PHN II : THIT K DAO TRUT RNH THEN

Dao trut l mt loi dng c ct c nng xut cao thng dng gia cng nhng b mt nh hnh trong v ngoi. Sau khi trut, b mt gia cng c th t chnh xc cp 8 7 v t nhn 6 8 ( Ra = 2,50 0,63 ). Cng c th t ti nhn cp 9 ( Ra = 0,32 ). Dao trut l loi dao chuyn dng. V vy ch cn thay i lng d, hoc kch thc b mt gia cng hoc vt liu chi tit l phi tnh ton thit k v ch to dao trut mi. Dao trut cho nng xut v nhn cao nhng c nhc im l lc ct ln v dao chng mn. Khi lng chy dao ln v khi lng chy dao nh th xy ra hin tng trt do nh hng ti cht lng gia cng. 1. Chn kiu dao trut v my trut. Theo ti ta gia cng b mt nh hnh trong do vy dng dao trut ko v tin hnh trn my trut ngang. - Theo bng 3 - 1/( 50 ) chn my trut kiu 7A510 c cc tnh nng k thut ca my nh sau: Lc Kiu my ko danh ngha (tn) Chiu di hnh trnh con trut (mm) Tc hnh trnh lm vic (m/ph) Tc hnh trnh lm vic (m/ph) Cng max 7A510 10 1250 min 100 max 13 min 1,5 25 sut (kw) 14 S vng quay(v/ph) 970 ng c in

2. Chn vt liu dao trut. Vi vt liu chi tit gia cng l gang GX15-32 ta chn vt liu lm dao l thp gi P18 v thp gi c cng kh cao, bn cao v kh nng chng mi mn cao. 3. Chn s trut.

S chut quyt nh yu cu k thut ca b mt gia cng. C cc loi s chut sau : 3.1. S chut theo lp : + u im: nhn c chnh xc v nhn b mt cao. + Nhc im : ch to rng dao phc tp nht l vi b mt c bin dng phc tp + Phm vi s dng : Gia cng b mt nh hnh n gin : l tr, b mt ngoi. 3.2. S chut n dn : + u im : ch to rng dao n gin hn so vi chut theo lp. + Nhc im : nhn b mt khng cao bng chut theo lp. + Phm vi s dng : gia cng cc b mt nh hnh c bin dng phc tp nht l s s dng s chut theo lp khng c li : l then hoa, l a din.... 3.3. S chut theo nhm : + u im : Chiu rng lp ct do mi rng ct ra nh, nn cho php tng chiu dy lp ct ln lm bin dng n v ca lp ct gim i. Do lc ct tc dng ln mi rng nh i, nng sut cao. + Nhc im : chnh xc v nhn so vi chut theo lp, ch to rng ct kh. 3.4. S chut t hp : m bo ch to n gin, va nhn c chnh xc v nhn cao.Theo s ny i b phn cc rng ct c to bin dng theo s chut n dn, cn 2 3 rng ct cui cng c to bin dng theo s chut lp . Qua cc phn tch v cc s chut trn, ta chn s chut n dn profin khng ging vi profin ca b mt gia cng. Ch c nhng rng cui cng mi c hnh dng ging vi b mt gia cng. Vic ch to rng dao n gin hn nhiu so vi chut theo s ct lp. Tuy nhin nhm v chnh xc

b mt gia cng thp hn so vi chut lp. S ny dng gia cng cc b mt nh hnh c bin dng phc tp. 4. Xc nh lng d gia cng. - Lng d khi trut ph thuc vo yu cu cng ngh, cht lng b mt ,kch thc b mt gia cng v dng gia cng b mt trc khi trut lng d gia cng tnh theo mt pha c tnh theo cng thc:
2 2 A = t1max d min + 0,5( d max ( d min bmax ) )( mm )

Trong : tmax: l khong cch ln nht tnh t y l n y rnh then Tra bng 9.1a [2] ta c : t = 48,38 mm dmin: l ng knh l nh nht : dmin = 45 + 0 = 45 mm bmax: l chiu rng rnh then ln nht bmax = 10 + 0,043= 10,043 mm A = 48,38 45 + 0,5 ( 45,062 (45 2 10 ,04 3
2

) = 3,978 ( mm )

5. Xc nh lng nng ca rng dao. Vic chn lng nng ca rng dao ph thuc ch yu vo vt liu gia cng, kt cu dao trut v cng vng ca chi tit, tr s lng nng S z nh hng ln n bng b mt ra cng, lc trut v chiu di dao trut. Nu chn Sz ln th chiu di dao trut tnh c s ngn, d ch to, nng xut cao, nhng lc trut s ln, lm rng dao s mn theo mt trc v mt sau nh hng xu n chnh xc v nhn b mt gia cng. Ngc li

nu chn Sz nh th dao trut s di, rng dao s rt kh ct vo kim loi gia cng v thng b trt lm cn nhanh li ct v gim nhn b mt gia cng. Khng nn chn Sz ln hn 0,15 mm khi gia cng thp v 0,2 mm khi gia cng gang. Ngc li lng nng ca rng ct th khng nn chn nh hn 0,02 mm v khi dao trut s di, rng dao rt kh ct vo kim loi gia cng v thng b trt v lm cn nhanh li ct dn n lm gim nhn b mt gia cng. Trng hp cn trut tinh c th chn Sz nh hn 0,015mm nhng phi nh bng c mt sau v mt trc ca dao ng thi nng mi li rng dao vi cht lng cao. Rng ct th u tin thng b tr lng nng bng 0 ch lm nhim v sa ng bin dng l phi, cc rng ct th cn li c lng nng bng nhau Tra bng 3.5[1] chut rnh then vi vt liu gia cng l gang GX 15-32 c lng nng Sz = 0,06 0,2 (mm),ta chn Sz = 0,2 mm trnh gim lc ct t ngt gia rng ct th v rng sa ng c b tr t 2 4 rng ct tinh vi lng nng gim dn. Thng chn 3 rng ct tinh vi lng nng c th c b tr nh sau: Lng nng s b ca rng ct tinh l: + Lng nng ca rng ct tinh th nht l: Szt1= 0,8.Sz = 0,8.0,2 = 0,16 + Lng nng ca rng ct tinh th hai l: Szt2= 0,6.Sz = 0,6.0,2 = 0,12 + Lng nng ca rng ct tinh th ba l: Szt1= 0,4.Sz = 0,4.0,2 = 0,08 6. Xc nh s rng dao Z. 6.1. Rng ct th: S rng ct th Zth ca dao trut c xc nh ph thuc vo s ct. Vi s trut lp: Z th = A At +1 Sz

( *)

Trong : A: Lng d tnh theo mt pha. At : Lng d ca cc rng ct tinh.

At = S zt = S zt1 + S zt 2 + S zt 3 = 0,16 + 0,12 + 0,08 = 0,36 ( mm )

A = 3,978 mm

Sz: Lng nng ca rng ct th : Sz = 0, 2 ( mm ) Vy ta c:

Z th = 3,978 0,36 +1 =19 ,09 0,2

(rng)

Ly Zth = 19 rng. 6.2.Rng ct tinh . Lm nhim v ct ht lng d cn li nng cao chnh xc gia cng, l phn d tr mi li cho rng ct th v gim rung ng khi ct. Vi s trut lp , s rng ct tinh chn t 2 n 4 rng . Ta chn Zt = 3 rng. Xc nh li Atinh thc t ( At.th )
At .th = Amax S z .( Z th 1) = 3,978 0,2.(19 1) = 0,378

Trong : A t .th = Szt1 + Szt 2 + Szt 3 Mt khc: Szt1 : Szt 2 : Szt 3 = 8 : 6 : 4 Suy ra ta c: Szt1 = Szt2 =
At .th .8 0,378 .8 = = 0,168 18 18 At .th .6 0,378 .6 = = 0,126 18 18

Szt3 = At.th ( Szt1 + Szt2) = 0,378 ( 0,168 + 0,126 ) = 0,084 6.3. Rng sa ng. Lm nhim v tng nhn v chnh xc b mt gia cng khng b tr lng nng, s rng sa ng c chn theo cp chnh xc ca b mt gia cng v kiu dao trut Theo bng 3-7[1] ta c Vi dao trut dnh then Zs = 4 (rng), lng nng bng khng . 7. Gc ca dao trut.

+ Gc sau : Gc sau nh hng ln n tui bn ca dao trut. Nu chn ln lm gim ma st, iu kin ct tt nhng li gim chiu cao ca rng khi mi li. Nu nh s lm tng ma st khi ct. Gc sau chn ph thuc vo kiu dao trut v c tra theo bng 3-8[1] i vi rng ct th: th = 3o : sai lch = +30 i vi rng ct tinh: i vi rng sa ng: t = 2o = 2o : : sai lch = +30 sai lch = +30

tng bn kch thc, trn mt sau ca rng sa ng c li di cnh vin f = 0,05 0,2 mm ( chn f = 0,1 mm ). + Gc trc : Chn ph thuc vo vt liu gia cng. - Theo bng 3 9[1] ta c: Rng ct th: Rng ct tinh: Rng sa ng:
th

= 5o

t = -5o
s

= -5o

8. Xc nh hnh dng rng, kch thc rng v rnh cha phoi. Dao trut c 3 dng rnh cha phoi: Dng lng cong, dng lng thng v dng y bng. Vi vt liu chi tit gia cng l gang GX15-32 to ra phoi vn, tng bn cho rng v d ch to , ta chn rnh dng lng thng . Hnh dng, kch thc rng v rnh cha phoi ph thuc vo vt liu gia cng v tit din phoi do mt rng dao ct ra. Din tch rnh cha phoi F c xc nh theo cng thc: F = f.k Trong : f: Din tch tit din phoi ( mm2 ) f = L.Sz = 38.0,2 = 7,6 ( mm2 ) L: Chiu di b mt c trut Sz: Lng nng ca rng ct th K: H s in y rnh - Theo bng 3 10[1] vi Sz = 0,2mm k = 2,5 Suy ra: F = 2,5.7,6 = 19 ( mm2 ) + Bc rng dao trut c xc nh :

t =(1,25 ). 15

L =1,5. L =1,5. 38 =9,246 ( m ) m

Chn t = 12 mm. - Theo bng 3 12[1] ta c c hnh dng kch thc rng v rnh phoi: Bc rng 12 h 4,5 Rng dng lng thng b r 4,5 2,5 F 19,3

*. Kim nghin kh nng cha phoi ca rnh theo iu kin: h 2 >k 4LSz Trong : h : Chiu su rnh cha phoi , mm L : Chiu di b mt c trut, mm Sz : Lng nng ca rng ct th, mm k : H s in y rnh Thay s ta c:
3,14.4,5 2 = 2,62 > k = 2,5 4.38.0,2

Ta thy iu kin trn tho mn kh nng cha phoi. thun tin cho vic ch to dao, bc rng ca cc rng ct th, ct tinh v rng sa ng u ly bng nhau.

 gim rung v nng cao chnh xc b mt gia cng t c thay i trong phm vi t = ( 0,2 1 ). 9. Xc nh s rng ng thi tham ra ct. Khi trut s rng ng thi tham gia ct lun thay i t tr s nh nht Zmin n tr s ln nht Zmax. + S rng nh nht tham gia ct: Z min = + S rng ln nht tham gia ct: Z max = Vy vi
L 38 = = 3,167 ; t 12

Zmin = 3 rng.

L + 1 = 3 + 1 = 4 rng . t

6 Zmax 3 m bo bn ko v nh hng tt cho dao

trut, bo m nng sut v cht lng b mt gia cng. 10.Xc nh kch thc rng. 1.Chiu rng rng dao (b) : p dng cng thc : b = Bmax - (0,005 0,01)mm. Ly 0,01mm Trong + Bmax :chiu rng ln nht ca rnh then. Bmax= 10,043 mm Thay s b = 10,043 - 0,01 = 10,033 mm. 2.Chiu dy thn dao B1: c chn ph thuc vo chiu rng rng dao b v c chn bng 3-19[1]. Vi b = 10,043 mm ta chn kiu A dng cho b 3 10 mm tnh B1 ta p dng cng thc : B1 = b + (2 6) = 10,043 + (2 6) = 12,043 16,043 (mm) Chn B1 = 14 (mm) 3. Chiu cao phn ct h1 ng vi rng ct u tin : Ta p dng cng thc h1 = 1,25.h = 1,25 . 4,5 = 5,625 mm Vi Sz =0,1 > 0,08 sai lch cho php ca chiu cao phn ct l +0,02 mm Do di dao chut rnh then b khng ch cht ch m bo bn ko, kh nng ct mt ln khng ht lng d yu cu .Cho nn c th khc phc bng cch m thm vo mt t bc dn hng mt s cn m c chiu dy

tng ng vi lng d cn ct ri tip tc chut hnh trnh tip theo .Trng hp ny chiu cao h1 c gi tr h* = h1 + h cn m 4.Chiu cao thn dao c tnh theo cng thc H0 = H1 - h1 Trong : H1 chiu cao phn u dao c tra trong bng 3-19[1] ta c H1 = 22mm Thay vo ta c Ho = 22 - 5,625 = 16,375 mm + Ho: khng thay i trong sut chiu di dao chut rnh then gim ma st gia mt sau ph vi b mt gia cng ,cn mi li ct bn nghing 1 gc 1 =(0o 30 2o). Ta chn 1 = 1o v nh rng . f =0,8 1 mm. Chn f = 1 mm. tra li cnh vin

5.Chiu cao ca rng ct th u tin: Chiu cao ca rng ct th ln hn rng ct trc n mt lng bng lng nng rng Szth = 0,2 mm. Nh vy ta c cng thc tnh chiu cao rng ct th nh sau: hn = h1 + ( h - 1 ). Szth + Vi hn : s rng n =19 Vi n = 2 h2 = 5,625 + (2 - 1).0,2 = 5,825 mm n = 3 h3 = 5,625+ (3 - 1).0,2 = 6,025 mm ... n = 19 h 19 = 5,625 + (19 - 1 ).0,2 = 9,225 mm. 6. Chiu cao ca rng ct tinh : Ta c ht1 = h19 + Szt1 = 9,225 + 0,168 = 9,393 mm ht2 = ht1 + Szt2 = 9,393 + 0,126 = 9,519 mm ht3 = ht2 + Szt3 = 9,519 + 0,084 = 9,603 mm T cc gi tr trn ta lp bng tnh ton nh sau:

hn 1 2 3 4 5 6 7 8 9 10 ht1 9,393 hs1 9,603

gi tr (mm) hn Rng ct th 5,625 11 5,825 12 6,025 13 6,225 14 6,425 15 6,625 16 6,825 17 7,025 18 7,225 19 7,425 Rng ct tinh ht2 9,519 Rng sa ng hs2 9,603

gi tr (mm) 7,625 7,825 8,025 8,225 8,425 8,625 8,825 9,025 9,225 ht3 9,603 hs3 9,603

11. Chn kt cu rnh chia phoi. Khi trut gang nhn c phoi vn nn khng cn b tr rnh chia phoi 12. Xc nh hnh dng kch thc u dao trut. Hnh dng, kch thc u dao trut c tiu chun ha. u dao trut rnh then c tra bng 3.19[1]. Kiu b Ktd n A 10 15 B(g6) Sai lch -0,018 H1(d9) Ktd n 22 Sai lch 10 6 70 c e l l1 a f d.tch t.d nh nht 220

13. Xc nh kch thc phn nh hng. 1. Xc nh kch thc phn nh hng trc. Phn nh hng trc dng nh v v m bo ng trc gia chi tit vi dao .Do lng d phn b u trn ton chu vi ca l .V vy s trnh cho dao ct khi b gy do qua ti nht l rng ct th u tin . Vi dao trut rnh then chiu cao phn nh hng trc (H4) ly bng chiu cao H1 = 22mm vi dung sai lp ghp lng e8. Tra bng ta c H4 = + +
22 0 ,,032 059 0

mm

Chiu dy phn nh hng trc (B4) ly bng chiu dy thn dao B1 B4 = B1 = 14 mm Chiu di phn nh hng trc c tnh theo L4 = (0,75 1)Lc (mm)

Trong : Lc chiu di rnh then cn chut Lc = 38 mm Chn L4 = Lc = 38 mm 2. Xc nh phn nh hng sau. i vi dao chut rnh then khng cn lm phn nh hng sau v dao c kp cht v dn hng trn bn dn ca my chut ,Nhng sau phn rng sa ng ko di thm mt on tng bn rng sa ng c tnh theo cng thc l7 = t + (5 10)mm Trong : + t l bc rng ca dao chut (t = 10 mm) .Vy l7 = 15 20mm Ta chn l7 = 20mm 3. Thit k bc dn hng dn hng v nh v phi cn phi s dng bc dn hng. Bc dn hng l bc hnh tr ba bc, c x rnh dc theo trc dao , dao trut s trt

trong rnh khi ct, bc I lp vo thnh l my trut , bc II kh chuyn ng tnh tin, bc III nh v phi . m bo bn cho bc dn hng phi tha mm iu kin : U 0,15.D U 0,15.D 14. Xc nh phn c trc . V dao trut rnh then yu cu ch to c chiu di nh ,tit din dao nh nn khng cn thit k phn c trc . 15. Xc nh chiu di dao trut.
A
Dao trut

D: ng knh l phi.

b A

A-A
D

tMax

H1

u
X B1

m in

Cn m Bc dn h ng Th m trut nh y

L1

L2

L3

Chiu di dao trut c tnh theo cng thc sau: L d = L + l5 + l6 + l7 + l8 Trong : L: khong cch t u dao n nh rng ct th u tin l5: chiu di phn rng ct c tnh theo cng thc l5 = (Zth + Zt).t = (19 + 3).12 = 264 (mm)

 l6: chiu di phn rng sa ng l6 = Zs.t = 4.12 = 48 mm l7: chiu di phn rng sa ng ko di thm 1 on l7 = 15 mm l8 : chiu di phn c trc (nu c) . l8 = 0 (khng s dng c trc ) Chiu di c dao c tnh qua hnh v di y :

L = L1 + Lh + Lm + Lb + Lc Trong : L1 = 70(mm) : chiu di u dao Lh : khe h gia mt u mn cp vi thnh my chut Lh = 1015 (mm) Chn Lh = 15 (mm) Lm : chiu di thnh my chut Lm = 2030(mm) Chn Lm = 20(mm) Lb : chiu di vnh ngoi ca bc t Lb = 10(mm) Lc : chiu di chi tit gia cng L = 38(mm) L = L1 + Lh + Lm + Lb + Lc = 70 + 15 + 20 + 10 + 38 = 153 (mm) Ld = L + l5 + l6 + l7 + l8 = 153 + 264 + 48 + 15 = 480 (mm)

Tit din u dao : B1. H1 = 14.22 = 308 (mm2) Tra bng 3.25[1] Ta c chiu di gii hn dao trut rnh then L = 10001100(mm) Ld = 480 (mm) < L = L = 10001100(mm) .Dao tha mn iu kin cng vng. 16. Tnh lc trut. Lc trut ln nht P max khi chut rnh then l:
Pmax = C p .S zx .b.Z max .K .K .K hs .K n

Trong : Cp : h s ph thuc vo vt liu gia cng v hnh dng dao trut. - Theo bng 3.26[1], ta c: Szth : Lng nng rng ct th: b : Chiu rng rnh then: Cp = 1370 Sz = 0,2 b = 10 ; ( mm ) ( mm ) Zmax = 4 x = 0,73.

Zmax : S rng ng thi tham gia ct ln nht:

K , K , K hs , K n : Cc h s iu chnh xt ti nh hng ca gc trc, gc sau, mn ca dao v dung dch trn ngui n lc ct. - Tra bng 3.27[1]ta c:
K = 1,1 ; K = 1 ; K hs = 1 ; K n = 0,9

Vy ta xc nh c lc ct ln nht l: Pmax = 1370.0,20,73.10.4.1,1.1.1.0,9 = 16755,9 (N) 17. Kim nghim lc trut v bn dao trut. 1.iu kin 1: + Mun lm vic c lc ko Q ca my trut phi ln hn lc trut Pmax < Q. + Lc ko danh ngha my 7A510 l 10 tn = 100.000(N) Pmax = 16755,9 (N) < Q = 100.000(N) Tho mn iu kin 1 2.iu kin 2: m bo bn ko cho dao cn tho mn iu kin:

Pmax [ ] (N/mm2) F

Tra bng 3.29[1] dao thp gi P18 dao trut rnh then [ ] = 200N/mm2 F l din tch ngang nguy him u kp : Fmin1 = C.H1 = 10.22 = 220mm2 Din tch rnh rng th nht Fmin2 = ( h1 - h ).b + Ho.B1 = (5,625 4,5).10 + 16,375.14= 240,5 mm2 Chn tit din ngang nguy him Fmin1 = 220mm2 v Fmin1 < Fmin2 =
16755 ,9 = 76 ,16 [ ] = 200 ( N / mm 2 ) 220

Dao m bo iu kin bn 18. iu kin k thut ca dao chut rnh then a) Vt liu lm dao : thp gi P18 b) cng sau nhit luyn + Phn rng v phn nh hng sau : HRC 6265 + Phn nh hng trc HRC 6062 + Phn u dao : HRC 4047 c) nhn b mt phi m bo : + Cnh vin rng sa ng t cp 9 : Ra 0,32 + Mt trc, mt sau ca rng v cc b mt nh hng t cp 8 Ra 0,65 + Mt y rng v cc rnh chia phoi t cp 7 Ra 1,25 + Cc b mt khng mi t cp 6 : Ra 2,5 d) Sai lch gii hn chiu cao rng ct v rng sa ng Vi lng nng ca rng ct th Sz = 0,2 mm th sai lch gii hn chiu cao rng ct th khng vt qu 0,02mm e) Dung sai chiu rng li ct ca rng ct v rng sa ng Ly bng 1/3dung sai chiu rng rnh then nhng khng ln hn 0,02 mm Trng dung sai phn b v pha m. Vi trng dung sai rnh then l ly chiu rng dung sai rnh then l b=
+ 10 0 0,043

f) Sai lch gii hn ca gc trc : 10 g) Sai lch gii hn gc sau : 30 h) Chiu rng cnh vin rng sa ng : fs = 0,2 mm Trn cc rng ct chiu rng cnh vin f = 0,05 mm i) Sai lch cho php chu su rnh cha phoi Vi cnh vin chiu su rnh cha phoi h= 3,6 mm, sai lch cho php chiu su rnh cha phoi khng vt qu +0,3 mm j) Sai lch bc rng Sai lch bc rng cho php ly bng 0,3 mm k) Sai lch tng cng chiu di dao trut Vi chiu di dao trut 585 mm sai lch tng cng chiu di dao khng vt qu 3 mm l) Cc sai lch khc khng song song ca cc b mt dao khng vt qu 0,012 mm khng vung gc gia cc b mt bn v mt y dao khng vt qu 0,012 mm m) Khc nhn hiu trn c dao + ng knh l trut + Vt liu dao trut + S hiu dao trut + Tn nh my ch to