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A Quy trnh cng ngh ch to chi tit dng cng

Cng l mt loi chi tit c mt hoc mt s l c bn m tm ca chng song song vi nhau hoc to vi nhau mt gc no . Chi tit dng cng thng c chc nng bin chuyn ng thng ca chi tit ny (piston ca ng c t trong chng hn) thnh chuyn ng quay ca chi tit khc (trc khuu). Ngoi ra, chi tit dng cng cn dng y bnh rng (khi cn thay i t s truyn trong cc hp tc ).

Hnh 9.22 Cc chi tit dng cng.

www.thegioicadcam.com Trn chi tit dng cng ngoi nhng l c bn cn c gia cng chnh xc, cn c nhng l dng kp cht, cc rnh then, cc mt u ca l v nhng yu t khc cn c gia cng. Nhng dng khc nhau ca cng c trnh by trn hnh 9.22. Trn hnh 9.23 l tay bin v tr lp ghp trong ng c t trong. y l loi chi tit c trng ca cc chi tit dng cng. 1 iu kin k thut Khi ch to cc chi tit dng cng cn m bo cc yu cu k thut sau: - Kch thc cc l c bn c gia cng vi chnh xc cp 7 9; nhm b mt Ra= 0,63 0,32. - khng song song ca cc tm l c bn trong khong 0,03 0,05 mm trn 100 mm chiu di. - khng vung gc ca tm l so vi mt u trong khong 0,05 0,1 mm trn 100 mm bn knh. - khng song song ca cc mt u cc l c bn khc trong khong 0,05 0,25 mm trn 100 mm bn knh mt u. - Cc rnh then c gia cng t cp chnh xc 8 10 v nhm Rz= 40 10 hay Ra=10 2,5. - Cc mt lm vic ca cng c nhit luyn t cng 50 55 HRC. 2 Vt liu v phi Vt liu dng ch to chi tit dng cng thng thng l thp cacbon 20, 40, 45. Thp hp kim 18CrNiMnA; 18Cr2Ni4A v 40CrMnA c bn cao. Cc loi gang xm GX12-28, GX 24-44 v gang rn 37-12, 4-35-10. i khi cng c ch to t kim loi mu. Vi nhng cng lm vic vi ti trng khng ln, c th chn vt liu l gang xm. Nhng cng c cng vng thp, lm vic c va p th nn chn vt liu gang rn. Cn nhng cng lm vic vi ti trng ln, tng bn nn dng vt liu l cc loi thp c nhit luyn. Cc dng phi thng dng ch to cc chi tit dng cng l phi c nh: gang, thp, kim loi mu, phi rn, phi dp. - Cng c va v nh nu sn lng t, phi c ch to bng phng php rn t do, nu sn lng ln dng phng php dp, sau p tinh trn my p va tng c tnh va chng cong vnh cho cng. Ty theo kt cu ca cng m c th dp phi tng i chi tit mt tng nng sut. Phi dp dng thun tin cho cc chi tit cng c mt u l li ln. Kt cu phi nh vy th din tch gia cng sau ny s gim. - Phi c dng cho cng bng gang, kim loi mu v c bng thp. Ty theo iu kin sn xut v sn lng m c th c trong khun ct, khun kim loi, khun mu chy. 2

69,5 +0.012
82 0,1

0,08

29 -0,06 -0,13

185 0,05 Hnh 9.23 Tay bin trong ng c t

www.thegioicadcam.com - Cng loi ln nu sn lng t, ch yu l dng phi hn, sn lng nhiu hn th kt hp dng hn v dp tm. 3 Tnh cng ngh trong kt cu ca cng Cng nh cc dng chi tit khc, i vi chi tit dng cng tnh cng ngh c ngha quan trng v n nh hng trc tip n nng sut v chnh xc gia cng. V vy, khi thit k cng nn ch ti kt cu ca n nh: - cng vng ca cng. - Chiu di ca cc l c bn nn bng nhau v cc mt u ca chng cng nm trn hai mt phng song song vi nhau l tt nht. - Kt cu ca cng nn i xng qua mt mt phng no . i vi nhng cng c cc l vung gc vi nhau th kt cu phi thun li cho vic gia cng cc l . - Kt cu ca cng phi thun li cho vic gia cng nhiu chi tit cng mt lc. - Hnh dng ca cng phi thun li cho vic chn chun th v chun tinh thng nht. 4 Quy trnh cng ngh ch to cc chi tit dng cng a. Chun nh v khi gia cng: W Khi nh v chi tit cng gia cng, phi bo m c v tr tng i ca cc b mt vi nhau, ca cc l vi nhau v vung gc ca cc l vi mt u ca n. V vy chun th ban u c chn l vnh trn ngoi ca l v mt mt u ca phi, chn chun nh vy gia cng mt u bn kia v gia cng l c bn. S nh v chi tit cng thc hin vic gia cng ny th hin trn hnh 9.24. Theo phng php ny, chi tit gia cng c nh v bng mt u pha di, vnh ngoi ca l c bn bn tri c nh v trn khi V c nh, vnh ngoi ca l c bn bn phi c nh v bng khi V di ng, lc kp W c tc ng qua khi V di ng ny. Vi cch nh v ny c th dng gia cng mt u bn kia v cng dng gia cng l c bn ca cng. bo m chnh xc th vic gia cng mt u cn c thc hin trc khi gia cng l c bn. W

Hnh 9.24 S g t khi gia cng mt u v l c bn ca thanh truyn.

Tuy nhin, nu ch vi mc ch gia Hnh 9.25 S nh v vo thn cng mt u ca cng nguyn cng u cng gia cng mt u. tin, c th chn phng n nh v vo phn thn cng khng gia cng. S nh v nh vy th hin trn hnh 9.25. Theo phng php ny chi tit cng thng nh v trn cc g t nh tm, nh vy mt u ca cng s 3

www.thegioicadcam.com m bo i xng qua mt phng, i xng ca cng v c th gia cng bng nhiu dao nn nng sut tng. gia cng l c bn ca cng c th dng phng n nh v nh trn hnh 9.24 trnh by. Tuy nhin, nn thay khi V c nh bng mt ci chp nh v vo mp trn ca vnh ngoi nh trn hnh 9.26. W Sau khi c l v mt u gia cng, chn W chun tinh thng nht l mt u v hai l c bn gia cng cc mt cn li ca cng. Trn hnh 9.27 th hin s nh v khi dng chun tinh thng nht l mt u cng t vo phin t khng ch ba bc t do, mt l cng lng vo cht tr ngn khng ch hai bc t do v mt l cng lng vo cht trm Hnh 9.26 S g t gia khng ch mt bc t do. cng l c bn ca cng. V tr ca cc cht nh v ty thuc vo v tr ca b mt cn gia cng trn cng. Khi dng phng n nh v nh trn gia cng cn lu mt s vn nh: - Nu nh cc mt u ca cng khng cng mt cao th ly mt u ln lm nh v chnh v phi dng cht t ph t vo mt u thp tng cng vng khi gia cng. - Khi nh v bng vnh ngoi ca l cng trn khi V th s c sai s nh v bng s dch chuyn tm ca l so vi tm vnh ngoi khi ng knh phi vnh ngoi thay i. loi tr sai s ny c th dng cc c cu V t nh tm. - Cng l loi chi tit km cng vng, trnh bin dng chi tit khi kp cht th im t ca lc kp phi t vo cc im t hay gn cc im t. Ngoi phng n nh v nh trn gia cng cng, trong mt s trng hp c th dng chun tinh thng nht l mt u v cc vu t ph (ng vai tr nh chun tinh ph). S nh v nh vy th hin trn hnh 9.28.

w A

Hnh 9.27 S nh v gia cng cng khi s dng chun tinh thng nht.

Hnh 9.28 S g t gia cng l c bn ca cng khi dng chun tinh thng nht l mt u v ba vu.

Khi thc hin theo phng n ny, sau khi gia cng xong mt u cng phi thc hin gia cng ba vu trn vnh ngoi hai u cng lm chun tinh ph. Sau khi c mt u v chun tinh ph, da vo lm chun thng nht gia cng tt c cc mt cn li ca cng. 4

www.thegioicadcam.com b. Th t cc nguyn cng gia cng cng:

T s phn tch chun trn y, cc nguyn cng ch yu gia cng cng bao gm: - Gia cng mt u. - Gia cng cc vu chun ph (nu c). - Gia cng th v tinh cc l c bn. - Gia cng cc l khc, cc l c ren. - Cn bng trng lng nu cn. - Kim tra. 5 Bin php thc hin cc nguyn cng a. Gia cng mt u: Nh trn bit, mt u ca cng thng li ln c din tch nh ri rc. Cc mt u ny thng dng lm chun cho cc nguyn cng khc. Ty theo chnh xc ca phi m c th gia cng mt u cng bng mi, chut, phay hoc tin. Phng php bo cng gia cng c nhng t dng v mt u nh, ri rc nn nng sut thp. - Trong sn xut hng lot ln v hng khi, nu phi c chnh xc cao thng gia cng mt u cng bng mi hoc chut. Bng phng php ny va t c nng sut cao, va t c chnh xc cao. - Trong sn sut hng lot va v nh, gia cng mt u cng bng phay hoc tin. Tuy nhin, nu chnh xc ca phi qu thp, th ngay c trong sn xut hng lot ln v hng khi vn p dng phng php phay gia cng. Ngoi ra, vic chn phng php gia cng cn ph thuc vo lng d gia cng ln hay nh, hay ni cch khc l ph thuc vo phng php ch to phi. Nu nh phi rn t do trong khun n gin sau li c p trn my p, lng d gia cng nh th c th khng dng phay c m phi mi. Ngc li khi lng d gia cng ln th dng mi s khng hp l m phi phay. Cc mt u ca cng c gia cng tng pha ln lt trn my phay nm ngang hay thng ng bng mt dao nh s hnh 9.24 hoc cng phay hai mt ca mi u trn my phay ngang bng mt b hai dao phay a ba mt ct. Lc g t phi trn cc nh v thch hp v iu chnh cc mt tng i vi dao nh cc dng c chuyn dng. Trn hnh 9.29 trnh by s nh v gia cng hai mt u ca bin tr kim my khu bng mt b hai dao phay a ba mt ct trn my phay nm ngang. Theo s ny, m bo hai mt u i xng so vi mt phng gia ca bin, chi tit c nh v vo phn thn bin khng gia cng.

Hnh 9.29 S nh v gia cng mt u ca bin my khu.

Vi s nh v , khi gia cng cc cng ln nh th, nng cao nng sut c th dng my phay nhiu trc, gia cng c c bn mt u cng mt lc nh trn hnh 9.25. 5

www.thegioicadcam.com tng nng sut khi phay, c th dng g gia cng nhiu chi tit cng mt lc (trn bn my t hai g ging nhau) v tin hnh gia cng theo kiu chy dao i li (hnh 9.30) hoc cc g c t ln mt bn quay (hnh 9.31). Lc ny vic g t phi ln g c tin hnh theo chu k, ngha l trong khi ang ct gt chi tit trn g th nht th tin hnh g lp phi mi ln g th hai. 1 2 2 4 2 3

3 4

Hnh 9.30 S kiu chy dao i li. 1. Dao phay ; 2. Chi tit gia cng ; 3. g ; 4. Bn my.

Hnh 9.31 S g t trn bn quay. 1. Dao ; 2. Chi tit gia cng ; 3. Bn quay ; 4. Bn my.

Mt u ca cng cng c th gia cng bng phng php chut. Khi chut mt u c gia cng ring tng u. Gia cng xong u ln ri mi gia cng u nh. My c dng l my chut mt v tr hoc nhiu v tr. Sau khi gia cng xong song song mt u c th t ti 0,1 mm. Trong mt s trng hp yu cu chnh xc cao, th sau khi phay hoc chut, mt u cng cn phi qua mi trn my mi phng hay my mi phng c bn quay. Mi cc mt u cng mt lc nu b dy bng nhau, mi xong mt pha lt li mi pha kia. Trng hp b dy khc nhau th mi u ln ring, u nh ring. Cng c th thc hin mi trn my mi chuyn dng gia cng c hai pha cng mt lc. b. Gia cng th v tinh cc l c bn trn cng: Cc l c bn ca cng c yu cu chnh xc bn thn cao v n lp ghp vi chi tit khc. N cng c yu cu chnh xc v v tr tng quan nh vung gc vi mt u, song song ca ng tm cc l. Ty theo sn lng v iu kin sn xut m c bin php gia cng thch hp. - Trong sn xut nh, sn lng t vi mi c ca cng l c bn c gia cng trn my khoan ng, khoan cn hoc trn my tin, my doa ngang bng phng php ly du v r g. - Trong sn xut hng lot, sn lng nhiu hn, cc l c bn ca cng c gia cng trn my khoan ng, khoan cn hoc my khoan c u rvnve bng phng php t ng ly kch thc nh bc lp trn phin dn. Bin php thc hin c nhng phng n sau:

Phng n th nht

www.thegioicadcam.com Gia cng mt l, sau dng l ny lm chun nh v cng vi mt u gia cng cc l tip theo. Theo phng n ny chi tit c nh v bng mt u v vnh ngoi ca mt u (hnh 9.24) hoc bng mt u v mp trn ca vnh ngoi (hnh 9.26). V ch gia cng mt l nn ch cn khng ch 5 bc t do, bc t do xoay quanh tm l cn gia cng khng nh hng n chnh xc cn t. L c gia cng qua 3 bc: khoan, khot, doa. Cng c th thay khot v doa bng phng php chut hoc thay doa bng nong l. Sau khi gia cng c 1 l, tin hnh gia cng cc l tip theo. Lc ny chi tit c nh v bng mt u, mt l va gia cng xong v mt mt no trn thn cng hn ch nt bc t do xoay. hn ch bc t do xoay ny c th dng khi V ty ng t vo vnh ngoi ca mt u cng. S g t ny th hin trn hnh 9.32. Theo phng n ny khong cch tm ca Nhn theo A cc l c m bo nh chnh xc khong Hnh 9.32 S nh v gia cch ca tm cht nh v v tm bc dn cho l cng l tip theo ca cng . tip theo. Gia cng cc l tip theo cng phi tun th theo ba bc nh i vi l u tin. a) Dng khi V ty ng chng xoay. b) Dng vu cn chng xoay. Phng n th hai Gia cng ln lt tt c cc l sau mt ln nh v. Theo phng n ny, chi tit gia cng phi c nh v 6 bc t do: mt u khng ch 3 bc t do; khi V t vo vnh ngoi khng ch 2 bc t do; khi V ty ng t vnh ngoi khng ch 1 bc t do (hnh 9.24). V tr v khong cch gia cc l do v tr cc bc dn lp trn phin dn quyt nh. Gia cng ln lt cc l theo cc bc khoan, khot, doa trn my khoan cn bng cch di chuyn u khoan, g c nh hoc trn my khoan ng bng cch di chuyn g. - Trong sn xut hng khi, gia cng cc l c bn c tin hnh trn my khoan nhiu trc hoc my t hp nhiu trc chnh. Dng my t hp c th t hiu qu kinh t cao v n c kh nng gia cng song song hoc song song lin tc tt c cc l trong mt ln g. Trn , nu dng dng c t hp c th xn c c mt u ca l.Theo phng n ny, chnh xc v v tr cc l bo m tt, song song gia cc l v khong cch gia cc l cng t c tt hn cc phng php trn. Hnh 9.33 trnh by s gia cng hai l bin cng mt lc. A b) Hnh 9.33 S gia cng hai l bin cng mt lc. A a)

Nu l c ng knh ln hn 30 mm, khi to phi c l sn, th trnh t s l tin rng (hay khot), gia cng tinh vi mt s l cn lp bc ng th sau khi gia cng tinh l ri mi ng bc vo, sau li phi gia cng tinh li bc ng. 7

www.thegioicadcam.com c. Gia cng cc l c ren, l kp cht: Thng thng cc l ny c yu cu chnh xc khng cao, thng l cp 10. Trng hp dng nh v ng v tr gia cng vi mt b phn khc, cc l ny phi gia cng t cp chnh xc 7. V d nh l nh v gia thn bin v np bin. Vic gia cng cc l ny thng c tin hnh sau khi gia cng cc mt u v mt hoc cc l c bn (s nh v c th nh hnh 9.27). i vi cc l c yu cu chnh xc khng cao th dng phng php khoan. Cn nhng l c yu cu chnh xc phi khoan, khot, doa. Ty theo sn lng m trn c s ca s nh v thit k cc g, cc thit b c nng sut ph hp. d. Kim tra cc chi tit dng cng: i vi cc chi tit dng cng, ngoi vic kim tra ng knh l v b dy ca cc u cng cn phi kim tra khong cch ca tm cc l c bn, vung gc gia mt u v ng tm l, khng song song gia cc tm l. - ng knh cc l c bn c kim tra bng thc cp, calp hoc ng h o l. - khng song song gia cc ng tm l c kim tra bng ng h so vi g nh hnh 9.34. 4 A-A

3 I A 7 5 2 6 II 1 A

Hnh 9.34 S kim tra khng song song hai l cng. Lp cng kim tra 6 ln cht nh v 2 qua l th nht. Cht 2 c c nh trn thn 1 (cng c th t ln hai khi V). Lng trc kim 3 vo l th hai ca cng. Quay cng quanh cht nh v 2 cho n khi trc kim 3 chm vo c t 7. Hiu s ca hai ng h 4 v 5 hai v tr I, II biu hin khng song song ca hai l cng theo hai phng ng v ngang. o khong cch gia cht nh v v trc kim tra bit khong cch hai l. V tr ng tm cc l di mt gc c kim tra bng g chuyn dng. vung gc gia l v mt u ca cng c kim tra bng g chuyn dng v ng h so. S kim tra c trnh by trn hnh 9.35. Lp trc tm vo l ca cng, quay trc tm mt vng. S ch chnh ca ng h so cho bit 8

Hnh 9.35 S kim tra vung gc ca l v mt u cng.

www.thegioicadcam.com khng vung gc vi bn knh t mi t ca ng h so vi tm quay. Ty theo sn lng v chnh xc yu cu m thit k g chuyn dng hay s dng mt s thit b kim tra vn nng c chnh xc ph hp. 6 Quy trnh cng ngh gia cng bin Bin ca ng c t trong (hnh 9.23) l mt trong nhng chi tit in hnh ca cng, n c yu cu k thut cao, li c hnh dng km cng vng, ng thi trong qu trnh ch to phi lp vi np bin. Sau y, gii thiu quy trnh cng ngh gia cng bin ng c t vn ti hnh 9.23. Quy trnh c trnh by bng 9.2. BNG 9.2 QUY TRNH CNG NGH CH TO BIN NG C T Th t nguyn cng 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Tn nguyn cng Mi s b hai mt u Khoan, khot l u nh Chut l u nh My My mi phng c bn quay t ng, kp bng in t My khoan ng nhiu trc My chut ng

Chut mt bn nguyt v mt lp ghp My chut ng vi np bin Chut mt np u bulng Gia cng th l lp bulng Khoan nhng l nh u to v vt mp Mi mt np Lp np bin v thn bin Khoan, doa l bulng Mi mt u c hai bn Khot v doa l u to p bc vo l nh Sa bc sau khi p Mi hoc tin kim cng l u to Mi khn l u to Kim tra My chut ng My phay, khoan, t hp hai pha My t hp 3 trc My mi phng c bn quay 2 trc Bn ngui My khoan ng nhiu trc My mi phng bn nam chm quay My khoan ng nhiu trc My p My khoan ng hoc my p My mi l hoc my doa kim cng My khn ng Cc dng c v trang b thch hp