Cac Phuong Phap Gia Cong Dac Biet

PHNG PHAP GIA CONG AC BIET
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LI NOI AU
PHNG PHAP GIA CONG AC BIET la mon khoa
hoc chuyen nganh c kh che tao may.
Phng phap nay ra i nham thay the giai quyet cho cac
phng phap gia cong co ien nh : Tien, Phay, Bao, Khoan,
Khoet, Doa, Mai, Xoc, Chuot, . . . V gia cong co ien gia cong
khong c hoac gia cong khong at hieu qua kinh te ky
thuat oi vi vat lieu mi, do vat lieu mi co ac iem : o
cng va o ben cao, Kha nang chu va chong mai mon cao,
chu ng tot trong moi trng hoa chat, . . .
PHNG PHAP GIA CONG AC BIET co kha nang
gia cong tat ca vat lieu mi vi bat ky c tnh nao, gia cong
hau hau het cac chi tiet phc tap, tiet kiem c nguyen vat
lieu, at o chnh xac cao va hoan toan c kh hoa, t ong
hoa.
PHNG PHAP GIA CONG AC BIET c xay
dng tng minh ve c s ly thuyet, nguyen ly lam viec, kha
nang cong nghe, ac iem ky thuat, kha nang ng dung, . . .
cua cac phng phap gia cong mi, tao ieu kien thuan li cho
oc gia quy hoach thc tien san xuat.
Quyen sach PHNG PHAP GIA CONG AC BIET
c hoan thanh sau nhieu nam tham khao, nghien cu va
giang day ai hoc Cong Nghiep TP.HCM. Ngoai chc
nang giao khoa cho cac he ai hoc, quyen sach con la tai lieu
nghien cu cho cac Ky s, hoc vien Cao hoc va can bo ky
thuat trong nganh che tao may.

Trang - 2 -
Tac gia xin chan thanh cam n :
Ban Giam Hieu trng ai hoc Cong Nghiep
TP.HCM
Ban chu nhiem Khoa C Kh cung ong nghiep luon
ong vien, giup va tao moi ieu kien thuan li cho Tac gia
hoan thanh nhiem vu.
ac biet xin cam n KS.oan Bui Minh The a tham
gia soan ban thao.
Du rat co gang va can than nhng do ieu kien khach
quan va chu quan nen kho tranh khoi sai sot. Tac gia mong
nhan c y kien ong gop xay dng cua ong nghiep va ban
oc.
Moi y kien xin gi ve :
Bo mon Che tao may Khoa C Kh Trng ai
hoc Cong Nghiep TP.HCM. 12 Nguyen Van Bao Phng
4 Quan Go Vap TP.HCM. So ien thoai : (08).9850875
Tac gia
INH VAN E
Trang - 3 -
MU C LU C
Chng 1 :
TONG QUAN VE CAC PHUONG PHAP
GlA CONG AC BlET
I. Nhu cau ve cac phng phap gia cong ac biet ............... 07
II. Phan loai cac phng phap gia cong ac biet ................. 09
III. ac trng cua cac phng phap gia cong ac biet ........ 10
IV. Tnh u viet cua phng phap gia cong ac biet ........... 13
Chng 2 :
CAC PHUONG PHAP GlA CONG CO
A . Gia cong sieu am
I. Khai niem ......................................................................... 14
II. Nguyen ly gia cong ......................................................... 14
III. C s ly thuyet cua gia cong sieu am ............................ 18
IV. Thiet b va dung cu ........................................................ 26
V. Cac thong so cong nghe .................................................. 30
VI. Mot so cong nghe gia cong bang sieu am
1) Khoan - Khoet - Doa bang sieu am ............................. 37
2) Mai - Cat - Xe ranh bang sieu am ............................... 42
VII. ac em - pham vi ng dung ....................................... 46
B. Gia cong tia nc va gia cong tia nc co hat mai
I. Khai niem ......................................................................... 50
II. Nguyen ly gia cong ......................................................... 51
III. C s ly thuyet ............................................................... 53
IV. Thiet b va dung cu ........................................................ 58
V. Cac thong so cong nghe .................................................. 77
VI. u iem va pham vi ng dung ...................................... 95
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C. Gia cong dong hat mai
I. Khai niem ....................................................................... 100
II. Nguyen ly gia cong ....................................................... 100
III. Mot so thong so cong nghe .......................................... 101
IV. Pham vi ng dung ........................................................ 101
Chng 3 :
CAC PHUONG PHAP GlA CONG HOA
I. Nguyen ly gia cong ........................................................ 102
II. Cac phng phap cong nghe
va kha nang cong nghe ....................... 102
III. Cac phng phap gia cong hoa
1) Phay hoa .................................................................... 106
2) Tao phoi hoa .............................................................. 107
3) Khac hoa ................................................................... 109
4) Gia cong quang hoa ................................................... 109
Chng 4 :
CAC PHUONG PHAP GlA CONG lEN HOA
I. Khai niem ....................................................................... 111
III. C s ly thuyet ............................................................. 113
IV. May va dung cu gia cong ............................................ 114
V. Cac thong so cong nghe ................................................ 116
VI. Pham vi ng dung ........................................................ 121
VII. Cac phng phap gia cong ien hoa
1) Mai ien hoa ............................................................. 122
2) anh bong ien hoa .................................................. 128
3) Gia cong lo ien hoa ................................................. 134
4) Lam sach bavia bang ien hoa .................................. 136
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Chng 5 :
CAC PHUONG PHAP GlA CONG NHlET
A. Phng phap gia cong tia la ien
I. Khai niem ....................................................................... 138
II. C s ly thuyet .............................................................. 138
III. Nguyen ly gia cong ...................................................... 142
IV. Dung cu va thiet b ...................................................... 144
VI. Phong chay va phong ho lao ong
trong gia cong tia la ien ...................... 188
VII. Cac ng dung cua gia cong tia la ien ..................... 188
VIII. ac iem va pham vi ng dung ................................ 195
B. Phng phap gia cong cat day tia la ien
I. Khai niem ....................................................................... 199
III. Dung cu va thiet b ...................................................... 201
IV. Cac thong so cong nghe .............................................. 206
V. u - Nhc iem va pham vi ng dung ........................ 206
C. Phng phap gia cong chum tia ien t
I. Khai niem ....................................................................... 208
III. C s ly thuyet ............................................................. 212
IV. Dung cu va thiet b ...................................................... 213
VI. Pham vi ng dung va hng phat trien ........................ 218
VII. u - Nhc iem ........................................................ 219
D. Phng phap gia cong chum tia laser
I. Khai niem ....................................................................... 221
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III. C s cua phng phap gia cong
bang chum tia laser.............................. 224
IV. Dung cu va thiet b gia cong ........................................ 227
VI. u - Nhc iem - Pham vi ng dung
va phng phap phat trien................... 233
E. Phng phap cat ho quang
I. Khai niem c ban ........................................................... 237
III. Dung cu va thiet b gia cong ........................................ 238
IV. Cac thong so cong nghe .............................................. 240
V. Pham vi ng dung ......................................................... 241
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Chng 1
TONG QUAN VE CAC PHUONG PHAP
GIA CONG AC BIET
Muc tieu : Sau khi hoc nghien cu xong chng nay, ngi
nghien cu co kha nang sau
- Hieu nhu cau ve phng phap gia cong ac biet.
- Phan loai cac phng phap gia cong.
- Biet c ac trng cac phng phap gia cong ac biet.
- Hieu biet tnh u viet cua phng phap gia cong ac
biet.

I. Nhu cau ve cac phuong phap gia cong dac bieI :
- Cac phng phap gia cong truyen thong, v du nh : tien,
phay, bao, khoan, khoet doa, . . . dung dung cu cat e tach
phoi ra khoi be mat gia cong nh bien dang pha huy (li cat
cua dung cu cat co hnh dang hnh hoc xac nh hoac co hnh
dang hnh hoc khong xac nh). Ngoai cac phng phap gia
cong truyen thong nay, co mot ho cac phng phap gia cong
s dung nhng c che khac e tach phoi trong suot qua trnh
gia cong. Thuat ng Gia cong ac biet lien quan en nhom
cac phng phap gia cong tach lng d bang ky thuat khac,
s dung nang lng c, ien, nhiet, hoa, hoac ket hp cac
dang nang lng nay. ac biet, nhng phng phap nay khong
s dung dao cat khi gia cong thong thng.
- Cac phng phap gia cong ac biet c s dung rong rai
t sau the chien th hai nham ap ng nhng dang gia cong
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ac biet va mi ma cac phng phap gia cong truyen thong
khong the giai quyet c.
- Nhng nhu cau va tam quan trong ve mat thng mai lan
cong nghe cua cac phng phap gia cong ac biet bao gom :
+ Nhu cau gia cong nhng vat lieu kim loai hay phi kim
loai mi phat trien. Nhng vat lieu mi nay thng co cac tnh
chat ac biet nh sc ben, o cng va o deo cao, rat kho gia
cong bang nhng phng phap cat got thong thng.
+ Nhu cau gia cong nhng chi tiet hnh hoc phc tap, bat
bnh thng, kho hoac khong the gia cong bang phng phap
truyen thong.
+ Nhu cau tranh lam hong be mat cua chi tiet do s xuat
hien cua cac ng suat phat sinh trong gia cong truyen thong.
- Trong cac thiet b bay, ngi ta thng s dung vat lieu co
o ben cao. Trong so o, co the ke ti la : hp kim Titan, cac
loai thep o ben cao va sieu ben, cac loai vat lieu phi kim loai
(Composite, si thuy tinh, . . .). Cac hp kim Titan co cung o
ben vi thep hp kim dung trong che tao may nhng khoi
lng rieng ch bang mot na, ong thi co tuoi tho chong an
mon cao trong hau het cac moi trng khac nghiet. Gia cong
cat got cac chi tiet lam bang nhng kim loai mi la rat kho
khan va trong mot so trng hp la khong the c. V ly do
o khi thiet ke may mi, oi khi ngi ta s dung vat lieu co
tnh chat s dung cha phai la hoan thien nh mong muon
nhng lai co tnh chat cong nghe at yeu cau. ieu nay lam
giam i cac ac tnh lam viec va ac trng chat lng cua
may. V vay tren the gii hien nay, tng ng vi cac vat lieu
mi c phat minh, ngi ta phai tch cc tm kiem cac
phng phap gia cong mi e gia cong nhng vat lieu nay.
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II. Phan Ioai cac phuong phap gia cong dac bieI :
Cac phng phap gia cong ac biet c phan loai da tren
nang lng chu yeu a vao vung gia cong. Do o c chia
lam 4 nhom chnh : C - IEN - NHIET - HOA.
1. Nhom c :
Nang lng c ay co dang khac vi tac ong cua mot
dung cu cat thong thng c s dung trong cac phng phap
gia cong truyen thong. S mai mon vat lieu cua chi tiet gia
cong bang dong hat mai hay dong lu chat (hoac ket hp ca
hai) chuyen ong vi van toc cao la mot dang tac ong c ien
hnh cua phng phap gia cong nay.
1. Thep 45
2. Thep 2Cr13
3. Thep Cr18Ni9Ti
4. Thep EI 395
5. Thep 4Cr12Ni8
6. Thep EI 376
7. Thep EI 827
8. Hp kim EI 867
9. Thep Jsi 6-Co
Hnh 1.1 :
Moi quan he tng ho gia cac tnh chat c-ly cua vat lieu
ben nong (a) va co o ben cao (b) vi kha nang gia cong
bang cat
a)
b)
Trang - 10 -
2. Nhom ien :
Nhng phng phap thuoc nhom nay s dung nang lng
ien hoa e tach boc vat lieu, c che ngc lai vi qua trnh
ma ien.
3. Nhom nhiet :
Phng phap nay dung nang lng nhiet tac dung vao
nhng be mat lam viec vi dien tch tiep xuc nho lam cho lp
vat lieu nay b tach ra bang cach nong chay hoac bay hi.
4. Nhom hoa :
Hau het cac vat lieu (ac biet la kim loai) eu de b tac
ong hoa hoc bi mot vai chat axt hoac chat an mon nao o.
Trong gia cong hoa, ngi ta s dung s an mon o e boc
tach lp vat lieu mot vung nho tren be mat chi tiet, trong khi
nhng be mat khac khong gia cong th c bao ve.
III. ac Irung cua cac phuong phap gia cong dac
bieI :
- Bang di ay neu len mot so tom tat cua cac phng
phap gia cong ac biet. Khi khao sat nhng bang nay ta can
nhac lai thong so cua phng phap tien truyen thong : o
nham be mat at t 0,816,1 m, toc o boc vat lieu t
2,731,6 m
3
/s, toc o vong t 1001000 vong/phut, o chnh
xac co the at c t 0,050,08 mm.
- ac trng cua phng phap gia cong ac biet la co nang
suat boc kim loai thap so vi gia cong cat got, co cong suat
rieng rat cao, at o chnh xac gia cong cao nhng toc o gia
cong thap, va thng th t lam hong be mat vat lieu hn so vi
phng phap gia cong truyen thong.
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Bang 1.1 : Phng phap gia cong ac biet bang phng phap
c.
Phng phap
o nham
be mat
(:m)
Nang suat
boc kim
loai
(dm
3
/ph)
Cong
suat
rieng
(HP/cm
3
.
ph)
Van toc gia
cong hay
van toc
tham nhap
(mm/ph)
o
chnh
xac
(mm)
Gia cong dong
hat mai
0,767,6 Thap Thap
0,025
0,1524
Gia cong bang
tia nc
0,41,8 Rat thap
Phu thuoc
vat lieu
0,0127
Gia cong tia
nc co hat mai
1,251,9 1,6 . 10
3
152540 0,12
Gia cong bang
sieu am
0,41,6 0,8 . 10
3
12,2 0,53,8
ien hoa.
Phng
phap
o
nham
be mat
(:m)
Nang suat
boc kim loai
(dm
3
/ph)
Cong
suat
rieng
(HP/cm
3
.
ph)
Van toc gia
cong hay
van toc
tham nhap
(mm/ph)
o chnh
xac (mm)
Gia cong
ien hoa
0,41,8
0,001 (W,Mo)
0,0026 (Cl)
0,002(thep,Al)
0,01 (Cu)
500 2,5412,7
0,0254
0,1254
Gia cong
mai ien
hoa
0,20,8
0,00016 (Cl)
0,002 (Al)
0,0042 (Cu)
0,0021 (Fe,Ti)
1,53,05
0,0127
0,1524
Lam sach
bavia bang
ien hoa
0,41,6

1,53,05
0,0254 hay
5% ng
knh lo
Trang - 12 -
nhiet.
Phng
phap
o
nham
be mat
(:m)
Nang suat
boc kim
loai
(dm
3
/ph)
Cong
suat
rieng
(HP/cm
3
.
ph)
Van toc gia
cong hay
van toc
tham nhap
(mm/ph)
o chnh
xac (mm)
Gia cong
bang tia la
ien
0,82,6 2,5 12,7 0,0040,05 0,12
Gia cong cat
day tia la
ien
0,81,6
(0,160,5)
10
-2
2,5 100254
0,0025
0,005
Gia cong
bang chum
ien t
0,86,3 0,8.10
3
609 152
0,005
0,025
Gia cong
bang tia
Laser
0,86,3 0,5.10
3
3658 2,54101
0,0127
0,013
Gia cong
bang dong ho
quang
Plasma
0,612,5 0,16 1,25 2,54304 0,53,4
hoa.
Phng
phap
o
bong
be mat
(:m)
Nang
suat boc
kim loai
(dm
3
/ph)
Cong suat
rieng
(HP/cm
3
.ph)
Van toc gia
cong hay van
toc tham nhap
(mm/ph)
o chnh
xac
(mm)
Gia cong
hoa
1,66,3 0,5 0,0250,05
0,025
0,15
Gia cong
quang hoa
1,6
6,35
0,5 0,010,05
0,025
0,05

Nang lng
hoa
537)2150
(A/m
2
) cong
suat 1 chieu
Trang - 13 -
IV. Tinh uu vieI cua cac phuong phap gia cong dac
bieI :
So vi nhng phng phap cat got thong thng, cac phng
phap gia cong ac biet co nhng ac tnh u viet sau ay :
1. Co kha nang gia cong tat ca cac loai vat lieu vi bat ky
tnh chat c ly nao v chung khong anh hng nhieu en nang
suat va chat lng.
ay la iem noi bat nhat.
2. Khong can s dung cac dung cu chuyen dung hoac cac
vat lieu mai (tr phng phap c ien hoa).
3. Tiet kiem rat ln nguyen vat lieu : nhat la khi gia cong
a quy nh hong ngoc, kim cng, thach anh va cac loai vat
lieu n tinh the dung trong cong nghe che tao transitor.
4. at o chnh xac gia cong cao : co the gia cong cac lo
cc nho hoac cac lo oi hoi o chnh xac cao t 25 m, gia
cong cac ong dan cua he thong thuy lc yeu cau khong co
bavia hoac vet xc cac khp noi.
5. Co the gia cong tng cho tren mot chi tiet rat ln
6. Co kha nang hoan toan c kh hoa va t ong hoa, nang
suat cao.
iem qua cac ac tnh u viet ke tren, ta thay trien vong
cua cac phng phap gia cong ac biet rat to ln. Hien nay
cac nc cong nghiep tien tien a che tao nhieu loai may
chuyen dung cho tng phng phap gia cong va a s dung
rong rai trong nganh che tao may.
Trang - 14 -
Chng 2
CAC PHUONG PHAP GIA CONG CO
A - PHUONG PHAP GlA CONG BANG
SlEU AM :
( Ultralsonic Machining - USM )
- Hieu khai niem gia cong bang sieu am.
- Hieu, biet nguyen ly gia cong bang sieu am.
- Tng minh ve c s ly thuyet gia cong bang sieu am.
- Biet tng tan cac thong so cong nghe.
- Tng minh mot so cong nghe gia cong bang sieu am.

I. Khai niem :
- Gia cong bang sieu am la truyen dao ong vao vung cat
di tan so sieu am. Dao ong nay va ap vao hat mai, hat
mai va ap vao vung cat tao nen be mat can gia cong.
- Sieu am la song an hoi co tan so t 20 kHz 1 GHz,
nhng dung e gia cong ch vi tan so t 1530 kHz. May sieu
am dung e gia cong cac chi tiet che tao t vat lieu cng va
don nh thuy tinh, gom s, a, germani, hp kim cng, kim
cng .v.v.
II. Nguyen Iy gia cong :
- Gia cong bang sieu am cac vat the ran chu yeu la ng
dung tan sac cua sieu am.
Trang - 15 -
- Gia cong bang sieu am cac vat the ran thc chat la ng
dung s co sat c hoc cua moi trng hai pha e tao nen tac
dung gia cong.
- Gia thiet trong mot moi trng chat long ton tai chat ran
co si xop. Di tac dung cua song sieu am co tan so trung
bnh, cac phan t cua chat long chuyen ong theo ung chuyen
ong cua am trng, con phan t chat si th ng yen. Sau o
do tac dung co sat cua chat long, co nhng phan t nho ri
rung t cac si vat the ran. Ngi ta co the tang cng tac
dung o bang cach rac them vao bot thach anh mn nh la mot
pha th ba. Cac bot thach anh cng, sac canh, l lng se
chuyen ong theo am trng, va chat long vi mc o chuyen
ong nhieu hay t tng ng vi kch thc cua chung. Trong
qua trnh chuyen ong, chung got giua vat the ran.

- Nguyen ly gia cong mot cach tong quat :
. Dao ong co tan so t 18-30 kHz c may phat sieu am
(6) truyen en bo bien t (5). Tai ay dao ong bien thanh dao

Hnh 2.1 :
Nguyen ly gia cong

Trang - 16 -
ong c hoc, co cung tan so, con bien o dao ong trong
khoang 510 m, e co the nhan c bien o dao ong can
thiet cho viec gia cong 3080 m can phai co thanh truyen (4)
at sau bo bien t (5).
. Dung cu (3) co hnh dang theo yeu cau gia cong uc
lap vao au cua thanh truyen (4). Dung dch hat mai (7) c
a vao vung gia cong pha au dung cu. Tong hp chuyen
ong (2) c ga at tren ban may (1) ban may co the chuyen
ong theo hai phng thang ng do au may thc hien.
. Khi chi tiet gia cong co nh th co the gia cong c lo
thong hoac lo khong thong, lo nh hnh hoac cong, cat ranh,
cat t . . . neu cung cap cho phoi hoac dung dch them mot
chuyen ong phu th co the thc hien c cac nguyen cong
phay, mai, tien, cat t, cat rieng.
- e gia cong bang sieu am, can phai co may phat sieu am.
Sieu am c dan vao au bien t e tao nen cac dao ong c
hoc co bien o can thiet. Thiet b nay lam viec tren c s s
thay oi chieu dai cua mot so kim loai (hien tng co ngan
nhiem t) nh sat, nikel, cobal va cac hp kim cua chung,
di tac ong cua ien trng hoac t trng. Hien tng nay
c goi la t giao va au bien t la thanh phan chnh yeu
trong may gia cong bang sieu am.
- Nguyen ly lam viec cua au bien t c trnh bay nh
hnh 2.2.
Dong ien co tan so cao cua may phat sieu am c a
vao cuon day kch thch 2 tao nen t trng thay oi co cung
tan so tac ong vao loi 1 cua bo rung ong. Loi 1 c che tao
t cac tam kim loai co tnh t giao. e s dung ac tnh t
giao tot hn, ta tao them mot t trng khong oi bang hai
cuon day t hoa 4 lap tren loi t 3. Dao ong doc xuat hien do
t giao trong bo rung ong co bien o t 510 m c truyen
qua thanh truyen 6. Thanh nay c lap gia hai vong kep 5,
Trang - 17 -
lam nhiem vu khuech ai bien o dao ong len gia tr can
thiet la 3080 m va truyen en dung cu cat 7 lap cuoi thanh
truyen.
Dung dch hat mai c a vao gia mat dung cu cat 7
va chi tiet gia cong 8. No chuyen ong vi tan so cao, tao nen
va ap lay i lng kim loai tren be mat chi tiet. Hat mai
thng dung la carbid bo, carbid silic, Corun, kim cng co c
loai t 280400. Chat long mang hat mai co dang huyen phu
co the la nc, dau la, dau cong nghiep. Dung dch mai c
a vao vung gia cong di dang ti. Trong trng hp gia
cong lo sau hn 5mm, phai dung dung dch co ap suat a qua
lo c hnh thanh ben trong dung cu hoac chi tiet gia cong.
Vat lieu dung cu thng dung la thep 45, 40Cr, Y8A, Y10A
.v.v. Khi gia cong hp kim cng, nang suat co the at 200
mm
3
lf; o nham 0,16<R
a
<0,32 :m, o chnh xac gia cong
0,020,04 mm.

Hnh 2.2 :
S o au bien t
Trang - 18 -
III. Co so Iy IhuyeI cua gia cong bang sieu am :
1) Mot so khai niem c ban :
- Nguon am la mot vat an hoi, noi chnh xac hn la mot
moi trng an hoi co the tao ra va truyen dao ong vao moi
trng tiep xuc vi no.
- Am lng la cong suat am tnh tren n v dien tch be
mat (erg/s.cm
2
= 10
-7
W/cm
2
).
- Ap suat am la ap suat am sinh ra trong moi trng do s
dao ong am (dyn/cm
2
= bar).
- Cng o am la mot thong so vat ly do am lng va ap
suat xac nh (phon).
- Am nghe c co tan so t 20 Hz en 15 kHz. Am co
tan so di 20 Hz goi la am hong ngoai. Am co tan so tren 16
kHz goi la sieu am. Am co cng o tren 130 phon goi la sieu
cao am.

Hnh 2.3 :
Cac vung am thanh
Trang - 19 -
- Nguon phat dao ong vung sieu am c khao sat vi
tnh cach la nguon am. C che kch thch dao ong khong anh
hng en xac suat xuat hien cua dao ong, xac suat nay ch
phu thuoc vao nang lng nguon am va tnh an hoi cua moi
trng dao ong. V moi nguon am eu co the dung e kch
thch ra sieu am, neu am lng cua no giam en mc thch
hp. Ngay nay oi vi nguon phat am c hoc, thay v phai tao
tan so cao, ngi ta oi hoi no phai cho am lng ln, bi v
trong vung sieu cao am viec gia cong vat lieu tien hanh trong
nhng ieu kien thuan li.
- Cac yeu cau oi vi nguon am :
+ Co kha nang hoa am.
+ Am lng co the bien oi.
+ On nh.
+ Kha nang phat song tot.
+ Co tan so thch hp.
+ Cong suat ln.
- Trong ky thuat sieu am, thong thng tac dung vat ly
cua dong ien c dung e kch thch dao ong. Qui trnh
thuan la bien dao ong ien thanh dao ong c, con qui trnh
nghch th bien dao ong c thanh dao ong ien. Nh vay
thiet b chuyen oi khong nhng c s dung nh nguon am,
ma con c s dung nh mot bo thu am.
- Cong viec quan trong nhat la phai la chon chnh xac
nhng nguyen ly va phng tien e co the lam ra bo phat am
co hieu suat cao, cong suat ln, co day tan so phat am rong.
Ch co mot t bo chuyen oi dao ong co the thoa man cac yeu
cau tren.
- Cac thiet b gia cong s dung trong cong nghe che tao
may chu yeu hoat ong vi may phat dung t giao lam nguon
phat dao ong, thnh thoang dung ien giao. Do vay di ay
ch e cap en loai t giao.
Trang - 20 -
2) Hien tng t giao :

- o la hien tng ma mot thanh hoac mot ong bang vat
lieu t at trong t trng song song vi truc doc cua no, th
chieu dai cua no b bien oi. Co the xac nh c s bien oi
kch thc cua vat sat t do tac dung cua t giao bang cac bieu
thc quan he vi tnh chat c hoc va t tnh.
- Xuat phat t 2 bieu thc ve vat lieu t di ay :

= ( ,
) ; = ( ,

)

Trong o :

(
: ng suat an hoi do t trng gay ra.

(
: Bien oi hnh dang do t trng gay ra.
H : Cng o t trng.

ao ham toan phan r va H co :

r
r
r r
r
d . dB .
B
d
=

r
r
d .
H
dB .
B
H
dH

=
Hnh 2.4 :
S o nguyen ly cua hien tng t giao.
L
max
L
o
h
Trang - 21 -
Ky hieu :
y
B
r
=
: Goi la hieu so hieu ng t giao.

=
r
H
: Goi la hieu ng ngc cua hieu ng t giao.

E
r
r
=
: Goi la moduyn an hoi.

1
B
H
: Goi la he so nghch ao cua t tham.
He so hieu ng t giao thuan va nghch co quan he vi
nhau nh sau :
y 4 =
T tham chan khong :

m
Henry
10 . 4.
A
V
. 10 . 4
7
m
0 7
0

= =
(4B sinh ra t he so tham)
- Vay trang thai cua vat lieu t vi s bien oi hnh dang
trong t trng co the dien at bang phng trnh :

r r
Ed dB d + = (thuan) (1)

r
yd 4 dB
1
dH +
= (nghch) (2)
Phng trnh (1) cho ta quan he bien oi t t nang
sang c nang :
B
r
= neu 0 d
r
= (b nen)
B
E
B
r
= = neu 0 d
r
= (t do)
Phng trnh (2) cho ta quan he bien oi quan he t
c nang sang t nang :

r
4 B = neu dH = 0
Trang - 22 -

r r
4 4 H = = neu dB = 0
- Mc o hieu ng t giao c bieu th bang thong so goi
la t le t gian do t giao
0
l
l
:
B
E l
l
0

Vi :
E
=
Trong o :
l : o bien oi kch thc
l
0
: Chieu dai cua thanh vat lieu sat t
Phng trnh bien dang an hoi co the c viet nh
sau :

= B
E
l l
0

- o bien oi kch thc oc lap vi hng cua t trng
ch phu thuoc vao cng o cua t trng, nhiet o trang thai
t hoa trc o va chat lng cua vat lieu.
- o bien oi kch thc tng oi
r
co o ln 10
-5
-10
-6
ch co the ghi bang phng phap quang hoc (hnh 2.4).
- Hnh 2.5 cho thay o bien oi kch thc doc tng oi
phu thuoc nh the nao vao cng o t trng.
- Tren hnh ve tr so dng ch s gian dai, tr so am ch
s co rut.
- Hieu ng t giao khong nhng gay nen bien oi kch
thc chieu dai, ma con gay nen bien oi the tch vi cng
o t trng nho, ch co bien oi kch thc chieu dai, thong
thng chung ta li dung hien tng nay e tao ra sieu am.
- Neu at mot thanh sat t vao trong ruot mot cuon day co
t trng xoay chieu th chieu dai cua thanh sat se bien doi vi
hai lan tan so. Co the thay ieu o, qua hien tng bien oi
kch thc oc lap vi hng cua t trng. Hien tng se
Trang - 23 -
khac i neu ngoai t trng xoay chieu con co t trng co t
trng mot chieu manh - goi la t hoa ong thi (va co t hoa
t trng xoay chieu va co t hoa vi t trng mot chieu).
Trong trng hp nay dong ien khong oi chieu ma ch co
bien oi bien o. S bien oi kch thc dao ong bang vi tan
so cua dong ien.

- Mot li khac cua t hoa ong thi la co the ieu chnh
nguon phat am sao cho t trng tao nen s bien oi kch
thc ln nhat. Cng o t trng tng ng vi oan co o
doc ln tren cac ng cong.
- Bien oi chieu dai cua thanh sat t se la ln nhat khi tan
so dao ong do s bien oi cua cng o t trng gay ra bang
vi tan so dao ong rieng cua thanh sat t (cong hng).
1 : 70% Co + 50% Fe
2 : 49% Co +49% Fe + 2%V
3 : 50%Ni + 50% Fe
4 : Co uc
5 : Fe
6 : Co
7 : Ni - Zn - Ferrit
100
80
60
40
20
0
-20
- 40
L/L
0 500 1000
1500
2000
H
1
2
3
4
5
6
7
Hnh 2.5 :
Bien oi chieu dai tng oi va cng o t trng
vi nhng vat lieu co t tnh khac nhau.
Trang - 24 -
- Phan phat cua thiet b sieu am t giao thng la bo dao
ong bang en ien t. Trong thc te tan so cua loai en nay
t khi at tren 100 kHz, ngha la bo dao ong ien t lam viec
trong pham vi song dai. Trong giai song nay lam thiet b co
cong suat c kw khong kho khan may. Dong ien t hoa mot
chieu co the la dong anod, hoac lay t mot nguon ien rieng.
3) S an mon xam thc :
- Neu sieu am c phong qua chat long, th trong o se
phat sinh ap lc cuc bo. Vi am lng thch hp th co the tao
nen s bien oi ap lc lam sinh noi ng suat ln en mc lam
mat i s lien ket gia cac phan t cua chat long va lam cho
chat long b pha huy. Hien tng nay co the biet c khi thay
nhng bot kh, c goi la bot kh xam thc. Nhng bot kh ch
ton tai trong thi gian ngan. Khi chung b tan th co ap lc cuc
bo rat ln, gan 1000 atm..
- Ngi ta ng dung hien tng nay e lam sach cac chi
tiet, e anh sach r, xuc tien nhanh cac qua trnh hoa hoc.
Hien tng nay du cha phai la vai tro bao trum, nhng cung
co vai tro trong viec gia cong cat got bang sieu am.
4) Tac dung c hoc :
- Khi phan tch tac dung cua sieu am oi vi moi trng
mang sieu am, ngi ta lien tng en qua trnh co xat c hoc
nao o. Am trng co the kch thch dao ong cua nhng phan
t nho, ran trong moi trng, co trong lng rieng khac nhau
va khac vi moi trng. Nhng phan t nho nay trong khi
chuyen ong, vi khoi lng quan tnh rieng se co xat vi
nhng phan t ln hn ang ng yen va s co xat nay lam
nay sinh ra tac dung co xat ac trng bang sieu am (hnh 2.6).
- Tren hnh 2.6 (a) co the thay trang thai cua nhng phan
t ran nho l lng trong am trng sieu am. Tat ca cac phan t
nho nay chuyen ong ung nh am lng quy nh. V vay
tren hnh chup te vi ta thay nhng vach. Tren hnh 2.6 (b) co
Trang - 25 -
the thay lan lon nhng phan t nho lan nhng phan t ln.
Nhng phan t nho chuyen ong giong nh trng hp trc,
nhng phan t ln hn th khong theo ung hoan toan s
chuyen ong cua trng. Co duy nhat mot phan t co khoi
lng ln khong chuyen ong, ieu o the hien tren hnh chup
te vi mot cham tron hoan toan.

- Hien tng nay luon luon co trong nhng he thong hai
pha. S chuyen ong tng oi gia cac phan t cung xay ra
ca khi nhng phan t l lng do quan tnh ln khong hoan toan
theo kp s chuyen ong cua moi trng. Trong trng hp
nay cac phan t cung chuyen ong i lai do quan tnh cua
chung va trong qua trnh o chung gay nen co xat.
- Tuy theo tnh chat, ma sat trong hai moi trng, kch c
cua cac phan t nho, s ong nhat ve kch thc cua cac phan
t nho, .v.v., ma se co mot nhom cac hien tng khac nhau,
Hnh 2.6 :
Am trng va s chuyen ong cua nhng phan t nho l
lng trong am trng.
(a) Nhng phan t nho chuyen ong theo am trng.
(b) Nhng phan t ln hn chuyen ong cham hn.
(a) (b)
Trang - 26 -
he qua cua chung la tao ra s hoa ong, s chuyen the va s
phan tan do tac dung cua sieu am (con goi la s tan sac).
IV. ThieI bj va dung cu :
- Mot may sieu am co nhng bo phan chnh sau :
. au t giao
. C cau mang dung cu cat
. C cau cap hat mai
. Bo tao song
- Hnh ben di mo ta mot thiet b trong gia cong sieu am.

Hnh 2.7 :
S o cau tao thiet b
gia cong bang sieu
am.
1) Dung cu
2) au noi
3) Thanh truyen song
4) au t giao
5) Vo may
Trang - 27 -
- Ben di dung cu con co ban may, mat ay cua bon cha
dung dch hat mai va mot so phu kien khac.
- Dung cu : Thng dung cu co nhieu hnh dang va kch
thc khac nhau tuy theo yeu cau. S dung nhieu nhat van la
dung cu co bien dang giong nh bien dang cua chi tiet gia
cong. Vat lieu lam dung cu la thep 45, thep dung cu Y8A,
Y10A, . . .
- au noi : Giao tiep gia thanh truyen song va dung cu co
mot bo phan goi la au noi. au noi c che tao ac biet sao
cho co the lap c cac dung cu vao thanh truyen song.
- Thanh truyen song : la bo phan truyen dao ong t au t
giao cho dung cu.
- Mot cong viec ma ngi ta cung het sc quan tam o la
giai quyet nhiet lng sinh ra trong qua trnh lam viec au t
giao bang cach thoi gio hoac lu chuyen dong chat long. e
at am lng ln trong au t giao th phai chu y en lam mat
v nhiet lng sinh ra rat ln. Co the tang am lng bang cach
ieu chnh bien o va tan so. Viec nang cao tan so se b gii
han, khong phai luc nao cung hp ly bi v :
. Tac dung sieu am tot nhat vao khoang 20 kHz.
. Trng hp sinh ra cong hng trong khi gia tang tan so
se lam giam cong suat.
. Chu yeu gia tang am lng bang bien o.
- Dao ong co the gay nen ng suat c hoc ln trong vat
lieu lam au t giao. V vay au t giao phai co sc ben c
hoc ln, ong thi phai co ton hao t va c nho. Neu la chon
vat lieu thch hp, cong nghe gia cong, lap rap tot, lam mat
thiet b tot, th hieu suat cua thiet b co the at 70%. Hieu suat
cao ch co the at c nhng thiet b c thiet ke va che
tao sau khi c xem xet can nhac moi mat.
- au chau bat dung cu khong n thuan ch co ren e van
vao, ma can anh bong va boi trn mot lp m mong khap cac
Trang - 28 -
be mat tiep xuc e co the truyen het dao ong. Trong mang
m se sinh ra ng suat keo va con gay ra hien tng xam thc,
ben canh o, phai ep chat bo phan noi dai (thanh truyen song)
va chau bat dung cu co ren noi vao thanh truyen song, co
ng sinh dang hnh non ma chop cua no pha au lap dung
cu. Cong viec nh vay co y ngha lam cho am lng tang ve
pha au dung cu va ta co the khuech ai dao ong cua t giao
len en 100 lan. iem ac biet ay la bien o dao ong
hai au thiet b rat chenh lech va o la nguyen nhan sinh ra
ng suat c hoc ln.
- Mot thiet b hoan chnh la sau khi th vi nhng dung cu
khac nhau, se co dao ong c hoc ung vi tan so cong hng.
* May sieu am van nang 4770 :
- May sieu am 4770 dung e gia cong cac dang lo tron,
nh hnh, cac hoc, khac, cat t . . . nhng vat lieu cng va
don. Khi gia cong, dung cu dao ong vi tan so sieu am theo
hng tien giao. Cung luc bm ly tam a dung dch mai vao
mat au dung cu.
- ac tnh ky thuat cua may :
+ ng knh lo gia cong : 0,510 mm
+ Chieu sau lo gia cong : (25)d
+ Lng di ong doc cua ban may : 80 mm
+ Lng di ong cua au bien t : 110 mm
+ o nhay cua c cau chay giao : (686980)10
-3
N
+ Tan so lam viec : (1819) kHz
+ Cong suat may phat : N = 0,25 kW
- S o ong c the hien hnh 2.8.
- Bo phan c ban cua may la au bien t 3 c lap tren
ban trt 5 pha trc. Ban may 2 di ong doc va ngang tren
song trt uoi en vi tay quay co cung chia o 0,02 mm. Di
ong ban trt 5 mang au bien t (3) c thc hien t ong
c ien 8, qua cap banh rang Z
3
/ Z
4
en banh rang-thanh rang.
Trang - 29 -
ong c ong lam viec theo che o ham, momen xoan c
tao ra tuy thuoc vao lc chay dao cua dung cu. Di ong cua
ban trt cung c thc hien bang tay qua banh rang-thanh
rang Z
1
- Z
2
. e chuyen ong em va chnh xac, ban trt 5 di
ong tren song lan cua than may 1 va dung oi trong 11 treo
tren day 10 quan qua ong 9 lap tren truc quay bang tay.
Chuyen ong cua ban trt c em nh bo giam chan bang
dau ep gom co xylanh 4 lap tren than ban trt 7, can pittong 6
co nh vao ban trt. ieu chnh van toc ban trt va lui
nhanh dung cac van tiet lu va van ngc dau ep.

Hnh 2.8 :
S o ong may sieu am van nang 4770
Trang - 30 -
- e nang cao nang suat, may sieu am thng ket hp vi
phng phap gia cong ien hoa. Nh the, ngoai chc nang gia
cong bang sieu am, may con co mach ien an mon ien hoa
bang cach noi thanh truyen mang dung cu cat vao cc am, chi
tiet vao cc dng cua nguon ien mot chieu. Trong trng
hp nay, dung chat ien phan la dung dch 15% nitrat natri
hoac dung dch 2040% nc muoi. Khi gia cong hp kim
cng vi lng chay dao 0,20,5 mm/phut; nang suat cua may
gia cong tong hp nay co the at 500600 mm
3
/phut.
V. Cac Ihong so cong nghe :
Cac thong so cong nghe chu yeu cua gia cong bang phng
phap sieu am la: nang suat, chat lng be mat, o chnh xac
gia cong, o mon cua dung cu. Trong cac thong so neu tren co
mot so thong so co lien quan vi nhau va anh hng lan nhau.
1) Toc o cat :
- Toc o cat trong gia cong sieu am c xac nh bi
cong thc sau :
v = 5,9 f (s/H)R.0,5.y.0,5
Trong o :
f : Tan so dao dao ong (Hz)
H : o cng be mat (HBN)
s : ng suat dung cu (kg/mm
2
)
R : Ban knh hat (mm)
y : Bien o rung ong (mm)
2) Bc tien gia cong :
- Qua trnh gia cong bang sieu am la tach tng hat vat
lieu ra khoi chi tiet gia cong. e thc hien c qua trnh o,
dung cu gia cong can phai co mot bc tien hanh la S nao o.
ai lung S lai phu thuoc vao nhieu yeu to nh cng o sieu
am, tan so va bien o dao ong am, vat lieu co kch thc D
h

tch tr nang lng lien ket e
lk
.
Trang - 31 -
- Thi gian gia cong lp vat lieu S la :

lk
h
h
lk
t t
s

s . t
t

=
=

Vay bc tien gia cong c thc hien vi mot van
toc nhat nh la :

lk
h
t t
s
v

= =

ng vi moi vat lieu khac nhau, ta co e
lk
khac nhau;
gia tr cua e
lk
va D
h
la co nh cho tng loai vat lieu, nen co
the tang toc o gia cong v bang cach giam thi gian t
lk.
-
Do o phai hieu chnh tan so f, bien o dao ong A,
cng o sieu am I, cung nh moi trng va hat mai . . . sao
cho at c nang lng thch hp.
3) Dung dch va hat mai :
- Cung la mot van e quan trong v no tac nhan trc tiep
gia cong vat lieu. Hat mai thng dung cacbit bo th nang suat
at cao nhat. Ngoai ra chat long dang huyen phu cung rat quan
trong; co the dung chat long la nc, dau ma dut, dau hoa,
con, dau may, dau gai . . . trong o nc at at nang suat cao
nhat. Dung dch hat mai co anh hng rat ln en o chnh xac
va o nham be mat.
- Bang di ay cho thay c ieu o :
Bang 2.1 :
Anh hng cua dung dch hat mai en o chnh xac va o
nham be mat.
o hat
cacbit bo
Gia cong thuy tinh
Ra (m)
Gia cong hp kim cng
Ra (m)
N10 12,5 3,2 6,3 - 3,2 16 - 0.8
N5 3,2 1,6 3,2 0,8 - 0,4
N5 1,6 0,8 1,6 0,2
Trang - 32 -
4) Nang suat :
- Nang suat gia cong sieu am co the c xac nh bi
thong so sau :
. e : Toc o tien dung cu (mm/phut)
. V
d
: Khoi lng vat lieu lay i trong 1 n v thi gian.
. v: La mot thong so c xac nh tren c s the tch
phoi trung bnh.
- Nang suat gia cong con phu thuoc vao o sau gia cong
va mat cat ngang cua dung cu. V vay ngoai thong so V
d
va e
e anh gia chnh xac nang suat con phai neu ro nang suat o
at c vi o sau gia cong bao nhieu va dung cu co pro-phin
mat cat g.
- Trng hp gia cong lo co ay khong sau, toc o tien
dao trung bnh (khong ke en viec nang dung cu len) la :

Trong o :
l
1
: Chieu sau cua lo co ay (mm).
t
1
: Thi gian gia cong (phut).
- Trng hp gia cong lo sau co ay, toc o tien dao trung
bnh (co ke en viec nang dung cu len) la :

Trong o :
n : So lan nang dung cu.
t
2
: Thi gian 1 lan nang dung cu (phut)
- The tch vat lieu c lay i trong n v thi gian
trng hp dung dung cu ac biet la :
V
d
= e . A
sz

Vi : A
sz
- Dien tch lam viec cua dung cu (mm
2
).
- Trng hp gia cong lo thong, vi dung cu hnh xuyen,
thong so nang suat ac trng la toc o tien dao e.
1
t
1
l
1
e =
2
nt
t
t
1
l n
2
e
+
+
=
Trang - 33 -
- Nang suat trung bnh la the tch vat lieu c lay i
trong n v thi gian c tnh tren dien tch lam viec cua
dung cu :

= =
ph
mm
mm . ph
mm
A
V
e
2
sz
D
3

- Nh vay toc o tien dao cung bang vi nang suat trung
bnh.
- So sanh phoi vi o mon dung cu :
% 100 .
V
V
e
sz
D
=
Vi : V
sz
- o mon cua dung cu (mm
3
/ph).
- T le mon dung cu co the c phan tch thanh t le mon
theo chieu doc va t le mon theo chieu ngang tc o con be
mat b mon i do tac dung cua bot mai.
- Nang suat gia cong con b anh hng bi cac yeu to sau:
+ Bien o va tan so dao ong.
+ Tnh chat c ly cua vat lieu can gia cong.
+ Phu tai tnh gia dung cu va vat lieu can gia cong.
+ Loai bot mai va nong o nhu tng cua bot mai.
+ Cach cho nhu tng vao bot mai.
+ Tiet dien dung cu.
+ Vat lieu lam dung cu va o mon cua no.
+ o sau cua lo.
5) Chat lng be mat gia cong :
- Thc te cho en nay, tren be mat a c gia cong bang
sieu am khong the hien s bien oi cau truc va o cng te vi
cua lp vat lieu tren be mat hoac mot ng suat d nao, do
nhiet o khong ln vung gia cong, khong gay ra sai so do
bien dang nhiet. Trong trng hp gia cong bang sieu am, trai
vi trng hp mai va cat bang tia la ien, khong thay co dau
vet ran nt hay vet chay tren be mat gia cong. Chnh v vay
Trang - 34 -
ma chat lng be mat gia cong ch lien quan en o nham be
mat.
- o nham be mat phu thuoc vao :
+ Kch thc hat mai.
+ Tnh chat c ly cua vat lieu gia cong.
+ Bien o dao ong cua dung cu.
+ o nham dung cu.
+ Chat long cha bot mai.
- Phu tai tnh gia dung cu va vat lieu gia cong thong
thng bien oi trong gii han rong khong co anh hng g
en o nham be mat. Trong trng hp phu tai tnh bien thien
t p = 0,4 kg/ mm
2
en p = 2,5 kg/ mm
2
, R
max
bien thien trong
pham vi 3,64,3 m. Vi vat lieu gia cong bang thuy tinh c
hat 100, bien o dao ong 30 m. Bien o dao ong tang th
kha nang o sau tham nhap cua hat tang. V du vat lieu gia
cong la thuy tinh, neu bien o bien thien t 388 m th R
max
=
3220 m.
- Neu thay nc bang dau may th R
max
se giam, nhng
can lu y rang trong trng hp gia cong can at o nham cao
th khong nen thay nc bang dau v nh the th nang suat se
giam xuong gap boi lan, ieu kien bo sung va luan chuyen cua
vat lieu anh bong cung xau i, ch khi nao dung bien phap
khac van khong at c o nham nh mong muon th luc o
mi thay nc bang dau.
- S khac biet cang ro ret hn khi dung bot mai co c hat
ln (c hat 280, 320, 360, 400 . . .) th khong co s khac biet
oi vi gia cong lo. Thc nghiem cho thay rang, o nham
thanh lo cung tang mot t. Bang cach han che tac dung bao
mai phu (bo sung hat mai qua tru rong cua dung cu . . .) ta
khong the lam giam bt s khac biet gia thanh va ay lo.
- De dang thay rang, xac suat co khuyet tat cung giam i
Trang - 35 -
nhieu, nen giam o nham mat ben cua dung cu va che tao
dung cu bang vat lieu chong mon.
6) o chnh xac gia cong :
oi vi cac vat lieu ran va gion, gia cong bang sieu am
phu thuoc vao nhieu yeu to, cac yeu to nay co the chia lam hai
nhom nh sau :
- Nhng yeu to phu thuoc vao thiet b va o chnh xac
ieu chnh may :
+ o chnh xac cua thiet b phu thuoc chu yeu vao sai
so trong chuyen ong theo hng tien cua dung cu va s ieu
chnh au dao ong so vi ban may.
+ S an khp va o ong truc cua cac bo phan cua au
t giao tao dao ong, bo phan noi, dung cu.
+ o chnh xac cua cac c cau dung e ieu chnh chi
tiet.
+ o chnh xac v tr tng oi gia dung cu va chi tiet
gia cong. Trc khi gia cong, phai kiem tra o chnh xac cua
may va tat ca dung cu phu tr neu tren nham giam en mc
toi thieu cac sai so.
- Cac yeu to phu thuoc vao ac tnh cong nghe :
+ Kch c hat mai.
+ S on nh cua khe h gia dung cu va vat gia cong.
+ o mon cua dung cu.
+ Hnh dang hnh hoc cua dung cu.
+ o sau gia cong.
oi vi gia cong lo, do ac iem khac nhau ma ngi ta
phan biet gia cong lo thong va lo khong thong. o chnh xac
cua phng phap at cap 2-3, con o bong be mat at cap 8-9
- o chnh xac gia cong lo thong :
o chnh xac cua lo thong co tiet dien khong oi do 3
yeu to quyet nh
+ o chnh xac che tao dung cu.
Trang - 36 -
+ o chnh xac chep hnh cua dung cu.
+ Dao ong co hai thang goc vi truc doc cua dung cu.
oi vi lo con hoac lo co bac th ngoai 3 yeu to tren,
o mon cua dung cu co tac ong rat ln en o chnh xac. Tuy
theo o chnh xac cua lo ma chon cap chnh xac che tao cua
dung cu nhat thiet phai chu y rang lo se co kch thc ln hn
dung cu. V du vi hat c 120 th kch thc ln hn vi
0,40,5 mm; C hat 320 th 0,030,04 mm, so vi kch thc
cua dung cu.
- o chnh xac cua lo khong thong :
+ Ngoai cac yeu to noi tren o chnh xac gia cong lo
co ay con phu thuoc vao o mon cua dung cu.
+ o con cung nh sai lech hnh dang cua dung cu eu
sao chep sang be mat gia cong. Do o dung cu phai lam bang
vat lieu chu mon.
+ Gia cong chnh xac lo co ay ch thc hien c bang
mot loai phng phap gan ung, nhieu lan thay dung cu vi
dung cu lam bang vat lieu chu mon.
+ Neu phai gia cong lo co ay tren vat lieu kho gia
cong (hp kim cng, thep toi) th ay lo se loi. o loi tang vi
o sau gia cong. Ly do la gia nong o cua bot mai loang
hn xung quanh. o chnh xac cua lo (ac biet ay lo)
khong at c 0,05 mm.
VI. HoI so cong nghe gia cong bang sieu am :
Gia cong bang sieu am c s dung e nang cao hieu qua
cua cac phng phap gia cong khac bang cach a giao ong
cua sieu am tac dung vao dung cu cat. Ngi ta a tm c
nhieu bien phap hp ly e nang cao nang suat cat va tuoi tho
cua dao trong gia cong tien, khoan, khoet, doa, mai, cat ren
.v.v. vi viec dung sieu am.

Trang - 37 -
1) Khoan - khoet - doa bang sieu am :
- Khoan sieu am da tren c s li dung tac ong co xat
va got dua cua song sieu am, thiet b khoan lam viec vi tan
so 2030 kHz, gom co au t giao dao ong vi tang so tren,
va bo cau noi c noi vi au giao ong, cau noi c truyen
giao ong, va qua dung cu dao ong c truyen sang vat can
khoan.
- Khac vi mui khoan quay thong thng, ay dung cu
khoan dao ong doc thang goc vi mat cua vat gia cong. Do
tac dung dao ong o, nhng hat mai nho tron lan l lng
trong chat long rach vat gia cong, m ra theo lo privet cua
dung cu. T c che khoan nh vay co the suy ra rang khong
nen khoan lo thung xuyen bang mui khoan ac, ma bang mui
khoan ong (xem hnh 2.9), neu kch thc va hnh dang lo cho
phep tao hnh mui khoan nh vay. Bang mui khoan nay, nhng
phan vat lieu c lay i co cho e don lai.
Hnh 2.9 :
Nguyen ly khoan bang
sieu am
a) au t giao dao ong
b) Cau noi
c) Dung cu
d) Bo lam mat
e) Chat long lam mat
f) Vat gia cong
g) Nhu tng co hat mai
anh bong.
b
c
g
f
e
e
a
d
Trang - 38 -
- Tren hnh 2.10 va 2.11 co the thay nguyen ly khoan sieu
am trong mot so trng hp cu the.

- Hnh 2.12 la au sieu am cua may khoan dung e tao
dao ong doc khi khoan, khoet lo. No co bo bien t 1 at ben
a b
Hnh 2 .10 :
Khoan sieu am vi cac dung cu khac nhau.
a) Phoi khong b hut i.
b) Phoi b hut i.
Hnh 2.11 :
S o nguyen ly khoan sieu am trong mot so trng hp
cu the
a) Khoan lo hnh tru co ay
b) Khoan xuyen lo tru bang dung cu co dang vanh
khan.
c) Khoan lo ay khong phai hnh tru.
d) Khoan lo xuyen khong phai hnh tru.
Trang - 39 -
trong than 2 va nhan nguon dao ong t may phat sieu am at
lien vi may khoan. Bo bien t bien dao ong ien co tan so
sieu am thanh dao ong doc c hoc. Chi tiet dang pheu 3 lap
pha di than 2 co chieu cao phu thuoc vao tan so dao ong.
Thanh truyen 4 c han vao bo bien t nham khuech ai van
toc va bien o dao ong. Lo con pha di dung e lap mui
khoan, mui khoet. au sieu am cung c lam nguoi bang
nc.

- e khoan, khoet, doa, cat ren ngi ta cung a s
dung mot cau truc mi la au sieu am dao ong xoan (Hnh
2.13). Loai nay cung co bo bien t 1 co dang vong, ben trong
no at tiep tuyen cac bo bien oi song 2. Phan tren cua loi
cong hng 3 co uoi con e lap vao truc chnh cua may; phan
di co lo con e lap dung cu cat 4. Khi cho dong ien co tan

Hnh 2.12 :
au sieu am cua may khoan.
Trang - 40 -
so cao qua cuon day bo bien t vao cac bo bien oi song 2,
cac dao ong doc xuat hien se tao nen tac dung xoan tng
oi vi truc au sieu am.

- Hat anh bong thng la hat cacbid borlum l lng trong
nc. Chung ta co the gia tang cong suat cua may khoan sieu
am. Neu chung ta hut i phoi vun ton ong trong mui khoan
ong (hnh 2.10b). Bang cach nay co the khoan lo sau t 4 mm
en 30 mm, toc o khoan tang len 5 lan.
- Bang 2.2 so sanh cong suat khoan trong trng hp
khong hut phoi vun va trong trng hp co hut.
- Bot mai s dung la hat cacbit borium c hat 220; trng
hp khoan kim cng, th dung bot kim cng. So lieu tren ng
vi thiet b khoan co tang so22 kHz, cong suat 30W, ien tch
cong tac la 27 mm
2
.

Hnh 2.13 :
au sieu am dao ong xoan
Trang - 41 -
Bang 2.2 :
Cong suat khoan trong cac trng hp
Nang suat khoan
mm
3
/phut
Vat lieu can khoan
Khong hut
phoi
Co hut
phoi
Mc o
hao mon
(*)
Thuy tinh
Mica
Ferit
Germansxum
Than
Tinh the thach anh
a ma nao
S cng
Ngoc trai
Dura
Ngoc o
Hp kim cng
ong thau
Cacbit borium
Thep tron 12%
Thep gio
Kim cng
200
150
150
200
100
100
60
50
50
6
8
5 . . . 7
2
1 . . . 4
1, 8
1, 8
1, 8
1000
800
800
600
500
400
320
250
250
40
30
30 . . .40
12
2, 5 m10
10
8
0, 05
1
1
3
3
1
2, 5
5
6
6
20
10
60
40
50
120
200
2000
- (*) Gia thiet co mui khoan co o cng bang nhau, va vat
gia cong bang thuy tinh, o hao mon cua mui khoan la 1, th
so lieu trong bang la o hao mon cua mui khoan trong trng
hp khoan cac vat lieu khac th so sanh vi trng hp khoan
thuy tinh.
- Khoan sieu am khong ch co u iem la co the khoan
bat ky vat co o cng nao va lo khoan co bat c profin nao ma
Trang - 42 -
con li hn khi khoan vat co kha nang dan ien, du cho oi
vi vat lieu nay co the dung phng phap khac. V du gia cong
bang tia la ien, e at c o bong tot th hoac phai khoan
cham, ma co khi ngay ca khi vay cung khong at c chat
lng be mat tot hn, hoac neu khoan nhanh th be mat lai rat
tho.
- Neu la chon loai bot mai co o mn thch hp va khong
co tap chat, th o nham toi a (R
max
) cua be mat gia cong sieu
am khong qua 1 m. ng knh lo ln hn ng knh mui
khoan khoang 60100 m tuy thuoc vao o mn cua hat mai.
ng knh cua lo khoan khong the nho hn 100 m. o chnh
xac toi a co the at c la 10 m vi may tot nhat. Cac may
thng dung hien nay co the co cong suat 35 kW. Nang suat
lay phoi la 15002000 mm
3
/ph khi gia cong thuy tinh; la 4050
mm
3
/ph oi vi hp kim cng.
2) Mai - cat - xe ranh . . . bang sieu am :
- Nh a noi khoan bang sieu am la cong nghe quan trong
nhat va pho bien nhat. cac loai gia cong khac ve nguyen ly
tng t nh gia cong lo. Trong nhng phan di ay, ch ban
nhieu ve mai, con cac loai gia cong khac th noi t. S d ban
ve gia cong mai nhieu hn v no co mot so tnh chat khac so
vi gia cong khoan. Cac nc tien tien (Lien Xo, My) ngi ta
ang chu y en mot ieu la lam sao co the ng dung nhng
ac iem cua phng phap gia cong thong dung nh (khoan,
mai phang mai tron, cat ren . . .) vao phng phap gia cong
bang sieu am.
- Khac vi khoan lo, khi mai mat phang th vat gia cong
co the chuyen ong di dung cu.
- Trong trng hp mai nhng cho chat, kho mai tren
nhng vat lieu gia cong bang vat lieu ran don (nh s) hoac
hp kim cng, th mai tren mat phang bang sieu am co tam
quan trong ln, v khong co phng phap nao khac gia cong co
Trang - 43 -
nang suat chap nhan c. Nhng ac tnh cong nghe khoan
cung co gia tr trong gia cong mai mat phang, nhng can bo
sung them bang toc o chuyen ong cua vat gia cong anh
hng ln en nang suat, chat lng be mat va o chnh xac.
Khi gia dung cu va vat gia cong co chuyen ong tng oi,
th ieu kien tiep xuc gia dung cu va vat gia cong se khac.
Lc tac dung vao mot so hat mai se thay oi, v ieu kien lam
viec se bien oi tren dien tch cua be mat lam viec cua dung
cu mi lan au tiep xuc vi vat gia cong. Tat nhien la vi c
che ong hoc nh vay ieu kien mai got cua be mat lam viec
cua dung cu se khac nhau trong tng giai oan.

- e co the chon toc o mot cach toi u tren vat gia cong
(e) th nen phan tch moi quan he V
D
= F(e) tren hnh 2.15
- T hnh 2.15 ta co the rut ra mot so ket luan sau :
+ Tren giai oan 1 cua cac ng cong nang suat ln,
nhng dung cu mau hong v coi nh a gia cong xong. Tang e
th nang suat giam en toi thieu.
+ au giai oan 2 nang suat rat nho sau o tien len
vi e va at tr so nang suat khi e = 0, o la nang suat khoan
bang sieu am. S d nang suat giam toi thieu v vi tr so gii
han e nao o hoac gan vi tr so o trong khoang thi gian
Hnh 2.14 :
Nguyen ly mai phang bang sieu am
Trang - 44 -
nhat nh, dung cu dch chuyen do tac ong cong hng theo
hng ngc vi hng chuyen ong cua vat gia cong. S
chuyen ong ngc nay thc te nhat quan vi s giam be mat
lam viec cua dung cu.
+ Giai oan 3 toc o tiep tuc tang th khong con lam
tang nang suat na.

- Can thiet phai lu y rang, khi noi nhng ieu kien tren
chung ta a so sanh cac thong so nang suat trung bnh, chung
ta khong chu y en cac ieu kien mai got khac nhau nhng
giai oan khac nhau cua dung cu.
- Toc o tien phai sao cho trong khi dung cu tiep xuc vi
vat gia cong mot thi iem th o an dao (f) khong vt qua
gii han (bk) ma kch thc hat mai quyet nh, ieu o bieu
th bang bieu thc sau ay :
e
bk
lm . f . e
<

Hnh 2.15 :
Bien oi cua phoi lay i vi van toc tien cua vat gia cong.
e (mm/ph)
V
d
(mm
3
/ph)
Trang - 45 -

- Phu tai tnh cung la mot thanh phan trong xung lc trc
tiep tao ra s phan tan vat lieu. Phu tai tnh toi u chu yeu do
be rong cua be mat lam viec cua dung cu quyet nh. Trong
trng hp chung quanh he nay theo ham mu e. Vi hat mai
quan he nay la : P
opt
= 2a
m
0,45
- Co the thay the bang ham parabol, o a
m
la be rong
cua be mat lam viec cua dung cu.
- Khi mai bang sieu am chat lng be mat khong nhng
phu thuoc vao cac tnh chat giong nh khoan ma con phu thuoc
nhieu vao toc o dao ong va o tien cua dung cu.
- Co the mai bang sieu am mat phang nam, ma ca mat
phang ng va mat phang hnh hoc nao o :
Hnh 2.16 :
T le o sau va kch thc hat mai
1. Dung cu
2. Hat mai
3. Vat gia cong
Trang - 46 -

VII. ac diem va pham vi ung dung :
1) ac iem :
* Iu dIem :
- Cho phep gia cong c nhng vat lieu vo cung cng,
ran, gion.
- Cho phep gia cong c nhng vat lieu phi kim loai.
- Khong gay ra hien tng nt te vi be mat.
- Khong gay ra tai nan lao ong.
* Nluoc dIem :
- o ln cua be mat gia cong : Khi be mat gia cong
nho, thao tac thc hien kha phc tap, kho khan. Cac may
khoan sieu am co the thc hien tren be mat toi a 750-1000
mm
2
, vi mot nang suat co the chap nhan c. Co the tang
tiet dien gia cong bang cach tang nang suat ra va tiet dien be
mat phat song cua au t giao. Cong viec nay oi hoi phai giai
quyet nhng van e ve am hoc rat phc tap.
- o sau co the gia cong c : Ch co the gia cong lo
va ranh khong sau lam. Tang o sau th giam nang suat, do
lam tang qua trnh mai phu, va gay kho khan cho viec a bot
Hnh 2.17 :
S o nguyen ly gia cong bang sieu am cac mat phang hnh
hoc co dang a cho (a-b) va mat phang ben (c)
Trang - 47 -
mai vao vung lam viec cung nh lay i vat lieu b mai mon
cua dung cu. Lo sau ch co the khoan theo kieu bac thang, khi
o nang suat se b giam.
- Nhu cau nang lng : Nhu cau nang lng bieu hien
bang t so gia cong suat au vao hoac cong suat phat ra cua
may phat sieu am va lng phoi trung bnh trong mot gi.
Q
ki
= N
ki
/ V
D
(kWh/cm
2
)
- Nang suat : Nang suat thap khi gia cong vat lieu t
hp kim cng va thep a toi, bang 1/20-1/50 nang suat khi gia
cong thuy tinh, thach anh, .v.v. Ben canh o dung cu mon
nhieu hn.
Khi s dung sieu am e bo sung cho cac cong nghe
truyen thong e gia cong vat lieu cng va kho gia cong, th
can phai chu y en nhng nhc iem cua cong nghe gia cong
sieu am a neu tren. Ngoai ra lam viec vi nhng thiet b
gia cong bang sieu am tan so tng oi thap (<16 kHz). Ngi
cong nhan chong met moi.
2) Pham vi ng dung :
Chung ta co the chia thanh cac ng dung nh sau :
- Gia cong ch bang phng phap sieu am : khoan, mai gia
cong ren, lam sach bavia, gia cong ranh.
- Gia cong bang sieu am phoi hp phng phap gia cong
khac : khoan , phay, xoi lo, mai, mai tinh, mai bang a, mai
bong bang ma sat.
- Gia cong khong cat got : Han, lam sach kim loai, lap
ghep bang ep, phan tch vat lieu co phan t ln, lam phat sinh
va xuc tien nhanh cac qua trnh gia cong hoa va ien hoa.
- ng dung trong viec lap ghep chi tiet :
Trang - 48 -

3) Xu hng phat trien :
- Nhu cau phat trien cong nghiep ngay cang oi hoi gia
cong cac vat lieu ban dan, gom hp kim cng va nhieu vat
lieu sieu cng ran, don khac. Do vay oi hoi phai phat trien
loai thiet b gia cong bang sieu am. S phat trien can thiet
khong nhng ch oi vi nhom gia cong th nhat, ma ca oi
vi nhng nhom gia cong phoi hp, mac dau hien nay nhom
nay cha co tam quan trong nhieu.
- Noi dung phat trien gom co cac van e : ong hoc, au
t giao, cac giai phap noi mi phc tap. Hien nay, ngi ta
1
5
3
4
2
10
7
8
9
6
Hnh 2.18 : Lap ghep bang sieu am
1. Dao ong doc
2. Dao ong hng knh
3. Chot
4. Cot e lap chot
5-6. Dung cu
7. May phat sieu am (1)
8. May phat sieu am (2)
9-10. ong c sieu am (au dao ong).
Trang - 49 -
ang nghien cu phat trien cac mach ien a mach, cac au t
giao va bo noi co the gia cong tren be mat ln, t ton that.
- Bang cac phoi hp gia cong sieu am, gia cong an mon
ien va gia cong ien hoa vi nhau, e gia cong cac vat lieu
co kha nang dan ien, ngi ta co the tang nang suat va giam
hao mon dung cu. Trong lnh vc phoi hp gia cong nen gia
cong sieu am bo sung cho gia cong truyen thong, can nghien
cu phat trien nhng loai thiet b mi.
Trang - 50 -
B - PHUONG PHAP GlA CONG TlA NUOC
( water Jet Cutting - wJC )
GlA CONG TlA NUOC CO HAT MAl
(Abrasive water Jet Cutting -AwJC)
- Hieu khai niem gia cong bang tia nc va tia nc co
hat mai.
- Hieu, biet nguyen ly gia cong bang tia nc va tia nc
co hat mai.
- Tng minh thiet b va dung cu.
- u nhc iem va pham vi ng dung.

I. Khai niem :
- Gia cong tia nc : La phng phap gia cong mi, dung
tia nc cong nghiep tac ong vao vung chi tiet can gia cong,
qua trnh c tien hanh lien tuc va dan dan tao thanh chi tiet gia
cong.
- Gia ong tia nc co hat mai : Co cau tao gan nh tng
t cau truc gia cong bang tia nc. Phng phap nay dung tia
nc c them vao cac phan t hat mai e cho qua trnh gia
cong manh hn, co hieu qua hn, nham tao kha nang cat cac
vat lieu cng hn nh : thep, thuy tinh, betong hay vat lieu
composite . . . Dong tia nc gia cong nay se khong gay ra
nhng hau qua do ap suat hoac nhiet len cac vat ma chung ta
ang gia cong.
Trang - 51 -
- Hien tng cat bang tia nc thc hien bang cach a mot
the tch ln nc qua mot ng ong nho. The tch nc khong
oi i qua mot ong tiet dien giam dan se lam cac phan t tang
toc mot cach nhanh chong. Dong c tang toc nay ra khoi
ong tac ong mot lc cat ln vao vat lieu gia cong. Ap suat
cc ai (2.10
8
Pa - 4.10
8
Pa) cua cac phan t nc a c gia
toc tiep xuc vi mot vung dien tch be (Vet cat hoac ranh co
o rong xap x 1mm, ng knh lo nho nhat co the cat c la
1,5 mm) cua chi tiet gia cong. Trong vung nay se phat trien
nhng vet nt nho do tac ong cua tia nc. Tia nc cuon troi
vat lieu b boc ra khoi chi tiet gia cong. Vet nt do tac ong
cua tia nc gi ay b at di dong nc. Ap suat cc ai va
tac ong cua cac phan t trong dong tia lam cho vet nt phat
trien cho ti khi vat lieu b cat hoan toan.
- au tien nc t thung cap nc i qua bo loc va hoa tron.
Sau o nh ong dan chat long i qua bo khuech ai e tang ap
en au phun. Tai au phun tia nc c phun ra manh hay
yeu la nh van tiet lu. Van nay c ieu khien bi mot bo
ieu khien. Tia nc sau khi ra khoi au phun co ap suat rat
ln, nh ap suat nay ma tao nen ap lc cat chi tiet gia cong.
- Khi gia cong tia nc co hat mai th hat mai c tron vi
nc trong ong tron trc khi c phun tra ngoai. Van toc cua
dong nc rat cao se tao ra vung chan khong va hut hat mai t
ngoai vao ma khong can bat c mot may nao khac e a
dong hat mai vao. Tia dung dch nay thong thng c ay
bang kh nen nham muc ch tang toc o cua dong chay. Be
mat c gia cong bang tia hat mai khong co vet xt nh be
mat gia cong bang cac phng phap khac (cac phng phap
gia cong con co tao phoi). Moi thanh phan cua dong tia la
nc va hat mai eu co muc ch rieng biet va ho tr : Muc
ch chnh cua vat lieu hat mai trong dong tia la cung cap lc
Trang - 52 -
mai mon; muc ch cua dong tia nc la co tac dung a vat
lieu hat mai en chi tiet gia cong e mai mon, tia nc cung
gia toc vi hat mai, mang ca dong hat mai va vat lieu b mai
mon khoi vung lam viec. Be mat trc khi gia cong bang tia
hat mai phai c tay sach bui, phoi, dau nhn, axit va cac tap
chat khac.

Hnh 2.19:
S o nguyen ly gia cong bang tia nc
Trang - 53 -

- Khi khach hang a ra mot ban ve, no se c so hoa va
ve lai bang phan mem CAD/CAM. Sau o ban ve c
chuyen oi thanh ngon ng ma may gia cong bang tia nc co
the oc c qua mot chng trnh c goi la gia cong nh
may tnh CAM (Computer Aided Manufacturing).
III. Co so Iy IhuyeI :
Do gia cong va tia nc va gia cong tia nc co hat mai co
ac iem cau tao cung nh nguyen ly gia cong tng t nhau,
v vay chung ta ch e cap ti phng phap gia cong manh
nhat va phc tap nhat trong 2 phng phap, o la phng phap
gia cong tia nc co hat mai.
Qua trnh a phan t hat mai vao trong nc :

Nc vao ap suat cao
Hat mai i vao
Dong tia nc co hat mai
c tap trung
Ong chu mai
mon
Hnh 2.20 : Gia cong tia nc co hat mai.
Voi phun
Nc toc
o cao
Trang - 54 -
- Hat mai c a vao sau giai oan hnh thanh tia nc
ap suat cao.
- Hat mai c a vao trc qua trnh hnh thanh tia
nc (trng hp khong pho bien).

Sau ay la nhng o th ch ro mot so moi lien he can thiet
trong qua trnh gia cong :
Nc ap lc cao
Hat mai
Ong tap
trung
Khuon
ai oc
Nut chan
Than ong
Voi phun
Hat mai
ai oc ham
Ong tap
trung
Voi phun
Dong tia nc
Ong tap trung
Goc ngheng
Hnh 2.21 :
Qua trnh tron hat mai vao tia nc
Trang - 55 -
Hnh 2.22 :
Quan he gia ng knh ong tap trung va ap suat bm
(Focus diameter and pump pressure)
Lu
lng
kh
thoi
vao
(l/mm)
Lu lng khoi
lng hat mai
a vao (g/s)
Kch thc ong tap trung mm
Ap suat bm MPa
Lu
lng
kh
thoi
vao
(l/mm)

ng knh ong
tap trung (mm)
Hnh 2.23 :
Quan he gia lu lng khoi lng hat mai va
hnh dang hnh hoc ong tap trung
Trang - 56 -
Lu lng hat mai g/s
Hnh 2.24 :
Moi quan he ga lu lng the tch khong kh, lu lng
khoi lng hat mai va s thay oi ap suat
Ap suat
(mbar)
Lu lng
kh thoi vao
(l/mm)
Toc o va cham ti
han (m/s)
Bot thach anh
(a) (b)
Bot thuy tinh
Kha
nang
gay
nc
v
(%)
Van toc hat (m/s)
ng knh hat (mm)
Hnh 2.25 :
Anh hng cac thong so len s v cac phan t ran.
a) Van toc tac ong va goc tac ong
b) Van toc tac ong va phan t
Trang - 57 -
Hnh 2.26 :
Anh hng cac thong so len s phan huy phan t hat mai
He so phan huy
Ap suat bm (Mpa)
Granat
Chieu dai ong tap trung (mm)
Thong so tng
t hnh (a)
(a) (b)
He so phan huy
(c) (d)
ng knh ong xa
hat mai (m)
He
so
phan
huy
Ap suat bm (Mpa)
ng knh ong tap
trung (mm)
Quy nh
Toi u
Thong so tng t
hnh (a)
Thong so tng t
hnh (a)
Trang - 58 -

IV. ThieI bj va dung cu :
Mot may gia cong tia nc gom cac bo phan chnh sau ay :
- Mot c cau au cat c dung e nh hnh tia nc.
- Mot he thong mang va hut e a cac phan t vao trong
dong tia nc.
- Mot bm tang ap e gia tang ap suat cua nc.
He so phan
huy
He so phan
huy
Lu lng khoi lng
hat mai (g/s)
ng knh hat mai (mm)
(e) (f)
Bo tr nc
Bo tao ap suat
He thong au cat
va dch chuyen
Hnh 2.27 :
He thong cua mot may gia cong tia nc
Trang - 59 -

1) Bo tang ap :
- Bo tang ap hoat ong nh mot bo khuech ai, no bien
oi nang lng t dong chat long co ap suat thap thanh dong
co ap suat rat cao. He thong thuy lc cung cap nang lng chat
long en mot piston chuyen ong qua lai trong mot oan trung
tam cua may tang cng. Mot cong tac gii han at cuoi
hanh trnh cua piston, bao hieu dong ien ieu khien oi chieu
van ao chieu va thay oi chieu chuyen ong cua piston.
- Viec lap rap bo tang ap vi mot bm piston hai ben
cua piston, se tao ra ap suat ca hai pha. Khi mot pha cua bo
tang ap ang th hut, th pha oi dien ang tao ra mot ap
suat cao ngo ra. Trong khi ngo vao cua bm hut nc a
c loc i vao xylanh cao ap thong qua van mot chieu. Sau
khi bm piston ao chieu th nc se c nen va thoat ra di
dang nc chu ap suat cao.
- Bo phan ieu ap lam eu s thay oi ap suat t may nen
cung cap mot dong nc co ap suat rat cao eu an en dung
cu cat hoac lam sach.
- Sau ay la mot so bo tang ap c dung trong may cat
tia nc, cung nh cat tia nc co tron lan hat mai.
Be
cha
ong c
Van tran
May
bm
Mui cat
Voi phun
oi tng
Hnh 2.28 :
S o cua he thong bm va cung cap nc
Trang - 60 -
Van
xa
Van
nap
Nc i ra khi
pittong di chuyen
qua phai
Nc i vao khi
pittong di chuyen
qua trai
Dau i ra khi pittong
di chuyen qua trai
Dau i vao
chuan b cho
hanh trnh tiep
theo
Buong ap suat
Bo phan pittong
Dau i vao ay
pittong
Dau i ra chuan
b cho hanh trnh
tiep theo
Hnh 2.29 :
Ket cau mot bo tang ap n gian (Bo tang ap n)
Bo phan lam giam ap suat
Nc i vao khi pittong
qua phai
Nc i vao khi pittong
qua trai
Xa
Hnh 2.30 :
S dung bo tch luy vi bo tang ap tac ong kep
Trang - 61 -
Hnh 2.31 :
C che hoat ong cua mot bo tang ap tac ong kep :
Nc c
nap vao
Ngo dau ra
Dau thuy lc
co ap lc ln
c a vao
1) Bm A bat au
co vao e hut nc,
B phun nc
Nc c
nap vao
2) Piston A bat au di
chuyen len, nen nc
trong khi B tiep tuc phun
nc a gia ap.
3) Piston A bat au
phun, trong khi B
ngng va co khuynh
hng co lai.
Trang - 62 -
2) Dung cu :
- Voi phun co ng knh 0,1-0,4 mm. e tia nc co u
nang lng cho qua trnh cat can cung cap mot ap suat len en
400 MPa va van toc phun ra len en 900 m/s. Lu chat c
tao ap lc ti mc can thiet nh mot bm thuy lc. au phun
gom co vong kep va voi phun. Vong kep c lam bang thep
khong r, va voi phun c lam bang ngoc bch, hong ngoc hay
kim cng. Dung kim cng th keo dai tuoi tho nhng gia
thanh cao. He thong loc phai c s dung e ngan phoi phat
sinh trong qua trnh gia cong. Nhng lu chat c dung rong
rai trong gia cong bang tia nc la cac dung dch polymer, v
chung co xu hng tao thanh mot dong ket dnh.

- Hnh 2.33 la mot loai c cau phun co kha nang ieu
chnh (trong mot pham vi nhat nh) tiet dien au ra cua ong
phun va voi phun, ong thi co kha nang ieu chnh ca khoang
cach gia chung. C cau gom than chnh 1 co ren ngoai e lap
cac than trc 2 va than sau 3. Tren than trc 2 co lap cac
bac dan thay oi (co ng knh trong t 4 en 14 mm) va ong
phun 5 nh ai oc 4 . e tao ra o con hai hoa t lo con cua
than trc 2 en ong phun 5 gia chung co lap cac vong em
trung gian 6 vi chieu day khac nhau. Cac vong em nay luon
luon c lap, ngoai tr trng hp khi s dung ong phun 5 co
Hnh 2.32 :
Hnh dang mot voi phun
trong thc te
Trang - 63 -
ng knh trong 14 mm. Tren than sau 3 co lap ong 7 ma
au cuoi cua no co lap voi phun kh nen 8. Ong c kep chat
nh ai oc 9. Tren ong 7 co lap ai oc moc 10 va nh mieng
em 11 e kep chat ong noi 12. Ong noi 12 c lap vi ong
dan kh nen. Tren than sau 3 co lap ai oc moc 13 cung vi
mieng em 14 e kep chat ong dan 15. Ong dan 15 c noi
vi ong dan dung dch hat mai.
Hnh 2.33 :
C cau phun
1) Than chnh
2,5) Than di
3) Than sau
4,9) ai oc
5) Ong phun
6) Vong em trung
gian
7) Ong
8) Voi phun kh nen
10, 13) ai oc moc
11,14) Mieng em
12.15) Ong noi
Trang - 64 -
- Cac voi phun kh nen 8 co ng knh au ra 414 mm.
Chieu dai cua chung t 52 en 64 mm, do o co the ieu chnh
khoang cach gia au ra cua voi phun va ong phun ong thi
co the ieu chnh c ca tiet dien cong tac gia voi phun va
ng knh trong cua than trc 2 e tang hoac giam lng hat
mai i qua. Khoang cach gia voi phun 8 va voi phun 5 c
ieu chnh bang vong em trung gian 6 (co chieu day 220
mm). Tiet dien ben trong cua ong noi 15 bang 284 mm
2
, con
tiet dien cua ong phun 5 (co ng knh ln nhat) bang 154
mm
2
. ieu nay cho phep cap dung dch hat mai ti ong phun
theo lng yeu cau. Cac kch thc cua ong noi 12, cua ong 7
va cua voi phun kh nen 8 phai am bao u tiet dien theo yeu
cau trong tng trng hp cu the.
- Hnh 2.34 la mot c cau phun e gia cong lo. C cau
gom than 1, nut dan hng 2, ong phun 3 va cac bac 4. Vong
em 5 co tac dung co nh v tr cua cac bac 4. Cac bac 4 co
cac lo e cho dung dch hat mai i ti buong tron 6. Buong
tron 6 on nhan kh nen e phun dung dch hat mai ti be mat
gia cong thong qua cac lo tren than 1. Hng cua tia hat mai
c xac nh bang profin cua cac ranh tren nut nh hng 2.
Vi cach phun dung dch nh vay, nut nh hng 2 va than 1
chong b mon, do o chung can c thng xuyen thay oi.
Hnh 2.34:
C cau phun e gia cong lo
1. Than 2. Nut dan hng 3. Ong phun
4. Bac 5. Vong em 6. Buong tron.
Trang - 65 -
- Cac thong so quan trong trong viec hnh thanh tia nc
cua voi phun :

13
0
2-5 lan ng knh
Hnh 2.35 :
Bo tao tia
Hnh 2.36 :
Anh hng chieu dai tia va goc co lo
Chieu
dai tia
Goc lo voi
A : ng knh voi 5mm
B : ng knh voi 8mm
Trang - 66 -
Chieu
dai tia
Chieu dai co bo tao tia
Hnh 2.37 :
Anh hng chieu dai tia so vi chieu dai
co bo tao tia

Goc ln tron au vao
Goc nhon
Phan
ap
suat
voi
Chieu dai tia
Hnh 2.38 :
Anh hng cua hnh dang goc vao voi len ap
suat voi cac chieu dai tia khac nhau
Trang - 67 -
3) Bo tron trong gia cong tia nc co hat mai :
- Trong gia cong tia nc co hat mai, ta quan tam en van
e tron hat mai vao tia nc, moi mot thiet b co mot c che
tron hat mai khac nhau. Nhng hnh di ay cho thay c
mot so c che c ap dung trong gia cong tia nc co hat
mai:
Hnh 2.39 :
Qua trnh tron hat
mai vao nc a
gia ap

Nc ap lc cao
Hat mai
Buong
tron
V tr cua voi tia
nc
Voi gia
cong a
tron lan tia
nc va hat
mai
(a)
Nc ap
lc cao
Nc ap
lc cao
Hat mai
(b)
Trang - 68 -
Hat mai Nc ap
lc cao
Buong tron
Voi phun
Than
nhieu
lo voi
Nhieu tia nc co the la
song song hoac hoi tu vao
co ngong cua voi phun.
Hnh 2.40 :
C che cap hat da
vao trong lng.

Buong tron
Voi phun
Hat mai va
kh c
a vao
Hat mai va
kh c
a vao
Nc ap
lc cao
Voi tia
nc
Hnh 2.41 :
C che cap hat cng
bc bang kh
Trang - 69 -
4) Thiet b :
u) Muy lIu nuoc don lluun :
- ay, nc c a vao bm cao ap tao nen ap suat
rat ln, t p = (14)10
3
bar, co may dung p = (49)10
3
bar.
Nc co ap suat cao c a en voi phun che tao bang ngoc
bch hoac kim cng, co ng knh 0,10,4 mm. Voi phun
at trong au cat a nc en ong hoi tu, tao nen tia nc co
nang lng pha huy ln tac dung vao be mat vat gia cong thc
hien qua trnh gia cong. Toc o cat phu thuoc vao vat lieu va
chieu day vat cat. Chieu day thng khong qua 15 mm e am
bao mat cat khong co bavia. Lu lng nc thng dung Q =
35 lt/phut va van toc tia nc co the at en v = 900 m/s
(gan 3 lan van toc am). Nc can loc vi bo loc te vi e am
bao hat ban khong qua 510 m.

h) Muy lIu nuoc co lul muI :
- e tang hieu qua ngi ta dung them thung hat mai
e a hat mai vao thung tia. Vi hat mai nho, cng, sac, tia
nc sau khi ra khoi au cat se tao nen tac dung pha huy ln
Hnh 2.42 :
Mot may gia
cong tia nc
n thuan
Trang - 70 -
hn loai tia nc n thuan. Loai nay co the gia cong tren mat
at va o sau tren 1000m. May tia nc co hat mai cung
phan thanh hai loai :
+ Loai thung hat mai khong co ap suat : Thanh phan
tia cat ch co nc va hat mai vi lng khong kh rat ln, nen
ch co the cat o sau khong qua 20m.
+ Loai thung hat mai co ap suat : neu thung hat mai
c ong kn va dan khong kh kho t bm cao ap, hoac dung
kh CO
2,
nit, heli co ap suat t 215 bar. Loai nay co the cat
o sau tren 1000m. hat mai thng dung la Al
2
O
3
va SiO
2
co
ng knh tot nhat la 0,070,08 mm. Ap suat gia cong co
the en p = 2000 bar. May thng dung e cat cac vat lieu phi
kim loai cng va giong nh thuy tinh CaF
2
, gom s SiO
2,
hay
silicon, mica, hoac dung e lam sach, anh bong .v.v.
- Thiet b dung trong gia cong bang tia hat mai c
phan loai theo phng phap cap dung dch hat mai ti c cau
phun va ti be mat gia cong. Nh vay, theo nguyen tac nay
thiet b c chia ra thanh 6 s o sau :
* S o 1 : Cap dung dch hat mai len cao va ti be
mat gia cong bang c cau phun nh kh nen (hnh 2.43). Thiet
b gom be cha 1 co c cau nh hng gom ong dan trung tam
5 va cac mang dan 6. Khi c cau khuay 2 quay, dung dch da
theo cac mang dan 6 chay len tren va xuong di, nh vay no
c tron eu (hat mai vi chat long). Tiep o dung dch theo
ong dan 7 c cap cho c cau phun 8 roi ti chi tiet gia cong
10 nh kh nen trong ong phun 9 ra khoi be mat gia cong, dung
dch chay xuong phan di cua thung cha 11 roi tr ve be
cha 1. Thiet b tren ay c dung khi can nang cao nang
suat gia cong.
Trang - 71 -

* S o 2 : Dung dch hat mai t chay ti c cau
phun va c phun nh kh nen (hnh 2.44). Thiet b gom may
bm 1 co nhiem vu cap dung dch vao be cha 3 (nam phan
tren cua buong cong tac 4) theo ong dan 2. T be cha 3 dung
dch t chay xuong c cau phun 5 va c phun ti chi tiet gia
cong nh kh nen trong ong phun 6. Trong qua trnh lam viec
co hn 50% dung dch t be cha 3 chay theo ong xuong phan
di cua buong cong tac 4, lam cho dung dch c khuay eu,
tao ieu kien e tang kha nang cat got cua hat mai. Thiet b
nay c dung trong san xuat n chiec va hang loat nho.
Hnh 2.43 :
Thiet b cap hat mai
theo s o 1.
1. Be cha
2. C cau khuay
3. ong c ien
4. Bo truyen
5. Ong dan trung tam
6. Cac mang dan
7. Ong dan
8. C cau phun
9. Ong phun
10. Chi tiet gia cong
11. Thung cha
Trang - 72 -

* S o 3 : Thiet b cap dung dch hat mai nh ap lc
cua kh nen (hnh 2.45). Thiet b gom be cha 1, ap lc cua no
c am bao trong pham vi 1,22 kG/cm
2
nh bo giam ap 2.
Di ap lc nay dung dch theo ong 3 c cap cho c cau
phun 4, c cau nay phun dung dch ti chi tiet gia cong 5 nh
kh nen co ap suat (ap lc) 46 kG/cm
2
theo ong dan 6. Dung
dch sau khi gia cong chay xuong phan di cua buong cong
tac 7. Chat long va hat mai c khuay eu trong be cha 1
nh c cau khuay 8. Dung dch c cap nh ap lc co chat
lng cao hn (c khuay eu hn) cac phng phap khac.
Khi ap lc cua kh nen trong be cha 1 tang, lng dung dch
c phun trong mot n v thi gian ti be mat gia cong tang,
do o lng kim loai c boc tach cung tang.
Hnh 2.44 :
Thiet b cap hat mai theo s
o 2 :
1. Bm
2. Ong dan dung dch vao be
cha
3. Be cha
4. Buong cong tac
5. C cau phun
6. Ong phun kh nen
7. Ong dan dung dch hat mai
xuong buong cong tac
8. Ban cong tac.
Trang - 73 -

* S o 4 : Thiet b khong phun tia dung dch (hnh
2.46). Thiet b nay c dung khi nang suat gia cong (lng
kim loai c boc tach) khong can cao. Dung dch trong be
cha 1 luon luon c gi di ap suat cua kh nen. Ap suat
cua kh nen trong be cha c ieu chnh nh bo giam ap 2
va c xac nh bang ap ke 3. Dung dch c khuay eu nh
c cau 4 va c cap (khong phun) ti chi tiet gia cong 7 qua
ong dan 5 va voi phun 6. Dung dch sau khi gia cong chay
xuong phan di cua buong cong tac 8 roi sau o (khi thiet b
dng hoat ong) chay xuong be cha 1.
Hnh 2.45 :
Thiet b cap hat
mai theo s o 3.
1. Be cha
2. Bo giam ap
3. Ong dan dung
dch ti c cau
phun
4. C cau phun
5. Chi tiet gia
cong
6. Ong dan kh
nen
7. Buong cong tac
8. C cau khuay.
Trang - 74 -

* S o 5 : Thiet b cung cap dch hat mai nh may
bm va kh nen (hnh 2.47). Dung dch t be cha 1 c phun
ti be mat cua chi tiet gia cong 6 nh may bm 2, ong dan
dung dch 3, c cau phun 4 va ong dan kh nen 5. Dung dch
sau khi gia cong chay t buong cong tac 7 xuong be cha 1.
Tai be cha nay dung dch c khuay eu nh c cau khuay
8. Qua trnh gia cong co hieu qua cao neu may bm cap dung
dch vi ap lc bang ap lc cua kh nen (57 kG/cm
2
). Neu ap
lc cua may bm thap hn ap lc cua kh nen th nang suat gia
cong cua thiet b (lng kim loai c ht trong mot n v
thi gian) giam, ac biet khi gia cong bang hat mai co kch
thc ln. Thiet b loai nay c dung chu yeu trong nganh
che tao may va cac lanh vc cong nghiep khac.
Hnh 2.46 :
Thiet b cung cap hat
mai theo s o 4.
1. Be cha
2. Bo phan ap
3. Ap ke
4. C cau khuay
5. Ong dan
6. Voi phun
8. Buong cong tac.
Trang - 75 -

* S o 6 : Thiet b cap dung dch hat mai nh
may bm va roto (hnh 2.48). Thiet b nay khong dung kh nen,
do o co the tiet kiem c chi ph gia cong. Dung dch hat
mai c cap ti be mat cua chi tiet gia cong nh may bm ly
tam 1, ong dan 2 va roto 3. Dung dch sau khi gia cong chay
xuong phan di cua buong cong tac 5 va theo ong dan 6 ti
may bm ly tam 1. Lng dung dch qua may bm nay chay
xuong buong cong tac di mot ap lc nao o, cho nen no luon
luon c khuay eu. ng knh cua roto phu thuoc vao toc
o cua dung dch hat mai can at va thng nam trong khoang
300500 mm. Cac ranh cua roto co be rong 50 mm, cac mep
ngoai cua chung c ve tron va c bao ve bang cac man
chan cao su e tang thi gian s dung. So vong quay cua roto
khoang 25008000 vong trong mot phut. Cong suat cua ong
c ien 510 kW. Roto c ay bang cac a kim loai. Khi
quay roto hat dung dch hat mai, tao thanh chum tia co goc
Hnh 2.47 :
Thiet b cung cap hat mai
theo s o 5.
1. Be cha
2. May bm
3. Ong dan dung dch
4. C cau phun
5. Ong dan kh nen
7. Buong cong tac
8. C cau khuay.
Trang - 76 -
nh 70 120
o
. Toc o cua cac hat mai trong thiet b nay cao
hn trong cac thiet b co dung kh nen. Vi toc o cao nh vay
co the s dung hat mai co kch thc nho hn e nang cao o
bong be mat trong khi van am bao c nang suat gia cong.

c) Muy lIu nuoc CNC :
- May tia nc thng dung c ieu khien bang he
thong NC/CNC. No co dang nh may phay ng. Tren xa
ngang lap au cat vi voi phun cho tia nc ap suat cao tac
ong vao chi tiet gia cong tren ban co the di ong theo truc X,
Y bang toa o ieu khien CNC. Di ban may co thiet b thu
hoi nc va c cau tuan hoan nc. Vi c cau nay may co the
trang b he thong ieu khien toa o e gia cong cac chi tiet
nh hnh.
- Ngoai ra hien nay, nhieu may tia nc CNC a cai
tien rat nhieu, he thong au cat c thiet ke gon hn, tien li
hn. Canh tay robot c ng dung (hnh 2.49) nham gia cong
Hnh 2.48 :
Thiet b cung cap hat
mai theo s o 6.
1. May bm li tam
2. Ong dan dung dch
t roto
3. Roto
5. Buong cong tac
6. Ong dan dung dch
ti may bm
Trang - 77 -
c rat nhieu v tr ma au cat thong thng khong thc hien
c.

1) Gia cong bang tia nc :
Cac thong so gia cong quan trong trong gia cong bang tia
nc bao gom : khoang cach gia cong, ng knh cac voi
phun, ap suat nc va toc o cat. Khoang cach gia cong la
khoang cach gia au voi phun va be mat gia cong. Thong
thng khoang cach nay la nho e tia nc phan tan ti mc
toi thieu trc khi kp ap vao be mat. Khoang cach gia cong
ien hnh la 3,2 mm. Kch thc cua lo voi phun anh hng
en o chnh xac cua qua trnh cat lo voi. Voi phun nho c
s dung tren nhng vat lieu mong. oi vi nhng vat lieu day
hn th can co nhng tia phun day hn va ap suat cao hn. Toc
o cat thng vao khoang t 5mm/s - 500 mm/s tuy theo o
day cua chi tiet gia cong. Phng phap gia cong tia nc
Cuon day chu ap suat cao
Voi phun
Chot tay quay
Bo phan tac ong
Hnh 2.49 :
Gia cong tia nc dang tay may
Trang - 78 -
thng c t ong hoa bang he thong CNC hay ngi may
cong nghiep. Pham vi gia cong : t 1,6 mm - 305 mm vi o
chnh xac la 0,13 mm.
2) Gia cong bang tia nc co hat mai :
- oi vi gia cong tia nc co hat mai khi them nhng hat
mai vao tia nc se lam phc tap qua trnh gia cong v phai bo
sung mot so thong so va nhng thong so nay phai c ieu
khien. Nhng thong so them vao cho qua trnh la loai hat mai,
c hat va toc o dong chay. Cac loai vat lieu hat mai thng
c s dung la Al
2
O
3
, SiO
2
va garnet, cac c khoang t 60
en 100 . Lng mai c them vao trong tia nc xap x
khoang 0,3 kg/phut sau khi thoat ra voi phun. ng knh h
cua voi khoang t 0,25 - 0,63 mm. S d kch c hn mot chut
so vi s gia cong bang tia nc la e co c toc o dong
chay cao hn va nang lng nhieu hn v ben trong no co cha
hat mai.
- Ap suat nc trong gia cong bang tia nc co hat mai
giong trong gia cong bang tia nc. Khoang cach cho phep
phai t hn e giam en mc toi thieu hieu qua phan tan cua
chat long cat ma hien gi co cha nhng hat mai. Khoang
cach cho phep ien hnh la khoang hay khoang cach trong
gia cong tia nc.
- Cac thong so can chu y khi gia cong tia nc co hat mai:
+ T le cap hat mai.
+ ng knh ong tron.
+ ng knh mieng voi phun.
+ Ap suat nc trong voi.
+ Kha nang cat vat lieu.
+ Chieu day chi tiet.
+ Chat lng can gia cong.
+ Cong suat may bm.
Trang - 79 -
u) Ho so gIu cong hung lIu nuoc lul muI u Iuc
cuo :
- Goc phun = 90
0
(hnh 2.50a). Trong trng hp nay
be mat c gia cong bang tia va ap.
- Goc phun = 0 (hnh 2.50b). Trong trng hp nay be
mat c gia cong bang tia trt.
- Goc phun = 090
0
(hnh 2.50c) - be mat gia cong
bang tia cheo.
- Khi gia cong vat lieu gion nen dung phng phap tia
va ap (hnh 2.50a) con khi gia cong vat lieu deo nen dung cac
phng phap tia trt va tia cheo (hnh 2.50b va hnh 2.50c).
- Dung dch khi va ap vao be mat gia cong tao ra mot
lp mang ma chieu day cua no phu thuoc vao thanh phan cua
dung dch (hnh 2.50d). Cac hat mai trong tia dung dch (tia hat
mai) pha v mang dung dch nay e at chat lng theo yeu
cau.
- Quang ng i cua hat mai qua mang dung dch
cang ln khi goc phun cang nho. Hat mai nao i ti phan cua
be mat gia cong th no chu sc can cua mang ding dch (do co
chieu day ln) cho nen chieu day phoi c cat giam xuong.
- Neu be mat gia cong co o phang ly tng th cac hat
mai b be mat hat len va khong ra mot cong ang ke nao (hnh
2.50e).
- Neu be mat di di ti cac nh nhap nho nay se b pha
v (hnh 2.50g). Qua trnh nay xay ra lien tuc cho en khi tat
ca cac nh nhap nho b san phang.
- Kch thc cua cac hat mai c chon phu thuoc vao
o nham be mat trc khi gia cong. Neu kch thc cua cac
hat mai (hnh 2.50h ben trai) qua nho so vi nhap nho (o
nham) th cac hat mai khong ch tac ong ti cac nh nhap
nho ma con tac ong ti ca ay cua chung na. Nh vay qua
trnh gia cong se tao ra be mat co prophin tng t nhng vi
Trang - 80 -
o nham thap hn. Neu kch thc cua cac hat mai qua ln th
chung khong the xam nhap xuong cac ay nhap nho c, do
o chung ch co kha nang san phang cac phan tren cua nhap
nho (hnh 2.50h ben phai). Hnh 2.50h ( gia) la s o kch
thc hat mai hp ly nhat.
- Lng hat mai trong dung dch tang cho phep nang
cao nang suat gia cong.
- Tuy nhien, neu lng hat mai trong dung dch qua ln
se lam cho chung va ap vi nhau qua nhieu, do o hieu qua
cat lai giam. Do o, lng hat mai trong dung dch (mat o hat
mai) phai c chon toi u.
- Tia hat mai va ap vao kim loai cng vi toc o toi a
V (m/s), se xam nhap vao kim loai cng o vi toc o U (m/s),
tao ra ap lc cat P (tan/m
2
).
) U V (
g 2
P
=
ay : - trong lng rieng cua vat lieu dong tia (tan/m
2
)
g - gia toc trong trng (m/s)
Ap lc cat nay co the at 280.000 Kg/cm
2

- Bang 2.3 la bang toc o cat cua mot so vat lieu cho
trc (mm/phut). May co ap suat 3800 bar dung 4,2 lt/phut,
mieng voi co ng knh 0,38 mm; voi dai 1,14mm; s dung
hat mai : 680 gram/phut.
h) Cuc yeu lo unl luong den nung suul gIu cong
vu do nlum he mul :
- Nang suat gia cong bang tia hat mai la ham so cua
nhieu yeu to va no phu thuoc vao muc ch gia cong be mat.
V du : Khi gia cong be mat nham tang o bong (giam o
nham) th can phai boc t kim loai, ngc lai khi gia cong be
mat nham at kch thc th lng kim loai c bong tach
trong mot n v thi gian phai at gia tr ln nhat.
Trang - 81 -
Hnh 2.50 :
Ho s gia cong tia nc hat mai.
a) Gia cong bang tia va ap; b) gia cong bang tia trt;
c)Gia cong bang tia cheo; d) mang dung dch bam vao
be mat gia cong; e) S phan xa cua tia hat mai; g) tia
hat mai pha v nh nhap nho;
1.Be mat gia cong; 2. Tia hat mai; 3. Ong phun; 4. Mang
dung dch; F. ng knh cua chum tia; F
1
. ng knh
ln cua vet hnh elip cua tia tren be mat gia cong; a.
chieu day cua mang dung dch
Trang - 82 -
Bang 2.3 :
Bang toc o cat mot so vat lieu cho trc
Vat lieu Chieu
day
(mm)
Cat bnh
thng
(mm/phut)
Cat chat lng
trung bnh
(mm/phut)
Cat chat
lng cao
(mm/phut)
12,7 475 193 122
38,1 132 43 25
ong
76,2 58 18 10
12,7 330 132 84
38,1 91 30 18
304SS
76,2 41 13 8
12,7 1021 414 259
38,1 284 97 58
Nhom
76,2 127 38 23
12,7 366 147 94
38,1 142 48 28
Thep t
Cacbon
76,2 64 20 13
12,7 511 208 130
38,1 254 86 51 Titanium
76,2 114 36 20
12,7 912 371 231
38,1 254 86 51
Granite
76,2 114 36 20
12,7 292 119 74
38,1 81 28 15
Inconel
718
76,2 36 10 8
- Cac thong so cong nghe cua qua trnh gia cong bang
tia hat mai phu thuoc vao muc ch cua nguyen cong, o cng
va o dai cua vat lieu gia cong va trang thai cua be mat trc
khi gia cong.
Trang - 83 -
- Cac yeu to cong nghe cua qua trnh c xet en la :
* Ap suat cua kh nen : a dung dch hat mai ti
thiet b phun P (kg/cm
2
), Phun dung dch hat mai P (kg/cm
2
).
* ac tnh cua thiet b phun : Lu lng kh nen
trong ong phun. ng knh cua voi phun kh nen d
k
(mm).
ng knh cua ong phun dung dch d
c
(mm). Tiet dien cua
luon kh nen f
b
(mm) hoac cua dung dch hat mai f
c
(mm) khi
chuyen vao buong hon hp. Chieu dai ong phun l (mm).
Khoang cach gia mat au cua ong phun va voi phun L(mm).
* ac tnh cua dung dch hat mai : Thanh phan cua
dung dch (nc, cac dung dch khac). Vat lieu hat mai (cat,
corun ien). Mat o cua hat mai trong dung dch K
o
(ty khoi
cua hat mai trong nc).
* V tr cua thiet b phun : Chieu dai cua tia L
(mm). Goc phun (o).
- Di ay ta nghien cu anh hng cua mot so yeu to
cong nghe en khoi lng kim loai c boc tach va o nham
be mat khi gia cong cac mau thep 45, 40X, Y9, thep nhiet
luyen 40X co o cng HRC 5560 va mot so vat lieu khac.
* Anh hng cua thi gian gia cong :
- Thc nghiem cho thay kho gia cong kim loai (cha
nhiet luyen, nhiet luyen va kim loai mau) khoi lng boc tach
kim loai ty le thuan vi thi gian gia cong bang tia hat mai
(hnh 2.51a). Khoi lng kim loai tren mot n v dien tch be
mat gia cong cung tang theo thi gian gia cong (hnh 2.51b).
- o hat : 36; 60; 90; 120; 150; 170; 250; 280; 320; 325;
400; 450. o hat 36 co kch thc ln nhat con o hat 450 co
kch thc nho nhat.
- Khi gia cong bang tia hat mai, o nham be mat giam
manh trong thi gian 60100 giay au tien. Sau o o nham
be mat hau nh khong thay oi theo thi gian (hnh 2.52). V
du, khi gia cong thep trong thi gian 100 giay o nham ban
Trang - 84 -
au R
z
= 10 m giam xuong R
z
= 3 m. Neu tiep tuc gia cong
en 160 giay th R
z
hau nh khong thay oi.

Hnh 2.51 :
Anh hng cua thi gian gia cong bang tia hat mai khoi
lng kim loai c boc tach
a) Che o gia cong; L = 70 mm; P
c
= 2 kG/cm
2
; o hat cua
hat mai 150; K
o
= 14; = 40
0
; P
e
= 6 kG/cm
2
;
1. thep 40 cha nhiet luyen;
2. thep 20 cha nhiet luyen;
3. nhom.
b) Che o gia cong; L = 100 mm; o hat cua hat mai 60;
K
o
= 90
0
; P
e
= 4 kG/cm
2

1. thep 40X nhiet luyen
2. thep 45 cha nhiet luyen
Trang - 85 -

* Anh hng cua mat o hat mai : Th nghiem c tien
hanh nh sau
- Gia cong thep 20 vi cac ap suat P
c
= P
c
= 5,5 kG/cm
2
,
mat o cua hat mai la 36; L = 80 mm va = 40
o
, d
c
= 4 mm.
- Gia cong thep 40X vi cac ap suat P
c
= P
c
= 4,5
kG/cm
2
, mat o cua hat mai la 270; L = 100 mm va = 45
o
,
d
c
= 4 mm.
- Ket qua cua ca hai th nghiem tren ay cho thay : khi
tang mat o cua hat mai trong dung dch khoi lng kim loai
c boc tach tang len.
- Ket qua tng t cung nhan thay c khi gia cong
thep 45 va uara (hnh 2.53). Trong trng hp nay khoi lng
Hnh 2.52 :
Anh hng cua thi gian gia cong bang tia hat mai
en o nham be mat.
1. thep 40X nhiet luyen; 2. thep 45 cha nhiet luyen.
Trang - 86 -
kim loai ln nhat t n v dien tch be mat c boc tach khi
gia cong thep co ty khoi cua hat mai trong dung dch
K
o
= 11,5 con khi gia cong uara K
o
= 12,5.
- Khi K
o
= 14 nang suat con giam 2025%, con gia
cong uara nang suat gia cong giam 1518%.

- Mat o hat mai trong dung dch khong co anh hng
nhieu en o nham be mat. V du, khi gia cong thep 40X co
nhiet lng ta co ng cong phu thuoc gia o nham be mat
va ty khoi cua hat mai trong dung dch nh tren hnh 2.54.
- o nham thap nhat khi gia cong ng vi ty khoi cua
hat mai trong dung dch nam trong khoang 1:6 en 1:9.

Khoi
kim
loai
c
boc
tach
T khoi cua hat mai trong dung dch
Hnh 2.53 :
Anh hng cua mat o hat mai en khoi lng kim loai
c boc tach khi gia cong thep 45 (ng cong 1) va gia
cong uara (ng cong 2)
Trang - 87 -

* Anh hng cua goc phun :
- Khi goc thay oi th lng kim loai c boc tach
cung thay oi (hnh 2.55).
- Ta thay : Khi goc phun tang trong trng hp gia
cong 40X (hnh 2.55a) th lng kim loai (Mgram) c boc
tach tang lenva at gia tr cc ai vi = 45
0
. Khi gia cong
thep 20 bang cac hat mai co o hat khac nhau (hnh 2.55b)
lng kim loai c boc tach trong mot n v thi gian
(gram/phut) at gia tr cc ai vi goc phun = 40
o
.
- Khi tang goc phun ti 90
o
lng kim loai c boc
tach giam.
- o hat cua mai mau cung anh hng en dang cua
ng cong, cu the la khi kch thc cua hat tang (o hat 36)
th ng cong phu thuoc gia lng kim loai c boc tach va

Hnh 2.54 :
Anh hng cua mat o hat mai en o nham be mat.
1 - o nham cua be mat trc khi gia cong
2 - o nham cua be mat sau khi gia cong
L = 100 mm; o hat la 270; P
c
=P
e
= 3,5 kg/cm
2
; = 45
0
;
thi gian gia cong 80 giay.
Trang - 88 -
goc phun = 30
o
45
o
s thay oi cua lng kim loai c boc
tach khong ang ke.
- V vay, khi gia cong co the bo qua s bien ong chut
t cua goc phun toi u.
- ieu nay co y ngha quan trong oi vi trng hp gia
cong cac be mat cong phc tap.

Khoi
kim
loai b
boc
tach
Goc phun
(a)
Khoi
kim
loai b
boc
tach
Goc phun
(b)
Hnh 2.55 :
Anh hng cua goc phun en lng kim
loai c boc tach
Trang - 89 -
* Anh hng cua khoang cach phun :
- Khoang cach phun L (khoang cach t au phun en
be mat gia cong) cung co anh hng en khoi lng kim loai
c boc tach. V du, khi gia cong cac vat lieu thep Y9 va
thep 20 vi cac thong so: L = 20160 mm, P
c
= P
c
= 5,86,1
KG/cm
2
; = 40, = 14, o hat mai 36, 120 va 325 ta co o
th quan he gia lng boc tach kim loai va khoang cach phun
nh tren hnh 2.56a.
- S o hnh 2.56a cho thay lng kim loai c boc
tach at gia tr cc ai khi khoang cach phun L = 80 mm. Con
trong trng hp tren hnh 2.56b lng kim loai boc tach at
gia tr ln nhat ng vi khoang cach phun L = 70 mm.
(a)
(b)
Hnh 2.56 :
Anh hng cua khoang cach phun en lng kim loai
c boc tach.
a-gia cong thep Y9 bang cac hat mai co o hat khac nhau
b-gia cong thep 20.
Trang - 90 -
- Khoang cach phun L cung co anh hng ang ke en
o nham be mat, ket qua o o nham cua cac th nghiem tren
ay cho thay moi quan he gia khoang cach phun L va lng
giam cua o nham be mat nh sau :
Bang 2.4 :
Quan he gia khoang cach phun va o nham
Khoang cach phun L (mm) o nham giam c (m)
20 0,1
40 0,13
60 0,13
80 0,35
100 0,37
120 0,34
140 0,25
* Anh hng cua ap lc kh nen :
- e xac nh anh hng cua kh nen P
e
(e a dung
dch hat mai ti thiet b phun) va P
e
(e phun dung dch hat
mai) en lng kim loai c boc tach (nang suat gia cong)
ngi ta gia cong thep Y9 vi cac ap lc kh nen khac nhau.
Ket qua thc nghiem cho thay khi tang ap xuat kh nen, lng
kim loai c boc tach tang (hnh 2.57a). ac tnh nay cung
c khang nh khi gia cong vi cac hat mai co o hat khac
nhau (hnh 2.58b).
- Ap lc kh nen cung co anh hng en o nham be
mat, cu the la khi tang ap lc kh nen th o nham be mat tang
gan nh theo quy luat tuyen tnh.
Trang - 91 -

* Anh hng cua kch thc hat mai :
- Th nghiem c tien hanh vi cac hat mai co o hat
36, 100, 120 va 325; Ko = 1:4 va Pc = Pe = 7kG/cm
2
. Ket qua
thc nghiem cho thay khi tang kch thc hat mai (t 325 en
36) th lng kim loai c boc tach tang. Vi ap lc Pc=Pe=7
kG/cm
2
va mat o hat 36, lng kim loai c boc tach ln
hn 4 lan so vi trng hp gia cong bang hat mai co o hat
325. Anh hng cua o hat en lng kim loai c boc tach
c the hien ro khi tang o hat en gia tr 100, neu trc tiep
tang o hat na th anh hng cua chung en lng kim loai
c boc tach yeu dan. V du tang o hat t 100 en 36 th
lng kim loai c boc tach ch tang 1012%.

(a)
(b)
Hnh 2.57 :
Anh hng cua ap lc kh nen en lng kim loai c
boc tach.
a) vi K
0
= 1:4; o hat 100 ; L = 90mm; = 37
0

b) vi L = 100 mm; = 45
0
; K = 1:5; thi gian gia cong la
80 giay
Trang - 92 -
c) Hul muI uung liong cong ngle lIu :
Hat mai dung trong cong nghe tia rat a dang, chung co
thanh phan, o cng, trong lng rieng va cong dung khac
nhau. Bang di ay la mot so hat mai thong dung c dung
trong cong nghe tia.
Ten hat
mai
Thanh
phan
o
cng
Trong
lng
rieng
(G/cm
3
)
Vat lieu gia cong
Thach anh SiO
2
7 2.65 Knh, thep, a, go
a nham Al
2
O
3
va
Fe
2
O
3

8 3.7 Kim loai, knh, go
Cacbit silic SiC 9 3.2 Gang, nhom,
ong, knh
Kim cng
khong ket
tinh
C 10 3.5
Vat lieu gion, cao
su, vat lieu giay
Kim cng
ket tinh
C 10 3.5
Kim cng va cac
loai a quy
Oxit Crom Cr2O3 - -
Thep, thep khong
g
Oxit sat Fe2O3 - 5.2 Kim loai, a, knh
Oxit Magie MgO 4.5 5.8 +
6.9
Thep, knh
Oxit Kem ZnO
Oxit thiec SnO2
Cacbrit bo B4C 10 - Cac loai thep
Ghi chu:
o cng cua hat c xac nh theo 10 cap t 1 en 10,
trong o cap 10 co o cng cao nhat va cap 1 co o cng
thap nhat.
Trang - 93 -
u) MoI liuong clul Iong vu llunl lun cuu uung
ucl lul muI :
- Khi gia cong bang tia hat mai th chat long la moi
trng lien ket cac hat mai. Chat long nay co kha nang truyen
cac hat mai t be cha ti be mat gia cong, giam ma sat gia
cac hat mai vi nhau, loai tr bui ban, lam nguoi va ra sach
chi tiet gia cong, ong thi thay the xch ong hoc cng gia
chi tiet gia cong va dung cu.
- Neu s dung cac cong cu ac biet th chat long co kha
nang tay sach axit va cac tap chat hoa hoc khac tren be mat
gia cong (giam c tnh an mon hoa hoc) ong thi tang kha
nang cat got cua hat mai.
- Thanh phan chu yeu cua dung dch hat mai la nc.
Ngi ta cung a th thay nc bang dau cong nghiep va dau
hoa. Dung dau hoa cho phep nang cao chat lng be mat gia
cong, tuy nhien dung dch dau hoa trang thai phun gay nguy
hiem (co the gay chay no), do o no khong c dung. Con
dau cong nghiep lai co o nht qua cao, lam cho hat mai phan
bo khong eu, do o cung khong nen dung. Dung dch tot hn
ca la emynxi co pha them dau cong nghiep.
- Thi gian x dung cua dung dch hat mai ln hn
nhieu (khoang 10 lan) so vi phng phap gia cong bang phun
hat mai kho. Khi gia cong lien tuc, dung dch hat mai co the
dung c 4070 gi.
e) Clul Iuong he mul llI gIu cong hung lIu lul
muI :
- Chat lng be mat (o nham be mat va tnh chat c ly
cua be mat) la yeu to quyet nh tnh chat s dung cua chi tiet
may. Chat lng be mat anh hng en tnh chong mon va
tnh chong an mon hoa hoc cua be mat chi tiet may, anh hng
en he so truyen nhiet va o ben moi cua be mat lap ghep.
Trang - 94 -
- Gia cong bang tia hat mai cung tao ra c chat lng
be mat vi cac mc o khac nhau.
+ o nham be mat : o nham be mat khi gia cong
bang tia hat mai nho hn nhieu so vi o nham be mat khi gia
cong bang cac phng phap cat phoi hoac phun hat mai
trang thai kho khac. Be mat sau khi gia cong bang tia hat mai
khong nhng co o bong cao (o nham thap) ma con co cac
ho cc nho e cha dau. ieu nay rat co li cho cac be mat
an khp vi nhau.
+ Bien cng be mat va o ben moi : Gia cong bang
tia hat mai cung c s dung e nang cao o ben cua chi tiet.
Sau khi gia cong tren lp be mat cua chi tiet co kha nang xuat
hien ng suat d keo. ng suat d nay co the giam gii han
chay chut t nhng no lai lam tang o ben moi cua chi tiet.
Chieu sau ng bien cua lp be mat khi gia cong bang tia hat
mai co the at t 2050 m (phu thuoc vao ap suat khi nen).
Mc o bien cng co the tang 2025% (so vi kim loai ben
trong). ng suat d nen tren lp be mat co gia tr trong khoang
4050 kG/mm
2
. Gia tr ng suat d nen nay u e gay anh
hng tot en tuoi tho cua chi tiet. Vi che o gia cong thap,
ng suat d nen ch tap trung lp be mat co chieu sau 48
m (ke t mat ngoai cua chi tiet) co ngha la trong vung xuat
hien ng suat ln nhat trong qua trnh lam viec cua chi tiet. V
vay, o ben moi cua chi tiet sau khi gia cong bang phng
phap phun hat mai kho (ng suat nam o sau ln hn). V du
o ben moi cua chi tiet sau khi gia cong bang phng phap
phun hat mai kho tang len 23% (so vi phng phap anh
bong c kh) th sau khi gia cong bang tia hat mai no tang len
36%.
+ Tnh chong mon va tnh chong an mon hoa hoc :
Nhieu thc nghiem cho thay sau khi gia cong bang tia hat mai
th tnh chong mon cua lp be mat co the tang len 50100% so
Trang - 95 -
vi phng phap mai bang a mai hoac nghien. Tnh chong an
mon hoa hoc cua be mat sau khi gia cong bang tia hat mai
cung tang len ang ke so vi phng phap gia cong khac. V
du, khi th mau thep CT3 (c anh bong bang phng phap
c kh) moi trng am vi nhiet o 1820
o
C th an mon la
10%, nhng cung mau thep ay c gia cong bang tia hat mai
th an mon hoa hoc xuat hien sau 334 gi va dien tch be mat
b an mon ch 0,7%. Tnh chong an mon hoa hoc la mot tnh
chat quan trong oi vi dung cu cat, ma phng phap gia cong
bang tia hat mai co the am bao c. V du, thc nghiem oi
vi dao khoan ( trong buong kn co o am 9395% vi nhiet
o 1825
o
C va o am 9597% vi nhiet o 4045
o
C) cho thay
tnh chong an mon hoa hoc cua no sau khi gia cong bang tia
hat mai cao hn cac dao khoan co ranh xoan c anh bong
bang phng phap mai thong thng.
VI. Uu diem va pham vi ung dung :
Cong nghe cat bang tia nc co nhng u iem so vi cat
bang dao kim loai nh sau:
- Dao kim loai sau mot thi cat se b cun, nhng tia nc
th luon luon sac.
- Dao kim loai can phai luon luon hng theo phng tiep
tuyen vi phng cat, nhng tia nc lai khong can nh hng
chnh xac.
- Dung dao kim loai rat kho cat doc theo cac ng cong,
ac biet la ng cong lom con tia nc khong phan biet hnh
dang ng bao.
- Mieng cat cua tia nc rat manh, do o co the tiet kiem
c vat lieu.
- Trong vung cat toa nhiet t, do o khong lam bien dang
vat lieu gia cong. Gia cong c nhng vat lieu rat mem
nhng co cung co the gia cong c nhng vat lieu rat cng.
Trang - 96 -
C s cua cong nghe gia cong bang tia nc ap lc cao la
ong lc hoc cua dong tia ma trong o ap lc ong cua tia
nc la mot yeu to quan trong co anh hng trc tiep en qua
trnh gia cong. Yeu to nay lai b anh hng cua ap lc cua ban
than thiet b, cua khoang cach t voi phun en be mat gia
cong, cua kch thc va hnh dang cua voi phun.
Tuy vay, cong nghe gia cong bang tia nc ap lc cao trong
lnh vc che tao may van con mi me ma nhieu van e ly
thuyet va thc tien cha c giai quyet hoac giai quyet cha
triet e.
1) Mot so u iem khac :
- Gia cong bang tia nc la mot phat minh quan trong cua
cac phng phap gia cong ac biet ca trong nhng ng dung
cong nghiep va trong kien truc, phng phap nay phu thuoc
vao vat lieu, chieu day va o phc tap cua cac ng cat.
- Tao ra li nhuan rat ln neu so sanh vi cac phng
phap gia cong khong truyen thong khac nh: phng phap cat
bang tien hay cat bang tia Plasma, tia Laser, tia la ien
(EDM). Cat bang tia nc co the cat nhng vat lieu tng
chng nh khong the gia cong bang nhng phng phap gia
cong thong thng c.
- Nhng thuan li cua phng phap gia cong nay vt ra
xa s canh tranh ve gia ca so vi ky thuat gia cong khac. Gia
cong bang tia nc cho phep gia cong nhng be mat kho khan
va phc tap nh : nhng goc nam ben trong, khp V, nhng
hnh dang kien truc nghe thuat, co the gia cong vi o chnh
xac ngang hoac cao hn cac phng phap cu. Bi v qua trnh
gia cong nay s dung phan mem CAD do o co kha nang gia
cong va lap lai ma cac phng phap khac khong co.
- Gia cong bang tia nc co the gia cong cac vat lieu tong
hp, nha ma khong gap phai dung sai do nhiet, hoac do s
Trang - 97 -
xuong cap cua cac chi tiet c kh. Khong phai tra chi ph cho
cac dung cu hay khuon mau kem theo.
- Cat bang tia nc la mot qua trnh gia cong lanh va sach
nen loai bo hoan toan cac vung anh hng nhiet, khoi oc,
phan lp khi uc, ng suat nhiet, lp bien cng be mat, s
bien dang cua kim loai...
- Chat lng vet cat rat cao. Vet cat co the bat au bat
ky cho nao ma khong can khoan moi trc va co the cat c
cac vat lieu can mong.
- Co the c dung e cat hoac tao hnh cac bo phan
bang thep, nhom, thuy tinh, cao su, vat lieu tong hp va cac
loai vat lieu khac.
- Co kha nang t ong hoa va ngi may hoa rat cao.
- Di ay la mot so tnh nang ac biet cua phng phap
gia cong bang tia nc :
+ Tnh hieu qua : Qua trnh s dung CAD/CAM va vet
cat rat nho khi gia cong bang tia nc cho phep chung ta s
dung cac vat lieu mac tien mot cach hieu qua nh : Titan, vat
lieu tong hp va cac loai thuy tinh quang hoc. Vet cat hep cho
phep thu c li nhuan toi u do s lap rap co dung sai rat
chnh xac 2,54 mm (0,1 inch) tuy theo loai vat lieu.
+ Tnh linh hoat va nhanh chong xac nh ng bien
cua chi tiet can gia cong : Cac au dung cu cat bang nc t
ong hoa co the cat theo bat ky hng nao, bao am cac hnh
dang phc tap luon luon c cat vi o chnh xac cao.
+ Tnh kinh te : Gia cong tia nc gia cong rat tot vi
nhng vat lieu de gay nh thuy tinh. Vi vat lieu nay khi gia
cong bang nhng phng phap thong thng t le that bai rat
cao. Khong co be mat chu anh hng nhiet hoac b bien dang
thng gap cac phng phap cat got khac. Cac nguyen cong
ke tiep nh la x ly nhiet, mai hoac gia cong lai la khong can
thiet. Hnh dang, kch thc sau cung at c ch sau mot lan
Trang - 98 -
gia cong. Qua trnh gia cong bang tia nc co the san xuat
hang loat do kha nang lap lai cua cac phan mem CAD/CAM.
+ Giam thieu h hong : oi vi cac phng phap gia
cong truyen thong do co ton tai ng suat d cua qua trnh cat
nen cac goc khong the cat c. Nhng vi phng phap nay
cac goc co the cat c tren cac vat lieu de v ma khong lam
v, nt chi tiet. Cat bang tia nc cac vat lieu nh a, gom va
s th hieu qua va sach se hn. Bat ky vat nao ma c ve
tren vi tnh eu co the gia cong bang tia nc. Nhieu vat lieu
nh a, s va thep khong r khong the gia cong thanh cac vat
the phc tap mot cach kinh te bat ky cach gia cong nao
khac.
+ Tan dung toi a : Dong nc dung e cat rat hep
giam thieu be rong cua ng cat, lam tang phan s dung cua
vat lieu. ieu nay co anh hng ac biet en gia thanh khi cat
cac vat lieu at tien nh titan, ong thiec, kevlar, teflon .v.v.
+ Bao ve moi trng : Dung cu cat, nc, cac chat
mai mon vo c co trong t nhien khong lam o nhiem moi
trng trai ngc vi viec s dung laser, plasma, . . . Gia cong
bang tia nc la mot giai phap mang tnh chat moi trng nhat
neu so vi cac giai phap gia cong phc tap khac. Qua trnh gia
cong sach se, khong thai ra cac hat mai, bui bam hoac o
nhiem khong kh bang hoa chat. Phng phap nay mang theo
cac vat lieu an mon, loai bo bui bam, khong gay o nhiem va
xa khoi nh cac phng phap gia cong khac. Dau va nhu tng
boi trn dung cho qua trnh cat khac th khong can thiet cho
phng phap nay.
2) Nhc iem :
Nhc iem chnh cua phng phap gia cong bang tia
nc la kho kiem soat o chnh xac ve kch thc (khi gia
cong cac loai chi tiet) va gia thanh thiet b con cao.
Trang - 99 -
- Tia nc ap lc cao co the c s dung trong cac lnh
vc sau ay :
* Cat t hoac cat nh hnh cac be mat kim loai hoac
phi kim loai.
* Khoan lo bang tia nc ap lc cao.
* ng dung tia nc trong cong nghiep lam sach be
mat.
* ng dung tia nc trong ky thuat ao ng ham.
- Gia cong bang tia nc co the c s dung co hieu qua
vi nhng ng cat hep cho cac loai chi tiet co dang tam
mong lam bang vat lieu nha, vai, composite, gach lat san, da,
tham va cat tong
- Ngoai viec s dung tia nc e cat got cac vat lieu e
at c nhng hnh dang mong muon, ngi ta con s dung
tia nc e lam sach be mat kim loai, cac be mat khac.
- Cac loai vat lieu co the gia cong bang tia nc :
Acrylic, Nhom, Arborite, ong thau, ong thanh, Vai, Tham,
Gom s, Thep can nguoi, ong, Amiang, Delrin, Si thuy tinh,
Vat lieu ma sat, Thuy tinh, Granite, Graphite, Thep can nong,
Inconel 600, Kevlar, Da, Lexan, Linoleum, Magnet, Thep
mangan, a cam thach, Nylon, Giay, Phenotic, Polyester,
Polyurethane, Cao su, Thep lo xo, a, Styrofoam, Thep khong
r dung trong y te, Teflon, Titanium(6AL4V, R2), Thep dung
cu, UHMW (Polythylene), Mica, Li thep, Go, . . . Trong
danh sach nay o chnh xac gia cong la 0,127- 0,254 mm (phu
thuoc vao vat lieu) vi chieu rong vet cat 0,762 - 1,27 mm.
- Gia cong tia nc c ap dung rat rong rai trong cac
nganh, lnh vc khac.
Trang - 100 -
C - PHUONG PHAP GlA CONG
DONG HAT MAl
( Abrasive Jet Machining - AJM )
- Hieu khai niem gia cong bang dong hat mai.
- Hieu, biet nguyen ly gia cong bang dong hat mai.
- Tng minh pham vi ng dung cua phng phap gia
cong dong hat mai.

I. Khai niem :
Gia cong dong hat mai la phng phap boc vat lieu khi dong
kh mang hat mai vi van toc cao tac ong len chi tiet.
- Khong c nham lan phng phap gia cong tia nc co
hat mai la gia cong dong hat mai mac du no cung co mot vai
net tng t gia cong tia nc co hat mai. Kh s dung thng
kho co ap suat t 1,42MPa va i qua voi phun co ng knh
t 0,0751 mm at van toc 2,55 m/s. Kh bao gom nhieu loai
nh khong kh, CO
2
, nit, heli . . .
- Qua trnh thng c ieu khien bi mot ngi, ma ngi
nay trc tiep ieu khien voi phun tai ni lam viec. Khoang
cach ac trng t mieng voi phun va be mat gia cong khoang
t 3,2 en 25,4 mm.
Trang - 101 -

III. HoI so Ihong so cong nghe :
Qua trnh gia cong c thc hien tren nhng vat lieu cng
va gion ( nh thuy tinh, Silicon, mica, ceramic) dang mong
va dep. Nhng hat mai c s dung trong gia cong dong hat
mai bao gom : hat oxit nhom (AL
2
O
3
), silicon carbide va thuy
tinh. Cac c hat co ng knh nam trong pham vi 1540 m
va phai ong eu ve kch thc cho mot lan gia cong. ieu o
rat quan trong trong viec s dung lai nhng hat mai, bi v
nhng hat mai sau khi s dung co the b nt gay va nhiem ban.
IV. Pha m vi ung dung :
Gia cong dong hat mai thng c s dung e gia cong
lan cuoi nh lam sach bavia va anh bong.
Hop hp kh
va hat mai
Van
Tay cam gan
vi voi phun
Tia kh va hat mai
Chi tiet gia cong
He thong hut
Hnh 2.58:
Nguyen ly gia cong dong hat mai
Trang - 102 -
Chng 3
CAC PHUONG PHAP GIA CONG HOA
- Hieu, biet nguyen ly gia cong bang hoa.
- Tng minh phng phap cong nghe, kha nang cong
nghe.
- Biet tng tan cac phng phap gia cong hoa.

I. Nguye n Iy gia cong :
Gia cong hoa la phng phap gia cong khong truyen thong,
trong o vat lieu c tach ra khi tiep xuc trc tiep vi 1 chat
khac hoa manh. Phng phap giac ong nay c ng dung
ngay sau chien tranh the gii th hai, au tien la trong cong
nghe san xuat may bay. Nhieu hoa chat khac nhau dung e
tach vat lieu t 1 chi tiet gia cong bang nhieu cach khac nhau.
Tuy theo yeu cau ma ngi ta ap dung cac phng phap phay
hoa, khac hoa, tao phoi hoa va gia cong quang hoa.
II. Cac phuong phap cong nghe va kha nang cong
nghe :
* Phng phap gia cong hoa gom nhieu bc tuy theo nhu
cau ng dung va dang gia cong ma cac bc thc hien se la :
1) Lam sach :
Bc au tien la nguyen cong lam sach chi tiet e am
bao cho vat lieu c boc i ong eu t mat gia cong.

Trang - 103 -
2) Tao lp bao ve :
Mot lp phu bao ve c ap len 1 so be mat nao o
cua chi tiet. Lp bao ve nay c lam bang vat lieu co kha
nang chong lai tac dung an mon cua chat khac axit. V vay no
se c phu len nhng be mat khongcan gia cong. Nhng vat
lieu cua lp bao ve la Neoprene, Polivinil Chloride va cac
Polyme khac. Lp bao ve co the c thc hien bang nhieu
cach nh : Cat va boc, Khang quang, Khang dung li.
ul Cul vu hoc : Trong phng phap nay, lp bao ve
c phu len be mat chi tiet bang cach ap, sn hay phun
sng vi chieu day khoang 0,025 - 0,125 mm. Sau khi lp bao
ve ong cng lai, ngi ta dung dao cat va boc i lp bao ve
tai nhng vung cua chi tiet can c gia cong. Nguyen cong
cat lp bao ve c thc hien bang tay, dan hng dao bang
mot tam dng mau. Phng phap cat va boc c ap dung
cho nhng chi tiet ln, so lng san pham t vi o chnh xac
khong cao. Phng phap nay khong the am bao sai so nho
hn 0,125.
hl Klung quung : Phng phap khang quang s dung
cac ky thuat chup anh e thc hien lp bao ve. Cac vat lieu
cua lp bao ve nay co cha nhng hoa chat cam quang. Chung
c phu len be mat chi tiet va tiep nhan anh sang qua 1 am
ban cua cac vung can c khac hoa. Sau o ngi ta dung ky
thuat ra anh e boc i cac vung nay cua lp bao ve. Qua
trnh nay se e lai lp bao ve tren nhng be mat chi tiet can
c bao ve. Thng c s dung e san xuat nhng chi tiet
nho so lng ln vi dung sai khac khe, co the nho hn
0,0125mm.
cl Klung llung IuoI : Lp bao ve c sn len be
mat chi tiet gia cong qua mot tam li bang lua hoac mot tam
thep khong r. Gan vi tam li nay la mot khung to,nham
tranh cho nhng vung can khac hoa khong b sn. V vay lp
Trang - 104 -
bao ve c sn len nhng ng dung trung gian gia 2 phng
phap tao lp bao ve kia ve mat o chnh xac, kch thc va chi
tiet san lng, dung sai at c cua phng phap nay la
0,075 mm.
3) Khac hoa :
- ay la bc boc vat lieu. Khi chi tiet c nhung
chm trong dung dch khac hoa, nhng phan cua chi tiet khong
co lp bao ve se b tac ong hoa hoc. Phng phap an mon
thng dung la bien vat lieu gia cong (v du nh kim loai)
thanh muoi hoa tan trong dung dch khac hoa, va do o vat
lieu c boc ra khoi be mat. Sau khi mot lng vat lieu mong
muon c boc i, chi tiet c lay ra khoi dung dch khac hoa
va c ra sach.
- S la chon chat khac hoa phu thuoc vao vat lieu cua
chi tiet gia cong, chieu sau mong muon va toc o boc vat lieu,
cac yeu cau ve o nham be mat. Cac chat khac hoa cung phai
phu hp vi loai chat bao ve e am bao rang vat lieu cua lp
bao ve khong tac ong hoa hoc bi chat khac hoa. Bang 3.1
liet ke mot so vat lieu c gia cong hoa bang cac chat khac
hoa thng dung. Trong bang cung bao gom toc o tham va he
so khac. Nhng thong so nay se c giai thch phan sau.
4) Loai lp bao ve :
Lp bao ve c tach ra khoi be mat chi tiet.
* Hai bc trong gia cong hoa co anh hng ang ke ve mat
phng phap, vat lieu, cac thong so gia cong la bc tao lp
bao ve (2) va khac hoa (3).
* Toc o boc vat lieu trong giac ong hoa thng c bieu
th bang toc o tham mm/phut. La toc o tac ong hoa hoc vao
vat lieu cua chi tiet gia cong, bi chat khac c hng thang
vao be mat. Toc o tham khong b anh hng bi dien tch be
mat. Cac toc o tham c liet ke trong bang 3.1 la cac gia tr
ien hnh cho vat lieu gia cong va chat khac a cho.
Trang - 105 -
Bang 3.1 :
Cac chat khac hoa tng ng vi vat lieu gia cong trong gia
cong hoa
Vat lieu gia cong
Chat khac
axit
Toc o
tham
mm/phut
He so
khac
axit
Nhom
Hp kim nhom
ong va hp kim ong
Magnesium va cac
hp kim
Silicon
Thep trung bnh
Titan
Hp kim Titan
FeCl
3
NaOH
FeCl
3
H
2
SO
4

HNO
3
.HF.H
2
0
HCl.HNO
3

HF
HNO
3
.HF
0,02
0,025
0,05
0,038

0,025
0,025
0,025
0,025
1,75
1,75
2,75
1,0

2,2
2,0
1,0
1,0
* Chieu sau cat trong gia cong hoa co the en 12,5mm cho
nhng tam chi tiet bang kim loai cua may bay. Tuy nhien trong
nhieu trng hp ng dung gia cong hoa, chieu sau yeu cau
ch vai phan nghn mm hay tham ch t hn. Cung vi tac ong
tham vao chi tiet, qua trnh khac hoa cung co the xay ra pha
di mat ben cua lp bao ve. Hieu ng nay goi la hien tng
cat lem va phai c tnh en khi thiet ke lp bao ve e phan
cat phat sinh co kch thuc xac nh c. oi vi 1 loai vat
lieu gia cong cho trc, lng cat lem co lien he trc tiep vi
chieu sau cat. Hang so t le oi vi vat lieu nay goi la he so
khac va c xac nh nh sau :
Fe = U/d
Trong o : Fe _ la he so khac. U _ o dai cat di
(mm), d _ chieu sau cat (mm). Cac kch thc U va d c xac
nh trong hnh ben di
Trang - 106 -

III. Cac phuong phap gia cong hoa :
Cac phng phap gia cong hoa chu yeu la : phay hoa, tao
phoi hoa, khac hoa, gia cong quang hoa.
1) Phay hoa (Chemical Milling) :
- Phay hoa la phng phap gia cong hoa au tien c
thng mai hoa. Trong suot chien tranh the gii lan II, mot
cong ty san xuat may bay cua My a bat au s dung phay
hoa e boc kim loai tao ra cac chi tiet trong may bay. Ngay
nay, phay hoa van con c s dung rong rai trong cong
nghiep hang khong e boc vat lieu canh va cac tam than
may bay nham lam giam bt trong lng. Phay hoa c dung
cho cac chi tiet ln ma trong qua trnh gia cong can boc i mot
lng gia cong kha nhieu. Phng phap cat va boc lp kim
loai bao ve thng c s dung. Ngi ta thng dung mot
tam dng mau e cat va phai chu y en hien tng cat lem
phat sinh trong qua trnh khac hoa.
Hnh 3.1 :
Hien tng cat lem trong gia cong hoa.
Trang - 107 -
- Phay hoa tao nen o nham be mat thay oi theo cac vat
lieu gia cong khac nhau. o nham be mat phu thuoc vao chieu
sau tham. Khi chieu sau tham tang th o nham tr nan toi hn
va gan vi gia tr ln hn cua pham vi cho trong bang 3.2
Bang 3.2 :
o nham be mat gia cong trong gia cong hoa
Vat lieu gia cong o nham be mat (:m)
Nhom va hp kim nhom
Magnesium
Thep trung bnh
Titan va hp kim Titan
1,8 - 4,1
0,8 - 1,8
0,8 - 6,4
0,4 - 2,5

2) Tao phoi hoa (Chemical Blanking) :
- Phng phap tao phoi hoa ap dung hien tng an mon
hoa hoc e tien hanh cat nhng chi tiet kim loai dang tam
mong co o day nho en 0,025 mm hay cat nhng mau phc
tap khac. Trong ca hai trng hp va nhng trng hp ca biet
khac, phng phap dap va ot truyen thong khong lam viec
Hnh 3.2 :
Trnh t cac bc trong phng phap phay hoa
(1) Lam sach chi tiet. (2) Tao lp bao ve, (3) Cat va boc
lp bao ve tai vung can c khac, (4) khac hoa, (5) boc
lp vo bao ve va lam sach be mat san pham.
Trang - 108 -
c v lc dap se lam h hong tam kim loai hay chi ph dung
cu cao qua. Tao phoi hoa tao ra cac chi tiet khong co bavia,
mot u iem hn han cac nguyen cong truyen thong khac.
- Nhng phng phap c s dung e phu lp bao ve
trong tao phoi hoa la phng phap khang quang hay khang
khung li. Phng phap khang quang c s dung cho nhng
mau nho, phc tap va dung sai khac nghiet. Con cho cac
trng hp khac th dung phng phap khang khung li. V
trong tao phoi hoa, kch thc cua cac chi tiet thng la nho
nen ngi ta khong s dung phng phap cat va boc lp bao
ve. Va phng phap e boc lp bao ve nay cung c thc
hien bang chnh nhng phng phap tren.
Hnh 3.3 :
Trnh t cac bc trong tao phoi hoa
(1) lam sach chi tiet, (2) tao lp bao ve bang cach sn
qua khung li, (3) khac 1 phan, (4) khac toan bo, (5)
boc lp bao ve va lam sach san pham.
Trang - 109 -
- Nhng ng dung cua phng phap tao phoi hoa thng
c gii han cho nhng vat lieu mong hay nhng chi tiet phc
tap v nhng l do a neu tren. Chieu day vat lieu ln nhat
khoang 0,76 mm. Tng t, nhng vat lieu c toi cng va
don co the c gia cong bang tao phoi hoa ni ma cac
phng phap c chac chan lam gay v chi tiet.
- Khi dung phng phap khang quang th co the at sai so
0,0025 mm tren vat lieu co chieu day 0,025 mm. Khi chieu
day vat lieu tang len th sai so cho phep cung tang len. Phng
phap tao lp phu bang khang khung li khong c chnh xac
bang phng phap khang quang.
3) Khac hoa (Chemical Engraving) :
- La 1 phng phap gia cong hoa dung e tao ra cac bang
ten, cac tam phang co ch hoac hnh anh minh hoa tren 1 mat.
Nhng tam nay co the gia cong tren may khac truyen thong
hay nhng phng phap tng t.
- Khac hoa co the tao nen nhng tam phang co ch chm
hoac noi bang cach ao ngc cac phan can khac cua tam nay.
Tao lp bao ve c thc hien bang cach khang quang hoac
khang khung li. Trnh t khac hoa dien ra tng t nhng
phng phap gia cong khac, ngoai tr nguyen cong ien ay
tiep theo sau, muc ch ien ay la e tao lp sn hay lp phu
khac tren cac vung chm c hnh thanh khi khac. Sau o tam
nay c nhan chm trong cac dung dch lam hoa tan lp bao
ve, nhng khong tac ong vao vat lieu phu. V vay khi lp bao
ve mat i, lp phu con lai trong nhng vung c khac lam noi
bat mau gia cong.
4) Gia cong quang hoa (Photochemical Machining) :
La phng phap gia cong hoa ma trong o phng phap
khang quang tao lp phu c s dung e gia cong kim loai
khi oi hoi ung sai so khat khe, hay mau phc tap tren nhng
chi tiet phang. Gia cong quang hoa cung c s dung rong rai
Trang - 110 -
trong cong nghiep ien t. e san xuat nhng mach phc tap
tren nhng san pham ban dan. Chnh cong nghe nay a tao
nen nhng mach tch hp qui mo ln (VLSI) trong vi ien t.
Co nhieu cach phi sang hnh anh mong muon. Hnh ve the
hien am ban tiep xuc vi be mat lp bao ve trong qua trnh
chieu sang, o la phng phap in tiep xuc. Cac phng phap in
anh khac cung co the thc hien thong qua mot he thong thau
knh e phong to hay thu nho kch thc cua mau in tren be
mat cua lp bao ve. Nhng vat lieu khang quang thong dung
th nhay vi anh sang cc tm, nhng khong phan ng vi anh
sang co nhng bc sang khac. V vay, neu chieu sang trong
x nghiep at yeu cau th khong can thiet phai thc hien nhng
bc gia cong trong 1 moi trng nh phong toi. Sau khi
hoan thanh gia cong tao lp phu th cac bc con lai giong vi
cac phng phap gia cong hoa khac.
Trang - 111 -
Chng 4
CAC PHUONG PHAP GIA CONG
IEN HOA
- Hieu khai niem gia cong bang ien hoa
- Hieu, biet nguyen ly gia cong bang ien hoa.
- Tng minh ve c s ly thuyet gia cong bang ien hoa.
- Tng minh ve may va dung cu gia cong
- Hieu pham vi ng dung cua gia cong bang ien hoa
- Tng minh cac phng phap gia cong ien hoa.

I. Khai niem :
ay la phng phap gia cong ac trng e gia cong nhng
be mat co hnh dang nhat nh bang phng phap an mon ien
hoa. Dung trong khoan lo ien hoa hay con goi la gia cong
ien hoa, mai ien hoa, lam sach bavia bang ien hoa (hay
anh bong ien hoa). Ban chat cua phng phap gia cong nay
la khong co s tac ong c kh cua dung cu ti be mat gia
cong.
- Phng phap gia cong ien hoa da tren c s nh luat
ien phan cua Faraday. Trong qua trnh gia cong, chi tiet c
noi vi cc dng con dung cu c noi vi cc am cua nguon.
Hai ien cc ieu c at vao trong be ng dung dch ien
phan. Khi ong mach ien va cac ieu kien ien phan hp ly,
Trang - 112 -
dong ien i qua be co tac dung lam hoa tan kim loai anod
vi 1 lng c xac nh theo nh luat Faraday. Lng chat
ket tua hoac hoa tan do ien phan ty le vi lng ien chay
qua.
- Lng cac hoat chat ket tua hoac hoa tan bang lng ien
tng ng, ty le vi thanh phan hoa tr cua chung (vi hp
kim co nhieu thanh phan nguyen to khac nhau).
- Neu ong thi vi s hoa tan anod, ma lay i lp be mat
co ket cau khong con chat che, th o la qua trnh mai ien
hoa. phng phap anh bong ien hoa th chung ta ch tan
dung tac dung ien hoa. Chung ta khong muon lam thay oi
hnh dang be mat, ma chung ta ch gia cong lam mat i nhng
gho ghe li ti tren be mat o ma thoi. phng phap gia cong
ien hoa, tnh chat vat ly cua nguyen lieu lam anod (vat gia
cong) khong anh hng en nang xuat lay phoi, v vay phng
phap nay thng dung e gia cong nhng vat lieu kho cat got.
* Theo nh luat Faraday phng phap gia cong ien hoa
c thc hien nh sau :
Neu dung catod lam khuon co hnh dang gan giong vi lo
ma ta muon gia cong th be mat gan nhat vi catod s hoa
tan anod dien ra manh nhat. Ly do la ien tr suat cua dd ien
phan ln hn cua kim loai. Nh vay dong ien tap trung vao
ien cc nho nhat tc la day co dong ien ln nhat, bang
cach o cc catod dan dan an vao anod.
Trang - 113 -

III. Co so Iy IhuyeI :
1) nh luat 1 Faraday :
m = KIt/F
- Trong o : m - Lng kim loai hoa tan (g); I - Cng o
dong ien (ampe); t - thi gian (gi); F - hang so Faraday, va
la ien lng can thiet e hoa tan 1 ng lng gam cua kim
loai F = 96496 colomb ; K - ng lng ien hoa tc khoi
lng cua chat (tnh bang mg) c giai phong khi co 1 ien
lng colomb i qua dd ien phan.
2) nh luat 2 Faraday :
- Cac ng lng ien hoa t le vi ng lng gam cua
cac chat c giai phong trong qua trnh ien phan. ng
lng gam bang t so gia trong lng nguyen t A va hoa tr
Hnh 4.1 :
S o nguyen ly gia cong ien hoa
Trang - 114 -
n. Vay : K =(1/F). (A/n) vi n v ; [K] = g/A.s ;g/A.ph ;
mm
3
/A.s ; mm/A.s
- Cong thc cua nh luat hp nhat :
m = (1/F). (A/n) . It = K.I.t
- Trong thc te khi gia cong kim loai khong tinh khiet
hoac cac hp kim cua chung gom nhieu hp chat khac nhau (v
du thep hp kim) th ng lng ien hoa cua chung c xac
nh 1 cach tng oi theo cac thanh phan hp kim nh sau :

n
n
2
2
1
1
thep
K
P
...
K
P
K
P
100
K
+ + +
=
Trong o : P
1
, P
2
, . . ., P
n
la thanh phan hp kim trong
kim loai, tnh theo phan tram trong lng ;

K
1
, K
2
, . . ., K
n
la
ng lng ien hoa cua moi thanh phan hp kim trong kim
loai.
IV. Hay va dung cu gia cong :
1) ien cc dung cu catod :
- Vat lieu che tao ien cc phai c che tao bang cac
kim loai co tnh dan ien cao, o ben chong r tot, ien hnh
nh thep khong r, thep chu nhiet, hp kim titan, grafit, . . .
- e tao bien dang cua dung cu co the s dung cac
phng phap sau : gia cong cat got uc chnh xac, ma chat
deo, phun kim loai.
2) Dung dch ien phan :
- Vai tro quan trong cua dung dch ien phan la tao s di
chuyen cua cac tia la ien bang cac ion gia cac anod va
catod. Ngoai ra cac ion cua dd ien phan con tham gia tch cc
vao cac phan ng ien cc. Dung dch ien phan c s dung
e hoa tan lien tuc kim loai cua chi tiet (anod) do o thanh
phan cua no phai c chon ung e tranh kha nang tao cac
chat khong hoa tan gay ra s tr hoa be mat cua chi tiet. V
Trang - 115 -
vay s ton tai cua cac ion hoac cac nhom ion trong dd ien
phan phu thuoc vao cac tnh chat cua no.
Bang 4.1
Cac thong so cua mot so vat lieu dung lam ien cc
Vat lieu
dung cu
Chat cach ien
Chieu day
lp phu
(mm)
ng dung
ong
thau
Men Silicat 0,15 0,2 Gia cong lo,
mat nh hnh
Polypropylen 0,3 0,35
Keo Epoxy 0,1 0,3
Notacryl 0,2 0,5
Tay bavia, gia
cong cac mat
nh hnh va cac
lo co ng
knh ln
Nha Polyuretan 0,1 0,2
Cao su Tectolit 0,5 5
Ebonit 0,5 5
Tay bavia, gia
cong cac be mat
co kch thc
ln
Thep
khong r
Men s 0,03 0,08
M rong cac lo,
ranh hep, lo
nh hnh va lo
sau
Keo Epoxy 0,1 0,4 M rong lo sau
Nhu tng 0,02 0,05
Teflon 0,08 0,2
Hp kim
Titan,
hp kim
chu
nhiet.
Polyclovinyl 0,08 0,2
M rong lo
ng knh nho
- Phan ng ien cc xay ra catod v vay can phai nghien
cu s phong cac ion a nap ien, chung khong oc kiem che
Trang - 116 -
qua trnh hoa tan cac anod. Tren catod khong nen co s ket tua
cac ion kim loai co tren dung dch ien phan v nh vay se lam
thay oi hnh dang cua catod va gay ra sai so hnh dang chi
tiet.
- Do o cac cation cua dung dch ien phan khong c la
kim loai v chung se tao s ket tua tren dung cu (lam bang vat
lieu la thep hoac ong . . .) thong thng cac cation la hidro,
kiem nh natri, kali, . . .
1) Nang suat gia cong :
- Nang suat gia cong c tnh bang lng nguyen lieu
c lay i trong 1 n v thi gian (cm
3
/phut) va t le thuan
vi cng o dong ien. Nh a xac nh theo nh luat
Faraday, toc o tien cua ien cc cung anh hng en nang
suat. Toc o nay la hang so vi dd ien phan thng dung la
NACL, KCL, va NANO
3
va nhiet o dung dch t 90125
0
C.
- Ngoai ra con cac yeu to nh ien ap, kha nang dan ien
cua dung dch ien phan, vat lieu lam ien cc cung anh
hng en nang suat gia cong.
- Tren hnh 4.3 trnh bay moi quan he vi mat o dong
ien va khe h gia dung cu va chi tiet. Khe h nay thng co
gia tr t 0,0750,75 mm, gia tr mat o thng la 2,32 en 3,1
A/mm
2
(15002000 A/inch
2
) va toc o boc vat lieu tng ng
la 16,38 mm
3
/phut/1000A.
- Trong qua trnh gia cong, gia vat gia cong va mat au
cua ien cc ton tai khe h (h).
- Trong trng hp khoan lo cut, th no co anh hng ti
o chnh xac va o sau cua lo. Vi toc o tien khong oi cua
ien cc, th khe h la ham so cua ien ap : U .
e
X
K
h
=
Trang - 117 -

- Trong thc te quan he o thay oi theo o th hnh 4.4.
- Co the thay rang o th khong phai la ng thang do
anh hng cua nhng yeu to khac nhau (nh dong chay). Co
the rut ra ket luan rang, bang cach nang toc o tien ien cc
th co the giam sai so cua khe h, tc la giam sai so gia cong,
tham ch co the nang ien ap len th se lam khe h tr nen
khong oi.
- Dong ien khong nhng ch i qua khe h mat au, ma
ca khe h gia thanh trong cua lo vi mat bao quanh ien
Hnh 4.2 :
Toc o tien cua Catod e va mat o dong S
Hnh 4.3 :
Moi quan he gia khe h gia cong, toc o tien
va mat o dong ien
Trang - 118 -
cc. khe h nay th tac dung ien hoa cua dong ien xay ra
cham hn. Toc o hoa tan t le nghch vi khoang cach gia
cac be mat cua ien cc. Do o trng hp gia cong lo bang
ien cc hnh tru th ng sinh cua lo co dang parabol.

Hnh 4.4 :
Quan he gia ien ap va khoang cach mat au (
h
) cua
ien cc vi toc o tien ien cc (e) khac nhau
( Nguyen vat
lieu gia cong :
thep C45 K=2,2
mm
3
/A. min)
Hnh 4.5 :
Hnh dang cua lo gia
cong bang ien hoa.
e: Toc o tien cc.
: Khe h ien cc.
h: Khe h mat au.
Trang - 119 -
- Kch thc cua khe h tren se la ham so cua o sau lo
nh a trnh bay hnh di ay :

- ay cung nhan thay rang neu tang toc o tien cc th
co the lam giam sai so hnh dang. Sai so hnh dang co the han
che bang cach tao hnh ien cc mot cach phu hp. Neu boc
cach ien chung quanh cho en canh cua mat au th co the
ngan chan s hoa tan mat ben, lo se co ng sinh song
song. Hnh dang ien cc pho bien nh tren hnh 4.7, o,
ng knh ngoai cua ong nha cach ien phai nho e khong
ngan can s lu thong cua dung dch. Ban knh ve tron chu vi
ngoai cua mat au ch la 0,13 - 0,18 mm
- Mat ay cua lo khong bao gi bang phang, ma co u noi
len, neu ta muon lam nhan th can co mot bc gia cong rieng.

Hnh 4.6 :
Quan he gia khe h ( ) vi o sau cua lo (h) vi
cac toc o tien ien cc (e) khac nhau.
Trang - 120 -

- Trng hp gia cong lo co tiet dien thay oi, th khong
dung c ien cc co vo cach ien. ay khoang cach ien
cc phu thuoc rat nhieu vao thong so hnh hoc va cac thong so
khac, do o trong thc te khong the chuan b trc mot ien
cc c tao hnh theo ung kch thc va hnh dang cua lo
can gia cong. Bang thc nghiem ngi ta tao hnh ien cc
phu hp. Phng phap nay kha ton kem, do o ch co trong san
xuat hang loat th mi co hieu qua kinh te. ien cc khong
mon, co the dung e gia cong nhieu lan, o chnh xac cua lo
co the am bao c 0,02 mm.
- Muon bao am at o chnh xac kch thc cao ngi ta
thng loc sach dung dch trong qua trnh gia cong.
Hnh 4.7 :
Hnh dang cua lo c gia cong dien hoa bang ien
cc boc cach ien mat bao quanh.
a: Vat gia cong
b: Dung dch dien phan
c: ien cc
d: Lp cach ien
e: Hng tien ien cc
Trang - 121 -
3) Chat lng be mat :
- o bong be mat khi gia cong bang ien hoa c hnh
thanh rat tot. Neu tang toc o tien cua dien cc va tang cng
o dong ien se lam giam o nhap nho cua be mat, nh vay
o bong be mat rat tot khi c gia cong vi cong suat ln.
ac biet la thep austenit. Vi thep cacbon th be mat tho hn
(R
max
= 510 m). Be mat sau khi gia cong co the anh bong
at R
max
<1 m vi thep khong r, chu nhiet va chu mai mon.
Vat lieu sau khi gia cong van gi c tnh chat cua no, khong
co s thay oi trong cau truc, khong co ng suat d va bien
cng be mat.
VI. Pha m vi ung dung :
- Lng phoi lay i khong phu thuoc vao cac tnh chat c
hoc cua kim loai. Cong nghe nay co tnh kinh te cao trong
trng hp ng dung e gia cong cac vat lieu cng, kho cat
got. Tr mot so kim loai hiem, con tat ca kim loai khac eu co
the gia cong bang cong nghe nay. Cacbon co tac dung kiem
che hien tng ien hoa, do o thep co thanh phan cacbon cao
th t co kha nang gia cong bang cong nghe nay. Gang th ac
biet kho gia cong v co hat grafit. Tng t nh vay vi
carbide cua titan va wolfram. Do o noi chung khong gia cong
ien hoa cac hp kim cng.
- Cong suat trung bnh th co gii han. Con lng phoi lay
c th khong, no tang khi be mat tang, v vay gia cong be
mat ln th co tnh kinh te cao. Khoan sau bang ien hoa ngay
cang c thc hien vi thiet b co nang suat lay phoi cang
ln. Hien nay a co thiet b 20.000 A vi nang suat lay phoi 33
cm
3
/ph, toc o tien ien cc la 12mm/phut va mat o dong
ien 800 A/cm
2
, loai thiet b nay co kch thc ln va cng
vng, v ap suat cua dung dch ien phan len en 10-24 atm,
lc tac dung len be mat vo cung ln.
Trang - 122 -
- o chnh xac gia cong lo rong la 0,02-0,03 mm, o nhan
be mat at Ra
max
= 0, 03 m. Mot pham vi ng dung ac trng
la gia cong lo nho, t 0,3 mm.
- Pho bien nhat la dung gia cong tao hnh khong gian phc
tap bang thep chu nhiet, chu mai mon va thep khong r. V du
ac trng la gia cong canh tuabin.
- Hai dien cc gia cong vi toc o tien cc e = 0,18mm/phut,
cung tien ong thi, va viec gia cong ch mat 5-10 phut. Tren
may mai th thao tac nay phai mat gan mot gi.
- Mot trng hp ng dung ac biet la : ien cc gia cong la
mot ong, c uon theo qui nh, tien theo mot hng nhat
nh, e tao hnh ma khong can lam mon het ca khoang the
tch vat lieu can phai lay i. ien cc la mot ong co se ranh.
Phng phap nay co the gia cong mot cach chnh xac nhng
vat quay oi xng (vat gia cong quay hay ien cc quay),
phng phap nay goi la tien mai bong, ng dung rat thch hp
e gia cong van hnh cau, cac ranh vanh khan . . .
- Trong nhng nam gan ay, cong nghe ien hoa chiem lnh
viec gia cong lo sau, kch thc ng knh nho, nhng ch
kinh te trong san xuat hang loat, oi hoi thiet b co san lng
ln.
- Cong nghe ien hoa ngay nay c ap dung pho bien
cac nc phng tay. Tuy nhien cung co nhc iem la chi ph
ln cho ien cc, may ln co gia tr rat cao. Trng hp gia
cong vi san lng trung bnh th khong u sc canh tranh vi
cat got thong thng.
VII. Cac phuong phap gia cong dien hoa :
1) Mai ien hoa :
- Mai ien hoa la dang ac biet cua phng phap gia
cong ien hoa trong o a mai quay (catod) la mot a mai
hnh vanh khan dan ien co gan cac hat kim cng, hoac
Trang - 123 -
carbid silic hoac co ranh ong, c dung e tang cng s
hoa tan cua be mat kim loai gia cong (anod). Vat lieu dung
cho mai ien hoa la oxt nhom va kim cng. Vat lieu ket dnh
hoac la kim loai (cho hat mai kim cng) hoac la nha tron vi
cac hat kim loai e tao thanh chat dan ien (cho oxt nhom).
Cac hat mai nho ra t a mai tiep xuc vi chi tiet gia cong
hnh thanh nen khe h trong mai ien hoa. Tac dung co xat
cua nhng hat mai cua a mai ngan can qua trnh t kiem che
cua anod. Dong dung dch ien phan i qua khe h gia cac
hat mai e thc hien chc nang cua no.
- Nhng hat mai co hai nhiem vu song hanh. Mot mat
chung la nhng hat cach ien, va quyet nh kch thc cua
khe h (0,02-0,08 mm), bao am s lu thong cua dung dch
ien phan va loai tr kha nang b ngan mach, mac khac chung
ay ra khoi dung dch ien phan lng vat lieu a b boc i va
lp con bam tren vat gia cong. ieu rat quan trong la s lay
phoi la ket qua cua qua trnh ien hoa, va tac dung mai bong
ay cha phai la quyet nh.
Hnh 4.8 :
Nguyen ly gia cong
mai ien hoa
Trang - 124 -
- Phng phap co nang suat cao gap 2 lan so vi phng
phap mai thong thng. Co hai phng phap mai bang ien
hoa :
+ Dung a mai dan ien.
+ Dung a mai trung tnh (khong dan ien).
- Trong trng hp th nhat ngi ta dung a mai dan
ien. Nang suat gia cong cua phng phap co the at 1000
mm
3
/phut. o chnh xac cua kch thc gia cong at cap 2, con
o bong be mat gia cong at cap 7-8, oi khi cap 10-12 (khi
lng d gia cong 0,01-0,05 mm). u iem cua phng phap :
co kha nang mai c bat ky kim loai nao, khong phu thuoc
vao o cng hay o deo va khong co phong ien ho quang hay
tia la ien. Nhc iem cua phng phap : mat o dong ien
ln oi hoi phai co cong suat nguon ien ln va tieu hao chat
ien phan ln. Phng phap nay c dung e mai ranh thoat
phoi tren cac dung cu hp kim cng va mai nhieu loai chi tiet
hp kim cng khac.
Hnh 4.9 :
S o mai ien hoa bang a mai
trung tnh.
1 - a mai khong dan ien
2 - Chi tiet gia cong (cc dng)
3 - Ong cc am
Trang - 125 -
- Hnh 4.9 la s o mai ien hoa bang a mai trung tnh
(a mai khong dan ien). Chat ien phan chay qua ong 3 ti
be mat cua chi tiet 2. a mai trung tnh 1 ch co nhiem vu tach
nhng hat nho kim loai tao ra do phan ng ien hoa t be mat
chi tiec gia cong. Qua trnh mai c tien hanh vi che o sau
ay : ap lc rieng cua a trong khoang 0,5-5 kG/cm
2
, mat o
dong ien 0,5-1,2 a/cm
2
, toc o vong cua a mai 20-30 m/giay.
o chnh xac cua phng phap at cap 2 va o bong be mat
at cap 8-9. Phng phap nay c dung chu yeu e mai mat
ngoai va e mai khuon lo. Phng phap cung co nhng u,
nhc iem nh mai bang a dan ien, nhng chi ph a mai
thap hn va khong oi hoi phai co cng o dong ien manh.
- Phng phap mai bang ien phan chu yeu s dung e
mai sac hp kim cng. Hp kim cng la mot hon hp khong
ong nhat, ma cac thanh phan co trang thai khac nhau oi vi
qua trnh ien hoa chat coban hoa tan va cho ra hai electron.
C
o
2e
-
= C
c
++

- Cac loai carbid kim loai (WC, TiC) trc tien hoa tan
thanh acid kim loai va ch sau o mi hoa tan t anod.
WC + 4H
2
O 8e
-
= WO
3
+ CO + 4H
2

TiC + 3H
2
O 6
e
-
= TiO
2
+ CO + 3H
2
- Toc o hoa tan cua ba thanh phan chnh nay khac nhau.
Coban hoa tan manh nhat, con TiC th hoa tan cham nhat.
- Can co nguon ien ac biet, v s dao ong cua ien ap
va dong ien anh hng rat ln en qua trnh mai. ien ap va
cng o dong ien khong c vt qua tr so cc ai cua
ien ap va cng o dong ien. Nh hnh di ay cho thay
can phai thay oi nh the nao cac thong so cong nghe khi tang
be mat gia cong.
Trang - 126 -

- Dung mot loai may phat ac biet, vi he thong phan hoi
s bien oi ien ap va dong ien e may co the t ieu chnh.
Hnh 4.10 :
ac tnh dong ien ien
ap cua qua trnh mai bang
ien phan
R
S
E
T
Hnh 4.11 :
S o may phat dung cho mai ien phan
T : May bien the; E : Chnh lu; R : Bo phan ieu
chnh;
S : Cac phan t lam bang phang song nhap nho.
Trang - 127 -
- ac iem chung :
+ Nang suat cao.
+ Cac thong so ve chat lng cua be mat c mai :
o bong be mat khi mai bang ien phan rat tot. o nham co
the at ti R
a
= 0,04 m. Hien tng ien hoa ong vai tro
chnh yeu. Do o tren be mat gia cong khong co nhng ng
gan nam theo hng tien cua ien cc gia cong. Cac hat tren
be mat van con nguyen. o bong rat t phu thuoc vao o ln
cua hat mai.
+ Cac thong so khac cua lp be mat giong nh trng
hp gia cong ien hoa. ay khong co ton hao nhiet nhieu,
cung khong co bien oi trong cau truc te vi va cung khong
thay co hien tng hoa cng be mat cung nh khong co ng
suat d ben trong. Do khong co ng suat d, nen ieu nay rat
thuan li cho viec gia cong hp kim cng, co the tranh c
hien tng ran nt khi mai.
+ a mon tng oi nhieu, trung bnh khoang 1015 %
the tch kim loai b tach ra khoi vat gia cong.
+ Mat o dong ien tren mat gia cong thap va do
khong co s tiep xuc cua kim loai vi nhau nen t b ot nong
va ot chay.
+ ien ap thap.
+ o chnh xac ve hnh dang hoan toan phu thuoc vao
o chnh xac cua a mai. Thong thng ngi ta ap chat vat
gia cong vao mat au cua a, nh co ban toa o ma co the
lam chuyen ong vat gia cong, va bao am o chnh xac gia
cong la 0,01 mm.
- Pham vi ng dung va tnh kinh te :
+ Phng phap mai bang ien phan chu yeu ng dung
mai sac cac dung cu bang hp kim cng, thnh thoang chung ta
thay ng dung trong mai mat au, mat phang hoac mat bao
quanh co vat lieu bang vat lieu kho cat got. Gan ay ngi ta
Trang - 128 -
ang th nghiem thanh cong viec mai khuon mat tru trong
bang mai ien phan.
+ Nang suat mai bang ien phan hp kim cng cao hn
nhieu lan so vi mai thong thng. Hnh sau so sanh gia mai
thong thng mai kim cng va mai ien phan ve o bong be
mat va nang suat lay phoi.

+ No cung co nhc iem la thiet b at tien hn, tuy
nhien nhn tong hp th u iem van troi hn. ay la phng
phap tien tien hang au e mai sac dung cu t hp kim cng
re nhat va chat lng cao nhat.
+ S dung trong phng phap mai khon ien hoa, mact
du gia thanh thiet b cao nhng phng phap gia cong nay
nhanh gap 5 lan phng phap mai khon truyen thong, va c
s dung chu yeu trong gia cong hoan tat be mat trong cua
xilanh.
2) anh bong ien hoa :
- La phng phap bo sung cho gia cong ien hoa. Muc
ch cua anh bong ien hoa khong phai la lay phoi ma la
anh bong be mat. Tat nhien co lay i mot chut t nguyen lieu.
Dung cu
a mai SiC
a mai kim
cng
anh bong
(mai bang ien hoa)
o nham m Lng phoi mm/ph
3
1
2 1
0
0,5
1
1,5
Hnh 4.12 :
u the ro ret cua mai bang ien phan the hien tren ca
hai phng dien : o bong va nang suat
Trang - 129 -
Khac vi cac phng phap gia cong ien hoa khac, ay
khoang cach ien cc ln hn, hnh dang cua vat lieu gia cong
se khong hnh thanh giong nh cua ien cc lam dung cu gia
cong, ien cc khong chuyen ong trong qua trnh gia cong,
mat o di chuyen cua dong ien thap hn va toc o di chuyen
cua chat ien phan thap hn nhieu, toc o boc vat lieu cung
giam.
- Trong phng phap anh bong ien hoa vat gia cong
(anod) va ien cc dng (catod) c nhung vao dung dch
mot cach oc lap nhau. Khi co dong ien i qua th s hoa tan
anod bat au, dong ien tap trung nhng iem nho len, con
cho lom la man muoi mong t dung dch ien phan tach ra. Be
mat go ghe dan dan mat i va tr nen nhan bong va ong anh
(goi la ong anh anod).
a
b
c
d
4
4
4
4
c
2
1
Hnh 4.13 :
Qua trnh tr nen bong nhan trong phng phap anh bong
bang ien phan.
a, b, c, d : cac pha tuan t trong qua trnh tr nen nhan bong
Trang - 130 -
- Nguyen ly anh bong ien hoa : Chi tiet gia cong 2 c
at trong be cha chat ien phan 1. Khi noi nguon ien 5 vi
dung cu 3 va chi tiet gia cong 2, nh va ay nhap nho 4, 6 dan
dan c san phang. Ta thay cac ng lc do ien cc tao ra
eu tap trung hng vao cac nh nhap nho 4, do o cac nh
nay c san phang nhanh hn cac ay 6. o bong be mat gia
cong co the at cap 12-13.

- Ba thong so anh hng en qua trnh o la :
+ Mat o dong ien tren be mat c anh bong.
+ Nhiet o cua dung dch ien phan gan phan vat gia
cong.
+ Thi gian anh bong.
- Ngoai cac yeu to tren, con co nhng yeu to khac cung
anh hng en qua trnh gia cong nh : vat lieu cua vat can
Hnh 4.14 :
S o anh bong ien hoa.
1) Chat ien phan
2) Chi tiet gia cong
3) ien cc dung cu
4,6) nh nhap nho tren be mat phoi
5) Nguon ien.
Trang - 131 -
anh bong, thanh phan dung dch ien phan, ien ap gia
catod va anod.
- Vi phng phap anh bong bang phng phap ien
hoa, co the anh bong cac vat lieu bang thep cacbon, thep hp
kim, ong, ong thau, thiec, nhom, niken .v.v. Tat nhien vi
cac dung dch ien phan khac nhau. e anh bong thep th
dung dch 65% acid photphoric, 15% acid nitric, 6% carbid
crom, va 14% nc. Thong thng dung dung dch co nong o
am. Sau khi a thanh thao, hieu k cac tnh chat cua dung
dch, th hay dung dung dch o. Khi dung th dung dch th
cho dan qua dung dch mot dong ien 12 A.gi/lt. Nhiet o toi
u cua dung dch la 70
0
C e anh bong 1 dm
2
th dung mot lt
dung dch qua 6 gi, sau o bo sung e phuc hoi dung dch.
- anh bong ien hoa khong ng dung e sa cha cac
be mat qua gho ghe. o gho ghe c giam nhieu lam cung
ch c 3-4 cap. anh bong ien hoa be mat tho du co tien
hanh trong thi gian dai cung khong lam mat i nhng vet ran
nho li ti va nhng nhap nho tren o.
- Neu sau khi anh bong bang phng phap thong thng
ma tien hanh anh bong bang ien phan, th be mat co kha
nang chu an mon tot va co ng suat chu moi tot, he so ma sat
giam ma khong gay tac hai nao tren be mat. Co the dung
phng phap quang hoc (phan chieu va giao thoa) e kiem tra
o bong.
- e co the gia cong anh bong bang ien phan, be mat
phai that sach, khong co dau m, va ch nh vay mi gia cong
c. Phng phap anh bong ien hoa tien hanh theo qui
trnh nh sau :
+ Lam sach m tren mat gia cong.
+ Lam kho.
+ Phu bang nha perclorvinil tren cac be mat khong
anh bong.
Trang - 132 -
+ anh bong bang ien phan.
+ Lam sach dung dch ien phan con d tren be mat gia
cong bang dung dch trung hoa.
+ Lam sach bang nc lanh.
+ Trung hoa bang dung dch 3% natri cacbonat.
+ Lam sach bang nc nong ang chay.
+ Lu y : lay vat gia cong ra khoi dd ien phan khi van
con ien ap , neu khong be mat se b en.
- Khoang cach gia vat gia cong va ien cc la kha ln.
S hoa tan nguyen lieu xay ra tren moi iem cua be mat,
nhng tren canh th nhieu hn. Cc catod can co hnh dang
sao cho ien trng phan bo ong nhat. Vat lieu ien cc
catod thng la ch.
- Hnh sau co the thay ien cc catod va vat gia cong co
hnh dang mat phang :

+
-
A
V
B
c
Hnh 4.15 :
Cach at ien cc khi anh bong mat phang
B: catod. C: Vat gia cong
Trang - 133 -
- Co the gia cong hang loat nhng vat nho, toc o cua
bang chuyen co the ieu chnh sao cho thi gian a qua dung
dch phu hp vi thi gian gia cong.

- Ngoai ra con co the anh bong mat trong cua lo cung
nh mat ngoai va trong mat tru.
- u iem cung nh tnh chat cua phng phap anh bong
ien hoa :
+ Nang suat anh bong bang 3-4 lan so vi anh bong
bnh thng
+ o bong be mat rat tot.
+ Co the anh bong be mat trong va be mat ngoai co
bat k hnh dang nao.
+ Nang suat gia cong tang ma khong oi hoi nhieu lao
ong bang tay.
+ Thiet b gia cong re va n gian.
+ Chat lng be mat c cai thien hn.
+ Co kha nang anh bong nhng be mat cng.
+ Khong co bien dang va thay oi cau truc lp be mat.
+ Co kha nang t ong hoa c qua trnh gia cong.
Hnh 4.16 :
Gia cong chi tiet nho tren bang chuyen.
a) Be dung dch; b)Bang chuyen; c) Vat gia cong; d)
Dung dch ien phan; e) Mam cap chi tiet gia cong
Trang - 134 -
+ Giam nhe ieu kien lao ong cua cong nhan.
- Nhc iem cua no la :
+ o bong be mat phu thuoc vao o ong nhat cua vat
lieu.
+ Kho gi ung c kch thc va hnh dang cu.
+ Tuoi tho cua dung dch ien phan co han.
+ Ch ap dung oi vi be mat khong qua go ghe.
- Co the ng dung phng phap anh bong ien hoa e
anh bong cac mau kim loai e soi knh hien vi. Hien nay a
che tao c loai thiet b anh bong co the theo doi qua trnh
anh bong qua knh hien vi.
3) Gia cong lo ien hoa :
- Gia cong lo ien hoa hay con goi la khoan ien hoa la
ng dung cua phng phap gia cong ien hoa trong viec khoan
cac lo rat nho bang cach s dung cac dong ien co ap ke cao
va dung dch ien phan axt. Dung cu nh la mot au thuy tinh
co ien cc ben trong. Ngi ta co the s dung mot ong thuy
tinh co nhieu nhanh e gia cong cung mot luc 50 lo. Cong
nghe nay c phat trien e khoan cac lo lam mat trong cac
tua bin cua ong c phan lc. Cac lo khong chu ap suat nay
co ng knh t 0,10,76 mm (0,0040,030 inch) vi t le
gia chieu sau va ng knh lo la 50:1, thong thng c
lam t hp kim nickel va cobal. Axt c dung e kim loai
hoa tan vao dung dch thay v ket tua.
- Phng phap gia cong nay co the c s dung e
khoan cac lo nh hnh lam bang kim loai kho gia cong, dan
ien. Vi cac lo chieu sau en 610 mm va ng knh t
0,51,27 mm th co the gia cong bang phng phap nay.
Phng phap nay co ac iem la dung ien ap 1 chieu thap t
510 volt va cac ien cc ac biet la nhng ong dai, thang,
khang axt c boc ben ngoai bang lp men cach ien. Dong
Trang - 135 -
axt c tang ap i qua ong va tr ve khe h (0,0250,05
mm) nam gia thanh ong va than cua lo.

- Chi tiet gia cong 1 la anod (cc dng) con dung cu la
ong ong 2 (cc am) c boc cach ly vi ben ngoai va c
an xuong chi tiet gia cong lo xo 3. Di mot ap lc nao o,
chat ien phan chay qua ong ong, tao ra khe h nho gia
phoi va dung cu, do o no ay nhng hat kim loai nho (hay
dung dch) cua phoi (cc dng) ra ngoai. Nh vay, lo tren
phoi (chi tiet gia cong) c hnh thanh. Hnh dang cua lo phu
thuoc vao hnh dang cua ien cc dung cu. Khi khe h gia
cac ien cc nho va dong ien phan manh, mat o dong ien
co the at 200300 a /cm
2
, con toc o boc tach kim loai theo
chieu dai ti 6mm/phut. o bong be mat gia cong at cap 8-9,
con o chnh xac gia cong khoang 0,02 mm.
Hnh 11.7 :
S o khoan bang ien hoa.
1- Chi tiet gia cong
2- Ong ong
3- Lo xo.
Trang - 136 -
4) Lam sach bavia bang ien hoa :
- Lam sach bavia ien hoa la 1 phng phap gia cong
ien hoa trong viec tach kim loai trong cac map hay goc cua
chi tiet bang cach hoa tan anod. S o bo tr cua phng phap
lam sach bavia ien hoa c trnh bay tren hnh 4.18. Phng
phap ien hoa rat thch hp cho viec anh bavia cac chi tiet co
hnh dang phc tap.
- Co hai cach lam sach bavia bang ien hoa :
+ anh bavia trong be ien phan : Cach nay giong anh
bong ien hoa, li dung hien tng ien trng tap trung
nhng canh goc, ay mat o ien ln nhat, nh vay vat lieu
c lay i nhieu nhat va nhanh nhat nen bavia c lay i
nhanh chong. Bavia nhng be mat khong b che lap cung b
lay i nhng vi mc o nho hn nhieu. Vi Bavia cao t 0,2
en 0,3 mm th co the tay hang loat, nang suat sao. u iem
noi bat la co the tay bavia tren be mat phc tap co hnh dang
bat ky.
+ anh bavia tren thanh pham : Cach nay co nang suat
cao hn 34 lan so vi cach tay bavia tren be mat ien phan.
ien cc dung lam dung cu tay bavia c noi vao cc am vi
hnh dang c cau tao sao cho khi at no doc bavia th se tao
ra 1 khe h nho. Dung dch ien phan c phun qua ranh o
vi toc o chay ln lam mat bavia 1 cach nhanh chong.
- Cach th 2 nay phc tap hn cach th nhat, phai sau 34
nam mi thu hoi c von mua thiet b. gan cac canh a tay
bavia thay co mau sam do o co oxt hoa, nhng tnh chat be
mat khong b anh hng g o khong can thiet phai tay i. Ca
hai cach tay bavia eu co the ng dung rong rai trong san xuat
t ong hoa.
Trang - 137 -
Hnh 4.18 :
S o lam sach bavia
A : Tay bavia tren rang
B: Tay bavia tren be mat rang
1. Dung cu tay bavia
2. Banh rang
3. em
4. Dong ien phan
Trang - 138 -
Chng 5
CAC PHUONG PHAP GIA CONG
NHIET
A - PHUONG PHAP GlA CONG TlA LUA lEN
( Electric Discharge Machining - EDM )
- Hieu khai niem gia cong bang tia la ien.
- Hieu, biet nguyen ly gia cong bang tia la ien.
- Tng minh ve c s ly thuyet gia cong bang tia la
ien.
- Tng minh mot so cong nghe gia cong bang tia la
ien.

I. Khai niem :
Phng phap gia cong tia la ien la phng phap phong
cac tia la ien len be mat vat lieu gia cong, lam cho lp vat
lieu can ht i b nong chay hoac boc hi bi mot qua trnh
ien nhiet.
II. Co so Iy IhyeI :
- at gan nhau hai ien cc trong moi trng cach ien, noi
hai ien cc vi ien ap mot chieu, th gia chung co ien
trng. Khi ien ap c tang len, th t be mat am cc co
ien t phong ra, tiep tuc tang ien ap th khoang cach gia
Trang - 139 -
hai ien cc se ion hoa, dong ien chay qua, tc la khoang
cach o tr nen dan ien. Hien tng nay goi la s anh thung
ien, vat b ion hoa goi la kenh dan ien. Dong ien tiep tuc
chay chng nao ien ap cha at en tr so bang tr so tat,
o qua trnh phong ien khong duy tr c na. Neu c
cung cap tiep nang lng, th dong ien duy tr en bat ky thi
gian nao. ay la trng hp co ho quang ien. Thi gian cua
qua trnh tia la ien rat ngan : t 2.10
-4
en 4.10
-4
giay.
- Hai hien tng tia la ien va ho quang ien rat khac nhau
ve tac dung. Khi co ho quang ien nhiet o 2000-5000
0
C, con
khi co tia la ien th nhiet o co the at en 12000
0
. Kenh
dan ien tia la ien nap hn nhieu so vi ho quang ien.
Mat o dan ien trong kenh dan ien co the at en 10
6

A/cm
2
. Tac dung an mon cua tia la ien tap trung hn, con ho
quang th an mon tren b rong, khong ong eu, kho eu
chnh, kho nh hng.
- e co the lam phat sinh tia la ien, mot ieu khong the
thieu c la sau mot thi gian ngan khi a co dong ien chay
qua th phai ngng cung cap tiep nang lng. e thc hien yeu
cau nay th phai dung may phat xung. n gian nhat la bo
phat xung RC cung cap xung rang ca. Hoat ong cua no nh
sau: ien ap cung cap U
0
qua ien tr R nap ien cho tu C.
Khi ien ap cua tu tch len en U
0
bang ien ap moi tia la
ien, th qua trnh phong ien bat au va duy tr cho en luc U
0

giam xuong tr so ien ap tat. Sau o tiep dien lai qua trnh
nap ien cho tu va tiep dien lap lai nh trc. Thi gian nap tu
xac nh bang thi hang T
1
= RC. Thi gian phong ien rat
ngan v tr so ien tr nho hn nhieu.
- Chu ky phong ien T gom co hai giai oan :
T = T
1
+ T
2

+ T
1
: La thi hang khi tu nap.
+ T
2
: La thi hang khi tu xa.
Trang - 140 -

- Bat au nap tu la thi iem dong ien tang cao ot bien.
Cuoi chu ky th qua trnh ion hoa cham dt. Nhng phan t
c sap xep lai, ien c phan bo eu. Neu thi gian tai tao
ngan hn thi gian can thiet e nap tu (T
2
) th qua trnh phong
ien se duy tr lien tuc, va ho quang sinh ra. e tranh hien
tng nay, th phai la chon mot cach thch hp t so gia ien
ap U
0
va ien dung cua tu, ong thi chon dung dch cach ien
mot cach hp ly.
- Tia la ien an mon be mat ien cc. T lau ngi ta a
nhan biet hien tng nay, v tia la ien lam huy hoai tiep
iem cua nhng may cat ien.
- Cap v chong ngi Lien Xo, Lazarenko, a tm c cach
ieu khien tia la ien e ng dung trong cong nghiep. Mot
ac iem cua s an mon la tren ien cc dng xuat hien
nhieu lo lom ln hn va nhieu vat lieu b lay i hon ien cc
am. Nang lng cua tia la ien trong thi gian phong ien T
2
,
Mo Ta Qua Trnh Nap Va Xa Tu
u i
i2
u 0
u1
u2
i /ph/
i1
T
T
2
T
1
Hnh 5.1 :
Mo ta qua trnh xa va
nap tu
Trang - 141 -
va cac tnh chat vat ly cua ien cc va cua chat cach ien anh
hng ln en tac dung nay.
- Bang ly thuyet ien - nhiet, do Zolotch phat trien, chung
ta co the giai thch hien tng tren, ma noi dung c ban co the
tom tat nh sau :
Tia la ien co the phan chia thanh 6 pha :
a) Do tac dung cua ien trng gia hai ien cc, ien t
phat ra t catod va gia toc, chay ve anod.
b) Do dung dch b ion hoa, vang quang ien t hnh
thanh, chung quanh no co nhng bot kh vi ien tch dng
bao boc.
c) am bot kh do co cha ien tch dng nen lam thu
hep dong chay cua ien t.
d) Tia ien t tap trung i en be mat anod.
e) Tu ien xa ien. ien tr cua kenh dan rat nho do o
ma cng o cua dong ien len en hang chuc ngan ampe (tr
so nh), ton tai trong thi gian rat ngan. Dong ien xung lam
nong chay anod trong pham vi be mat c gii han, va lc
ien ong lam ban nhng giot kim loai vao bot kh, o do
nhiet cao ma chung no ra.
f) ien ap cua tu can bang. Bot kh nguoi i, bien thanh
giot dung dch, s tai sinh ien tch c xay ra. ong thi vi
qua trnh tren, nhng ion mang ien tch dng vi nang lng
nho hn nhieu chay ve pha catod, va chung cung an mon ien
cc vi mc o t hn. (Xem tren hnh 5.2 tr so am cua U
0
va
i
2
)
- Ngoai nhng tac dung neu tren, nhieu tac dung khac cung
tac ong en qua trnh an mon cua tia la ien, v du nh lc
ien tnh, dong ien, qua trnh hoa hoc do nhiet, lc t, s
phong ien t do nhiet.
Trang - 142 -

III. Nguyen Iy gia cong :
- Nguyen ly gia cong tia la ien (EDM) hay an mon ien la
s an mon kim loai bang tia la ien. Trong gia cong bang tia
la ien, dung cu va chi tiet la hai ien cc, trong o dung cu
la Cathod va chi tiet la Anod. Hai ien cc nay c at trong
dung dch cach ien luon co cac ion di chuyen t do. Di anh
hng cua dong ien mot chieu co tan so 50500 kHz, ien ap
50300 V va cng o dong ien 0,1500 A gia hai ien cc
co ien trng. Khi ien ap tang len th t be mat am co ien
t phong ra, tiep tuc tang ien ap th chat long gia hai ien
cc b ion hoa lam cho khoang chat long o tr nen dan ien.
Hien tng nay goi la hien tng anh thung ien, vat b ion
hoa goi la kenh dan ien. Dong ien tiep tuc chay chng nao
ien ap cha at tr so bang tr so tat, o qua trnh phong
ien khong duy tr c na.
- Thi gian cua qua trnh phong tia la ien rat ngan t
2.10
-4
en 4.10
-4
giay. Khi co tia la ien, nhiet o co the at
12.000
o
C, mat o trong kenh dan ien co the at en 10
6
Hnh 5.2 : Qua trnh hnh thanh s phong tia la ien
Trang - 143 -
A/cm
2
. e co tia la ien lien tuc th sau mot thi gian ngan
khi dong ien chay qua, phai ngng cung cap nang lng. Yeu
cau nay c thc hien nh mot may phat xung RC n gian.
Nguyen ly hoat ong cua no nh sau : ien ap cung cap U
o

qua ien tr R nap cho tu C. Khi ien ap cua tu tich len en U
o

bang ien ap moi tia la th qua trnh phong ien bat au va
duy tr cho en luc U
o
giam xuong tr so ien ap tat. Sau o
tiep dien lai qua trnh nap ien cho tu va lap lai nh trc.
- Do thi gian phong ien ngan (khoang 10
-4
en 10
-8
giay)
nen nhiet truyen ti chi tiet gia cong t va khong sau chu yeu
tap trung tren be mat vi nhiet o rat cao lam chay va boc hi
kim loai trong vung nay. Phoi cua qua trnh gia cong la cac got
kim loai b tach khoi cac ien cc va ong ac lai thanh nhng
hat nho dang hnh cau. Khi cac hat b ay ra khoi vung gia
cong, khe h gia hai ien cc ln len va s phong ien khong
con na. e tiep tuc gia cong can ieu chnh hai ien cc lai
gan nhau va qua trnh tren c lap lai lien tuc.
- Trong qua trnh gia cong co s an mon ca hai ien cc
(chi tiet gia cong va dung cu) nhng s an mon nay khong oi
xng. Bang cach la chon cac thong so nh : o phan cc, tnh
dan nhiet, nhiet o nong chay cua vat lieu, thi gian keo dai
cng o xung ien mot cach thch hp ta co the at c o
mon 99,5% cho ien cc chi tiet va 0,5% cho ien cc dung
cu.
Hnh 5.3 :
S o nguyen ly gia
cong tia la ien.
Trang - 144 -
IV. Dung cu va IhieI bj :
Mot he thong gia cong tia la ien bao gom ien cc dung
cu va ien cc chi tiet c noi vi dong ien mot chieu, c
at trong dung dch cach ien va c ieu khien bang chng
trnh so.
1) Thiet b :
* May gia cong tia la ien thang ng (Vertical EDM
Machine) la may gia cong co ien cc chuyen ong. Khe h
gia chi tiet va dung cu c ieu chnh nh ong c servo sao
cho khe h gia dung cu va chi tiet luon khoang 0,010,02
mm. Hnh dang cua chi tiet c quyet nh bi hnh dang cua
dung cu. Loai may nay thch hp gia cong cac be mat nh
hnh, khoan lo thong va khong thong, gia cong cac loai khuon
mau.
- May tia la ien lam viec tren c s s dung nang lng
cua tia la ien c phong ra trong thi gian rat ngan
(24)10
-4
s e gia cong cac lo co nhieu hnh dang khac nhau.
Nguyen ly lam viec cua no c trnh bay tren hnh 5.4. e
gia cong lo tren chi tiet 1, no can nhung vao thung dung dch
cach ien 2 va noi vao ien cc dng cua nguon ien mot
chieu F (hnh 5.4a) lam chc nang cc anod. Dung cu cat 3 la
cc catod c noi vao cc am va lap vao can trt 4 co the di
ong len xuong. Neu can 4 a dung cu cat 3 cham vao chi
tiet 1, th se co dong ien chay t cc am cua may phat F sang
cc dng qua bien tr R uo lam thanh cuon t day kim loai
mong. Thay oi gia tr ien tr R se ieu chnh c cng o
dong ien va co the kiem tra bang ampe ke A. e tao c
cac xung ien ke tiep nhau, gia ien cc 3 va chi tiet 1 ta lap
song song mot tu ien C. Neu cong tac Ct ong lai khi hai ien
cc tach ri ra, th trong thi iem au dong ien c ch ra
ampe ke A giam nhanh xuong bang 0. Trai lai volt-ke V ch
ien ap tang dan en gia tr do may phat tao ra la U
0
(hnh
Trang - 145 -
5.4b). ieu o co ngha la tu C a nap ien. Neu gia hai ien
cc co mot khoang cach phu hp th, s phong ien se xay ra.
Luc o, tat ca nang lng tch luy trong tu ien eu c
phong ra qua khoang cach gia hai cc. Lng d tr cang ln,
lng an mon ien tren anod (tren chi tiet gia cong) cang ln.
- Sau khi phong ien dong ien gia ien cc va chi tiet
giam en 0, v toan bo nang lng tch luy trong tu ien eu b
tieu tan het. Viec nap ien vao tu C lai bat au, qua trnh tren
lai tiep tuc, cac xung ien xuat hien ke tiep nhau e thc hien
qua trnh gia cong. Trong thi gian gia cong, ien cc 3 khong
c tiep xuc vi chi tiet 1, v neu khong, se xay ra ngan
mach. Gia chung phai luon gi mot khe h nhat nh goi la
khoang cach phong ien. e at c ieu nay, ngi ta dung
nhieu bo ieu chnh t ong khac nhau, trong o bo ieu chnh
n gian nhat la dung ong day 5 lap pha tren can trt 4
(hnh 5.4c). Ben trong ong day 5 co loi sat cung di ong vi
can trt. Hai au cua cuon day c lap hai pha cua bien tr
R.
Hnh 5.4 :
Nguyen ly lam viec cua
may tia la ien
Trang - 146 -
- Khi ien cc 3 cham vao chi tiet 1, mach ien cua may
b ong lai va mot dong ien xuat hien ben trong mach. Khi
hai au cua ong day 5 co chenh lech ien ap, dong ien cung
xuat hien cuon day lam loi sat trong ong b nhiem t, keo
no vao ben trong ong va cung keo can trt 4 mang ien cc 3
i len pha tren. Khoang cach phong ien gia ien cc va chi
tiet c khoi phuc, dong ien trong mach ien cc bien mat
va dong ien trong mach ong day cung mat theo. Loi sat ben
trong ong day b kh t, khong b hut vao ong va t di ong
xuong, di tac dung cua trong lng rieng. Cung vi no can
trt 4 mang ien cc cat 3 cung di ong xuong di. Gia
ien cc va chi tiet gia cong lai xay ra phong ien. C the tiep
tuc cho en khi nao lo khoet c thc hien xong. Cuon day
ieu chnh 5 c tuan t t ong ha ien cc 3 cho en het
chieu sau can cat. Neu nh ien cc 3 c coi nh dung cu
cat, th cuon day 5 giong nh c cau chay dao.
- Tuy theo yeu cau, ien cc 3 c che tao co bien dang
giong nh lo can gia cong. Neu ng knh lo ln hn 6mm,
ien cc can lam rong. Vat lieu ien cc thng dung la ong
thau.
* May tia la ien van nang : May tia la ien van nang
thng co cau truc giong nh hnh 5.5. Cac c cau may c
at ben trong cua than 1. Tren song trt 2 cua than may lap
ban dao doc 5 va ban dao ngang 6 di ong tren song trt cua
ban dao doc. Ban may 3 lap chi tiet gia cong 9 c at trong
chau ng dung dch 4 co the di ong theo chieu thang ng
nh ong c ien Bo ieu chnh t ong lng chay dao 7
truyen chuyen ong thang ng cho ien cc 8. Khi gia cong
lo cong, ban dao 5 am bao cho ien cc 8 co the quay quanh
truc nam ngang A (hnh 5.5b). Trong trng hp nay ien cc
8 c hnh thanh theo dang cung tron, co ng knh bang vi
ng knh cung tron lap ien cc tren gia kep 10. Gia kep
Trang - 147 -
nay co the quay quanh truc A nh day 11 co au tren lap vao
bo ieu chnh 7.
Hnh 5.5 :
May gia cong tia la ien
2- ien tr
3- Tu ien
4- Bo ieu chnh lng chay dao
5- ien cc dung cu
7- Be cha dung dch va cho tiet gia cong
8- o ga
9- ong c ien
10,11- Cac au day.
Trang - 148 -

* ay chung ta khong co ieu kien vao chi tiet cac thiet b
gia cong tia la ien. Chung ta cung can noi them rang ngoai
thiet b ma chung ta lam c s e ban luan la loai may phat
xung kieu RC, th con co nhieu loai thiet b khac co the tao ra
tia la ien. Bang nhng nguyen ly khac nhau nhng thiet b
o tao ra xung dong ien. Chung ta phan lam hai loai : may
phat ieu chnh phu thuoc va may phat ieu chnh oc lap.
- May phat xung ieu chnh phu thuoc la loai may ma
dong ien va ien ap khong the ieu chnh oc lap vi nhau.
Hnh 5.7 trnh bay s o cau tao cua loai thiet b nay, ay Z
la khang tch ien, Z
o
la khang tch tr nang lng, Z
1
la khang
phong ien, chung co the gom nhieu cuon cam hoac ien tr
to hp, tuy o ma tnh chat cua may phat khac nhau. Nguon
ien ap cung cap co the la mot chieu, hoac xoay chieu.

Hnh 5.6 :
Hnh dang chung cua may tia la ien van nang
Trang - 149 -

Hnh 5.7 :
S o nguyen ly chung cua may phat xung
ieu chnh oc lap.
Hnh 5.8 :
S o nguyen ly may phat xung
Hnh 5.9 :
S o nguyen ly may phat
xung ong c may phat
Trang - 150 -

- may phat ieu chnh oc lap, th cac thong so ien co
the ieu chnh oc lap vi nhau. Co 3 kieu nh sau :
+ kieu bo oi noi (hnh 5.8) co may bien the xung
tao ra xung vuong, theo chu ky cat dong ien cua bo oi noi.
+ Kieu ong c may phat (hnh 5.9) th co ong c quay
may phat xung, cung tao ra xung vuong. Nang suat gia cong
rat tot.
+Kieu may phat phat bang en ien t (hnh 5.10)
dung trong gia cong chnh xac.
- Chau Au may phat loai ieu chnh phu thuoc c s
dung rong rai. Nhng tren the gii th ngay cang chiem lnh v
tr s dung la loai ieu chnh oc lap.
* Gia cong tia la ien con oi hoi cong nghe ac biet va
nhng thiet b ac biet khac. ay chung ta khong co ieu
kien i vao chi tiet. Nhng can noi mot ieu la e am bao o
chnh xac v tr cua lo can phai am bao o song song cua ien
cc va hng chuyen ong, am bao v tr ga lap cua vat gia
cong c chnh xac s chuyen dch vat gia cong chnh xac, va
v tr ga lap tng oi vi nhau gia dung cu gia cong va vat
gia cong. e giai quyet nhiem vu th nhat, ngi ta thng
Hnh 5.10 :
S o nguyen ly may phat xung bang en ien t.
Trang - 151 -
cau tao mam cap cho thiet b khoan va gia cong bong nh tren
hnh 5.11. e ga lap vat gia cong th mot th du tren hnh 5.12
co the giai quyet c. Co the ieu chnh cua vat gia cong
bang cach dung ban toa o nh tren hnh 5.13.b Chau ng
dung dch co the thao lap c. e co the xac nh v tr cua
dung cu va vat gia cong th co the dung nhng phng phap
nh trong cat got c kh.
Hnh 5.11 :
Mam cap cho thiet b
khoan tia l ien
Hnh 5.12 :
o ga lap khi gia cong tia la ien.
Trang - 152 -

2) Dung cu :
- Trong gia cong tia la ien, dung cu (ien cc) ong vai
tro cc ky quan trong v o chnh xac gia cong mot mat phu
thuoc vao o chnh xac cua ien cc. ien cc thng c
gia cong bang cac phng phap : cat got, uc (uc chnh xac),
ep, phun kim loai, ma ien phan . . . Vat lieu lam ien cc
phai am bao cac yeu cau :
+ Co tnh dan ien tot.
+ Nhiet lng rieng ln.
+ Co nhiet o nong chay cao.
+ Co tnh dan nhiet tot.
- Vat lieu lam ien cc thng la: ong o, ong thau,
bac hay kem.
- Khi gia cong bang tia la ien hnh dang va ien cc
c sao chep qua vat gia cong. ieu nay ch co the gan ung
v ien cc b hao mon, v vay mot phan viec quan trong nhat
khi thiet ke cong nghe la xac nh kch thc cua ien cc.
Di ay chung ta ch ban en ien cc khoan va khoan lo e
lap rap.
Hnh 5.13 :
Ban toa o
Trang - 153 -
* KIcl lluoc lIel uIen cuu dIen cuc :
Tren c s gia cong th phai chon ien cc co kch
thc nho hn lo can gia cong : D
e
= D
io
- 2
Cung co the s dung phan chay cua khuon dap e lam
ien cc, neu kch thc can thiet cua khe h bang vi khoang
cach tia la ien. Ke ca o con cua lo cung co li, neu chung
ta bat au gia cong t mat di cua khuon dap.
Kha nang chu tai cua ien cc phu thuoc vao vat lieu,
hnh dang cua ien cc.
Tiet dien tron nho nhat cua ien cc co the dung tren
may Erosimat C30.
N
4
N
3
N
2
N
1
S
5
S
4
S
3
S
2
S
1
ong Thau 1500 600 400 200 50 - - - -
Zamar 1500 600 400 200 50 - - - -
ong o 500 200 140 70 15 5 1 2 1
Thep - - - - - 50 12 7 5
* Clon clIeu uuI dIen cuc :
Trong trng hp gia cong lo thong va cut th chieu dai
ien cc c chon theo cach khac nhau.
+ Trng hp gia cong lo suot : e co the am bao c
kch thc tiet dien th au ien cc phai vt qua lo. Chieu
dai hu ch cua ien cc gom 4 oan :
I. oan b mon hoan toan.
II. oan c lam to len dan dan.
III. oan co tiet dien khong b giam nhng co tham
gia trong qua trnh gia cong (co hi kim loai ngng ong tren
be mat)
IV. oan con nguyen.
Chieu dai cua phan nhu ra khoi lo : l
t
= C. l
m
= a.
100
. l
m

Trang - 154 -

Quan he ve kch thc : He so nhu ra cho ta biet cach tnh
c oan nhu ra bang phan may cua chieu dai cua vat gia
cong l
m
. He so nay phu thuoc vao o hao mon tng oi cua
ien cc, kch thc cua vat gia cong, cung nh hnh dang cua
no, c bieu hien bang he so hnh dang a. Tr so cua a bien
thien t 3 en 8, v du: ien cc tiet dien tron a = 3. Chieu
dai an toan l c chon khoang 10% - 20% cua l
t
. e thiet ke
can biet tr so . Neu khong co tr so nay, th co the dung theo
phng phap gan ung ma s dung co ket qua, phac hoa tren
hnh 37. ng dung trong trng hp lam nhan vet ien cc
ong hoac bang thep, trng hp gia cong tho vi ien cc
ong thau.
oan ien cc e ga lap co the viet : L
SZ
= l
b
+ l
c
+ l
m
l
Tuy theo cach ga lap, tr so l
b
c chon t 1530 mm.
Tr so l
c
ln hn chieu cao cua mieng chau 13mm.
Hnh 5.14 :
Chieu dai cua mot thanh ien cc
Trang - 155 -

+ Trng hp gia cong lo cut : Khong the khac phuc s
meo mo do ien cc b an mon bang cach cho ien cc nhu
them. Do o phai cau tao ien cc sao cho khi gia cong en o
sau can thiet th cung co c lo can thiet. Hien nay cha co
nhng hieu biet chnh xac ve van e nay. Do o phai dung
nhieu ien cc tiep nhau e gia cong en o sau giong nhau,
Nhng ien cc nay lay i so lng vat lieu giam dan theo t
le can bac may cho en luc at c lo bong can thiet.
Viec xac nh so lng ien cc can thiet la quan trong.
Trng hp gia cong bong co hnh dang phc tap, th ay la
viec kho khan ac biet, v hnh dang cua bong cung anh hng
en o mon cua ien cc. Co the tien hanh gan ung nh sau :
Chung ta phan tch bong co hnh dang phc tap thanh nhng
khoi hnh ch nhat. Co the xac nh rang gia cong khoi nao th
Hnh 5.15 :
Mot so hnh dang cua ien
cc gia cong lo suot
Trang - 156 -
ien cc b mon nhieu nhat. Thong thng khoi o sau nhat.
Neu hnh khoi ti han nay ma c gia cong chnh xac, th
nhng khoi khac phai c gia cong chnh xac hn. Neu tren
be mat con co iem cc ai khac ma lai hep hn, th o co
hnh khoi ti han va o la c s tnh toan cua chung ta.

Da vao hnh sau ay, chung ta hay xet cac moi quan he :
Hnh 5.16 :
Gia cong lo cut bang nhieu ien cc lien tiep nhau
Hnh 5.17 :
Phan tch nhng bong phc tap thanh nhng khoi ch nhat
Trang - 157 -

ay h la chieu sau ln nhat cho phep va t la dung sai
cua no. ien cc i tren oan ng h va gia cong c chieu
sau m
l
. o giam cua chieu dai :
l
1
= h m
1
Vi hao mon trung bnh () cua ien cc th :
c
1
= . m
1

o :

100
=
T o ta co the viet :
h = m
1
(1+) (1)
Tc la :

+
=
1
1
h e
1

oi vi ien cc th hai, chieu dai con lai cua hnh khoi
la :

+
=
1
1
h e
1

Nhng trong qua trnh gia cong ien cc cung b mon vay
ch gia cong c bong nho hn.
T (1) co the viet :
Hnh 5.18 :
Moi lien he cua mot so kch thc lien quan en
ien cc
Trang - 158 -

+
+
=
+
=
1 1
1
h
1
1
1 m
1 2

Nhng oan c gia cong tiep nhau bang nhng ien cc
tao nen chuoi so hnh hoc :
...
1 1
1
h
1
1
h ... m m
2 1
+
+
+
+
+
= + +
Thng cua day so la :

+
=
1
q
ieu nay co ngha la kch thc chnh xac ch co the gia
cong c bang vo so ien cc. Trong thc te th chung ta
muon gia cong kch thc h vi gii han cua dung sai t nh vay
so ien cc t hn va va u.
Tong cua chuoi so co n so hang la :

1 q
1 q
m S
n
1 n
= (2)
Dung sai gia h
n
va S
n
la t :
h t = S
n
(3)
Thay the cac so hang vao (2) va (3), sau khi sap xep co,
co :

n
1 h
t
=
Ngha la co the xac nh lng ien cc, n :
+ 1
log
log
h
t
n
Viec tnh toan phc tap, thay vao o e n gian viec tnh
toan ngi ta dng nhng toan o.
Neu bong kn co mat sn la nhng canh song song, th
co the gia cong bang ien cc dai qua n bc, neu tng luc
chung ta sa ien cc co dang nh cu.
Trang - 159 -
* Vul IIeu dIen cuc :
Viec la chon hop ly vat lieu ien cc la mot yeu to quan
trong. ieu nay khong nhng ch anh hng en o chnh xac
gia cong, ma con anh hng en tnh kinh te thong qua nang
suat va o hao mon ien cc trung bnh. Gia cua ien cc co
the chiem 80% cua chi ph gia cong.
Co the thay nang suat va o mon trung bnh cua ien cc
bang hp kim ong grafit trong trng hp gia cong tho tren
thep hp kim Cr-Ni-Mo-V. Nhng tr so nay ch la nhng ch
so hng dan, v thong so cua may cung co anh hng rat ln.

Trong trng hp gia cong hp kim cng th o mon se
ln hn, co the thay tren o th hnh 5.20.
Tren thc te, khong co vat lieu nao co the thoa man ay
u nhng yeu cau at ra cho vat lieu lam ien cc, do o can
phai co s nhan nhng khi chon. Thong thng khi gia cong
tho va gia cong tinh, ngi ta dung cac vat lieu ien cc khac
nhau. Khi gia cong tho, pho bien nhat la dung ien cc ong
Hnh 5.19 :
Nang suat va o mon trung bnh cua ien cc
bang hp kim ong grafit trong trng hp
gia cong tho tren thep hp kim Cr-Ni-Mo-V
Trang - 160 -
thau va zamak, vi tiet nho th dung ong va wolfram, may
ln th dung dura. Khi gia cong tinh th co the dung ien cc
ong; cung co trng hp dung ien cc thep, ac biet khi
lam dao cat. Gia cong hp kim cng th thng dung ien cc
ong, ong thau, ong wolfram. mot so nc th dung ien
cc bang ong ep vi bot silic-carbid. Gan ay nhat th chu
yeu dung ien cc grafit e gia cong tinh bong kn.

Bang 5.1 :
Vat lieu lam ien cc
LOAI
GIA
CONG
Vat lieu
cua vat
lam
o
n
g

Z
a
m
ax
o
n
g

o

T
h
e
p

G
a
n
g

D
u
r
a

G
r
a
f
i
k
H
o
p

t
h
e
p

B
o
t

k
i
m

l
o
a
i

Thep + + 0 - 0 + + + -
THO
HKC + - + - 0 - + + 0
Thep + + + + + + 0 + - BAN
TINH
HKC - - + + + - 0 + 0
Thep - - + + + - - + -
TINH
HKC - - + + + - - + 0
Hnh 5.20 :
T le gia o mon va cac vat lieu lam ien cc
Trang - 161 -
Chu thch ky hieu :
(+) : Nen dung
(-) : Khong nen dung
(0) : Ch nen dung trong trng hp ac biet.
* GIu cong dIen cuc :
Viec gia cong ien cc ong vai tro cc ky quan trong
trong gia cong tia la ien. o chnh xac gia cong mot mat phu
thuoc vao o chnh xac cua ien cc, mat khac ien cc khi
gia cong b h hong do o phai chnh lai cho phu hp vi vat
gia cong. Chi ph che tao anh hng ln en tnh kinh te cua
cong nghe.
Nhng phng phap gia cong chu yeu la : Cat got, uc
(uc chnh xac), ep, cat, phun kim loai, ma ien phan.
+ Phng phap cat got : Nguyen ly c s cua viec gia
cong ien cc bang cat got la che tao vat co dang loi thng
de hn che tao lo cua no. Ben canh o, dao cat co the che tao
t nhieu bo phan eu canh, de got cat. Vi ien cc e khoan
hoac khoet, th can chu y la khi gia cong, e tranh sinh ra
nhng ng gan doc, v nhng gan nay se in hnh tren lo.
Phng phap cat got chu yeu dung e gia cong ien cc co
hnh dang n gian, hoac chung ch s dung trong san xuat n
chiec. Can phai noi rang, vi phng phap nay th khong the
gia cong chnh xac ien cc bang ong o.
+ Ep : Chu yeu s dung e gia cong ien cc dung
trong gia cong lo sau. Trong phan ln trng hp ngi ta ep
nhng ien cc ma sau nay se s dung e gia cong mot khuon
mi. Trng hp gia cong so lng ln ien cc, th cung co
the lam khuon rieng. Can phai chu y en o co ngot cua ien
cc sau khi ep.
+ Phng phap cat : Dung e che tao ien cc, bang
cach dung mot cai chay co san e cat t tam kim loai ra nhng
mieng giong nhau; sau o ghep chung lai thanh cay la tan inh
Trang - 162 -
lai. Co the dung hoa chat e sa cha kch thc theo yeu
cau.
Trng hp gia cong lo phc tap th dung loai ien cc
che tao bang cong nghe phun kim loai. Co the lam nhieu
khuon bang thach cao t mot ien cc mau. Bang phun kim
loai tren khuon thach cao chung ta co c ien cc. Can chu
y rang be sau cua lo khong c ln hn hai lan be rong. e
tranh hien tng phat nong qua mc, phai tien hanh phun kim
loai tng bc. Mc o chnh xac bang vi ien cc lam bang
phng phap ep. ien cc c phun kim loai co o xop, do
o neu dung vat lieu ac e che tao th ien cc co o mon t
hn.
Bang cong nghe ien phan, co the che tao ien cc co o
chnh xac 0. 01-0. 02mm. Nguyen ly cua phng phap nay la
ien phan, v du ong e lam ay khuon thach cao. Vat lieu
ien phan rat tinh, o la ieu co li. Khong phai au t nhieu
cong, bi v co the tien hanh ien phan qua nhieu ngay ma
khong can trong coi. nc chung ta th cong nghe nay t pho
bien.
* Clon dIen cuc lleo luong lu lluc :
Trong qua trnh gia cong tia la ien co nhieu kh sinh ra
vi so lng ln. Chat kh nay co the lam xau qua trnh gia
cong trong trng hp gia cong lo hoac bong sau. Do o phai
lam lo thoat kh tren ien cc, nh tren hnh 5.21.
Ngoai ra can phai lay i san pham b an mon ra khoi khe
h ien cc, bang cach lam luan chuyen dung dch gia cong,
goi la suc ra. Thng co bon cach suc ra nh sau :
+ Phun tia.
+ Lam chay bang dong ien mot chieu.
+ Lam chay bang dong ien ngc chieu.
+ Lam chay bang ap lc.
Trang - 163 -

Phac hoa mo ta nhng phng phap nay vi phng phap
khoan lo bong trong ien cc :

Hnh 5.21 :
Lo thoat kh tren ien cc
Hnh 5.22 :
Cac phng phap suc ra.
a) Phun tia.
b) Lam chay bang dong ien
mot chieu.
c) Lam chay bang dong ien
ngc chieu.
d) Lam chay bang ap lc.
Trang - 164 -
Trng hp gia cong lo dai, sau, th gan ien cc tren
thanh dan va tng giai oan thay oi tren ien cc. u iem la
de sc ra, de chnh, va mac dau lo dai khong can e nhu ra
nhieu au ien cc, tc la khong can dung tam em day.
Ngoai ra co the thay ien cc gia cong tho va gia cong tinh
tiep nhau vi nhieu mc ieu chnh nh nhau. Co the giam en
toi thieu o con cua thanh lo hoac bong bang ien cc co ranh
bac thang. Phoi kim loai lot vao ranh va o no khong lam
rong lo ra. Chieu cao cua vai thay oi dan theo bac thang. Ch
co vai trc phai cat got nhieu, con nhng vai sau ch got i
vai phan tram milimet. o con co the giam xuong 3.
Mat e di cua dao cat phai lam co o con ln. ien cc
dung ay goi la ien cc co chan e. au cua ien cc con
trong qua trnh b mon se hnh thanh cong co chieu ngc lai.

Co the gia cong mot lan nhieu lo song song bang ien cc
nhom ma van co the bao am v tr chnh xac . . . e am bao
tiep xuc tot, ngi ta han nhng tam ien cc tren mot cam
cap.
Hnh 5.23 :
Mot so au ien cc con
Trang - 165 -

3) Dung dch gia cong tia la ien :
- Vi s hien dien cua chat long cach ien trong vung gia
cong th s phong ien c thc hien theo mot kenh xac nh
ro va on nh lam cho nang lng tap trung tot va c dung
vi hieu suat cao e boc vat lieu gia cong.
- Nhiem vu th hai cua chat long gia cong la lay cac chat
can sinh ra trong vung gia cong va em chung i ni khac. e
Hnh 5.24 :
Mam cap co gan nhieu tam ien cc.
Hnh 5.25 :
Gia cong nhieu lo
song song bang
ien cc nhom
Trang - 166 -
thc hien tot nhiem vu nay, chat long phai co o long tot. Tom
lai chat long gia cong phai at cac yeu cau ky thuat sau :
+ o cach ien cao (nh o nang cao nang suat)
+ Dan nhiet tot (tren 30
o
C th nang suat giam nhieu)
+ Chat long phai trung tnh ve hoa hoc, khong pha huy
ien cc, chi tiet gia cong va cac chi tiet may.
+ Co o nht nho (e de lam ay khe h ien cc)
+ Khong c co mui kho chu, khong co kh oc, nhiet
o chay u cao e khong nguy hiem.
+ Co kha nang phuc hoi nhanh sau khi b anh thung v
tia la ien.
+ Chat long phai duy tr c tnh chat cua no cang lau
cang tot trong moi ieu kien gia cong.
+ De tm va gia thanh hp ly.
+ iem no cao va san pham do phan huy nhiet khong
gay ngo oc.
- Hien nay cac chat long thng dung lam dung dch gia
cong la Hydrocarbua, cac loai dau Silicon, pho bien la dung
dau hoa, v no cach ien tot va co o nht nho. Dung dau hoa
con co u iem cho viec mai nhan v cho phep tao hnh chnh
xac. Nhc iem cua dau hoa la de chay va mang theo phoi
kim loai. V vay, khi dung dau hoa phai co bo loc tot. Dau
bien the co o ben cach ien cao, co the dung trong gia cong
tho, u iem la de loc. Ngoai ra co the dung nc va nc cat
lam dung dch gia cong nhng ch dung trong gia cong phu, v
du e lay i cac manh dao b gay.
- nc ngoai co nhieu loai dung dch khac c s dung
rong rai, nhat la Kerosine, dau tho cat, dau co goc silic,
cacbontetra-chloride. Theo nghien cu mi nhat th oi vi
ien cc kim loai, dung dch ac biet phu hp la hon hp
triehyleneglycol - nc - monoethyl - ether. Nhng oi vi
ien cc grafit th khong co li.
Trang - 167 -
1) Van toc cat :
La lng vat lieu b boc i theo n v thi gian. Noi mot
cach gan ung, toc o gia cong t le vi cng o dong ien
gia cong. Ngoai ra, nang lng cac xung ien cung anh hng
en toc o gia cong v nang lng cua xung ien c xac
nh bi nhieu yeu to, khi can thiet ta co the xet anh hng
rieng le cua tng thong so nay en toc o gia cong. Mot cach
tong quat, mot xung ien phong co cng o dong ien cao se
cho van toc gia cong ln hn xung ien co cng o dong ien
yeu.
2) Che o gia cong :
Cac thong so xac nh nang lng cua xung ien phong
la: dong nh, thi gian xung, phan cc cua mach xung c
ieu khien, gia tr cua ien dung va ien the nap tromg trng
hp may tao xung dung tu ien. Trong ca hai trng hp, dong
ien trung bnh va thi gian ngh gia hai lan phong ien
khong tham gia trc tiep vao che o gia cong. Cac yeu to khac
nh vat lieu gia cong, vat lieu ien cc, loai chat cach ien va
phng thc lu thong cua no co anh hng. Nhng chung ta
co the noi mot cach tong quat rang cac che o gia cong phu
thuoc vao cac thong so lien quan en nang lng cac xung
ien.
Bang 5.2 :
Mot so thong so ve che o gia cong.
Cng o dong ien (A)
Dang gia
cong
Nang
lng xung
d tr (J)
Mach nap
Mach
phong
ien
dung cua
tu C (F)
Tho
Trung bnh
Tinh
0,55
0,050,5
0,0050,05
> 5
1 5
< 1
> 100
10100
< 10
> 100
10100
< 10
Trang - 168 -
Bang 5.3 :
Cac ac tnh gan ung ve ien cac dang gia cong
Che o
gia cong
Cong
suat
(kVA)
o dai
xung
(s)
Tan so
lap lai
(s
-1
)
Lng
ht
kim loai
(mm
3
/ph)
o
nhap
nho
(m)
Tho

Ban tinh

Tinh
30 3

5 0,3

< 1
10000
100
500 200

< 20
50
3000
1000
10000
> 3000
30000
100
200 30

< 30
1000
50
25 6

1
3) Nang suat gia cong :
- Nang suat gia cong phu thuoc vao rat nhieu yeu to ma
quan trong nhat la khoang cach gia hai ien cc, cng o
dong ien, tan so tia la ien, ien dung, dien tch be mat gai
cong, chat lng cua ien cc, chat cach ien va loai may phat
xung. Tren hnh neu len moi quan he gia ien the va khoang
cach can thiet gia hai ien cc e phong ien trong cac moi
trng khac nhau. Anh hng cua khoang cach ien cc en
nang suat gia cong. Vi khoang cach nho th U
cmax
nho, tan so
tia la ien ln nen nang lng tch luy trong xung ien nho
va do o nang suat thap. Neu khoang cach ln th U
cmax
ln,
tan so tia la ien thap, nhng dong ien trung bnh nho dan
en nang suat van thap.
- Gia hai khoang cach o, can tm mot khoang cach toi
u, lam sao khoang cach o s phong ien dien ra eu an
va nang suat co the chap nhan c. Da tren hnh 5.27 chung
ta xem tr so o.
N
C
=
T
0
t C
dt . I . U
T
1

Trang - 169 -

- Qua trnh phong ien dien ra theo o th tren hnh. Ham
cua U
c
va I
t
trong thi gian la :

=

RC
T
0 c
e 1 U U

RC
T
z t
e . I I

=
o : T _ Thi gian tch ien (s)
R _ ien tr trong mach tch ien (Ohm)

R
U
I
0
z
=
dong ien ngat mach (A)
C _ ien dung cua tu, Farad
Hnh 5.26 :
Quan he gia ien
the U va khoang
cach gia 2 ien
cc khi phong ien.
Hnh 5.27 :
Tr so dong ien va hieu
ien the khoang cach
phong ien toi u
Trang - 170 -
Ta co : dt e e 1 .
T
I . U
dt . I . U .
T
1
N
RC
T
T
0
RC
T
T
0
z 0
t C C

= =
Goi - He so tch ien

RC
T
c
max c
e 1
U
U

= =
Thay vao tch phan va sau khi tch phan ta co ket qua :

p z 0
2
z 0 c
a . I . U
1
1
ln . 2
. I . U N =
=
o :

=
1
1
ln . 2
a
2
p

a
p
: la he so cong suat, he so nay cho ta biet la co bao
nhieu phan tram cua dong ien I
0
= I
z
c s dung e tch
ien.
Hnh 5.28 :
Quan he gia he so tch
va he so cong suat ap
trong gia cong tia la ien.
Trang - 171 -
- Tren hnh co the thay o th quan he cua a
p
vi , va
thay rang a
p
co tr so ln nhat vi 8 . 0 6 . 0 = . Nh vay can
ieu chnh khoang cach ien cc phu hp vi tr so nay va bo
phan ieu khien phai gi on nh trong khoang cach o.

- Quan he gia nang suat va ien ap co the thay tren
hnh: va tien gan en ien cc, gan ien ap t U
0
en U
sz
, th
lng vat lieu c lay ra se tang dan, sau o lai giam xuong.
Tren c s o, ien ap toi u se la :

0
opt
sz
U 7 , 0 U =
Cung co the thay tren o th, lng tieu hao cua ien cc
( ) ien ap o cung t nhat.
- Neu giam ien tr, th dong ien tch se tang len, con
nang suat gia cong th ban au tang theo t le, sau khi at en
tr so ln nhat se ot ngot giam xuong. Ly do tan so cung tang
vi dong ien, a tr nen qua cao en noi s dao ong ep
dung dch ra xa khoi ien cc, do o qua trnh phong ien dien
ra trong moi trng kh.
Hnh 5.29 :
Quan he gia nang suat va ien ap
Trang - 172 -

- Nguy c bien thanh ho quang cang tang hn. Co the
thay tren o th rang lng tieu hao nho nhat cua ien cc co
c vi dong ien nho, hn la vi cong suat ln nhat. Nen
dung gia tr nay e lam iem cong tac. Ga tr nay the hien
tren o th hnh 5.31, vi ien cc bang grafit, co dien tch 206
cm
2
. Co the chu y thay rang vi ien cc co vat lieu va dien
tch khac nhau, o th bien thien va cng o dong ien toi u
se khac nhau.
Hnh 5.30 :
Quan he gia cng o dong ien va nang suat
1. ien cc than tiet dien 412cm
2

2. ien cc than tiet dien 206cm
2
.
3. ien cc ong 206 cm
2

Hnh 5.31 :
Quan he lng
tieu hao ien cc
vi dong ien
Trang - 173 -
- N ien ap
opt
SZ
U chung ta giam ien dung, th nang suat
gia cong ban au gi khong oi, nhng sau o ot ngot giam
xuong (hnh di), roi lam vao vung co nguy c sinh ra ho
quang.

- Lng tieu hao ien cc lai tang len khong co ngha l g
neu gia cong vi ien dung nho hn ien dung ti han c
k

- Tac dung cua be mat gia cong oi vi nang suat c
the hien tren hnh sau :
Hnh 5.32 :
Quan he gia ien ap va ien dung
Hnh 5.33 :
Tac dung cua be mat
gia cong oi vi nang
suat
Trang - 174 -
- Sau oan tang len gan tuyen tnh th en oan giam dan
xuong sau khi tr so ien tch at gia tr ti han F
kr
. Co the giai
thch ieu nay rang v a vt qua dong ien ti han, khi o
viec lay vat lieu ien cc b tieu hao ra khoi khe h ien cc
tr nen kho khan hn.
- phan ln may gia cong tia la ien, ngi ta ieu
chnh dong ien va ien dung theo mot quan he nhat nh, vi
ch mot cong tac ong m tng cap.

- Co the nhan biet rang vi nang suat nho th be mat ti
han cung nho. ieu kien lam sach ien cc cung anh hng
ln en nang suat gia cong. V du khoan lo cang sau th viec
lam sach lo cang kho, do o nang suat cung kem hn, v nhng
phan t nho cua vat lieu a tach ra ngan can viec hnh thanh
s gia cong theo ung kch thc. Theo o lng tieu hao ien
cc cung tang. Hien tng ang chu y la khi gia cong tinh th
viec tang ap suat e lam sach ien cc se nang cao nang suat,
con khi gia cong tho th ngc lai, tc la lam giam nang suat.
- ieu nay co the giai thch rang, khi gia cong tho e co
the ra sach ien cc th khe h c ieu chnh hep va nhng
Hnh 5.34 :
Quan he gia nang
suat, cap gia cong, va
be mat gia cong.
Trang - 175 -
phan t vat lieu ln b ket trong khe, gay dong ngan mach va
qua trnh gia cong b nhieu loan.
- Vat lieu ien cc cung co anh hng en nang suat gia
cong. Cho en nay co c li giai thch hp ly hoac chng
minh mot cach nhat quan ieu ly thuyet cho rang kha nang
dan ien va dan nhiet la nhng yeu to quyet nh. Tnh chat
cua gia cong tinh va gia cong nh vat lieu cua chi tiet gia cong
cung co anh hng en nang suat trung bnh.

- Trong so tay ve nhng may gia cong tia la ien, ngi
ta ch dan may co the at cong suat phoi nh the nao vi
nhng mc o gia cong khac nhau. Trong bang di ay la
mot v du ve may cua Hungary, k hieu Erosimat 30C. Nhng
so lieu nay tat nhien mi co tnh chat nh hng, con tuy
thuoc rat nhieu vao ieu kien cu the.
- Nang suat cua thiet b gia cong tia la ien trong nhng
nam gan ay a c nang cao ang ke. Vi gia cong tinh,
nang suat la 0,1-50 mm
3
/ph, th gia cong tho nang suat at
en 800 mm
3
/ph khong phai la hiem co, tham ch co trng
hp ac biet co the at en 4000 mm
3
/ph.
Hnh 5.35 :
Nang suat, lng tieu hao cua ien cc co the
at c trong trng hp gia cong kep K
1

bang ien cc t cac vat lieu khac nhau
Trang - 176 -

GIA CONG TINH BANG
IEN CC THEP A TOI
GIA CONG THO BANG IEN
CC
ONG THAU
1 2 3 4 5 1 2 3 4 5
0,1 0,25 1-1,5 6-8 10-15 25-30 50-60 100-110 230-250

mm
3
/
phut
- Dung cu gia cong tia la ien thng tien theo chieu an
sau. Toc o tien cua dung cu cung co the dung e xac nh
nang suat. V du chung ta hay xem thi gian gia cong khoan
bien oi the nao vi chieu sau gia cong.

- o chnh xac gia cong chu anh hng cua cac thong so
sau :
+ o chnh xac may gia cong tia la ien (v tr tng
oi gia dung cu va vat gia cong).
+ Hnh dang, kch thc va o mon cua dung cu.
+ Khoang cach phong tia la ien gia dung cu va be
mat c gia cong.
Hnh 5.36 :
Quan he gia thi gian
gia cong va chieu sau
gia cong khoan lo
Trang - 177 -
- Chung ta co the theo doi qua trnh hnh thanh cua lo
c khoan bang tia la ien, co the thay ng knh cua lo
bao gi cung ln hn ien cc, v quanh ien cc co tia la
ien. ong thi lo co hnh con ma chop pha di, v phan
tren tham gia lau hn trong qua trnh b an mon nen ng
knh lo ln hn. Ta thay ay lo co dang con cut au. Trong
qua trnh gia cong nhng phan t vat lieu phoi cung gop phan
tao ra o con, nhng phoi nay do tia la ien sinh ra mat ben
lay ra. Lo cang sau th s chenh lech ng knh phan tren
va phan di cang tang. Hien nay cha xac nh c mot
cach chnh xac nhng yeu to chi phoi tr so va , v vay o
th ch khoang cach ien cc bao gi cung the hien trong day
dung sai.

- Quan he co tnh chat tuyen tnh, ien ap cang ln th
khoang cach ien cc cang ln.
Hnh 5.37 :
Qua trnh hnh thanh lo trong gia cong khoan bang
tia la ien
Trang - 178 -

- Anh hng cua nang suat gia cong cung rat quan trong.

- So lieu thu c may Erosimat 30C cho thay rang
mc o gia cong ban tinh th dung sai se tang cung vi tr so .
- Tr so cua na goc con tng ng vi khoang cach ien
cc the hien tren o th.
- Tr so na goc con cua lo khoan bang may Erosimat :

Hnh 5.38 :
Quan he gia hieu ien the va khoang cach ien cc
Hnh 5.39 :
Tr so cua na goc con
tng ng vi khoang
cach ien cc
Trang - 179 -
Cap gia cong 1 2 3 4 5
Na goc con, , phut 25-30 30-35 40-50 50-60 60-70
Khoang cach ien cc,
m
30-32 34-38 45-55 60-70 70-80
- Nhng lo co canh sac, theo kinh nghiem th ch co the
coi gan nh canh c ve tron.

- Be mat ien cc co the phan thanh nhng phan nho,
va moi phan nho lay i t be mat oi dien cua vat gia cong
mot lng phoi, nhng goc th lng phoi phai lay i nhieu
hn nhieu lan va nh vay ien cc b mon i, canh tr nen
tron. S hnh thanh profil nay co the thay hnh 5.41a.
ien cc
Vat gia cong
Hnh 5.40 :
Hnh dang ien cc khi gia cong nhng lo sac canh
Trang - 180 -

- Hnh 5.41b la trng hp ma canh ngoai cua no c
gia cong. ay phoi nhet ay goc trong cua dung cu. Do o
vat gia cong khong the c gia cong hoan toan neu khong
chap nhan co canh ve tron. Tac gia Vologyin bang thc
nghiem a xac lap cac so lieu ve mc o ve tron canh :
Bang 5.4 :
Ban knh ve tron canh trong khi gia cong lo bang tia la ien
GOC CUA BE MAT, o CAP GIA
CONG 15 30 45 60 75 90

BAN KNH VE TRON (mm)
BAN
KNH
TRUNG
BNH
THO 0, 3 0, 3 0, 4 0, 4 0, 3 0, 4 0, 35
BAN TINH 0, 25 0, 2 0, 3 0, 3 0, 3 0, 4 0, 29
TINH 0, 05 0, 1 0, 1 0, 1 0, 05 0, 1 0, 07

(a)
(b)
Hnh 5.41 :
Hnh dang goc khi gia cong bang tia la ien
Trang - 181 -
Bang 5.5 :
Ban knh ve tron canh ngoai khi gia cong bang tia la ien
GOC CUA BE MAT, o CAP GIA
CONG 15 30 45 60 75 90
BAN KNH VE TRON (mm)
Tho
0,2 0,3 0,4 0,6 - 1,1
Ban tinh 0,25 0,3 0,5 0,6 - 1,0
Tinh 0,25 0,25 0,4 0,6 - 1,0
Ban knh TB 0,23 0,28 0,43 0,6 - 1,07
- Vi so lieu bang ben tren co the thay rang mc o ve
tron canh trong khong phu thuoc vao goc giao nhau cua cac be
mat, nhng lai chu anh hng cua cap gia cong. Ngc lai so
lieu bang ben di cho thay mc o ve tron canh ngoai lai
phu thuoc vao goc , con cap gia cong th khong co tac dung.
Viec nang ien cc len tng luc lam giam ban knh, v nh o
phoi a tch luy b ay ra khoi goc.
- Cuoi cung o chnh xac kch thc phu thuoc nhieu vao
cau tao cua may, trong catalo cua may ngi ta cho o chnh
xac gia cong. Chung ta khang nh rang o chnh xac chnh
may thong thng khoang 0,01 mm va dung sai kch thc nho
nhat khi lam phang cung bang 0,01 mm. may khoan toa o
bang tia la ien, o chnh xac chnh may at en 0,002 mm
va o chnh xac gia cong la 0,0025 mm.
5) Chat lng be mat gia cong :
- o nham la mot trong cac ch tieu quan trong e anh
gia chat lng be mat. Be mat b an mon co nhng vet lom
hnh ban cau chong mep len nhau. Theo ly thuyet th o nham
be mat c hnh thanh nh tren hnh 5.42.
- Trong thc te th khong co s eu an nh tren hnh ve.
Hi kim loai ngng tu lai lam bien dang rat nhieu.
Trang - 182 -

- Hnh ve co phan lech, v ay chieu cao gho ghe cua
be mat c phong ai len 60 lan. Co the thay rang be sau cua
lom rat khac nhau. Nhieu nghien cu a chng minh rang t so
cua ng knh lom oi vi be sau lom dao ong gia 0,1 -
0,3. Be mat gia cong tho th co o nham kem hn nhieu. o
nham trc het phu thuoc vao nang lng cua mot lan phong
ien. Mot phan cua ien tch cua tu tao nen lom, v vay the
tch cua lom t le vi nang lng phong ra cua tu :
Q =
2
1
2
SZ
U . C
o :
Q : ien tch cua tu.
Hnh 5.42 :
o nham be mat gia cong khi gia cong bang tia la ien
Hnh 5.43 :
Cau truc te vi cua be
mat khi gia cong
bang tia la ien.
Trang - 183 -
U
SZ
: ien ap gia ien cc
C : ien dung cua tu
V = K.
2
SZ
U . C
V : The tch lom.
K : He so phu thuoc vao vat lieu va ieu kien gia
cong.
Gia thiet rang the tch t le vi lap phng cua chieu
sau, th :
R
max
= K C U
2
SZ
= K
3 / 1 3 / 2
SZ
C U
Vi ien ap gia ien cc khong oi th : R
max
= mC
1/3

- Thc te cung xac nhan bieu thc nay, o th sau ay cho
ta thay quan he chu yeu cua chieu cao o nhap nho oi vi
ien dung, vi ien ap va vi ien cc. Co the rut ra ket luan
rang neu chung ta muon at c o nham nho th phai dung
tu co ien dung nho.

- o nham tang theo ien ap gia 2 ien cc, tc la tang
vi khoang cach ien cc. Hnh ve khong phai la o th khong
gian ma ch la nhng ng nghieng ve vi net manh, noi ket
nhng tr so cua khoang cach ien cc va o nham trong cung
mot cap gia cong.
Hnh 5.44 :
Quan he gia U
SZ
, C va R
Max

Trang - 184 -

- Quan he gia o nham va nang suat gia cong trong tng
cap gia cong. o nham tang theo nang suat. o th cho thay
ieu nh the (do co cung dung sai nen o th co 2 ng gii
han mien dung sai).
- So lieu ve o nham khi th nghiem tren may Erosimat
30C vi vat lieu thep va hp kim cng. So lieu tren bang cho
thay rang vi vat lieu cang cng th o nham cang nho.
- Be mat gia cong tia la ien co the anh bong tot, tot
hn be mat c mai. Kinh nghiem cho thay rang be mat gia
cong tia la ien rat thuan li cho viec boi trn. Trong trng
hp ap lc ln cung khong the lam ban dau ra khoi lom cau,
do vay em dau gi c lau.
- Ngoai nhng yeu to tren con co nhng yeu to khac cung
co anh hng en o nham - o la vat lieu ien cc, chat
Hnh 5.45 :
Quan he gia o nham va nang suat gia cong, khoang
cach ien cc va o nham trong tng cap gia cong
Trang - 185 -
lng cua dung dch ien moi, .v.v. nhng viec la chon chung
th phu thuoc vao nang suat, v the chung ta khong ban ay.
Bang 5.6 :
o nham khi gia cong tren may Erosimat 30C
Vat lieu
Thep Hp kim cng
Cap
gia
cong
o
nham
R
z

(mm)
V
b

(mm
3
/ph)
H
q
(mm)
V
b

(mm
3
/ph)
H
q
(mm)
1
2
3
4
5
0,003
0,013
0,053
0,5
3
0,1
0,25
1
6
8
0,7 0,8
1,1 1,5
2,4 2,7
4 4,5
4,7 5,7
0,1
0,2
0,6
2,5
3
0,6 0,7
1 1,1
1,5 1,7
1,8 2,2
2,5 - 3
- Nhieu ngi khong muon ng dung gia cong tia la ien
v nhng tac dung cua tia la ien oi vi lp be mat. Do qua
trnh an mon nen lp ngoai tren be mat b pha huy. Mot
phan cua kim loai nong chay nhiet o cao khong tach khoi
be mat ma ong bam lai. Cacbon trong dung dch cung de bam
tren be mat, hien tng nay cung tao ieu kien cho hien tng
ong bam lai cua kim loai.
- Di be mat hnh thanh 3 lp :
Hnh 5.46 :
Cac lp cau truc be mat sau khi gia cong tia la ien.
Trang - 186 -
- Lp ngoai cung la dai be mat co cacbon tch tu nhieu,
la mot lp rat cng do hi kim loai ong cng lai thng c
goi la lp trang. Lp nay co cau truc ledeburite c hnh
thanh do ham lng C cao va do lam nguoi nhanh. Trong lp
th 2 co nhng cau truc khac nhau tuy thuoc vao toc o lam
nguoi va tnh chat cua vat lieu; con lp trong cung co cau truc
c ban.
- Hnh di cho thay s phan bo cua o cng te vi theo
chieu sau tnh t tren mat, vat lieu la thep chu nhiet. Tren
hnh co ghi nhng dang cau truc cua vat lieu c toi va u cua
lp a thay oi cau truc nh neu tren.

- Be day cua nhng lp o phu thuoc vao nhiet o, thi
gian tac dung cua nhiet va toc o lam nguoi. Be day cua lp
bien cng thong thng la 0,01-0,8 mm (hnh 5.48).
- Quan he gia be day cua moi lp vi ien dung cua tu
co the thay rang cac gia cong tho tc vi cong suat ln moi
lp day hn rat nhieu. Co the s dung moi quan he nay e
ieu chnh be day cua gia cong tinh sao co the lay i lp con
lai sau khi a gia cong tho. Lp ngoai cung cung co the cha
nhieu vet nt te vi. Vi cong suat ln th ieu nay cang ung.
Trng hp chon thong so cong nghe ung th nhng vet nt
Hnh 5.47 :
S phan bo cua o
cng te vi theo
chieu sau tnh t
tren mat
Trang - 187 -
nay khong lan en lp trang va khong lam giam tuoi tho nhieu
oi vi vat c gia cong. Lp nay co tnh chu mon cao, do o
khi gia cong mot so dung cu (v du khi khoan lo e lap) th tuoi
tho co tang len nhng trong trng hp chu lc tac dung thay
oi va lap i lap lai nhieu lan (o ben moi) th nen lay i lp
nay. ng suat d keo cung lam giam gii han moi. Hnh sau
cho thay s phan bo ng suat d trong cac lp be mat khi toi
vat lieu C35 tren may Erosimat, gia cong tho cap hai, di be
mat co ng suat d keo 50 Kp/mm
2
, khong co li. Nguyen
nhan cua tnh trang nay las ong cng nhanh cua lp a b
nong chay.

Hnh 5.48 :
Quan he gia be day cua moi lp vi ien dung cua tu
Hnh 5.49 :
S phan bo ng suat d
trong cac lp be mat
khi toi vat lieu C35 tren
may Erosimat
Trang - 188 -
VI. Pho ng chay va phong ho Iao dong Irong gia
cong Iia Iua dien :
- Khi co tia la ien phat sinh th kh sinh ra va vi nhiet o
khi phong ien th chung co the boc chay khi tiep xuc vi
khong kh. Trong qua trnh gia cong phai am bao khoang
cacg o sau can thiet trong dung dch, e cho kh thoat len en
be mat dung dch th a nguoi. Phai bao am chat kh c hut
i.
- Nhng chat kh nay phan nhieu co tnh oc, trong o co
oxy-cacbon (CO). V vay ni gia cong phai thong thoang.
Ngoai ra con co chat an da trong dung dch, do o phai boi da
e bao ve gia khi lam viec.
- ien ap lam viec cua thiet b ln hn 42V, do vay cung rat
nguy hiem. Do vay v tr gia cong phai c bao che can than,
va ch khi nao ong bo phan bao che mi c khi ong may
gia cong.
VII. Cac ung dung cua gia cong Iia Iua dien :
- Tuy theo tnh chat cua cong viec, cac thiet b gia cong tia
la ien c chia lam 6 nhom sau :
+ May gia cong lo.
+ May khoan lo nho.
+ May mai theo hnh dang.
+ May mai dung cu.
+ May cat t.
+ May gia cong khuon mau.
- Pho bien nhat la may gia cong lo. ng dung e gia cong lo
co ay hoac lo suot. ac trng cua may la ien cc chuyen
ong thang e an sau vao chi tiet, tren mot so thiet b co the
phoi hp ien cc co the chuyen ong thang vi chi tiet quay,
hoac chi tiet quay ma ien cc chuyen ong thang. Co nhieu
phng an e hnh thanh nhng be mat khac nhau ma ngi ta
Trang - 189 -
thiet ke ra nhng thiet b phu hp vi chung. Trong so o,
chung toi xin gii thieu di ay mot vai may co s to hp
nhieu loai chuyen ong, vi lu y rang khong phai may nao
cung thch ng vi moi viec c thc hien bi cac quy trnh
ong tac khac nhau.

- Tren may mai tao dang bang tia la ien co the mai thanh
nhng mat co dang khac nhau vi o bong thch hp. ay
toc o tien cua dung cu mai la t. Trong trng hp dung cu
mai hoac vat gia cong quay, hnh dang cua dung cu c chep
qua vat gia cong. e lam c viec nay ien cc cung di
chuyen mot t. Tren hnh co the thay mot so loai chuyen ong.
Tren o day nho quan lien tuc thay the cho ien cc la dung
cu.
Hnh 5.50 :
Mot so phng phap gia cong bang tia la ien
Trang - 190 -

Hnh 5.51 :
Mot so loai chuyen ong khi gia cong tia la ien
Hnh 5.52 :
Nguyen ly mai sac dao
Trang - 191 -
- T cac hnh tren co the thay ro rang, oi vi moi phng
phap khac nhau can co may chuyen dung rieng biet, o chnh
la ieu han che trong viec pho bien cong nghiep mi nay mot
cach rong rai.
- Cong nghe mai sac dung cu bang tia la ien chu yeu
dung cho hp kim cng. Nang suat cao hn cong nghe mai
thng. Hnh 5.52 trnh bay nguyen ly mai. ien cc lam dung
la mot cai a bang gang hoac bang ong o. Chuyen ong
cua vat gia cong co the thc hien bang may moc hoac bang
tay. Cung nh trong cac trng hp gia cong bang tia la ien
khac, ay cung co ac iem la be mat gia cong b hoa cng
do s bien oi nhanh cua nhiet o cao vi van toc lam nguoi
nhanh ma hnh thanh mot lp diwolframcarbid (wolfram carbid
kep) co tnh chat rat cng. V du o cng cua hp kim
94WC+6Co trong qua trnh gia cong tia la ien co the tang t
1796 kg/mm
2
len 2500 kg/mm
2
. T o tuoi ben cua dung cu
c mai sac bang tia la ien cao hn dung cu c mai sac
bang cong nghe thong thng.
- May cat chi tiet bang tia la ien cung c biet vi nhng
giai phap khac nhau. S o cau tao cua may co the thay tren
hnh di :
Hnh 5.53 :
Nguyen ly may cat tia la ien
Trang - 192 -
- Cach a tng t nh cach dung ca a, cach b nh dung
li ca. Gan ay bat au pho bien cach c dung day nho (hay
con goi la cat day tia la ien se c e cap phan sau).
Cach nay cung s dung e tao hnh dung cu cat. Bat au ngi
ta khoan mot lo, sau o luon day qua lo va gia cong. Bang
may khoan tia la ien thong thng ngi ta thng gia cong
cac chi tiet co ng knh en 100 mm. Trong trng nay, ien
cc la mot tam day 1mm ma lng tieu hao la 100-200%.
- Mot nhom rieng gom nhng may tia la ien e gia cong
dung cu dap, mui khoan xoan oc, mui khoan ren. Yeu cau la
khong co phoi thai. V vat gia cong thng co kch thc ln,
nhng may nay c che tao theo kieu chat cach ien c
un vao khe h ien cc, sau o hng tren mam. Ngi ta
cung hay cach ap chat vao be mat gia cong mot cai a on
ay cang, co o bam tot, bang cach o chat cach ien c
gom lai va dan i. Nhng may nay dung e gia cong nhng lo
co o chnh xac khong cao lam.
- Khi gii thieu ve phng phap gia cong bang tia la ien,
chung ta phai noi rang do tac dung an mon cua tia la ien ma
be mat cua ien cc tr nen cng. Chung ta li dung hien
tng nay trc tien vao viec x ly li cat cua cac dao cat
bang thep gio. ay muc ch khong phai lay phoi, va v vay
chung ta dung vat gia cong nh la cc catod. Hi kim loai
ngng tu se xuc tien them qua trnh bien cng, v vay khong
khong dung ding dch long, qua trnh phong ien xay ra trong
moi trng cach ien la khong kh. Hnh 5.54 gii thieu s o
nguyen ly cua thiet b, tng t nh trng hp cat got bang tia
la ien.
+ ien cc c ieu khien bang tay tren vat gia cong, va
tia la ien c phong va nh co bo dao ong. Be mat gia
cong c nung nong len 12-15000
o
C tai cho co tia la ien
phong len la nguoi i rat nhanh. Noi ng suat rat ln sinh ra
Trang - 193 -
trong lp kim loai a b nong chay va ong lai nhanh. Mot
phan hi kim loai ngng tu lai tren be mat. Do o lp be mat
tr nen cng co tnh chu mai mon rat tot.

+ Mot so nha nghien cu giai thch qua trnh lam cng
bang c che tac dung cua nhiet. Y kien khac lau giai thch
bang qua trnh di chuyen va tch tu lai cua vat lieu ien cc
lam bang hp kim cng, goi o la qua trnh ma bang hp kim
cng. Co le do tac dung cua ca hai hien tng tren. Mot lp
trang c hnh thanh vi o cng rat cao (600-800 Hv), be
day cua no khoang vai phan tram milimet. Trong lp nay ay
bong kh. Khoi u li ti bang carbid, va nhieu vet nt chan chim.
Lp trang chu yeu thanh hnh t nguyen lieu chnh. Di o co
mot vung 0,1 mm ma chat lng nhiet luyen cua no cung anh
hng ln en tnh chu mai mon.
+ Cac ac trng cong nghe lam cng be mat bang tia ien
t la ien dung, ien ap, cng o dong ien va thi gian gia
cong. ien ap khong nguy hiem ve tiep xuc ien, ch la <32V.
Can phai chu y en quan he gia ien dung va cng o dong
ien sao cho khong e phat sinh ho quang ien. Cong suat
Hnh 5.54 :
S o nguen ly thiet b lam cng be mat bang tia la ien.
Z: Tong tr; E: Chnh lu; R: ien tr; C: Tu; Vi: Bo dao
ong; M: Vat gia cong (dung cu); T: Ban may
Trang - 194 -
tang th lam tang lp be mat c lam cng nhng no tr nen
su s hn. Duy tr ung thi gian gia cong la rat quan trong.
Thi gian qua dai th co the lam chay be mat. e kiem tra be
mat th sau khi anh sach se be mat bang ban chai ong se soi
knh hien vi. Neu be mat co anh bac, khong co bien mau khac
th at. Vi thep gio a c gia cong nh vay th at o cng
65-68 HRc.
+ Nguyen lieu lam ien cc co the la hp kim cng,
grafit hoac gang. Kch thc thch hp la 2 x 20mm.
+ Hien nay phng phap gia cong nay a c ap dung
thanh cong e lam cng be mat cac dung cu sau ay : dao cat,
got go, dao cat kim loai, khuon ren, dao cat, co van, canh bm
nc, mui khoan mo, khoan a, mui uc a, cac chi tiet may
nong nghiep. oi vi dao cat got kim loai, trc khi lam cng
th can phai mai cac canh dao that ky. ien cc c a i
song song vi canh cua dao, khoang cach vi canh ch c
0,1-0,3 mm, neu khong th canh cua dao se b pha v. a
ien cc i suot be mat. Be rong c lam cng t 1 en 4
mm, tuy theo dung cu gia cong.
+ Ngi ta thng lam cng be mat, mat nao phai chu
nhieu tac dung nhat, tc la mat trc cua dao tien tho, mat
lng cua dao tien tinh, mat lng cua dao phay, mat lng va
canh trc cua mui khoan v. v. . .
Hnh 5.55 :
Lam cng be mat lng cua dao tien tinh, be
mat a toi cua mui khoan
Trang - 195 -
+ Cong nghe lam cng be mat bang tia la ien la cong
nghe n gian, cong nhan co tay nghe khong cao lam cung co
the thc hien c. Nang suat lao ong cung tng oi cao. V
du muon lam cng mot be mat 1 cm
2
ch can thi gian t 30
giay en 1 phut.
+ Khi to chc ni gia cong, can chu y en tac dung lam
loa mat cua tia la ien, do o phai co anh sang manh e
chieu sang ni lam viec.
+ Tnh chu nhiet mai mon cua dao c tang len ang
ke, song cung cha bang vi hp kim cng. Trong qua trnh s
dung, khong c tang qua ln toc o cat, va no cung khong
co kha nang gia cong c nhng vat lieu ma dao cat che tao
bang thep dung cu a khong thc hien c.
VIII. ac diem va pham vi ung dung :
1) ac iem :
- Gia cong tia la ien chu yeu e gia cong nhng vat
lieu kho gia cong ma cac phng phap truyen thong khong
lam c.
- Nang suat gia cong phu thuoc vao vat lieu ien cc va
toc o tien cua dung cu.
- o chnh xac phu thuoc cac yeu to : o chnh xac may,
dung cu, khe h phong ien, . . .
- o nham be mat phu thuoc vao nang lng mot lan
phong ien.
- ien ap lam viec cua thiet b ln hn 42V nen rat nguy
hiem, khi chuan b gia cong phai ong bo phan bao che roi
mi khi ong may.
- Nhc iem quan trong cua gia cong tia la ien la thiet
b tng oi at tien, so vi phng phap gia cong cat got th
nang suat thap hn, lai s dung ien cc vi so lng ln.
nhng may ln th o nham be mat ln, lp be mat sau khi gia
Trang - 196 -
cong con mot so tnh chat bat li. Do o khi ng dung phng
phap nay can phai co s can nhac nhat nh.
2) Pham vi ng dung va tnh kinh te khi gia cong tia la
ien :
- Pham vi ng dung quan trong nhat cua phng phap nay
la gia cong kim loai co o cng khong gii han. e gia cong
th no co li the la tao hnh mot cach t ong ranh cat va ranh
thoat hnh con, co the gia cong chi tiet co hnh dang phc tap
vi o chnh xac phu hp.
- Co the thay the cho phng phap cat got truyen thong
trong nhng trng hp phng phap nay khong kinh te hoac
khong at o chnh xac mong muon.
- Trong mot so trng hp, no co the giup bo nhng quy
trnh trung gian nao o nh nhiet luyen, nan thang, sa bavia,
lap chi tiet, dao, .v.v.
- Co the s dung phng phap nay trong mot so trng
hp sau : Bien cng be mat chi tiet, lam tang kha nang mai
mon. Che tao va phuc hoi cac khuon dap a toi va khuon bang
hp kim cng. Cac li sang, ray bang cach gia cong ong thi
cac lo bang ien cc rat manh. Mai phang, mai tron, mai sac
hoac lam rong lo. Gia cong cac lo co ng knh nho 0,15mm
cua cac voi phun cao ap co nang suat cao (t 15 en 30
s/chiec), gia cong lo sau t 60mm cho sai so 5m. Lay cac
dung cu b gay va ket trong chi tiet (bulon, taro . . .). Gia cong
khuon mau va cac chi tiet can o chnh xac cao bang vat lieu
hp kim cng, v.v
- Hien nay phng phap nay c ap dung e lam cng
cac dung cu sau : Dao cat got go, dao cat kim loai, Khuon ren
dao cat, canh bm nc, mui khoan nho, khoan a, mui uc
a, cac chi tiet may cong nghiep.
- Do tnh chat phc tap cua cong nghe, ma khong the noi
mot cach nhat quan ve tnh kinh te. No phu thuoc rat nhieu
Trang - 197 -
vao nhiem vu a cho, v vay phai xem xet trong tng trng
hp cu the. Trong bang di ay la nhng so lieu co tnh chat
thong tin ve thi gian e che tao dung cu ep nha co kch
thc ln, khi gia cong bang cat got va gia cong bang tia la
ien.
Bang 5.7 :
Thi gian can thiet e che tao khuon ep nha gia cong cat got
va tia la ien
Gia cong truyen
thong
Gia cong tia la ien
NG DUNG
Gi Gi Gi Gi Gi Gi Gi Gi
Tam noi
Chot ch thap
au
Long ong m
Mam cap cuon
day
Khuon cua en
tn hieu hng
210
160
710
340
50

250
210
130
240
145
85

100
420
290
950
484
135

350
28
44
24,5
15
12

13
105
62
130
60
41

30
90
50
144
156
13

48
223
156
298,5
231
66

91
47
46
69
51,3
51

74
- Cong nghe tia la ien la phng phap gia cong mi, v
vay con nhieu trien vong phat trien na. Trc tien ngi ta co
gang nang cao nang suat cua may, nh o sc manh canh
tranh cua no tang len trong tng trng hp gia cong kim loai
mem chu yeu nh dung loai may phat ieu chnh oc lap ma
nang suat tang len. o th tren hnh 5.56 mo ta s tang trng
cua nang suat. Ve phng dien o chnh xac cung co s phat
trien quan trong. Hien nay co the at o chnh xac 0,005mm,
khi thiet ke may ngi ta lo lc nhieu e giam o hao mon cua
Trang - 198 -
ien cc. Ngay nay ngi ta con che tao nhng may chuyen
dung c ieu khien bang chng trnh so.

- nc ta con qua t may gia cong tia la ien c s
dung trong cong nghiep, v vay chung ta con rat nhieu viec
phai lam e cho ky thuat gia cong hien ai nay ngay cang
c ng dung rong rai va mang lai hieu qua kinh te lp.
Hnh 5.56 :
S tang trng cua nang suat
Trang - 199 -
B - PHUONG PHAP GlA CONG CAT
DAY TlA LUA lEN
(Electric Discharge wire Cutting - wire EDM)
nghien cu co kha nang sau :
- Hieu khai niem gia cong cat day tia la ien.
- Hieu, biet nguyen ly gia cong bang cat day tia la ien.
- Tng minh dung cu va thiet b.

I. Khai niem :
La phng phap gia cong tia la ien nhng khac cho
ien cc c lam bang mot day manh, c cuon lien tuc
chay theo ng gia cong nh trc.
T khi ky thuat NC/CNC c s dung rong rai, may tia la
ien co ien cc cat khong phai dang nh hnh, ma la day kim
loai c ap dung a phat trien nhanh chong. ay la may
EDM bang day, nen goi la may cat day tia la ien.
- Tng t nh gia cong tia la ien. Nhng co them mot
cong oan : Day ien cc c hng rat thang, o la mot
yeu cau vo cung thiet yeu, v vay tng oan no c nung
nong bang dong ien va c keo cang ra, trong qua trnh o
no c lam nguoi va mat i trang thai b cong. Day c
luong dan qua khe lo dan hng en vat gia cong, e tranh
day b uon cong.
- Trong trng hp nay ien cc la mot day ong, vonphram
hoac molipden (hnh 5.58). Phoi 1 c ga tren ban may co
kha nang dch chuyen i lai theo hai hng vuong goc vi
Trang - 200 -
nhau. Day ien cc 3 (hay ien cc day) c chuyen t cuon
day 4 sang cuon day 5 nh mot ong c chuyen dung. Cac con
lan dan hng 2 va 7 c dung e gi day ien cc tng oi
so vi phoi 1. Qua trnh cat ranh prophin c thc hien theo
dng 6 hoac theo chng trnh phan mem cua may. Dng 6
co the kep chat hoac dan (bang keo) tren phoi 1.

Hnh 5.57 :
S o nguyen ly gia cong
cat day tia la ien
Hnh 5.58 :
S o gia cong bang ien cc day.
1) Phoi
2,7) Cac con lan dan hng
3) Day ien cc;
4,5) Cac cuon day
6) Dng chep hnh
Trang - 201 -
III. Dung cu va IhieI bj :
1) Thiet b :
- May gia cong cat day (Wire-cut EDM Machine) la may
gia cong ien an mon s dung cac chuyen ong ieu khien
theo chng trnh so e gia cong cac ng bao theo mong
muon, hoac e tao hnh be mat ma khong can dung cac ien
cc co dang ac biet. May cat day tia la ien s dung mot
day chuyen ong lien tuc nh mot ien cc. ien cc (day cat)
co the che tao t ong thau, ong o hay bat k mot vat lieu
dan ien nao khac, ng knh t 0,05 en 0,3 mm. ng i
cua day cat c ieu khien theo mot ng bao nam trong he
truc toa o XY, cat thanh mot khe h nho xuyen qua chi tiet
gia cong. Chuyen ong c ieu khien nay tao thanh mot
ng lien tuc vi o chnh xac khoang 0,001 mm va chuyen
ong nay phai c cai san trong may.
* May cat day tia la ien NC 4532 3 :
- May 45323 la may day ien cc ieu khien so dung
e gia cong cac loai khuon, mau, dng, dao . . . bang vat lieu
hp kim cng, gom, hp kim kim loai gom, kim loai mau .v.v
ien cc cat la day quan lien tuc co ng knh t 0,050.3
mm. Gia cong c thc hien trong dung dch nc ky thuat
hoac dau hoa. Nguon ien dung may phat tiristo xung ngan.
- ac tnh k thuat :
Kch thc ln nhat cua chi tiet gia cong : 250x160x75mm
Trong lng ln nhat cua chi tiet gia cong: 45kg
o chnh xac bien dang gia cong : 0,032mm
Nang suat gia cong : Thep : 35mm
2
/phut
Hp kim cng: 18 mm
2
/phut
ong : 36 mm
2
/phut
Kch thc may : 1200x790x1570 mm
Trang - 202 -

Hnh 5.59 :
S o ong may NC 45323
Trang - 203 -
May dung bo ieu khien NC Kontur 2-67 vi c cau
cau noi suy ng. May cung co the trang b may tnh mini va
nh the co the dung chng trnh bang xuyen lo, bang t hoac
ban phm.
- Truyen ong cua may : Trong than may at chau dung
dch gia cong va cac c cau dch chuyen toa o. May co cac
xch truyen ong nh sau
+ XIcl nung cluu uung ucl : Trong chau dung
dch 1 at ban may dang ch L ngc 2. Tren ban may lap chi
tiet gia cong va c nang, ha nh ong c
1
co N=0,18 kW,
n = 2800 vong/phut, qua c cau truc vt- banh vit
77
2
ti truc
vit II co bc t = 4 mm vi lng di ong la :
s = 2800 ph / mm 300 4 .
77
2
=
+ XIcl uI dong gIu uuy : Chuyen ong tao hnh la
chuyen ong tng oi trong mat phang nam ngang cua day
at tren gia day 3 di ong theo hai hng thang goc nhau. Gia
day dung e ieu chnh va kep chat cac thiet b va c cau am
bao viec quan va cang day ien cc. Cac c cau thc hien cac
chuyen ong nay eu at trong cac than rieng, di ong tren
cac song lan t hai ong c bc
2
va
3
qua hai hop toc o
co hai cap banh rang nh nhau. ong c bc nhan cac xung
t bo ieu khien so. Moi xung lam truc ong c quay 1,5
0
, tc
la truc vitme V hoac IX co bc ren t = 5mm se di ong gia 3
theo hng ng hoac ngang mot ai lng
mm 002 , 0 5 .
75
24
.
60
18
.
360
5 , 1
0
0
=
Di ong doc bang tay : thc hien trc tiep bang cach
quay truc vitme IX
Trang - 204 -
Di ong ngang bang tay : bang cach quay truc VI qua
cap banh rang
28
28
e quay truc vitme V
+ XIcl quun uuy : e khac phuc anh hng o an
mon day ien cc, ta cho no chuyen ong vi toc o khong ln
trong qua trnh gia cong. Viec quan day c thc hien t
ong c
4
co N = 10 W va n = 1200 vong/phut qua puli chu
ong co ng knh 45mm. Toc o quan c ieu chnh
trong pham vi 820 mm/s bang cach thay oi so vong quay
ong c
4
. Chuyen ong c truyen qua day ai 4 quay cuoc
day ien cc a gia cong 5. Hng chuyen ong cua day
vung lam viec la t tren i xuong. Sap xep day ien cc tren
ong bang chuyen ong thang i- ve cua truc ong. Xch nay
cung c thc hien cung t ong c ien
4
, qua ba cap banh
rang co ty so truyen
80
20
quay cam mat au 6 va on bay 7.
2) Dung cu :
- oi vi may gia cong cat day, vat lieu lam ien cc
phai co cac tnh chat sau :
+ Co tnh dan ien tot.
+ Co o gian dai cao.
+ Co nhiet o nong chay cao.
+ Co tnh dan nhiet tot.
- Day ien cc thng dung co ng knh t 0,020,3
mm bang vat lieu ong thau. oi vi cac day ng knh nho,
thng dung volfram, molibden hay tungsten v cac loai nay co
o ben keo cao, o nong chay cao. Khi cat ranh, chieu rong
mach cat c xac nh bang ng knh day, khoang cach
phong ien, che o cat va o nhan yeu cau.
Trang - 205 -
Bang 5.8 :
Mot so loai day cat dung trong cat day tia la ien.
ong o, bac, kem ong thau
ng knh
day cat (mm)
Khoi lng
(g)
ng knh
day cat (mm)
Khoi lng
(g)
0,05
0,07
0,10
0,12
0,15
0,17
0,20
0,22
0,25
0,27
0,60
200
300
400
500
600
700
800
900
1000
1100
1200
0,05
0,07
0,10
0,12
0,15
0,17
0,20
0,22
0,25
0,27
0,60
100
150
200
250
300
350
400
450
500
550
600
3) Dung moi dung trong gia cong :
- Dung moi (dung dch) e gia cong la au hoa hoac nc.
Trong trng hp dung dau hoa th phoi phai c mgam trong
dau hoa, con trong trng hp dung nc th can phun tia vao
vung gia cong.
- Dung moi co anh hng ln en o on nh va nang suat
gia cong. Dau hoa va nc co o nht va mat o khac nhau rat
t nhng tnh dan ien cua nc ln hn tnh dan ien cua dau
khoang 40 lan.
- Khi dung dung moi la nc cat, nang suat gia cong cac
kim loai mau (ong, niken, nhom, v.v) at 10-20 mm
2
/phut,
nang suat gia cong thep (thep ket cau, thep dung cu, thep
khong g) at 5-8 mm
2
/phut, nang suat gia cong hp kim cng
(BK8; BK20M) at 6-12 mm
2
/phut.
Trang - 206 -
IV. Cac Ihong so cong nghe :
- Nang suat cua phng phap c xac nh bang toc o
tang dien tch cua be mat ranh F (mm
2
/phut) :
F =
H . L

ay : L - chieu dai ranh (mm)
H - chieu dai cua phoi (mm)
J - thi gian cat ranh (phut)
- o chnh xac gia cong co the at 0,2-0,3 mm. o chnh
xac nay phu thuoc vao cac yeu to sau ay :
+ Sai so cua he thong o cua may.
+ Sai so cua quy ao chuyen ong cua ban may.
+ Rung ong cua may.
+ o cng vng cua may.
- Be rong cua ranh b (mm) c gia cong bang ien cc day
co ng knh d (mm) c xac nh theo cong thc :
b = d + 2a
ay: a - khe h mot pha gia day ien cc va mat ranh
(mm)
- Can nh rang khi gia cong chi tiet co chieu dai ln (>30
mm), ranh gia co be rong ln hn hai au, ngha la xuat
hien sai so hnh dang, c goi la o tang trong. sai so nay co
the c giam nh ieu chnh dung cu ung hng keo cang
day ien cc.
V. Uu - Nhuoc diem pham vi ung dung :
- May day ien cc hien ai eu c ieu khien bang he
thong NC/CNC. No c s dung rong rai trong nganh che tao
dung cu, ien t, c kh chnh xac e gia cong cac lo va ranh
hep, h va thong suot, gia cong cac bien dang phc tap thang
va cong, cac ranh co o chnh xac cao, gia cong cac cam a
Trang - 207 -
hp kim cng, gia cong cac dng chep hnh, cac khuong mau
va cac loai banh rang thang an khp trong va ngoai, v.v
- u iem chnh cua phng phap la o chnh xac gia cong
cao, ket cau cua may n gian va co kha nang t ong hoa
nguyen cong.
Trang - 208 -
C - PHUONG PHAP GlA CONG
CHUM lEN TU
(Electron Beam Machining - EBM)
nghien cu co kha nang sau :
- Hieu khai niem gia cong bang chum ien t.
- Hieu, biet nguyen ly gia cong bang chum ien t.
- Tng minh ve c s ly thuyet gia cong bang chum ien
t.
- Tng minh ve dung cu va thiet b
- Hieu pham vi ng dung va hng phat trien
- Hieu, biet u va nhc iem gia cong chum ien t.

I. Khai niem :
T lau ngi ta s dung nang lng cua ien t chuyen
ong vi toc o cao vao en Rngen, en ien t va knh hien
vi ien t .v.v. Trong cac thiet b tren phan ln nang lng cua
ien t b ton that di dang nhiet nang. Muc ch cua cong
nghe gia cong bang tia ien t chnh la bien oi ien nang cua
ien t thanh nhiet nang vi ty le cao hn va nh vay bang
cach lam nong cuc bo ma ta co the tien hanh nhieu phng
phap gia cong bang nhiet khac nhau. Noi chung gia cong bang
chum tia ien t (EBM) la phng phap gia cong dung nang
lng chum tia ien t hoi tu tai be mat gia cong lam nong
chay va boc hi vat lieu.
Trang - 209 -
- Nguyen ly hoat ong chung cua chum tia ien t c
trnh bay tren hnh 5.60. Chum tia ien t c phat ra t
Cathod 1 cua au phat tia. Cac ien t chuyen ong vi toc o
rat cao va hoi tu lai nh thau knh ien t 4 thanh vet rat nho
len be mat gia cong 5. Cac ien t va ap vao be mat gia cong
va chuyen ong nang thanh nhiet nang nung nong, lam chay
hoac boc hi bat ky vat lieu nao.

- Trong hnh 5.61, noi rat ro ve s o gia cong chum tia ien
t. Ban chat cua phng phap gia cong bang chum tia ien t
nh sau: chi tiet gia cong 4 c at trong mot buong chan
khong 3, mot chum tia ien t co toc o va ong ln c tap
trung hng vao be mat cua chi tiet gia cong, nung nong no va
Hnh 5.60 :
Nguyen ly tao chum tia ien t.
1. Catod b nong
2. Mui hoi tu
3. Anod
4. thau knh ien t e hoi tu
Trang - 210 -
lam boc hi vat lieu gia cong. Nguon sinh ra ien t t do
thong thng la mot si day vonphram 1 (cc am). Nang lng
cao cua cac ien t at c nh ien the cao c tao ra bang
cc dng 8. Cac ien t chuyen ong (tap trung thanh chum
tia) hng ti chi tiet gia cong vi toc o gan bang toc o cua
anh sang. ng knh cua chum tia sau khi i qua he thong tap
trung 2 va thau knh t 6 co the at ti phan tram hoac phan
nghn mm, con mat o cong suat co the at ti vai nghn kW
tren 1mm
2
. Nang lng tac ong c o bang cac xung co
thi gian 10
-3
10
-4
giay. Khi gap be mat gia cong, nang lng
cua chum tia ien t chuyen thanh nhiet nang va nung nong
cuc bo lp be mat gia cong. Neu vung tiep xuc trc tiep cua
chum tia vi chi tiet gia cong nhiet o len en 300-4000
o
C
cach o khoang 1m nhiet o khong vt qua 300
o
C. Cach
truyen nhiet nh vay cho phep gia cong bat ky vat lieu nao ma
khong anh hng en cau truc cua vat lieu vung ngoai gia
cong. e quan sat qua trnh gia cong ngi ta lap them he
thong quang hoc 7. He thong 5 co tac dung anh nghieng
chum tia i mot goc mong muon.
- Can nh rang oi vi nhieu loai vat lieu chieu sau tham
nhap cua chum tia ien t (chieu sau gia cong) co the ln gap
100 lan ng knh. Nh vay, chum tia tap trung co ng knh
0,01 mm cho phep cat t tam day 1 mm. Bang chum tia ien
t co the gia cong lo neu dung he thong anh nghieng chum
tia 5 tren hnh 5.61 (xem he thong 1 tren hnh 5.62) hoac c
cau dch chuyen phoi tng oi so vi chum tia (ban ch thap)
ong thi co the cat t va phay cac mat nh hnh trong cung
nh ngoai hoac cat bien dang tren phoi tam 2 ( hnh 5.62).
- Chu ky gia cong chi tiec tren may co s dung chum tia
ien t co the c t ong hoa hoac ieu khien theo chng
trnh so.
Trang - 211 -

Hnh 5.61 :
S o gia cong
bang chum tia ien
t.
1) Cc am
2) He thong tap
trung chum tia
3) Buongchan
khong
5) He thong anh
nghieng chum tia
6) Thau knh t
7) He thong quang
hoc
8) Cc dng.
Hnh 2.62 :
S o cat bien dang bang
chum tia ien t.
1) He thong anh nghieng
chum tia.
2) Phoi tam.
Trang - 212 -
III .Co so Iy IhuyeI :
- Neu nhng tia co nang lng cc ln c phong len kim
loai hoac mot vat lieu trong suot khac th nang lng am
thung vi o sau nho vao vat lieu, ong thi phan ln nang
lng c bien thanh nhiet nang.
- Neu mat o nang lng cua chum tia u ln th be mat co
the nong chay va boc hi cuc bo.
- Khi nhiet sinh ra i vao vat chat bang con ng truyen
dan. Cach tao ra chum tia co nang lng ln tng t nh cach
tao chum tia sang bang he thong quang hoc.

- Trong he thong quang hoc chum tia anh sang i t nguon
sang S tap trung bien thanh chum tia song song ma tieu c
c ieu chnh bang lang knh th hai (lang knh th nhat co
tieu c nguon sang S). Bang cach tng t nh the, nhng
ien t phong ra t mot day kim loai nung nong c chuan
Hnh 5.63 :
He thong quang va he thong tia ien t
A. He thong knh quang hoc
B. He thong quang ien t.
Trang - 213 -
trc do tac dung ien trng cua tam ien cc th nhat va sau
o do tac dung hieu the gia hai tam ien cc c gia toc.
Sung ien t c at trong chan khong nay phong ra chum tia
ien t c hoi tu nh mot cuon day ien t (lang knh). Neu
thiet ky nguon phong ien t va he thong hoi tu, th tieu c
co the co mot chum tia rat nho. Mat o nang lng cua tia
ien t nh the co the vt qua 10
8
w/cm
2
. Tac dung cua tia
dien ra trong thi gian rat ngan, nen ch co the xay ra s nung
nong cuc bo phu thuoc vao kha nang dan nhiet.
- Co the ieu khien nhanh chong tia ien t, nh vay trong
10
-6
giay co the phong ra ien t va co the ieu chnh chnh
xac cong suat.
- Trong qua trnh gia cong (v du phay) dung cu (tia la
ien) phai chuyen ong. Vi ien trng hoac t trng ngoai,
tia ien t co the phong vi toc o100 m/giay. V du khi gia
cong ban dan qua trnh gia cong co the ieu khien theo chng
trnh va do vay se at c hieu qua rat cao.
- Ch co the s dung tia ien t trong chan khong va ngi
ta co the tao ra chan khong nh co may bm chan khong cong
suat ln va buong chan khong ln.
IV. Dung cu va IhieI bj :
- Cac loai may s dung tia ien t chu yeu la may khoan,
phay va cat. Trong thiet khoan va phay ng knh cua tia
ien t thong thng nho hn 10 m va t o dao ong cua
ien ap cho phep toi a bang 1/10
3
-1/10
4
cua ien ap nh
mc, yeu cau nay c giai quyet nh co he dao ong co tan
so t 30 en 100 khz va bo khuyech ai ien ap, cach nay co
li v noi tr cua nguon dao ong vi cng o dong ien phu
tai a cho sfx tang theo ham mu. Trng hp co s co th se
khong co dong ien ngan mach keo dai ma co the lam h thiet
b hoac gay tai nan chet ngi.
Trang - 214 -
- Nhng yeu cau ky thuat oi vi thiet b gia cong bang tia
ien t la:
+ Mat o cong suat tap trung cao tren mot dien tch nho.
+ Viec cung cap nang lng lien tuc ch keo dai trong thi
gian ngan.
+ Phoi hp khoang cach tac dung cua tia ien t vi ien
ap lam gia toc ien t.
+ Bao am ieu khien va dan tia ien t theo yeu cau gia
cong.
- Thiet b khoan bang chum tia ien t :
+ May khoan tia ien t dung e khoan cac lo nho (co
ng knh khoang 10 m) nhng cho kho gia cong nh canh
turbin, buong ot cua turbin may bay trc thang, ac biet
nhng lo lech vi mat phang (co the lech en 20
o
), co bien
dang phc tap va nhieu.
+ V du buong ot cua turbin may trc thang co hn 3700
lo vi nhieu ng knh khac nhau, at sai lech nhau vi dung
sai khong qua 0,1 mm, co nhieu lo lech so vi mat phang.
Toan bo chu trnh gia cong ieu khien bang CNC ch ton 40
phut, bao gom thi gian thay phoi, ga at, nh v, tao chan
khong buong lam viec.
+ May co the lam lech tia neu dung mot lang knh va hai
cuon day lam lech tia. Chum tia co the chuyen ong vi van
toc v 10
6
10
7
m/s. T le gia chieu sau va ng lo co the
at L/d = 220 vi d = 1030 m.
+ Nguon ien ap toi a 150 kV. Cong suat can thiet e
khoan la 20-60 kW. Dung sai o lech cua iem ien t phong
quyet nh s dao ong cho phep va s on nh bat buoc cua
ien ap nguon.
+ Muon khoan th phai tap trung tia vao mot iem, muon
xe ranh hoac phay mat phang th di ong tia. Neu ng knh
cua tia tang len cho phong len mat phang, th co the gia
Trang - 215 -
cong lo hoac ranh to hn. e khoan ngi ta thng dung ban
toa o at trong chan khong. Nh vay co the at nhieu vat gia
cong nhng khoang cach nhat nh. Co the lam lech tia ien
t khi khoan cac lo cach nhau, nhng ng tam cua lo se
khong thang goc vi mat phang. Khi phay ranh ac biet ranh
khong sau, th cho tia chieu lech va at ket qua theo yeu cau.

- Phay bang chum tia ien t : co the phay ranh rong t
1020 m
Hnh 5.64 :
Thiet b khoan bang
chum tia ien t.
a. Catod
b. Lang knh Wehnelt
c. Anod;
d. He thong ieu chnh
e. Tam ngan co knh
bang Vonfram
f. Knh hien vi Stereo
g. Knh bao ve
h. Lang knh t trng
i. Cuon day ien trng
e lech tia
j. Tia ien t
k. Vat gia cong
Trang - 216 -
- Cat t bang chum tia ien t : cac loai mang mong trong
c kh chnh xac, trong cong nghe vi ien t. Cat t, cung nh
khoan, phay cac vat lieu rat cng nh thep, wolfram, platin,
titan, molipden, silic, kim cng, thuy tinh .v.v.
- e gia cong bang tia ien t can co thiet b chuyen dung
e tao ra chum tia ien t va lam chung chuyen ong vi toc
o rat cao :v 10
6
-10
7
(m/s), van toc cac ien t c xac nh
bang cong thc :

7
g
U 10 . 93 , 5 v = hay
7
g
U 600 v = km/s
Trong o:U
g
ien the gia toc (Volt).
- Cong suat cua chum tia ien t c truyen i (khong ke
s tieu hao do phan xa va bc xa) tnh theo cong thc :
W
ch
= I . U
g

Trong o: I Cng o dong ien cua chum tia ien t
(Ampe).
- ong nang cua mot ien t trong ien trng la :
W

= m . v
2
/2 = e . U
g

Trong o:
m Khoi lng cua mot ien t, m = 9,1.10
-29
(gam);
V Van toc chuyen ong cua ien t
e ien tch cua ien t, e = 1,6.10
-19
(Coulomb)
U Hieu ien the cua moi trng ien t i qua (V)
- Khi hoi tu chum tia tren be mat gia cong, cac ien t va
ap len o, toan bo ong nang cua chung se bien thanh nhiet
nang th cong suat cua nang lng o c xac nh gan ung
theo cong thc sau :
P = I . U
g
va I = n . e/t
Trong o:
I - Cng o dong ien cua chum tia (Ampe)
n - So lng ien t trong chum tia
Trang - 217 -
t - thi gian (s)
U
g
- ien the gia toc (Volt).
- o chnh xac gia cong : Hng va cng o cua tia ien t
co the ieu khien c,v vay co the am bao gia cong chnh
xac. Co the phay nhng rang rong 10-20 :m, cach nhau 10-20
:m, co canh goc thang va hoan toan song song vi nhau. Co
the kiem tra o chnh xac bang knh hiem vi. o sau phay co
the thc hien c bang cach ieu chnh nang lng va cng
o cua tia ien t. Co the khoan lo vi o chnh xac cao.
Nhng can lu y rang khi khoan lo sau (L/d=2-20) th giai
oan b that lai o o van lo co ng knh 10-30 :m en
1/1000 :m. o o van nay khong ang ke so vi ng knh lo.
ng knh lo ln hn ng knh cua tia ien t. Be mat gia
cong c trn bong khi khoan cung nh phay. Khi thc hien
cac nguyen cong khac nhau nh han, nung chay, gia cong at
kch thc v.v chum tia ien t can phai co mat o nang
lng can thiet, xac nh theo cong thc :

)
d
d
lg( . d
1
. T . . 47 , 3 W
o
e
e
c md
=
Trong o:
W
md
- Mat o nang lng tao nen s chay long trong
vung co ng knh bang chieu day cua kim loai (W/cm
2
)
T
c
Nhiet o chay cua kim loai (
o
C)
8 - He so dan nhiet cua kim loai (W/cm
2
.
o
C)
d
o
ng knh phan na tren vien ngoai cua no co
nhiet o T
o
= 0 va khong thay oi (mm).
Trong bang 5.5 co tr so cua mat o nang lng e lam
chay mot so kim loai trong ieu kien d
o
= 2mm, d
o
= 10 d
e
, h =
d
e

Trang - 218 -
Bang 5.9 :
Tr so mat o nang lng e lam chay mot so kim loai
Kim loai W/cm
2
Tc,
o
C Wm,
W/cm
2

Toc o chay
Vc,cm/s
Vonfram
Dong
Bac
Molipden
Vang
Nhom
Berilli
Tantan
Sat
Manhe
Niken
Thep khong r
Kem
Uran
Titan
zirconium
4940
4000
3890
3730
3250
2790
2745
2093
1230
1090
600
520
440
378
315
296

3377
1087
960
2577
1063
659
1284
2994
1539
650
1455
1425
420
1130
1672
1859
865
700
680
653
658
488
480
367
215
191
105
91
77
66
55
52
1,36.10
-5
3,97.10
-7
4,12.10
-7

7,86.10
-7

5,80.10
-8
2,57.10
-11
7,14.10
-6
4,95.10
-6

3,90.10
-6

1,36.10
-2
6,04.10
-6

6,04.10
-6

1,23.10
-4
1,28.10
-11
0,42.10
-6
1,85.10
-8
VI. Pha m vi ung dung va huong phaI Irien :
- Pham vi ng dung : Bang tia ien t, noi chung ngi ta
co the gia cong cac vat lieu co cau truc nh thep, wolfram,
platin, tantal, molipden, silic, germani, grafit, kim cng, hong
ngoc, oxit nhom, s, thuy tinh, thach anh va cac hp kim cng
khac do co pham vi s dung rat rong rai va a dang trong lnh
vc c kh chnh xac va trong nhng lnh vc khac. Ngi ta
cung thng s dung e gia cong nhng profin phc tap, phay
ranh, khoan lo tinh vi, va gia cong nhng kch thc nho, khac
hoac nau chay. ac biet dung rat hieu qua e khoan va phay
nhng lo ranh co kch thc t 0,01 en 1 mm, ke ca tren hp
Trang - 219 -
kim cng. Co the gia cong nhng lo trong pham vi 515 mm
vi cong suat trung bnh t 1 en 10 W. T le gia ng knh
va chieu sau la 1:10 en 1:20. Ngoai kim loai, con co the gia
cong co hieu qua tren nhng vat lieu dan ien kem, tren knh,
gom v.vTrong qua trnh gia cong, gian n nhiet rat ln, do o
tranh c rang nt nen nung nong trc vat gia cong.
- Phng hng phat trien : Trong vai nam gan ay ngi
ta mi biet en viec s dung tia ien t nh la mot dung cu e
gia cong vat lieu, mot phan e thc hien cac nhiem vu nghien
cu, mat khac e thc hien nhng van e cong nghe cu the
(nh che tao nhng truc kim cng nho, nhng vanh xuyen
bang nha, gia cong nhng lo ranh trong vat lieu cng khac
nhau). Trong lnh vc c kh chnh xac co nhieu li the trong
viec trien khai cac ng dung cua phng phap nay. ay la mot
cong nghe con non tre, kho ma oan c tam quan trong cua
no trong tng lai xa. Nhng co the khang nh rang co the
ng dung vao viec gia cong nhng vat lieu can thiet cho che
tao may, o la vat lieu kho hoac hoan toan khong gia cong
c (s, thuy tinh, kim loai rat cng ) va v le o cho phep
chung ta hy vong cong nghe nay se c s dung rong rai
trong nganh cong nghiep che tao may.
VII. Uu - Nhuoc diem :
- u iem :
+ Co the gia cong bat ky loai vat lieu nao.
+ Mat o cong suat ln (MW/cm
2
).
+ Gia cong chnh xac do kha nang t ham cua ien t
trong mot lp mong cua vat lieu.
+ Co the ieu chnh tc thi cng o va v tr cua tia
ien t.
+ Bao am sach ve mat hoa hoc nh co buong chan
khong.
Trang - 220 -
- Nhc iem :
+ Ch co the gia cong trong buong chan khong.
+ Gia thanh gia cong tng oi cao.
+ Co nguy hiem ve phong xa Rnghen.
Trang - 221 -
D - PHUONG PHAP GlA CONG
CHUM TlA LASER
(Laser Beam Machining - LBM)
- Hieu khai niem gia cong bang chum tia Laser.
- Hieu, biet nguyen ly gia cong bang chum tia Laser.
- Tng minh ve phng phap gia cong chum tia Laser.
- Tng minh thong so cong nghe
- u va nhc iem cua gia cong chum tia Laser.

I. Khai niem :
- Laser c s dung nh la mot dung cu phat ra tia nang
lng tap trung rat manh ma trong tng lai gan trong mot so
lnh vc nao o, no la mot cuoc cach mang ky thuat trong gia
cong kim loai. Hien tai th co the s dung thanh cong trong
viec gia cong sieu tinh, trong cong nghe han nhng iem rat
nho va trong luyen kim. Gia cong chum tia laser la qua trnh
x ly nhiet trong o tia laser c dung lam nong chay va boc
hi vat lieu.
- May tia laze la may cat bang tia sang hoat ong theo che
o xung. Nang lng xung cua no khong ln, nhng no c
hoi tu trong mot chum tia co ng knh khoang 0,01 mm va
phat ra trong khoang thi gian mot phan trieu giay tac ong
vao be mat chi tiet gia cong, nung nong, lam chay va boc hi
vat lieu. Tia sang ay c goi la tia laze, viet tat theo tieng
Anh la LASER (light Amplification Simulated Emission of
Trang - 222 -
Radiation) va thng dch ngha ra tieng Viet la may phat
lng t anh sang
- Hnh 5.65 ch ra nguyen ly gia cong tia lazer tren may
K-3M.

- Nguon ien cong nghiep 1 qua bien the va nan dong c
nap vao he thong tu. ien ap toi a cua tu la 2 kV e ieu
Hnh 5.65 :
Nguyen ly gia cong chum tia laser.
2) Buong phan xa anh sang
3) en phat xung
4) Thanh hong ngoc
5) Gng phan xa toan phan
6) Gng phan xa 50%
7) Thau knh hoi tu
9) Ban ga
10) Te bao quang ien
Trang - 223 -
khien s phong ien ti en phat xung 3 at trong bo phan
phan xa anh sang 2. Bo phan nay co dang hnh tru vi tiet
dien mat tru cat ngang la elp. Khi en 3 phat sang, toan bo
nang lng se tap trung tai v tr co at thanh hong ngoc 4.
Nhng ion Cr
+3
cua thanh hong ngoc b kch len mc nang
lng cao, khi tut xuong chung se phat ra nhng lng t. Nh
he dao ong cua cac gng phang 5 va 6, nhng lng t nay
se i lai nhieu lan qua thanh hong ngoc va kch cac ion Cr
+3

khac e roi cung phong ra chum tia lng t. Gng 5 co o
phan xa anh sang gan 99%, con gng 6 gan 50%. Nh o,
mot mat ta van nhan c chum tia lade pha di, mat khac
khoang 1% chum tia phat ra qua gng 5 se c te bao quang
ien 10 thu lai va qua he thong chuyen oi ta biet c nang
lng cua chum tia a phat ra khoi may. Chum tia nhan c
qua gng 6 se c tap trung bi he quang hoc 7 va tac dung
len chi tiet gia cong 8 (at tren ban may 9) co kha nang di
chuyen toa o theo ba phng X, Y, Z.
- Khi tap trung tia laser vao v tr gia cong can chon he
thong quang hoc va che o gia cong nh nang lng chum tia
ti, thi gian xung tac dung cua chum tia, tieu c cua he thong
quang hoc va so xung laser.
- Qua trnh tac dung cua chum tia laser vao v tr gia cong
c chia ra cac giai oan sau :
+ Vat lieu gia cong hut nang lng cua chum tia laser va
chuyen nang lng nay thanh nhiet nang.
+ ot nong vat lieu gia cong ti nhiet o co the pha hong
vat lieu o. Giai oan nay ng vi qua trnh truyen nhiet trong
vat ran tuyet oi b gii han ve mot pha theo phng tac dung
cua chum tia ke t be mat tac dung..
+ Pha hong vat lieu gia cong va ay chung ra khoi vung
gia cong. Giai oan nay ng vi qua trnh truyen nhiet ma be
Trang - 224 -
mat tac dung luon luon thay oi theo phng tac dung cua
chum tia laser.
+ Vat lieu gia cong nguoi dan sau khi chum tia laser tac
dung xong.
III. Co so cua phuong phap gia cong bang chum
Iia Laser :
- Nam 1954 N. Pronhorop thuoc vien Han Lam Khoa Hoc
Lien Xo va cung luc o P. Godon, H. J. Zeigi va C. H. Taun
thuoc Trng ai Hoc Colombia a c giai thng Nobel ve
viec lan au tien tren the gii a che tao thanh cong may phat
lng t -MASER ma ve sau c thay the bang danh t
LASER (LIGH APLICATION BY STIMULATED EMUSION
OF RADIOTION)- Co ngha la s khuech ai anh sang bang
bc xa cng bc.
- Laser la mot dung cu phat tia sang, co the ra phong xa
song song cc manh. Ve phng dien quang hoc co the hnh
dung nguon sang nay nh la mot iem sang at trong vo cc,
nho en mc kch thc cua mot iem cham. iem anh sang
la thng nay phong ra nang lng bang nhng nguyen t
c kch thch trong trang thai kha on nh (metastabil).
- Tren s o nguyen l lam viec cua laser co the thay mot
khong gian quang hoc cha ng thanh laser, khong gian Laser
nay la mot dung cu phat tia sang, co the ra phong xa song song
cc manh. Ve phng dien quang hoc co the hnh dung nguon
sang nay nh la mot iem sang at trong vo cc, nho en mc
kch thc cua mot iem cham. iem anh sang la thng nay
phong ra nang lng bang nhng nguyen t c kch thch
trong trang thai kha on nh (metastabily chung la hai pha
la hai knh phan chieu, va gia chung la thanh laser, nhng
nguyen t cua no b kch thch vao nhng trang thai kha on
nh, nhng photon c phong ra. Photon phong ra t pha
Trang - 225 -
nhng trong so o nhieu photon hng vao truc quang hoc cua
thanh laser. Trong luc o co nhng nguyen t ang trang thai
b kch thch va cham nhau, va do o photon tiep tuc c
phong ra, nhng photon nay noi tiep nhng photon trc ve
pha cung nh ve hng. Qua trnh nay tiep dien cho en luc
cac photon chuyen ong doc theo truc quang hoc va sau nhieu
lan phan xa tr lai, mot phan cua chung ri bo au ra cua
thanh laser. ay mot bo phan i qua knh phan chieu bo
phan, con bo phan khac c phan xa tr ve thanh laser co
mot phan chieu 100%, mat ra cua no nh hng cho nhng
tia sang ap len no.

- Khi tia sang a xuyen qua knh phan chieu au ra, th
hnh thanh mot tia noi tiep nhau, a c chuan trc rat manh.
Tia laser c hnh thanh nh vay co the c s dung nh la
mot dung cu lam viec che o xung. Tia anh sang c ieu
chnh tieu c, hng vao mat phang cua vat gia cong, tuy theo
kha nang hap thu cua vat lieu ma tren lp be mat se co nhiet
o cc cao. V du: chieu vao mot khoi than tia laser trong choc
lat se co mot ngon la phut len cao va trong mot mili giay
nhiet o cuc bo co the tang len en 8000
o
C.
- Noi tom lai, cac photon trong ieu kien nao o, co the
kch thch cac nguyen t cua vat chat va cac phan t hay
nguyen t nay se bc xa ra cac photon th cap giong y nh
Hnh 5.66 :
S o nguyen ly lam
viec cua laser
Trang - 226 -
vay. Cac photon th cap nay cung pha vi cac photon ban au.
Nh vay trong vat chat co the xuat hien qua trnh nhan photon
va bc xa ra song ien t vi bc song nhat nh. o la
nguyen l chung cua cac loai laser.
- Cac loai tia laser tuy theo yeu cau ky thuat, co the trong
cac moi trng hoat tnh khac nhau : moi trng kh, moi
trng ran, moi trng long, moi trng ban dan.
+ Moi trng kh : Loai Laser kh c pho bien kha rong
rai, s kch thch phong ien va ieu khien no tng oi n
gian. Co 3 loai laser kh : loai nguyen t trung hoa, loai ion
hoa va loai phan t. Hien nay c dung pho bien nhat la
laser CO
2
. Laser kh CO
2
co the dung dang tinh khiet va
neu them vao cac kh N
2
hoac H
2
theo t le nao o th se han
che c ton that do nang lng bc xa nhiet va do o hieu
suat cua laser kh CO
2
cung co the c tang them.
+ Moi trng ran : trong cac tia laser ran moi trng hoat
tnh la chat ran thng la hong ngoc nhan tao (Meiman che
tao ra nam 1960). Ngoai hong ngoc ra ngi ta con s dung
mot so loai khac nh : hp chat thuy tinh Ne-o-din Nd, Cu-
ropi-Eu.
+ Moi trng ban dan : Tren ly thuyet moi cap electron
va 2 lo trong gap nhau, chung se trung hoa vi nhau va phat
ra anh sang. Do hieu suat cua moi laser ban dan chung ta co
the bien oi c cong suat cua chung bang phng phap bien
oi dong ien kch thch v vay c ap dung rong rai trong
cong nghiep ien t.
- Laser dang long cha ng dung c e gia cong kim loai
ngay ca trong phong th nghiem. Hien nay ngi ta ang tiep
tuc nghien cu ng dung laser trang thai ran vao gia cong kim
loai. Phan ln laser trang thai ran dung thanh rubin nhan tao
mau hong (thanh hong ngoc). Theo s o khoi thiet b laser
cho thay v tr at vat lieu laser trong he thong thiet b.
Trang - 227 -

IV. Dung cu va IhieI bj gia cong :
- Tren c s o may phat tia laser e gia cong kim loai gom
3 bo phan chnh :
+ au phat tia laser.
+ Bo phan cung cap ien va ieu khien.
+ Bo phan ga at chi tiet gia cong.
- e tao laser tren vat the ran ta co the s dung cac tinh the
cua cac khoang chat khac nhau hoac cac thuy tinh cua cac chat
cua cac nguyen to hiem, v du : tinh the hong ngoc (rubi), thuy
tinh neodim (Nd) .v.v.
- Co nhieu cach phan loai laser, nhng thong thng ngi
ta phan loai theo vat lieu cau tao nen moi trng hoat tnh cua
chung. Co 4 loai laser chnh : laser ran, laser long, laser kh va

Hnh 5.67 : S o khoi thiet b Laser
a) Nguon ien cao the va tch tr nang lng
b) Bien ap
c) Thanh hong ngoc
d) en chp
e) Tia laser
Trang - 228 -
laser gama. Nhng thong dung nhat la laser ran (laser hong
ngoc).

- Laser kh CO
2
rat thch hp trong viec gia cong thuy tinh
hap thu toan phan bc song 10, 6m. e cat ong thuy tinh
ngi ta gan chung len gia co the xoay xung quanh truc cua
ong. Thi gian cat phu thuoc vao cong suat cua tia laser, chieu
dai ong thuy tinh nhng moi xung thng khong qua 1/10 giay.
Be mat moi cat khong b rang nt, ieu nay rat quan trong khi
han kn cac chi tiet thuy tinh vi kim loai. Phng phap nay
c ng dung rong rai va co hieu qua kinh te cao trong cong
nghiep san suat thiet b chan khong, en ien t.
- Tap trung tia laser thong qua he thong lang kn va chieu
len mot dien tch nho th co the khoan lo nho tren vat lieu co
nhiet o nong chay cao. Ve phng dien ly thuyet th iem
chieu len be mat vat lieu, ng knh (d) cua cham sang c
bang chieu dai song. Thc te co the tao ra cham sang co
Hnh 5.68 :
S o may phat tia laser kieu
MLC 1
1) May phat quang lng t
2) Mang ngan
3) Ong ngam
4) Vat knh cua knh hien vi
5) Tam knh bao ve
7) Bo nguon
Trang - 229 -
ng knh 100-250 m. Cng o anh sang a c tap trung
bang lang knh gap 40 lan cng o anh sang mat tri.
- Co the khoan lo co ng knh 2-5 m bang he thong lang
knh hoi tu va he thong ieu chnh c kh. Gia cong lo ln hn
vai mm, th dung mot lang knh. Kim loai lo gia cong boc
thanh hi kim loai, co the ieu chnh o sau cua lo bang cach
ieu chnh thi gian va so lan xung phong tia laser.
- Hien nay ngi ta a cai tien va tao ra may gia cong tia
laser ieu khien bang so. o la may CNC, loai may naycho
phep ta gia cong chnh xac va thuan li khi gia cong nhng
hnh dang phc tap. May tia laser thng c che tao theo
dang may khoan, may han, may cat t. Cac loai may mi
thng s dung ccong nghe NC/CNC e ieu khien chuyen
ong cua ban may mang phoi theo toa o X,Y. Khi can thiet
ngi ta cung che tao may tia laze ieu khien CNC 3 toa o
vi viec s dung bo noi suy ng thang va ng cong . . .
- Hnh 5.69 gii thieu s o cau truc cua may laze CNC
SCM-1000 cua hang FEHA GmbH (c).May dung au laze 1
dung nguon laze kh CO
2
. Tia laze c dan qu a gng chan
dong 2, gng dong 3 en he lang knh hoi tu 4 e tac ong
vao be mat chi tiet gia cong 5 qua au cat laze 6. vat lieu b
boc hi trong qua trnh cat c thoi ra ngoai bang kh nen.
Kh nen c a vao cat qua ong 7. e tang hieu qua cat
trong trong mot so vat kieu ngi ta s dung oxy thay khong
kh.
- Thong so ky thuat cua may CNC-1000 gom co :
+Cong suat max : 1 kW
+ Bc song : 10,6 m
+ Van toc cat max : 8 m/phut
+ Kch thc may : 5,2x2,2x1,7 m
- He thong CNC ieu khien hai toa o cua ban may 8 vi o
chnh xac dch chuyen la 2 m.
Trang - 230 -

- Kha nang gia cong lobang tia laser tuy thuoc vao kha nang
hap thu cua vat lieu c bao nhieu lng anh sang va nhiet
o can thiet e lam boc hi vat lieu. o cng cung nh nhng
tnh chat kim loai hoc khong co y ngha g. Nhng kha nang
dan nhiet cua vat lieu lai co anh hng rat ln en kha nang
gia cong, co the gia cong mot cach de dang lo kha sau trong
thep khong r, con vi ong th rat kho gia cong, tham ch ch
co the khoan vi o sau nhat nh, hn na th khong c. o
la v ong dan i nhanh lng nhiet sinh ra t nang lng c
hap thu vao, va do o khong the at en nhiet o boc hi trc
khi nang lng ln cua tia laser phan phoi vao kim loai.
- Qua trnh gia cong bang tia laser co the tach lam 2 pha :
Hnh 5.69 :
S o may tia Laser CNC
Trang - 231 -
+ Anh sang laser boc lp be mat co kha nang phan chieu
ln.
+ Sau o vat lieu mau gan en hap thu nang lng cua
chum tia laser.
- Trong giai oan sau qua trnh phat nong tang len rat manh
va nhiet o toa ra moi hng t lo khoan. T o co the thay
rang ng knh cua lo se ln hn ng knh cua tia laser, s
khac biet cang ln neu thi gian chieu tia laser cang dai.
- Nang lng can thiet e boc i lp be mat tren cung phu
thuoc vao loai vat lieu. Vat lieu nao co kha nang phan chieu
tot, nhiet o soi cao, t trong ln, t nhiet ln, th lp be mat
kho b boc i. Can phai ieu chnh chnh xac nang lng cua
chum tia laser e co the khoan mot lo co kch thc a cho.
Tuy thuoc vao toc o cung cap nang lng, ma qua trnh nung
nong, nong chay hoac boc hi co the dien ra hay khong. Qua
trnh ieu chnh nay thong thng c dien ra bang cach thay
oi thi gian xung cua tia laser.
Hnh 5.70 :
S o quan he gia nang lng va thi gian xung
Trang - 232 -
- Bien thien cua nang lng va thi gian xung co the bieu
th bang mot tap hp ng cong phu hp vi cac ac tnh
nhiet cua vat lieu.
- Rat can thiet phai nhan manh rang anh sang laser la mot
phng thc duy nhat e truyen dan nang lng i vi mat o
nang lng ln. Co the xam nhap vao chan khong, gar, hoac
len be mat cua chi tiet a c cay trong bat k vat lieu trong
suot nao nh co kha nang ieu chnh tieu c cua tia sang rat
chnh xac ma co the gia cong rat chnh xac, ngay ca tren be
mat b bao boc bi mot cau trong suot a c han kn.
- Nang lng c tch luy trong nguon phat co the toi a la
6000W giay (joule) va nh cao cua cong suat la 5000 W. May
co the c mot giay th phat ra tia chp, cha ng nang lng
10 Wgiay(joule). tren mat ban thao tac, chum tia co the tiet
dien tron hoac ch nhat dai. Co the ieu chnh ng knh cua
iem cham sang hoac be rong cua ranh t 101000 m, chieu
dai ranh toi a la 15mm.
- Nh u iem la tap trung nhiet o rat cao tai mot iem nao
o (8000
o
C) vi ban knh iem can chieu co the at ti 0,05
mm cho nen lien xo t nam 1964 a san xuat hang loat cac
thiet b laser cong nghiep SU1, va K3 e han cac cong tac
trong cac linh kien ban dan (transistor, diod, cac au cap nhiet
ien). Nhat la dung thiet b laser SU1 e ieu chnh tr so
danh nh cua cac ien tr trong cong nghiep san xuat vi mach
a lam tang nang suat lao ong len en 10-12 lan va chat
lng san pham cung c nang cao ro ret.
- oi vi thiet b laser hong ngoc nh K-3M, IL-2M, IL-
20M, cho nang lng bc xa en 30 Joule, thi gian keo dai
xung ieu chnh trong cac mc 1, 3, 5, 7 ms. Tan so cua xung
la 12 xung/ phut, thiet b nay co bo suy giam nang lng anh
sang loi ra t 2, 10, 25 en 50 lan. ng knh tia sang hoi tu
Trang - 233 -
toi thieu la 0,05 mm co the han cac chan vi mach ien t va
han cac kim loai kho nong chay co chieu dai 0,05mm.
- Ngoai ra bang 5.10 cho ta biet mot so loai laser khac.
- Cac yeu to anh hng en nang suat cat va chat lng vet
cat la cong suat bc xa laze, chieu day vat cat, van toc cat va
thi gian tac dung. Chieu day toi a oi vi thep thng la
6mm, thep g :3mm, phi kim loai :10mm.
VI. Uu - Nhuoc diem - Pham vi ung dung - Phuong
phap phaI Irien :
1) u iem :
- Khong can dung buong chan khong.
- Khong co van e ien tch trong moi trng.
- Khong co phong xa rnghen.
- Cong suat bc xa cao, qua trnh cat khong phu thuoc
vao c tnh cua phoi lieu, nen no co the khoan, han, cat t
cac vat kieu co o ben cao, phi kim loai, kho gia cong bang
phng phap truyen thong.
- Thi gian nung nong vat lieu ngan, vung chu tac ong
hep, vet cat nho, t bien dang, nen am bao o chnh xac va
chat lng be mat gia cong cao.
- Khong dung dung cu cat, khong co lc cat.
- Cat c nhng be mat phc tap, v tr kho tiep can.
- Chnh nhng u iem nay ma phng phap gia cong
bang tia laze ang c quan tam phat trien chang nhng trong
nganh che tao may, ma con trong nganh truyen thong, y hoc,
o lng . . .
2) Nhc iem :
- Hieu suat rat thap (di 1%).
- Vi mot so loai tia laser, kho hoac hoan toan khong co
kha nang ieu chnh cong suat ra.

Trang - 234 -
Bang 5.10 :
Mot so loai laser thng mai
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Trang - 235 -
- Kha nang ieu chnh o lech tia kem hn so vi tia ien
t.
- ng knh nho nhat cua iem chat sang phu thuoc vao
bc song anh sang.
* Can nhac u iem va nhc iem co the khang nh rang
gia cong bang tia laser se tr thanh cong nghe rat quan trong
e gia cong nhng lo at biet va e cat kim loai, nh co kha
nang co the nang cao tan so phat sung chum tia laser vi nang
lng 510 joule/xung va kha nang nang cao hieu suat s
dung cua tia laser.
- Trong cong nghiep laser c s dung vao viec han,
khoan, cat cac loai vat lieu co o nong chay cao ke ca phi
kim.
- Gia cong bang chum tia lade rat co hieu qua oi vi lo
nho. ng knh lo nho nhat co the at 4:m. s dung chum tia
lade co the gia cong c cac vat lieu khac nhau nh kim loai,
thach anh, kim cng, rubi, v.v Chieu sau lo gia cong co the
at 12,7 mm. Khi gia cong ng knh lo 0,1-0,2 mm th o
chnh xac co the at 2-5 :m.
- Laser con c dung e kiem tra chat lng cac san
pham uc, kiem tra o tinh khiet cua chat long hoac kh, cac
san pham ien t.
- Trong y khoa laser c ng dung trong viec giai phau,
ieu tr benh bong vong mac mat, khoan rang, cham cu.
- Ngoai ra laser con tham nhap vao cuoc song cua chung
ta qua cac bang t, may in laser, may photo laser va nhieu ng
dung khac na . . .
4) Phng phap phat trien :
- Cong nghe tia laser co the ng dung rong rai hn, neu
co the tang hn nang lng cua chum tia laser va keo dai hn
Trang - 236 -
thi gian mot xung, en mc co the van hanh lien tuc hoan
toan.
- Can nang cao hieu qua kinh te, can co thiet b hoan
chnh hn. Nhat thiet phai nang cao hieu suat. cac thiet b
hien nay, ngi ta dung tu e tch luy nang lng, nguy hiem
va at tien. Ngi ta ang th nghiem thiet b tch luy nang
lng khac. Nhat thiet phai che tao loai en chp tuoi tho cao,
loai nguon phat sang khac.
- Ch nh vay mi a c cong nghe tia laser vao ng
dung trong cong nghiep, m ra va phat trien nhng pham vi s
dung mi. Neu co the at nhng thanh tu mi trong viec giai
quyet nhng van e neu tren.
Trang - 237 -
E - PHUONG PHAP GlA CONG
CAT HO QUANG
(Plasma Arc Cutting - PAC)
- Hieu khai niem gia cong bang cat ho quang.
- Hieu, biet nguyen ly gia cong bang cat ho quang.
- Tng minh ve dung cu va thiet b.
- Tng minh ve pham vi ng dung va hng phat trien.

I. Khai niem co ban :
- Ve phng dien vat ly, Plasma la chat kh a phan huy va
ion hoa manh, tc la hon hp cua phan t, nguyen t, ion va
ien t theo mot t le nhat nh.
- Mot vat chat co trang thai Plasma neu ong nang trung
bnh (W) cua cac phan t hat ln hn the nang ion hoa (U) (bat
au) co s phan huy nguyen t, ien t tach ra t hat cua
nguyen t, ion c cau thanh, nhng nho hn 10
6
eV. Plasma
la mot trang thai vat chat th t, la hon hp co n thanh phan
(ion, ien t va phan t trung tnh).
- Gia cong bang tia Plasma la cong nghe dung tia Plasma
sinh ra t ho quang chay gia catod va anod (vat gia cong au
phun) hoac bang tia ho quang Plasma.
- La phng phap gia cong dung dong plasma co nhiet o t
10.000 14.000
0
C e cat kim loai bang cach lam cho no nong
chay cuc bo tai v tr va vung ap lc cua dong kh ay phan
Trang - 238 -
kim loai nong chay ra khoi v tr o. Qua trnh cac plasma c
chia lam 2 phan :
+ au tien dong kh nong lam nong chay va xuyen thung
vat lieu.
+ Sau o dong plasma c dch chuyen theo ng dan
a c vach san e cat vat lieu.
- Dong plasma la mot hon hp kh cua cac electron t do,
cac ion dng, nguyen t va phan t. Cac loai kh thng dung
e tao plasma la nitrogen, Argon, Hidrogen hay hon hp cac
kh nay. Dong plasma c phat sinh gia ien cc (Catod)
ben trong voi phun (thng la tungsten) va chi tiet gia cong
(Anod).
- Dong plasma i qua dong nc lam nguoi au voi phun
va no c thu hep lai thanh tia e tac ong trc tiep vao v tr
yeu cau. Tia plasma en chi tiet gia cong co van toc cao va
nhiet o cc nong tai tam cua no, nhiet o nay u e cat t
mieng kim loai day 155,4mm.
III. Dung cu va IhieI bj gia cong :
- Ho quang Plasma c dung trong nhieu thiet b nh han,
cat, tien: trong phan nay xin gii thieu thiet b tien bang
plasma.
- Qua trnh xay ra khi tien bang plasma khong phai la qua
trnh toa nhiet, tc la khong nung nong vat lieu can lay i ma
dung tia plasma cc manh va mat o tap trung cao lam nong
chay be mat gia cong, bang ong nang no ay kim loai a
nong chay.
- Tia Plasma cc manh va mat o tap trung cao lam nong
chay be mat gia cong, bang ong nang no ay i lim loai kim
loai a nong chay. Dung chat kh ma ong nang cua no ( W
k
=
2
v . m . 2
1
) la ln mot nhiet o nhat nh. Hon hp kh argon-
Trang - 239 -
hidrogen co the thoa man yeu cau nay. Qua trnh ong lc
trong tien bang tia Plasma cung giong nh tien tren ban tien
thong thng, ch co ieu khac la thay v dung dao tien, ay
chung ta dung au phun Plasma.
- e tien th nen dung au phun co ho quang trong, v trong
trng hp nay ien cc c lam mat bang nc noi vi cc
am cua nguon phat ien mot chieu va t ien cc o no qua
ien cc cua voi phun v cc dng cua nguon phat.
- e cho qua trnh c on nh th phai gia goc nghieng
gia voi phun plasma vi mat phang thang goc vi mat gia
cong khoang 60
0
.

Hnh 5.71 :
Chuyen ong tng oi cua au phun Plasma so
vi vat gia cong
Hnh 5.72 :
V tr tng oi cua au phun Plasma so vi vat gia cong
Trang - 240 -
IV. Cac Ihong so cong nghe :
- Cac thong so cong nghe tien bang tia Plasma :
+ Toc o (V
k
)
+ Toc o tien cua voi phun (e).
+ Cng o dong ien (I).
+ ien ap (V).
+ Toc o chay cua gaz (V
g
).
+ Goc at cua voi phun.
- Viec ieu chnh khoang cach gia au phun va chi tiet gia
cong la quan trong. Kch thc cua mot ien cc co the c
dung e gia cong vat lieu co be rong hay be day bang cach
ieu chng thch hp cac thong so nh mc nang lng, loai
kh, toc o phun kh, toc o di chuyen cua au phun va goc cat
- Bang thc nghiem ngi ta tm ra nhng tr so toi u vi
nhieu vat lieu khac nhau. Bang 5.11 cho ta cac tr so cu the.
- e cac bien dang a vach san co the ieu khien voi phun
plasma bang tay , tuy nhien o chnh xac khong cao. e cai
thien ieu nay ngi ta cho gan au phun plasma vao mot tay
may c ieu khien bang chng trnh so nh vay khong
nhng tang o chnh xac ma toc o cat cung c tang len.
Phng phap gia cong bang ho quang plasma co the cat c
bat c kim loai dan ien nao, cac vat lieu thng cat bang ho
quang plasma la thep cacbon, thep khong r va nhom.
- u iem cua cat ho quang plasma ieu khien bang chng
trnh so la toc o cao.Toc o cat doc theo mot ng dan nao
co the len en 0,182 m/s cho mieng nhom day 6,35 mm; 0,085
m/s cho mieng thep day 6,35 mm. Toc o cat nay giam dan
vi tam vat lieu day hn .V du toc o toi a khi cat mot mieng
nhom day 100 mm la 0,0085 m/s.
- Khi s dung tia Plasma, ngoai cac bien phap an toan lao
ong oi vi cong nhan con can them nhng qui nh nghiem
ngat e e phong tai nan. ien ap khong tai cua nguon la 100-
Trang - 241 -
400 V, ien ap lam viec la 80-120 V, co nguy c ien giat, can
chu y noi at va cach ien tot, ong thi tang cng cac bien
phap chong nong va chong bc xa (tia rngen, tia hong ngoai,
tia cc tm . . .).
- Can ac biet chu y chong ngo oc, chong no gaz. Trong
qua trnh lam viec co nhng chat nong va hi oc sinh ra, nen
cho san xuat can chu y lap he thong thong hi manh. Cung
can lo viec chong tac dung cua tieng on.
Bang 5.11 :
Cac thong so thc nghiem tien bang ho quang plasma.
Vat lieu
can gia
cong
Tnh
chat
gia
cong
Cng
o dong
ien (A)
ien
ap ho
quang
(V)
Toc o
(m/ph)
Toc o
tien cua
voi
phun
(mm/s)
Lng
vat lieu
lay i
Cong
xuat
(ma
lc)
Inoel Tinh
Tho
300
170
100
90
12
23
4
1.25
65
11
145
250
Rone 4 Tinh
Tho
325
240
95
90
16
32
4
2
80
32
130
250
Hasleney Tinh
Tho
200
140
100
130
9
18
2.5
1.25
56
11
110
250
Thep
khong r
ac biet
cng
Tinh
Tho
300
170
90
92
15
61
4
1
72
32
130
250
V. Pham vi ung dung :
- Hau het ng dung cua gia cong bang plasma la gia cong
cat tam kim loai.
- ot lo hay gia cong cat doc theo nhng ng dan xac
nh
Trang - 242 -
- Co the gia cong c bang tay hoac bang ieu khien CNC.
- Co the gia cong bat c kim loai nao. Nh : thep cacbon,
nhom, thep khong g.
Trang - 243 -
TAI LIEU THAM KHAO
[1] Cac phng phap gia cong mi _ PGS-TS. Trng Ngoc
Thuc (1995)
[2] May cat kim loai _ GS-TS. Nguyen Ngoc Can
[3] Gia cong tia la ien CNC _ TS. Vu Hoai An (2003)
[4] Cac phng phap gia cong _ TS. Pham Ngoc Tuan (ong
tac gia) (2005).
[5] Working metals by elctro-sparking _ Nosov A.V
[6] Bevezetez az elektro Kanaba _ Preisich M
[7] Todmaking by park and electrochemical erosion the
plastics. Intitue. Transaction and Journal (1963)
[8] Fizicseszkife osznovi elecktroiszkrovoj obrabotki metallow
_ Zolotih B.N
[9] Chemical machining mass production _ Walk W.F (1963)
[10] Obrabotka metallov impulszami elektricsean-kava toka _
Levinszon E.M
[11] Spark erosion technology, Plastics (1963) _ Maillet M
[12] Galvanotechnika _ Bartfai B

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PHNG PHAP GIA CONG AC BIET

: Goi la hieu so hieu ng t giao.

: Goi la hieu ng ngc cua hieu ng t giao.

: Goi la moduyn an hoi.

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