu v cng dng cng khc nhau ty theo yu cu lm vic. c im ca cc chi tit hp l c nhiu vch, dy mng ca cc vch khc nhau, trong cc vch li c nhiu gn, nhiu phn li lm; nhiu mt phng phi gia cng lm mt tip xc; c bit trn hp c nhiu l phi gia cng chnh xc thc hin cc mi lp ghp. Nhn chung, hp l loi chi tit phc tp, kh gia cng, khi ch to phi m bo nhiu yu cu k thut khc nhau. 8.1.1- Yu cu k thut Hp c nhng b mt chnh nh mt y, mt l yu cu chnh xc kh cao.
Lu c bnh - B mn Ch to my - Khoa C kh - Trng i hc Bch khoa
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Ngoi ra, cn c cc b mt ph nh b mt y np, l bt bulng... Nhng yu cu k thut c bn ca hp l: - khng phng v khng song song ca cc b mt chnh trong khong 0,05 0,1 mm trn ton b chiu di, Ra = 5 1,25. - Cc l c chnh xc cp 6 8, Ra = 2,5 0,63 i khi cn t cp 5 vfa Ra =0,32. Sai s hnh dng cc l l 0,5 0,7 dung sai ng knh l. - Dung sai khong cch tm gia cc l ph thuc vo chc nng ca n, nu l l lp trc bnh rng th dung sai khong cch tm l 0,02 0,1 mm. Dung sai khng song song ca cc tm l bng dung sai khong cch tm. khng vung gc ca cc tm l khi lp bnh rng cn v trc vt - bnh vt l 0,02 0,06 mm. - Dung sai khng ng tm ca cc l bng 1/2 dung sai ng knh l nh nht. - khng vung gc gia mt u v tm l trong khong 0,01 0,05 trn 100 mm bn knh. 8.1.2- Vt liu v phng php ch to phi Vt liu ch to cc chi tit hp thng dng l gang xm, thp c, hp kim nhm v nhng thp tm hn. Ty theo iu kin lm vic, s lng hp v vt liu m phi c ch to bng cc phng php khc nhau. Ph bin nht l phi gang c, phi thp c, phi hp kim nhm c, trong mt s trng hp ngi ta dng phi dp, phi hn. * Phi c bao gm c phi gang, thp hoc hp kim nhm l nhng loi phi ph bin nht ch to cc chi tit dng hp. Thng dng cc phng php c sau ch to phi c: - c gang trong khun ct, mu g, lm khun bng tay. Phng php ny cho chnh xc thp, lng d gia cng ct gt ln, nng sut thp, i hi trnh cng nhn cao. Phng php ny thch hp i vi dng sn xut n chic v lot nh. - c gang trong khun ct, mu kim loi, lm khun bng my. Phng php ny cho chnh xc cao, lng d gia cng ct gt nh. Phng php ny thch hp i vi dng sn xut hng lot v hng khi. - c trong khun v mng th chi tit c ra t chnh xc 0,3 0,6 mm, tnh cht c hc tt. Phng php ny dng trong hng lot ln v hng khi nhng thng ch dng c cc chi tit c trng lng nh. - c p lc c th to nn cc chi tit hp c nh c hnh th phc tp. Cc chi tit hp c ra thng ngui khng u, gy ra bin dng nhit v ng sut d. Cho nn cn c bin php kh ng sut d trc khi gia cng ct gt. * Phi hn c ch to t thp tm ri hn li thnh hp. Loi ny c dng trong sn xut n chic v lot nh v s rt ngn c thi gian chun b phi, t hiu qu kinh t cao (so vi phi c). Phi hn c 2 kiu: - Kiu th: Hn cc tm thp li thnh hp ri mi gia cng.
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- Kiu tinh: Hn cc tm thp c gia cng s b cc b mt cn thit thnh hp, sau mi gia cng tinh li. Phi hn th lun c ng sut d v vic kh ng sut d ca phi hn thng gp kh khn. * Phi dp c dng i vi cc chi tit hp nh c hnh th khng phc tp dng sn xut lot ln v hng khi. Ta c th dp nng i vi thp cn hp kim mu th c th dp ngui. Phng php dp to c c tnh tt v t nng sut cao. 8.1.3- Tnh cng ngh trong kt cu Tnh cng ngh trong kt cu ca chi tit hp c ngha c bit quan trng bi v n khng nhng nh hng rt ln ti cng sc lao ng khi ch to m cn c nh hng ti vic tiu hao vt liu. V vy, ngay t khi thit k phi m bo cc yu cu v tnh cng ngh ca kt cu nh: - Hp phi c cng vng khi gia cng khng b bin dng v c th dng ch ct cao, t nng sut cao. - Cc b mt lm chun phi c din tch nht nh, phi cho php thc hin nhiu nguyn cng khi dng b mt lm chun. Ngoi ra, b mt chun cn phi to iu kin g t chi tit nhanh khi gia cng v lp rp. - Cc b mt cn gia cng khng c c vu li, lm; phi thun li cho vic n dao, thot dao. Kt cu ca cc b mt phi to iu kin cho vic gia cng ng thi bng nhiu dao. - Cc l trn hp nn c kt cu n gin, khng nn c rnh hoc c dng nh hnh, b mt l khng c t qung. Cc l ng tm nn c ng knh gim dn t ngoi vo trong. Cc l nn thng sut v ngn. - Khng nn b tr cc l nghing so vi mt phng ca cc vch khi gia cng trnh hin tng dao (khoan, khot, doa) b n dao lch hng. - Cc l kp cht phi l cc l tiu chun. 8.1.4- Quy trnh cng ngh gia cng chi tit hp a) Chun nh v Khi lng gia cng chi tit dng hp ch yu l tp trung vo vic gia cng cc l. Mun gia cng nhiu l trn nhiu b mt khc nhau qua cc giai on th, tinh... cn to nn mt chun tinh thng nht cho chi tit hp. Chun thng l mt mt ngoi no v hai l chun tinh ph vung gc vi mt phng . Hai l chun tinh ph ny phi c gia cng t n chnh xc cp 7 v c khong cch cng xa cng tt. Khi nh v chi tit hp trn g th mt ngoi s tip xc vi nh v mt phng, hai l s c tip xc vi hai cht (mt cht tr, mt cht trm). Nh vy, chi tit c nh v 6 bc t do. Hai l chun tinh ph thng c dng trong s cc l bulng trn ca hp.
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Tuy nhin, khng nht thit lc no cng dng hai trong s cc l bt bulng em gia E cng chnh xc lm chun ph, m c th cn c vo kt cu c th ca hp nh rnh, sng trt, B thm ch c l chnh xc ca hp khng ch cc bc t do cn li. V d, khi gia cng hp dng mt bch. Ta chn chun l mt A u (c ng knh A), l chnh Hnh 8.1- Chn chun nh v trn mt bch B v mt trong hai l bt bulng. S g dt c tnh cht in hnh nh trn (mt mt phng v hai l vung gc vi mt phng ) cho php g t chi tit qua nhiu nguyn cng trn nhiu g, trnh c sai s tch ly do vic thay i chun gy ra. To c chun tinh nh th, g cng n gin i nhiu v tng t nhau nhiu nguyn cng. V vy i vi chi tit dng hp, sau khi lm sch, kh ng sut bn trong, ct u rt, u ngt th nguyn cng u tin phi l gia cng to mt chun. Vic chn chun th cho nguyn cng ny ht sc quan trng v n nh hng n lng d gia cng cng nh chnh xc cc nguyn cng tip theo. Ta c th dng nhng phng n chn chun th nh sau: Mt th ca l chnh khng ch 4 bc t do (hnh a). Mt th khng gia cng bn trong khng ch 3 bc t do (hnh b). Mt trn g vai khng a) ch 3 bc t do (hnh c). Trong cc b mt c th lm chun th ni trn, quan trng nht l l chnh v nu chn n lm chun th th bo m c lng d v sau cho bn thn l b) c) u n, to iu kin cho vic Hnh 8.2- S nh v khi chn chun th gia cng l d dng. Khi chn nguyn cng u tin chun th, nu khng ch n mt trong khng gia cng s c th lm cho khe h lp ghp gia n vi cc b phn bn trong (nh bnh rng, tay gt...) khng m bo. Trong sn xut hng lot nh v n chic, do vic ch to phi km chnh xc v khi khng dng g chuyn dng, c th thc hin nguyn tc chn chun nh trn bng phng php ly du. Khi ly du, c th kt hp chn chun th ny, ng thi kim tra chun th kia, chia lng d cho tho mn cc yu cu khc nhau. Tuy
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nhin, ly du v gia cng theo du c nng sut rt thp, do gi thnh tng. b) Trnh t gia cng cc b mt ch yu ca hp Qu trnh cng ngh gia cng chi tit dng hp gm hai giai on chnh sau: * Gia cng mt phng chun v cc l chun lm chun thng nht. * Dng chun thng nht trn lm chun nh v gia cng cc b mt cn li nh: - Gia cng cc mt phng cn li. - Gia cng th v bn tinh cc l lp ghp. - Gia cng cc l khng chnh xc dng kp cht. - Gia cng chnh xc cc l lp ghp. - Tng kim tra. 8.1.5- Bin php cng ngh thc hin cc nguyn cng chnh a) Gia cng mt chun Mt chun gia cng chi tit dng hp gm mt mt phng v hai l chun. * Gia cng mt phng chun Vi hp c kch thc khc nhau v sn lng t, ta c th dng my phay hay bo vn nng gia cng. Nu cc hp c ln c b mt chun vung hoc gn trn, c th gia cng trn my tin ng; cn hp c nh th ngoi bo v phay, ta cn c th gia cng trn my tin vn nng bng cch dng mm cp 4 chu nh v hoc dng g chuyn dng. Trong sn xut hng lot ln v hng khi, vi hp c ln hoc trung bnh, gia cng mt phng chun c thc hin trn my nhiu trc hoc my c bn quay; vi hp c nh c th dng chut mt phng hoc my t hp hay my chuyn dng. * Gia cng hai l chun Nu sn xut hng lot ln hoc hng khi nn dng my nhiu trc chuyn dng. Ch rng khi gia cng hai l chun ny phi ln lt tin hnh khoan, khot, doa trong mt ln g v phi dng bc dn hng m bo t c nhm b mt v chnh xc ca bn thn l cng nh m bo khong cch tm hai l nm trong phm vi dung sai cho php. Nu sn lng nh, c th gia cng bng cch ly du v thc hin trn my khoan ng. Vi hp ln, c th gia cng hai l chun trn my doa ngang. b) Gia cng cc mt ngoi ca hp Cc mt ngoi ca hp thng l mt phng, c gia cng bng cc phng php bo, phay, tin, mi v chut. Trong sn xut n chic v hng lot nh, thng dng phng php bo v n gin v r tin. Nng sut ca bo tuy thp nhng c th khc phc bng cch g nhiu chi tit gia cng cng mt lc. Trong sn xut hng lot va v ln, vic gia cng mt ngoi c th bng phng
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php phay. Vi hp c kch thc nh th xp nhiu chi tit gia cng cng mt lc. Hp c kch thc ln th gia cng mt ngoi trn my phay ging hoc bo ging. Trong sn xut hng khi th v ang s dng phng php phay lin tc trn my phay c bn quay v my phay c tang trng gia cng hai mt phng song song cng mt lc bng hai dao. Ngoi ra, hin nay cn s dng rng ri c phng php chut gia cng mt phng ca hp. Nhng hp c mt ngoi v mt trong trn xoay c gia cng trn my tin ng. Gia cng tinh cc mt ngoi ca hp trong sn xut hng lot ln v hng khi c thc hin trn my mi, cn trong sn xut n chic v lot nh thng dng phng php co. c) Gia cng cc l lp ghp Khi ch to cc chi tit dng hp, vic gia cng cc l nht l cc l lp ghp chim thi gian kh ln. V vy, vic chn phng php gia cng hp l s to iu kin nng cao nng sut, gim gi thnh rt c hiu qu. Bin php gia cng cc l lp ghp ca hp ph thuc vo sn lng ca chi tit. C th gia cng trn my doa ngang vn nng hay my t hp nhiu trc chnh. Trong mt s trng hp, c th gia cng trn dy chuyn t ng hoc cng c th gia cng trn my khoan ng, khoan cn, i khi c th gia cng trn my tin ng hay my tin thng. ng knh cc l gia cng ph thuc c bn vo kch thc ca dao (dao nh hnh), hoc ph thuc vo vic iu chnh kch thc ca mi dao lp trn trc dao. chnh xc v khong cch tm, song song v vung gc gia cc ng tm l vi nhau, cng nh cc yu cu khc v v tr ca l c m bo bng hai phng php sau: - Gia cng cc l theo cc bc dn hng trn g. - Gia cng cc l theo phng php xc nh bng ta nh cc vch kch thc trn my (my doa ta ). * Trong sn xut hng lot ln v hng khi, cc l lp ghp ca hp c gia cng trn my doa, my t hp nhiu trc theo cch gia cng song song hoc song song lin tc trn hai hoc ba b mt ca hp. Khi , v tr cc l c m bo theo cch b tr cc trc chnh trn my. Khi gia cng trn my t hp nn chia ra thnh hai nguyn cng th v tinh, hon thnh trn hai my ca mt ng dy hoc chia lm hai bc hon thnh ti hai v tr ca my. Nhng l chnh ca hp c kch thc khng ln lm, c th c gia cng trn my khoan ng nh bc dn hng v u khoan nhiu trc gia cng cc l trn mt b mt cng mt lc, hoc trn my khoan cn c dng bc dn. * Trong sn xut hng lot, cc l chnh xc ca hp c gia cng trn my doa ngang c dng bc dn hng. Khong cch tm v song song ca chng c bo m bng s dch chuyn bn my v bng cc bc dn hng. Cn vung gc
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gia cc ng tm l c m bo nh quay bn my mang chi tit so vi trc doa. Nu l cn doa ngn, khi gia cng cn dng bc dn hng cho trc doa pha trc hoc pha sau. Khi l cn doa di th nh hng trc doa c pha trc v sau.
Chi tit Chi tit Bc dn Chi tit Bc dn
Hnh 8.3- S nh hng dng c khi doa l chi tit hp
Nu c nhiu l ng trc trn mt hng, c th thc hin gia cng trn my doa vi bin php thch hp. m bo chnh xc ca hng l nn chia ra hai nguyn cng th v tinh. Khi gia cng th, trc tin gia cng l ngoi cng mt pha ca hp bng trc dao cngxn. Sau gia cng l tip theo, lm nh vy cho n khi xong mt na s l trn hng l . Quay bn my i 1800 gia cng cc l cn li pha i din ca hp vi bin php nh cc l pha bn kia. Lm nh vy cho n ht. Khi gia cng tinh, c th tin hnh theo hai cch. Cch th nht l gia cng lin tc cc l bng cch s dng cc l va gia cng c dn hng cho vic gia cng cc l tip theo. Cch th hai l ln lt gia cng hai l ngoi ca hai mt ngoi cng i din ca hp, sau dng hai l ny dn hng cho dng c ct cho vic gia cng cc l cn li gia. V d, cn gia cng 4 l trn mt hng l ca chi tit hp nh sau: - Gia cng th: + Bc 1: Gia cng l 4. + Bc 2: Gia cng l 3. Sau , quay bn my quay chi tit 1800 v tip tc gia cng. + Bc 3: Gia cng l 1. + Bc 4: Gia cng l 2. - Gia cng tinh: + Nu dng cch th nht, gia cng l 4 trc. Sau , dng l 4 (gn bc dn hng) dn trc dao gia cng l 3. C nh vy, dng l 3 nh hng gia cng cho l 2, dng l 2 nh hng gia cng l 1. + Nu dng cch th hai, tin hnh gia cng l 4 trc. Sau , quay bn my quay chi tit 1800 gia cng l 1. Dng hai l 4 v 1 va gia cng xong
1 2 3
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dn hng cho trc dao gia cng cc l 3 v 2. * Trong sn xut lot nh v n chic, vic gia cng l hp c th thc hin trn my khoan cn hay my doa ng, doa ngang khng cn bc dn hng cho dng c ct m tin hnh bng phng php r g theo ng vch du trn phi. Th t vic gia cng l hp theo phng php ny nh sau: - G t v kim tra chi tit hp trn bn my sao cho ng tm ca l ly du song song vi ng tm trc chnh. - a ng tm trc chnh ca my trng vi tm l u tin s gia cng. - Gia cng l . - Dch chuyn bn my cng vi chi tit gia cng theo nhng khong cch tm cho ti khi trng vi ng tm ca l cn gia cng tip theo. d) Gia cng cc l kp cht Trong cc chi tit dng hp, ngoi nhng l c bn, chnh xc cn c cc l dng kp cht v cc l c ren. Khi gia cng cc l ny ta cng cn c vo san lng chn bin php gia cng. - Khi sn lng t, vi mi c kch thc ca hp, cc l kp cht c gia cng trn my khoan ng hoc khoan cn, khong cch tm gia cc l c m bo bng cch ly du hoc nh cc phin dn, bc dn khoan. i vi cc hp qu ln, c th dng my khoan di ng kp thng vo chi tit gia cng hoc l cho my khoan di ng trn nn xng. - Trong sn xut hng lot va, cc l kp cht c cg trn my khoan cn c lp u Rvnve, trn c lp nhiu dng c gia cng khc nhau theo th t gia cng. Lm nh vy s gim c thi gian tho lp dng c. - Trong sn xut hng lot ln v hng khi vi cc chi tit c va, cc l ny c gia cng trn my t hp hay my khoan nhiu trc gia cng nhiu l cng mt lc. i vi chi tit c nh, nguyn cng ny c thc hin trn my t hp cng vi mt s nguyn cng khc. Trong sn xut hng khi, cc l ny cn c th c gia cng trn cc ng dy t ng. Vi cc l c ren, khi gia cng chng ta phi c thm bc ct ren. Ty theo sn lng, kt cu v yu cu chnh xc cng nh kch thc ca ren m ta chn cc phng php ct ren cho hp l. e) Gia cng chnh xc cc l lp ghp Nu trong chi tit dng hp c cc l cn m bo chnh xc cp 6, 7 th phi gia cng tinh ln cui. Cc phng php gia cng tinh ln cui c th l doa mng (doa lng), mi hnh tinh, mi khn, ln p thm ch c th mi nghin, co... - Doa mng dng gia cng l t chnh xc cao v kch thc, hnh dng hnh hc v thng ca ng tm. c im ca phng php ny l gia cng vi vn tc rt cao, lng n dao nh, chiu su ct nh. My c th l my mt trc chnh, nhiu trc chnh, my doa
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ngang, doa ng, doa chuyn dng. - Mi hnh tinh dng gia cng tinh l c ng knh ln (hn 180 mm). Phi s c g c nh trn bn my, mi s quay tng i so vi tm ca trc chnh, ng thi quay hnh tinh (tc l quay tng i so vi l gia cng). Lng n dao dc do bn my thc hin, n dao ngang l do dch chuyn ca mi. Phng php ny c nng sut thp, kt cu my phc tp nn t dng. - Mi khn dng gia cng tinh cc l c ng knh t 25 500 mm. Mi khn thng c thc hin trn my mi khn mt trc chnh. y l phng php c nng sut kh cao v kinh t. - Ln p l phng php gia cng tinh bng bin dng do trong trng thi ngui. N dng gia cng mi vt liu chu tc dng ca bin dng do c cng nh hn 40 HRC. f) Kim tra Trong qu trnh ch to, ta phi kim tra. Vic kim tra gia cc nguyn cng c tin hnh sau khi gia cng cc b mt quan trng, c yu cu chnh xc cao. Cn cui giai on gia cng phi tng kim tra cc yu t ra trong yu cu k thut nh thng, phng ca cc mt phng, song song, vung gc, ng tm v khong cch gia cc l... * thng ca mt phng c kim tra bng cch dng thc hoc ng h so. phng ca mt phng c kim tra bng ng h so hoc bng nhng bn r trn c bi lp sn p vo mt cn kim tra. * chnh xc v kch thc l th c kim tra bng dng c o thch hp ty theo hnh dng v kt cu l. Nu l c chiu su nh th dng thc cp, calip; nu l c chiu su ln th dng ng h o l. * chnh xc hnh dng hnh hc c kim tra bng ng h so. * ng tm ca cc l c bn c xc nh bng trc kim tra. o ng tm ca hai l ta dng trc kim tra v ng h so vi s nh hnh bn. Ta lp hai trc chun vo hai l cn o ng tm (lp khng c khe h, nu l qu to th ta c th g trc trong bc), cho trc bn tri quay. Sai lch ch th ln nht v nh nht trn ng h sau Hnh 8.4- S o ng tm hai l mt vng quay chnh l sai lch gia khong cch ln nht v nh nht t cc im trn tit din o n ng tm quay trc bn phi, chnh l o hng tm gia hai trc, bng hai ln ng tm gia hai trc. Ngoi ra, kim tra ng tm cn c th dng g chuyn dng, phng
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php quang hc v mt vi phng php khc na. * Khong cch gia hai tm l th c o nh sau: Ta a hai trc c ng knh 1 v 2 vo hai l cn 2 o khong cch tm. + Nu l c cp chnh xc cao (trn cp 7) v lp khng c khe h (H7/ h6). A M + 2 N A=M 1 2 Bc im + Nu l c cp chnh xc thp (di cp 8) th lp trc vo bc im (bc im 1 c cn 1/500 1/200, khi lp bc im vo l th s Hnh 8.5- S o khong cch tm hai l khng c khe h). * o song song gia cc l c tin hnh bng ng h so. Dng hai trc 1 kim 4 v 5 cho vo hai l cn kim tra 4 dng bc iu chnh 2 cho khng cn khe h. Lp tay treo s 3 c mang ng h 1 v 2 vo trc 5, quay tay treo 3 cho mi t ca ng h so 1 v 2 t vo trc 4, ti chnh cc 3 5 ng h so v s 0. Tho tay treo ra, quay ngc li 1800 v lp v pha i din ca trc 4 v 5. Tin hnh o nh Hnh 8.6- S kim tra song song theo hai phng trn ta c kt qu: - Hiu s ch trn ng h s 1 l sai s v khng song song theo phng thng ng ca hai ng tm trn chiu di bng khong cch gia hai u lp tay treo. - Hiu s ch trn ng h s 2 l sai s v khng song song theo
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phng nm ngang gia hai ng tm . * song song gia ng tm l v mt y. Cho ng h so r trn trc chun (lp trong l) v pha bn phi, chnh cho ng h v s 0 khi mi d tip xc vi ng sinh cao nht ca trc. R ng h so v pha u bn tri ca trc, gi tr trn ng h so l gi tr Hnh 8.7- Kim tra song song gia ng tm l ca song song gia tm v mt y l v mt y. * vung gc gia tm l v mt u c xc nh bng ng h so hoc bng calip chuyn dng. ng h s c lp trn trc kim, cho hp quay quanh tm trc th ch s trn ng h s cho ta bit gi tr vung gc. Thng thng, trc a) b) kim s c g trong mt bc kim (c Hnh 8.8- S kim tra vung gc gia tm l v mt u a) Bng ng h so; b) Bng calip chuyn dng cn). * vung gc gia tm cc l c xc nh bng ng h so hoc calip.
a) Hnh 8.9- Kim tra vung gc gia cc l a) Dng ng h so; b) Dng calip
b)
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8.2- quy trnh cng ngh ch to chi tit dng cng Cng l loi chi tit c mt hoc mt s l c bn cn gia cng t chnh xc cao m ng tm ca chng song song vi nhau hoc to vi nhau mt gc no . Ngoi ra, trn cng cn c cc l dng kp cht, cc rnh then, cc mt u v cc yu t khc cn phi gia cng. Chi tit dng cng thng c chc nng bin chuyn ng thng ca chi tit ny thnh chuyn ng quay ca chi tit khc. Ngoi ra, chi tit dng cng cn dng y bnh rng di trt khi cn thay i t s truyn trong cc hp tc . Cng gt, cng ni, cnh tay n, n kp, n gnh, tay bin v nhng chi tit tng t l cc khu ng hc ca cc c cu my, dng c, trang b cng ngh u thuc nhm chi tit dng cng. 8.2.1- Yu cu k thut Khi ch to cng cn m bo cc yu cu k thut sau: - Kch thc cc l c bn c gia cng t chnh xc cp 7 9; nhm b mt Ra = 0,63 0,32. - khng song song ca tm cc l c bn khong 0,03 0,05 mm trn 100 mm bn knh. - khng vung gc ca tm l so vi mt u khong 0,05 0,1 mm trn 100 mm bn knh. - khng song song ca cc mt u cc l c bn khc trong khong 0,05 0,25 mm trn 100 mm bn knh mt u. - Cc rnh then (nu c) c gia cng t cp chnh xc 8 10 v nhm b mt Rz = 10 40. - Cc b mt lm vic ca cng c nhit luyn t cng 50 55 HRC. 8.2.2- Vt liu v phng php ch to phi Vi nhng cng lm vic vi ti trng khng ln th dng vt liu l gang xm GX 12 - 28, GX 24 - 44. Nhng cng c cng vng thp, lm vic vi ti trng va p th nn chn gang do GD 37 - 12, gang rn. Cn nhng cng lm vic vi ti trng ln, tng bn nn dng cc vt liu l thp ccbon 20, 40, 45; thp hp kim 18CrNiMoA, 18Cr2Ni4WA, 40CrMoA c bn cao... Ty thuc vo vt liu v iu kin c th, chi tit cng c th c to phi bng nhiu phng php nh c, rn, dp. - Cng c kch thc va v nh, nu sn lng t th phi c ch to bng rn t do; nu sn lng nhiu th dng phng php dp. - Phi c dng cho cng bng gang, kim loi mu, thp. Ty theo iu kin sn xut, sn lng m c th c trong khun ct, khun kim loi, khun mu chy. - Cng loi ln, nu sn lng t th dng phi hn; nu sn lng nhiu th
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kt hp dng hn v dp tm. 8.2.3- Tnh cng ngh trong kt cu Cng nh cc dng chi tit khc, i vi chi tit dng cng tnh cng ngh c ngha quan trng v n nh hng trc tip n nng sut v chnh xc gia cng. V vy, khi thit k chi tit cng nn ch ti kt cu ca n nh: - Cng phi c cng vng cao. - Chiu di ca cc l c bn nn bng nhau v cc mt u ca chng cng nm trn mt mt phng tin g t. - Kt cu ca cng nn c i xng qua mt mt phng no . - Kt cu ca cng phi thun li cho vic gia cng ng thi nhiu chi tit. - Hnh dng ca cng phi thun tin cho vic chn chun. 8.2.4- Quy trnh cng ngh gia cng chi tit cng a) Chun nh v Yu cu k thut quan trng nht ca chi tit dng cng l khong cch tm gia cc l c bn, v tr tng quan gia l c bn so vi cc b mt l khc hoc mt u. V vy, khi nh v chi tit dng cng phi m bo c v tr tng i ca cc b mt vi nhau, ca cc l vi nhau v vung gc ca cc l vi mt u ca n. Do vy, chun th ban u c chn l vnh ngoi ca l v mt mt u ca phi. Chn chun th nh vy l gia cng mt u kia v gia cng l c bn. S nh v chi tit cng thc hin vic gia W cng to chun tinh nh bn. Chi tit c nh v bng mt u pha di, vnh ngoi ca l c bn bn tri c nh v bng khi V c W nh, vnh ngoi ca l c bn bn phi c nh v bng khi V di ng, lc kp Hnh 8.10- S g t khi gia cng mt u v l c W c tc ng thng qua bn ca thanh truyn (nguyn cng to chun tinh) khi V di ng ny. Sau khi c c l c bn v mt u gia cng, chn chun tinh thng nht l mt u v hai l c bn gia cng cc mt cn li ca cng. S nh v gia W W W W cng vi chun tinh thng nht nh bn, mt u cng t vo phin t, mt l cng lng vo cht tr ngn, l kia
Hnh 8.11- S nh v vi chun tinh thng nht
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lng vo cht trm (ch hng nh v ca cht trm). b) Trnh t gia cng cc b mt Cc chi tit dng cng rt a dng, tuy vy c th gia cng theo trnh t tng qut nh sau: - Gia cng mt u. - Gia cng th v tinh cc l c bn. - Gia cng cc l khc nh l ren, l du... - Cn bng trng lng (nu cn). - Kim tra. 8.2.5- Bin php cng ngh thc hin cc nguyn cng chnh a) Gia cng mt u Ty theo chnh xc ca phi m c th gia cng mt u ca cng bng nhiu phng php khc nhau nh phay, tin, mi, chut. Phng php bo t c dng v mt u c din tch nh ri rc nn c nng sut thp. - Trong sn xut hng lot ln v hng khi, nu phi c chnh xc cao th thng gia cng mt u bng mi hoc chut. Lc , va t c nng sut cao, va t c chnh xc cao. - Trong sn xut hng lot nh v va, gia cng mt u ca cng bng phay hoc tin. - Tuy nhin, nu chnh xc ca phi qu thp th cc dng sn xut u dng phay gia cng mt u cng. Ngoi ra, chn phng php gia cng mt u cng cn ph thuc vo lng d gia cng hay ni cch khc l ph thuc vo phng php ch to phi. Nu lng d nh c th khng dng phay c m dng mi; nu lng d ln th dng mi s khng hp l. Cc mt u ca cng c gia cng tng pha ln lt trn my phay ngang hay ng bng mt dao vi s nh v nh hnh 8.10. Hoc cng c th phay hai mt ca mi u trn my phay ngang bng mt b hai dao phay a ba mt. Phi c g t trn cc nh v thch hp v iu chnh cc mt tng i vi dao nh cc dng c chuyn dng. Nh W W s hnh 8.12, m bo hai mt u i xng so vi mt phng gia ca tay bin, chi tit s c nh v vo phn thn tay bin khng gia cng. Vi s nh v ny khi gia cng cc Hnh 8.12- S nh v
phay hai mt u bng dao phay a ba mt Lu c bnh - B mn Ch to my - Khoa C kh - Trng i hc Bch khoa 129
cng ln, nng cao nng sut c th dng my phay nhiu trc gia cng c bn mt u cng mt lc. Trong mt s trng hp yu cu chnh xc cao th sau khi phay hoc chut, mt u ca cng phi qua mi trn my mi phng c bn quay. Mi cc mt u cng lc nu chng c b dy bng nhau, mi xong lt li mi pha kia; nu b dy khc nhau th mi u ln ring, u nh ring. Cng c th thc hin trn my mi chuyn dng gia cng c hai pha cng mt lc. b) Gia cng th v tinh cc l c bn trn cng Cc l c bn ca cng c yu cu chnh xc bn thn cao v n s lp ghp vi chi tit khc. Ty theo sn lng, iu kin sn xut m c bin php gia cng ph hp: * Trong sn xut nh, sn lng t vi mi c ca cng, l c bn c gia cng trn my khoan ng, khoan cn hoc my tin, my doa ngang bng phng php ly du, r g. * Trong sn xut hng lot, sn lng nhiu, cc l c bn c gia cng trn my khoan ng, khoan cn hoc my khoan c u Rvnve bng phng php t ng t kch thc nh bc lp trn phin dn. tin hnh gia cng c th dng hai cch sau: Cch 1: Gia cng mt l, sau ly l ny lm chun nh v cng vi mt u gia cng l tip theo. Lc ny s gia cng nh hnh 8.10. V ch gia cng mt l nn ch cn khng ch 5 bc t do nh vy l ri, bc t do cn li l xoay quanh tm l cn gia cng khng cn khng ch v n khng nh hng n chnh xc cn t. L c gia cng qua ba bc: khoan, khot, doa. Cng c th thay khot, doa bng chut hoc thay doa bng nong l. Sau khi gia cng mt l xong, tin hnh gia cng cc l tip theo. Lc ny chi tit c nh v bng mt u, mt l va c gia cng xong v mt mt no hn ch nt bc t do xoay quanh tm l s gia cng. hn ch bc t do ny ta dng khi V ty ng t vo vnh ngoi ca Hnh 8.13- S nh v gia cng l tip theo u cng c l s gia cng. Theo cch ny, khong cch tm ca cc l c m bo nh chnh xc khong cch ca tm cht nh v v tm bc dn cho l tip theo. Khi gia cng cc l tip theo phi tun th theo nh l u tin. Cch 2: Gia cng ln lt tt c cc l sau mt ln nh v. Theo cch ny, chi tit gia cng phi c nh v c 6 bc t do (s nh
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v nh hnh 8.10): mt u c khng ch 3 bc t do, khi V t vo vnh ngoi khng ch 2 bc t do, khi V ty ng t vo vnh ngoi khng ch bc t do cn li. V tr v khong cch gia cc l do v tr cc bc dn lp trn phin dn quyt nh. Gia cng ln lt cc l theo cc bc khoan, khot, doa trn my khoan cn bng cch di chuyn u khoan, g c nh hoc trn my khoan ng bng cch di chuyn g. * Trong sn xut hng khi, gia cng cc l c bn c tin hnh trn my khoan nhiu trc hoc my t hp nhiu trc chnh. Dng my t hp c th t hiu qu kinh t cao v n c kh nng gia cng song song hoc song song lin tc tt c cc l trong mt ln g. S nh v s nh hnh 8.14. Theo phng n ny, chnh xc v v tr cc l m bo tt, song song gia cc l v khong cch gia cc l Hnh 8.14- S nh v gia cng hai l cng mt lc cng t c tt hn. Nu l c ng knh ln hn 30 mm, khi to phi c l sn th trnh t s l tin rng l (hay khot), gia cng tinh vi mt s l cn lp bc ng th sau khi gia cng tinh l ri mi ng bc vo, sau li gia cng tinh li bc ng. Khi l c bn yu cu c rnh then, then hoa th c th gia cng bng phng php xc hoc chut. Nu dng xc gia cng rnh then hoa th phi dng thm u phn , lc nng sut thp v chnh xc km; cn dng chut th nng sut cao, chnh xc nhng li t tin. c) Gia cng cc l khng c bn Cc l khng c bn ca chi tit dng cng l cc l c ren, l kp cht, l bt v m... Thng thng, cc l ny c yu cu chnh xc khng cao, thng l cp 10. Trng hp dng nh v ng v tr gia cng vi mt b phn khc, cc l ny phi gia cng t chnh xc cp 7 (nh l nh v gia thn bin v np bin). Vic gia cng cc l khng c bn thng c tin hnh sau khi gia cng cc mt u v mt hoc cc l c bn, s nh v nh hnh 8.10. Cc l ny c gia cng sau cng trc khi nhit luyn. i vi nhng l yu cu chnh xc khng cao th dng phng php khoan.
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Cn nhng l c yu cu chnh xc phi khoan, khot, doa. Ty theo sn lng m trn c s ca s nh v thit k cc g, cc thit b c nng sut ph hp. d) Kim tra i vi chi tit dng cng, ngoi vic kim tra ng knh l v b dy ca cc u cng cn phi kim tra khong cch tm cc l c bn, vung gc gia mt u v ng tm l, khng song song gia cc tm l. * ng knh cc l c bn c kim tra bng thc cp, calip hay ng h o l. B dy ca u cng cng c kim tra bng thc cp, calip. * Khong cch tm cc l c bn c kim tra nh ca chi tit dng hp. * khng song song gia cc ng tm l c kim tra bng ng h so vi g nh sau: Ta cho hai trc kim vo hai l cn kim tra khng song song. t trc kim l ln hn ln hai khi V ging nhau, u kia c bng mt cht nh v, chi tit c nh v 5 bc t do khi kim tra. Cho ng h so o mt bn u trc kim, chnh ng h so v s 0. Sau , cho ng h sang o u bn kia. Ch s trn ng h so l khng song song ca hai l cng. thc hin c chnh xc vic o, mi d ca ng h so phi d ng ng sinh trn cng. Ngi ta s thay Hnh 8.15- S kim tra khng mi d ca ng h so c dng li song song ca hai l cng ngang nh mt con dao tin ct t. * vung gc gia l v mt u ca cng c kim tra bng g chuyn dng v ng h so. S kim tra nh sau: Lp trc tm (trc ny c mt cn nht nh) vo l cng cn kim tra. G trc tm ln hai mi tm, quay trc tm i mt vng. S ch chnh lch ca ng h so cho bit vung gc vi bn knh t mi t ca ng h so n tm quay. Ch : i vi mt s cng khng c ng trc i xng th thun tin cho vic g t, ngi ta s to thm mt s
Hnh 8.16- S kim tra vung gc gia tm l v mt u cng
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vu lm chun tinh ph hoc kp cht. Sau khi gia cng xong th ct b i. Nu khi lng cng vt qu yu cu th chn nhng ni m khng nh hng n cng vng, bn ca cng (mt u cng) khoan i vi l gim khi lng. 8.3- quy trnh cng ngh ch to chi tit dng hp Trc l loi chi tit c dng rt ph bin trong ngnh Ch to my, n c nhim v truyn chuyn ng quay, mmen xon cho nn chu bin dng phc tp xon, un, ko, nn. Cc chi tit dng trc c b mt c bn cn gia cng l mt trn xoay ngoi, mt ny thng dng lm mt lp ghp. Ty theo kt cu m ta c th chia ra cc chi tit dng trc ra cc loi sau: - Trc trn: trn sut chiu di l, trc ch c mt kch thc ng knh d. Vi l/d < 4 l trc trn ngn; 4 l/d 10 l trc trn thng; l/d > 10 l trc trn di. - Trc bc: trn sut chiu di l ca trc c mt s kch thcng knh khc nhau. Trn trc bc c th c rnh then, rnh then hoa hoc c ren. - Trc rng: c tc dng lm gim trng lng v c th lm mt lp ghp. - Trc rng: l loi trc m trn c bnh rng lin trc. - Trc lch tm: l loi trc c nhng c trc khng cng nm trn mt ng tm nh trc khuu. 8.3.1- Yu cu k thut Khi ch to cc chi tit dng trc cn bo m cc iu kin k thut sau: - Kch thc ng knh cc c lp ghp yu cu cp chnh xc 7 10, mt vi trng hp cn cp 5. - chnh xc hnh dng hnh hc nh cn, van ca cc trc nm trong khong 0,25 0,5 dung sai ng knh c trc. - Dung sai chiu di mi bc trc khong 0,05 0,2 mm. - lch tm gia cc c trc lp ghp khng qu 0,01 0,03 mm. - khng song song ca cc rnh then hay then hoa i vi tm trc khng qu 0,01 mm trn 100 mm chiu di. - nhm ca cc c trc lp ghp t Ra = 1,25 0,63; cc mt u Rz = 40 20; cc b mt khng lp ghp Rz = 80 40. - Tnh cht c l ca b mt trc nh cng b mt, thm ti th ty tng trng hp c th m t iu kin k thut. Ngoi ra, i vi mt s trc lm vic tc cao th cn c yu cu v cn bng tnh v cn bng ng kh rung ng trong qu trnh lm vic. 8.3.2- Vt liu v phng php ch to phi Vt liu ch to cc chi tit dng trc thng thng l thp cacbon nh thp
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35, 40, 45; thp hp kim nh 40Cr; 40Mn, 50Mn... dng cho trc chu ti trng ln. i vi cc trc c bit nh trc cn, trc khuu, trc chnh my ct kim loi thng c ch to t gang c bn cao, gang cu v nhng vt liu ny c tnh chng mn cao v gim rung ng tt. Khi ch to trc trn th tt nht l dng phi thanh. Vi trc bc c ng knh chnh nhau khng ln lm th dng phi cnnng. Trong sn xut nh v n chic, phi ca trc c ch to bng cch rn t do hoc rn t do trong khun n gin trn my ba, i khi dng phi cn nng. Phi ca trc ln c ch to bng cch rn t do hoc hn ghp tng phn li. Trong sn xut hng lot ln v hng khi, phi ca trc c ch to bng dp nng trn my dp hoc p trn my p; vi trc bc c th rn trn my rn ngang hoc bng phng php c. i vi phi trc bng gang bn cao c ch to bng phng php c. Phi c cho php gim lng d v khi lng gia cng trong qu trnh ch to. 8.3.3- Tnh cng ngh trong kt cu Khi thit k chi tit dng trc cn phi ch cc vn sau: - Cc b mt trn trc c th gia cng c bng cc dao thng thng. - ng knh cc c trc nn gim dn v hai u. - Gim ng knh trc n mc c th m vn m bo kh nng lm vic. - i vi trc di th phi ch n vic b tr luynt c d dng. - Chn v b tr cc b mt nh then, ren, rnh xon... phi thch hp v thun li cho qu trnh gia cng. Mt vn cn ch l quy tnh cng ngh ch to trc trn khc hn trc bc v tnh n gin v tnh kinh t, v vy cn nghin cu kh nng thay trc bc bng trc trn nu c th. 8.3.4- Quy trnh cng ngh gia cng chi tit trc a) Chun nh v i vi chi tit dng trc yu cu v ng tm gia cc c trc l rt quan trng. m bo yu cu ny, khi gia cng trc cn phi dng chun tinh thng nht. Chun tinh thng nht khi gia cng chi tit dng trc l hai l tm hai u trc. Nu l trc rng th dng mi tm kha nhm truyn mmen xon.
a)
b)
Hnh 8.17- S nh v trc bng hai mi tm a) Hai mi tm thng; b) Hai mi tm c kha nhm
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Khi dng hai l tm lm chun c th gia cng tt c cc mt ngoi, phay rnh then, then hoa, ren trn trc. Khi dng hai l tm lm chun v c nh v trn hai mi tm gia cng mt ngoi th khng c sai s chun cho kch thc ng knh, nhng s c sai s chun cho kch thc hng trc nu mi tm tri l mi tm cng khi gia cng cc bc trc theo phng php iu chnh sn dao t kch thc bi v trong qu trnh ch to hai l tm c sai s v chiu su ca l tm, trong khi mi dao c iu chnh sn cch mi tm bn tri mt kch thc khng i. iu dn n kch thc t mi dao n u bn tri ca trc s thay i nu l tm cn ca trc su, cn khc nhau. khc phc sai s ny, ta thay mi tm cng bn phi bng mi tm ty ng. Khi dng hai mi tm lm chun th phi dng tc truyn mmen xon, nu gia cng trc trong mt ln g tin ht chiu di th c th dng mi tm c gn tc mt u. Khi gia cng mi tm sau c th c nh khi s vg quay ca chi tit gia cng nh, nu s vng quay chi tit gia cng > 500 v/ph th s lm mi tm c nh b chy cho nn phi dng mi tm quay. Ngoi hai l tm cn c th ly chun l mt ngoi ca trc gia cng cc mt ngoi ca bc trc khc, gia cng rnh then, then hoa, mt u. Cn c th dng chun phi hp c mt ngoi v l tm. i vi chi tit l trc rng, khi gia cng tinh mt ngoi, chi tit c nh v bng mt trong l gia cng m bo ng tm gia mt trong v ngoi. b) Trnh t gia cng cc b mt Chi tit trc c th c gia cng theo trnh t nh sau: * Gia cng chun b: ct t phi theo chiu di, kho hai mt u v khoan tm, nu trc di cn dng thm luynt th phi gia cng c . * Gia cng trc nhit luyn: m bo cng vng ca trc, khi gia cng ngi ta gia cng cc on trc c ng knh ln trc, ri gia cng cc ng knh nh sau. - Tin th v bn tinh cc mt tr. - Tin tinh cc mt tr. Nu l trc rng th sau khi tin th v bn tinh phi khoan v doa l ri mi gia cng tinh mt ngoi. - Mi th mt s c trc chi tit khi phay. - Nn thng trc c ng knh < 100 mm v l/d > 10. - Gia cng cc mt nh hnh, rnh then, rnh cht, rng trn trc... - Gia cng cc l vung gc hoc l thnh vi ng tm trc mt gc, cc b mt c ren, mt khng quan trng. * Gia cng nhit luyn. * Nn thng sau khi nhit luyn khc phc bin dng.
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* Gia cng tinh sau nhit luyn: - Mi th v tinh cc c trc. - Mi th v tinh cc mt nh hnh (nu c). - nh bng. 8.3.5- Bin php cng ngh thc hin cc nguyn cng chnh a) Kho mt u v khoan tm Khi ch to cc trc c chiu di l > 120 mm t phi dp hay phi thanh th hai l tm c dng lm chun nh v. Trong trng hp ny, vic kho mt u v khoan l tm c th thc hin theo cc phng php sau y: * Trong sn xut n chic v lot nh, thng phay hai mt u ca trc sau ly du ri khoan l tm. Cng c th g trc ln my tin, tin mt on gia ri kho mt u v khoan l tm; sau tr ngc u trc kia, kp on tin nguyn cng trc ri kho mt u v khoan l tm cn li. * Trong sn xut hng lot ln v hng khi, vic kho mt u v khoan l tm c thc hin theo mt trong ba cch sau: - Phay mt u trn my phay c tang quay, sau khoan l tm trn my khoan hai pha. - Phay mt u trn my phay ngang, khoan l tm trn my chuyn dng. G hai chi tit ln cc khi V nh v 1, kp I cht bng khi V 2. Cc chi tit c khng ch 4 5 2 dc trc bng cht t 4. 3 Trc a vo gia cng II v tr II l trc c gia cng mt u nh v 1 tr I. Sau khi gia cng Hnh 8.18- S gia cng mt u trc xong v tr II l trc trn my phay ngang c gia cng c hai u. Vi hai cch trn, vic gia cng mt u v khoan l tm c chia thnh hai nguyn cng. - Phay mt u v khoan l tm c hai pha trong mt nguyn cng trn my chuyn dng. Chi tit c nh v 1 v kp cht nh cc khi V 2. Sau khi gia cng xong mt u bng hai dao phay, bn xe 2 dao 1 s chy n v tr ca hai mi khoan tm.
136 Hnh 8.19- S gia cng ng thi mt u trc v l tm trn my chuyn dng
Gia cng xong th bn xe dao li chy v v tr ban u tho chi tit ra v thay phi mi vo. b) Tin th v tinh cc bc trc Tin th v tinh cc bc trc c th c thc hin trn my tin vn nng, my tin c bn dao chp hnh thy lc, my bn t ng chp hnh thy lc, my tin mt trc nhiu dao. Chn loi my no l ty thuc vo iu kin sn xut v sn lng. - Trong sn xut nh v n chic, vi phi cn v rn t do ty theo hnh dng bn ngoi v kch thc ca trc cng nh t l gia cc ng knh ln, nh m tin hnh tin lin tc trn my tin vn nng. Khi l tm c gia cng theo phng php ly du. - Trong sn xut hng lot nh, c th gia cng cc bc trc trn cc my tin c trang b bn dao chp hnh thy lc. Vi loi my ny c th rt ngn thi gian gia cng t 2,5 3 ln so vi gia cng trn my tin thng. - Trong sn xut hng lot ln v hng khi, vic gia cng cc bc trc c tin hnh trn my bn t ng mt trc nhiu dao, my nhiu trc... Tin nhiu dao trn bt c my loi no cng u c u im hn tin mt dao l gim c thi gian gia cng c bn. Ngoi ra, cn dng c my bn t ng chp hnh thy lc gia cng cc bc trc trong sn xut hng khi. Vi loi my ny n s c cc u im sau so vi tin nhiu dao: + Thi gian iu chnh gim i 2 3 ln. + Nng sut gia cng cao v c th ct tc cao. + Thun li i vi cc trc km cng vng. + Tin tinh c cc trc di c yu cu nhn bng b mt cao m tin bng nhiu dao khng th thc hin c. c) Mi th v tinh cc c trc Mi c trc c th c thc hin trn my mi trn ngoi, vi cc trc bc ngn v trc trn c th mi trn my mi v tm. Khi mi trn my mi v tm th mt nh v chnh l mt gia cng. Khi mi trn my mi trn ngoi, trc c nh v bng hai l tm trn hai mi tm. Lc , chnh xc ca c trc sau khi mi ph thuc vo chnh xc cc l tm v mi tm, do vy trc nguyn cng mi tinh phi sa l tm loi tr cc sai hng do b mt l tm b xy ha hoc b chy trong khi nhit luyn. Vi my mi trn ngoi c th tin dao theo phng ngang hay phng dc. - Mi tin dao ngang khi chiu di mi l < 80 mm, dng khi chiu di on gia cng nh hn b rng hoc khi gia cng cc mt nh hnh trn xoay. - Mi tin dao dc khi chiu di mi l > 80 mm, trng hp ny c s
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dng ph bin khi mi trc. Khi mi, do thi gian ph kim tra chi tit l kh ln. V vy, nng cao nng sut, khi mi thng dng thit b kim tra kch thc gia cng ngay trong qu trnh gia cng (xem CNCTM II/ 181). d) Gia cng cc mt nh hnh Cc mt nh hnh trn trc gm cc mt c ren, bnh rng, then hoa, rnh then, cc mt lch tm... Phng php gia cng cc mt ny c cp Chng 6 Cc phng php gia cng b mt chi tit my. * Gia cng mt c ren trn trc - Gia cng ren theo chiu trc: i vi ren kp cht nu sn lng t th dng tin ren, bn ren; sn lng nhiu th dng dao tin rng lc, u ct ren, cn ren. Nu l ren truyn lc (ren hnh vung, hnh thang) vi sn lng t th dng tin thng, sn lng nhiu th dng phay ren. - Gia cng ren trn cc l lm vi ng tm trc mt gc: Loi l ren ny thng dng bt bulng kp cht cc chi tit khc ln trc. Ren thng c ct bng tar tay nu sn lng t v bng tar my nu sn lng nhiu. * Gia cng rng trn trc Phng php gia cng rng trn trc cng ging nh phng php gia cng bnh rng. Vic thc hin bng ct rng bao hnh hay nh hnh l ty thuc vo dng sn xut v iu kin sn xut. * Gia cng rnh then v then hoa Rnh then trn trc thng c gia cng trn my phay vi dao phay ngn hay dao phay a. Lc , trc c nh v trn hai khi V hoc l tm. Mt then hoa trn trc th thng c gia cng bng phng php phay, ngoi ra cn c th gia cng bng phng php bo, chut hay cn ngui. * Gia cng cc mt lch tm Cc chi tit trc c cc mt lch tm l cc loi chi tit nh trc cam, trc khuu trong ng c t trong. e) Gia cng cc l chnh xc dc trc i vi cc loi trc nh trc chnh ca my ct kim loi, nng sng... thng c cc l rng bn trong v trn c nhng b mt cn hay tr i hi chnh xc v kch thc cng nh ng tm vi mt ngoi ca trc. C th quan nim cc loi trc ny cng ch l mt dng trc bc c l rng bn trong. V vy, ch cn ra bin php gia cng cc l chnh xc bn trong sao cho ng tm vi mt ngoi ca trc. Ty theo dng phi m ta c bin php gia cng thch hp: - Nu phi c t thp cn, rn hay dp th sau khi tin th c cc bc ngoi ca trc, tin hnh gia cng th mt l bng khoan, sau gia cng tinh bng khot, doa hoc tin trong. Khi gia cng tinh xong l, dng l ny nh v cho gia cng tinh mt ngoi.
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- Nu phi c c l sn th dng chnh l th lm chun gia cng th mt ngoi ca trc. Sau , dng mt ngoi nh v gia cng l. Ri li dng mt l va gia cng xong nh v gia cng tinh mt ngoi. Ring vi trc chnh my ct kim loi th li dng mt ngoi tinh ny nh v cho qu trnh mi l cn u trc. f) Khoan l vung gc vi ng tm trc khoan l loi ny thng dng my khoan, kiu my v cch nh v ph thuc vo hnh dng trc v cng dng ca l. Thng thng, chi tit c nh v trn hai khi V, dng thm mt cht t hn ch chuyn ng chiu trc. Ngoi ra, cng c th nh v trn hai mi tm cng. Khi gia cng cc l nghing vi ng tm trc mt gc th vic nh v vn th, ch khc l ta iu chnh nh v sao cho l gia cng ph hp vi hng chy ca dao. g) Gia cng tinh ln cui i vi cc trc c chnh xc thng thng th ch cn mi tinh l . Tuy nhin, i vi cc trc c yu cu chnh xc cao nhr trc chnh my ct kim loi, trc khuu th sau khi mi tinh cc c trc phi qua gia cng tinh ln cui bng nh bng, mi khn hoc mi siu tinh xc. h) Kim tra i vi cc chi tit dng trc, thng phi kim tra kch thc, nhm b mt b mt, hnh dng hnh hc cc b mt. - Kim tra kch thc bao gm kch thc ng knh, chiu di cc bc trc, kch thc then, then hoa, ren trn trc... C th dng thc cp nu yu cu dung sai > 0,02 mm; nu dung sai nh hn c th dng panme, calip, ng h so, dng c quang hc, g chuyn dng. - Kim tra hnh dng hnh hc ca cc c trc c thc hin nh ng h so. Chi tit c g trn mi tm my tin hay g chuyn dng. Kim tra mt tit din ng gi c van, a cnh; kim tra nhiu tit din dc trc suy ra cn. - Kim tra v tr tng quan gia cc b mt bao gm: + dao ng gia cc c trc c kim tra bng cch t trc ln khi V, cn u o ca ng h th t vo c trc cn o. Hiu s ca hai ch s ln nht v nh nht ca ng h sau khi quay trc i mt vng l tr s dao ng . + song song gia nh, chn v mt bn ca cc then, then hoa so vi ng tm ca cc c cng c kim tra bng ng h so. Chi tit cng c t ln hai khi V, dng ng h so r trn nh, chn, mt bn ca then, then hoa s c song song so vi ng tm cc c . + Kim tra ng tm cc c trc. Nh g mang theo ng h so quay quanh mt
Lu g bnh - B mn Ch to my - Khoa C kh - Trng i hc Bch khoa c
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bc trc trong khi mi t ca ng h t vo bc trc cn kim tra. 8.4- quy trnh cng ngh ch to chi tit dng bc nng cao tui th ca thit b, n gin ho v gim bt khi lng gia cng cc my mc thit b, ngi ta thng lp cc chi tit h bc. Chng thng c dng lm chi tit lt , chu mi mn v c bit l kh nng thay th c. Bc l nhng chi tit c dng trn xoay, hnh ng, thnh mng, mt u c vai hoc khng c vai, mt trong c th tr hoc cn. Bc c th nguyn hoc x rnh, mt lm vic ca bc c rnh du, trn bc c l ngang tra du. V mt kt cu, c th chia cc chi tit dng bc ra cc loi nh:
a)
b)
c)
d)
Hnh 8.20- Mt vi dng kt cu ca bc
- Loi bc trn khng c g (hnh a). - Loi bc c g hoc mt bch (hnh b, c). - Loi bc c l hnh cn (hnh d). - Loi bc c x rnh. - Loi bc c thm lp hp kim chng mn. - Loi bc mng c x rnh. Nu da vo my gia cng cc nguyn cng chnh ca bc, c th chia bc ra thnh 6 nhm theo ng knh gm: Di 25 mm; 25 32 mm; 32 40 mm; 40 50 mm; 50 65 mm; 65 100 mm. c trng quan trng v kch thc ca bc l t s gia chiu di v ng knh ngoi ln nht ca chi tit. T s ny thng nm trong khong 0,5 3,5. 8.4.1- Yu cu k thut Khi ch to chi tit dng bc, yu cu k thut quan trng nht l ng tm gia mt ngoi v mt l, cng nh vung gc gia mt u v ng tm. C th l phi m bo cc iu kin sau: - chnh xc v kch thc ca b mt ngoi t cp 7 10. - chnh xc v kch thc ca b mt l t cp 7, i khi cp 10, nu l
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bc cn lp ghp chnh xc c th yu cu cp 5. - dy ca thnh bc cho php sai lch trong khong 0,03 0,15 mm. - ng tm gia mt ngoi v mt l thng thng > 0,15 mm. - khng vung gc gia mt u v ng tm l khong 0,1 0,2 mm/ 100 mm bn knh. Nu l loi bc chu ti trng dc trc th khng vung gc ny khong 0,02 0,03 mm/ 100 mm bn knh. - nhm b mt: + Vi mt ngoi cn t Ra = 2,5. + Vi mt l, ty theo yu cu m cho Ra = 2,5 0,63; c khi Ra = 0,32. + Vi mt u Rz = 40 10, c khi cn Ra = 2,5 1,25. 8.4.2- Vt liu v phng php ch to phi V c im ca bc l lm vic c s chuyn ng tng i, do vy vic la chn vt liu ch to chi tit dng bc phi da trn c s cc cp vt liu ma st cho ph hp. Cc loi vt liu thng dng ch to chi tit dng bc l thp, ng, gang v cc hp kim c bit khc; ngoi ra cn dng cht do v gm. Vic chn phi ch to chi tit dng bc ph thuc vo iu kin lm vic, hnh dng v sn lng, c th: - Vi bc c ng knh l < 20 mm thng dng thp thanh nh hnh v thp thanh cn nng hoc l phi c c vi vt liu l hp kim ng, gang. - Vi bc c ng knh l > 20 mm thng dng phi ng hoc phi c l c sn. Thng thng c trong khun ct, lm khun bng tay; khi sn lng ln c th dng c ly tm, c trong khun kim loi, c p lc... - i vi bc c thnh mng v x rnh, thng ngi ta lm bng ng thau hoc ng hoc dng ng l cun li. - i vi cc loi bc yu cu lm vic sut i v khng th thay c th dng hp kim xp, sau thm du vo trong qu trnh lm vic nhit tng ln du s t tit ra. - Vi cc loi bc rt nh, nh nh trong ng h, vt dng gia nh, ngi ta thng dng cht do lm bng cch p li, nu lm bng s th p li, sau thiu kt. 8.4.3- Tnh cng ngh trong kt cu Khi gia cng cc chi tit dng bc trc ht cn ch n c trng quan trng l t s gia chiu di v ng knh ngoi ln nht ca chi tit. T s ny thng nm trong khong 0,5 3,5. Cn phi lu n kch thc l ca bc v vi cng mt ng knh, vic gia cng l s kh hn gia cng trc. Ngoi ra, b dy ca bc cng khng c mng qu s gy kh khn trong vic kp cht gia cng (thng dng ng kp n hi, c cu kp bng cht do).
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8.4.4- Quy trnh cng ngh gia cng chi tit bc a) Chun nh v m bo c hai iu kin k thut c bn ca bc l ng tm gia mt ngoi v mt trong, vung gc gia mt u v ng tm l, c th dng mt trong cc phng php gia cng sau: - Gia cng mt ngoi, mt l, mt u trong mt ln g. Phng n gia cng ny c th thc hin khi ch to cc bc t phi thanh hoc phi ng vi vic ct t bc cui cng, lc chi tit c nh v bng mt ngoi v mt mt u. Nu l phi c tng chic, mun gia cng theo phng php ny cn phi to Hnh 8.21- Gia cng cc mt ca thm cc vu li di lm chun, lc s bc trong mt ln g tng ph liu v gim h s s dng vt liu. - Gia cng mt ngoi, mt l, mt u trong hai ln g. ln g u tin, chi tit c nh v bng mt ngoi v mt mt u gia cng mt l v mt u kia. Sau , nh v chi tit bng mt l v mt u gia cng gia cng mt Hnh 8.22- Gia cng cc mt ca ngoi v mt u cn li. bc sau hai ln g - Gia cng mt ngoi, mt l, mt u trong ba ln g. Ln g u tin, chi tit c nh v bng mt ngoi v mt mt u gia cng mt phn mt ngoi, mt mt u
Hnh 8.23- Gia cng cc mt ca bc sau ba ln g
v gia cng th mt trong. Tip n, nh v chi tit bng mt phn mt ngoi v mt u gia cng ln g trc gia cng phn mt ngoi, mt u cn li v gia cng tinh mt trong. Sau , nh v chi tit bng mt l gia cng gia cng tinh mt ngoi. Nh vy, vi vic nh v vo mt l bc gia cng mt ngoi c u im hn so vi nh v mt ngoi gia cng l v nu nh v bng mt l, c th dng trc g n hi th sai s g t hoc khng c (nu dng chng tm) hoc rt nh (nu kp trc g ln mm cp); ngoi ra, khi dng l tm lm chun gia cng mt ngoi th lch tm gia l v mt ngoi c loi b.
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b) Trnh t gia cng cc b mt Khi lp trnh t cc nguyn cng gia cng cc b mt v my gia cng cn da vo hnh dng ca phi v sn lng. Tuy nhin, trnh t gia cng cc b mt ca bc thng nh sau: - Gia cng cc mt chnh ca bc (mt ngoi, mt trong, mt u). - Khoan cc l ph. - Gia cng cc mt nh hnh. - Nhit luyn. - Gia cng tinh cc l, cc mt ngoi. - nh bng cc mt yu cu c bng cao. - Kim tra. 8.4.5- Bin php cng ngh thc hin cc nguyn cng chnh a) Gia cng cc mt chnh ca bc Bin php gia cng cc mt chnh ca bc ph thuc vo dng phi v sn lng. * Cc bc ch to t phi thanh - Nu sn lng t, c th tin hnh gia cng trn my tin vn nng trong mt ln g qua cc bc: xn mt u, khoan mi, khoan l, tin trong, tin ngoi, ct t. - Nu sn lng nhiu, vic gia cng cc mt chnh ca bc c thc hin trn my rvnve t ng mt trc hoc nhiu trc trong mt ln g qua cc bc: xn mt u, khoan l, tin mt ngoi, vt mp, doa th v ct t. * Cc bc ch to t phi ng Bin php gia cng bc t phi ng cng ging phi thanh ch khc l khng c nguyn cng khoan l v thay bng khot v doa l. * Cc bc ch to t phi c hoc rn tng chic - Nu sn lng t, vi chi tit c ln v va th thc hin gia cng trn my tin ct, tin ng; vi chi tit c nh c th gia cng trn my tin vn nng thng thng. - Nu sn lng nhiu, vi chi tit c nh v va th gia cng trn my tin mt trc nhiu dao hay my tin nhiu trc nhiu dao. Ch : i vi cc bc c thnh mng, km cng vng khi gia cng cc mt chnh, vic nh v khng khc g vi cc loi bc ni trn nhng lc kp phi theo phng hng trc trnh gy bin dng hng knh trng v sau khi gia cng. Vi nhng bc c kt cu c bit cn phi c bin php thch hp nh: bc c l cn th c khot, doa bng dao hnh cn; bc c mt lp hp kim chng mn th sau khi gia cng tinh l s tin hnh c lp hp kim ln mt l, sau phi gia cng tinh li lp hp kim... b) Gia cng cc l ph Cc l ph trn bc thng l cc l tra du, l c ren kp cht vi cc chi
143
tit khc. gia cng cc l ny, bc thng c nh v bng mt ngoi v mt u hoc mt trong v mt u. - Nu sn lng t, l c khoan trn my khoan ng vi g c bc dn hng hoc khoan theo du. - Nu sn lng nhiu, c th dng my khoan c u rvnve hoc u khoan nhiu trc gia cng tt c cc l cng mt lc; vi chi tit c va c th gia cng trn my t hp. c) Gia cng th v tinh cc mt nh hnh trong v ngoi Nhng mt nh hnh ny gm rnh then, rnh du, rng kha, rnh then trong. - Rnh then: Nu sn xut nh, n chic th gia cng trn my xc; nu sn xut lot ln th gia cng trn my chut. Rnh then mt ngoi c gia cng bng dao phay ngn trn my phay ng hoc dao phay a trn my phay ngang nh i vi chi tit dng trc. - Rnh du hoc mt nh hnh mt trong: thng c gia cng bng phng php chp hnh. Nh gia cng rnh du mt l bc bng tin chp hnh; rnh nh hnh trn mt ngoi bc nh rnh cam thng c gia cng bng tin chp hnh hoc phay chp hnh. - Rng kha trn bc hay bnh rng lin bc: c gia cng bng phng php phay, bo, xc (xem Chng 9 - Gia cng bnh rng). d) Gia cng tinh cc b mt sau nhit luyn Cc b mt chnh xc ca bc sau khi nhit luyn cn phi gia cng tinh li (thng l cc mt trong, c khi l mt ngoi). m bo ng tm gia mt trong v mt ngoi cn ly mt ny lm nh v gia cng mt kia. Vic gia cng tinh cc b mt thng thc hin trn my mi. i vi chi tit c ng knh ln kh gia cng trn my mi th phi dng dao hp kim cng hoc dao kim cng tin mng trn my tin ct, tin ng vi cc g thch hp. Nu b mt bc cn nhn bng v chnh xc cao hn th c th dng phng php mi khn hoc mi nghin gia cng tinh ln cui. e) Kim tra Khi gia cng cc chi tit dng bc thng phi kim tra cc yu t nh ng knh ngoi, ng knh trong, chiu dy thnh bc, nhm b mt, ng tm gia mt ngoi v mt trong, vung gc gia mt u v ng tm l... - Kim tra cc yu t kch thc nh ng knh trong, ng knh ngoi, chiu dy thnh bc bng cc dng c o vn nng nh thc cp, calip...; kim tra v nhm b mt bng cch so snh vi mu. - Kim tra ng tm gia cc b mt: thng dng ng h so v g kim tra ging nh s kim tra cc bc trn chi tit dng trc. - Kim tra vung gc gia mt u v ng tm l: c th dng ng
Thc gc
144
Trc tm
h so (nh i vi chi tit dng trc) hoc dng thc gc vi s bn. s ny, lp thm trc tm vo l bc, sau cho mt cnh ca thc gc ln trc tm, dch n vo tip xc vi mt u bc.
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Gio trnh: Cng ngh ch to my

Gio trnh: Cng ngh ch to my

1.2- qu trnh sn xut v qu trnh cng ngh

Gio trnh: Cng ngh ch to my

1.3- cc thnh phn ca quy trnh cng ngh

Gio trnh: Cng ngh ch to my

Gio trnh: Cng ngh ch to my

1.3.5- ng chuyn dao

Khoa C kh - Trng i hc Bch khoa

Gio trnh: Cng ngh ch to my

1.4.2- Dng sn xut hng lot

Gio trnh: Cng ngh ch to my

Khoa C kh - Trng i hc Bch khoa

Gio trnh: Cng ngh ch to my

Cht lng b mt chi tit my

Khoa C kh - Trng i hc Bch khoa

Gio trnh: Cng ngh ch to my

ng y Hnh 2.1- nhm b mt chi tit.

Khoa C kh - Trng i hc Bch khoa

Gio trnh: Cng ngh ch to my

Khoa C kh - Trng i hc Bch khoa

Gio trnh: Cng ngh ch to my

Khoa C kh - Trng i hc Bch khoa

Gio trnh: Cng ngh ch to my

Hnh 2.4- Qu trnh mi mn ca mt cp chi tit.

Gio trnh: Cng ngh ch to my

Khoa C kh - Trng i hc Bch khoa

Gio trnh: Cng ngh ch to my

Khoa C kh - Trng i hc Bch khoa

Gio trnh: Cng ngh ch to my

2.2.4- nh hng n chnh xc cc mi lp ghp

Khoa C kh - Trng i hc Bch khoa

Gio trnh: Cng ngh ch to my

- Khi S < 0.1 mm/vg th R z =

r. h min S 2 h min + 1 + 8.r 2 S2

Gio trnh: Cng ngh ch to my

b V(m/ph) 0 20 100 200

Hnh 2.7- nh hng ca vn tc ct n nhp nh t vi Rz

Gio trnh: Cng ngh ch to my

Gio trnh: Cng ngh ch to my

Khoa C kh - Trng i hc Bch khoa

Gio trnh: Cng ngh ch to my

Khoa C kh - Trng i hc Bch khoa

Gio trnh: Cng ngh ch to my

chnh xc gia cng

Gio trnh: Cng ngh ch to my

3.2.1- Phng php ct th tng kch thc ring bit

Gio trnh: Cng ngh ch to my

Gio trnh: Cng ngh ch to my

Gio trnh: Cng ngh ch to my

Khoa C kh - Trng i hc Bch khoa

Gio trnh: Cng ngh ch to my

Gio trnh: Cng ngh ch to my

Khoa C kh - Trng i hc Bch khoa

Gio trnh: Cng ngh ch to my

0,089.Py .L3 48.E.I

x = 0,2343 , cng L 48.E.I vng ca phi: J = p 0,089.L3

Khoa C kh - Trng i hc Bch khoa

Gio trnh: Cng ngh ch to my

Khoa C kh - Trng i hc Bch khoa

Gio trnh: Cng ngh ch to my

Nhn cc h s chnh xc sau i ln ct, ta c:

Gio trnh: Cng ngh ch to my

Gio trnh: Cng ngh ch to my