3.1 Phay mt bc thng gc. 3.2 Phay rnh thng gc, phay ct t. 3.

3 Phay rnh then trn trc. 3.4 Phay rnh nh hnh. 3.4.1 Phay rnh ch V. 3.4.2 Phay rnh ch T. 3.4.3 Phay rnh ui n. 3.4.4 Phay cht ui n.

3.1 Khi nim chung v mt bc

- Bc l vt to bi hai mt phng vung gc vi nhau. Chi tit c th c 1, 2, 3 hay nhiu bc. - Bc c nhng yu cu k thut rt khc nhau, ph thuc vo cng dng sn phm, dng sn xut, chnh xc v kch thc, v hnh dng, v tr tng i, nhm b mt gia cng ca chi tit. - Cc yu cu k thut nh hng trc tip n vic chn phng php phay, ch phay, loi dao phay.

- Gia cng mt bc c thc hin trn my phay ng v my phay nm vn nng bng dao phay a, dao phay ngn, dao phay mt u, dao phay nh hnh hay t hp dao phay.

3.1.1 Cc phng php phay mt bc 1. a) Phay mt bc bng dao phay a Chn dao: - Trn my phay nm mt bc c phay bng 1 hoc 2 dao phay a. - Tu tng cng vic c th m ta c th dng dao phay a 1, 2 hoc 3 li ct vi rng thng, rng nghing, rng lin hay rng chp. - Chn loi dao v kch thc dao phay a ph thuc vo vt liu v kch thc vt liu gia cng. Vi vt liu d gia cng, chiu su ct ln ta dng dao phay c rng ln v ngc li, vt liu kh gia cng chiu su ct khng ln lm ta chn loi dao c rng nh. Nu phi mm, do th dng dao t rng ( rnh cha phoi rng) v ngc li.

- Chn dao c b mt rng b ln hn chiu rng ca bc B cn phay t nht 1mm c th hon thnh bc trong mt lt ct.

- Chn ng knh dao va , sao cho khi phay ht chiu cao ca bc m trc dao (k c bc chn) khng chm vo mt trn ca bc. Khi chn cn tho mn iu kin sau:

b) G phi - Tu theo kch thc v hnh dng m phi c g trc tip ln bn my hoc g trn t my ... ging nh khi phay mt phng. Ngoi yu cu chung l nh v tt, kp cht m bo cn cn ch sao cho khng b vng hoc dao khng b chm vo g. c) iu chnh my: - Dch chuyn bn my cho mt bn ca dao chm nh vo mt bn ca chi tit. Sau h bn my xng v iu chnh bn my dch chuyn xc nh kch thc b rng ca bc (ta nn li mi mt khong 0,2 - 0,3 gia cng tinh). - Nng bn my ln cho ng knh ngoi ca dao chm nh vo b mt ca chi tit, sau li phi ra khi dao v ly chiu sao ct, li lng d gia cng tinh.

2. Phay mt bc bng dao phay tr ng a ) Chn v g lp dao - Thng thng c th dng dao phay tr ng tiu chun c chui cn hoc tr trong cc rng dao thng cch nhau khng u nhn b mt gia cng khng b vt dao (v nu khng mt rng no lm xc th rng khc xo i v vng quay tip sau khng b lp li hin tng ).

Khi phay cc phi c cng ( c, rn ) vi lng d ln, nn dng dao tr ng c rnh x phoi cc li ct trn mt tr

Cng c th dng dao phay tr ng ghp hai mnh hp kim cng c ng knh ti 60mm hoc ln hn

ng knh ca dao phi ln hn chiu rng ca bc cn phay v chiu di phn lm vic ca dao phi di hn chiu cao ca bc cn phay.

Dao phay tr ng loi c chui cn c lp trn my bng cch cm chui cn vo l trc chnh ca my v c trc rt pha cui trc my. Dao phay tr ng c nh c chui tr c kp thng qua ng kp xen ga.

G lp phi: Phi c g nh trong trng hp phay bng dao phay a. Ln lt phay tng bn bc thang t chiu rng v chiu su. iu chnh my:tng t nh iu chnh my i vi dao phay a

3. Phay bng t hp dao phay a - Khi gia cng mt nhm cc chi tit ging nhau c hai hoc nhiu bc... c th dng t hp cc dao. - t c kch thc yu cu gia cc bc ngi ta t cc vng nh v vo gia cc dao trn trc g.

4. Phay mt bc bng dao phay mt u - C th thc hin trn my phay ng hoc my phay ngang. - Vi cc chi tit gia cng c bc i xng c th g trn g hai v tr. Sau khi phay xong bc th nht ngi ta quay g i 1800 v t v tr th 2 gia cng bc cn li.

3.3 Phng php kim tra - Kch thc c kim tra bng thc cp, thc o su. - Gc vung c kim tra bng ke vung, thc o gc vn nng. - song song c kim tra bng thc o su, ng h so. 3.4 Cc dng sai hng - nguyn nhn bin php khc phc * Dng sai hng - Kch thc ca bc khng ng - Cc mt ca bc khng song song vi nhau i mt - nhn b mt khng t * Nguyn nhn: - Do nhm ln khi thao tc xc nh v tr tng quan gia dao v phi - Do d ca vtme bn my lm cho phi b x dch trong khi phay - Thao tc o kim khng chnh xc - Nu hai mt phng ngang ca hai bc khng song song vi nhau l khi g khng xc nh tt v tr. - Nu hai mt thng ng ca bc khng song song vi nhau th ngoi nguyn nhn nh trng hp trn th cn c th do phi b x dch trong qu trnh gia cng.

Do ch ct khng hp l (lng chy dao qu ln), dao cn, dao b o, hoc khng ti dung dch trn ngui.

* Bin php khc phc. - Xc nh chnh xc v tr tng i khi so dao v chi tit. - Kh ht d ca trc vt me, kho cc chiu chuyn ng khng cn thit ca bn my - Kim tra thc trc khi o v thao tc o chnh xc . - G li phi, r m bo song song - Kim tra li ch ct, dao v ti dug dch trn ngui.

3.2 Phay rnh vung, phay ct t 3.2.1 Khi nim chung. - Rnh l vt c to bi nhiu mt phng hoc nhiu mt nh hnh. - Rnh vung l rnh thng c hai vch thng gc vi y rnh. Theo c im cng ngh ta phn bit hai dng rnh thng sut v rnh kn u

3.2.2 Cc phng php phay rnh vung. 1.Phay rnh vung bng dao phay a * Chn dao: - c tnh v phng php chn dao tng t nh trong trng hp phay mt bc nhng y thng s dng dao phay a 3 mt ct vi cng vng cao. chnh xc v kch thc dng hnh hc, v tr tng i - Cn c vo vt liu gia cng m ta chn loi dao, vt liu lm dao, v chn cc thng s khc ca dao. + Chn chiu rng ca dao B cn c vo chiu rng ca rnh b ( B b) + ng knh dao phi chn sao cho nh nht nhng khng c chm vo trc g dao khi phay ht chiu su ca rnh

* G lp phi: - Tu theo kch thc v hnh dng m phi c g trc tip ln bn my hoc g trn t my ... ging nh khi phay mt bc. Ngoi yu cu chung l nh v tt, kp cht m bo cn cn ch sao cho khng b vng hoc dao khng b chm vo g. * iu chnh my:

- Cho mt bn ca dao chm nh vo mt bn chi tit, h bn my

xung cho dao ri khi phi v dch bn my mt khong a.

a=B+T Trong :

a: L khong cch dch chuyn B: b rng dao ct. T: B rng t mt ngoi vo rnh - Nng bn my ln cho ng knh ngoi ca dao chm vo mt trn ca chi tit sau li bn my ra theo trc X ta ly chiu su cho mi lt ct. - Ta nn li mi mt khong 0,2 0,3 phay tinh m bo kch thc cng nh nhn b mt.

Ch : nng cao chnh xc ca rnh khi s dng dao phay a ta c 3 bin php sau: - Nu rnh c kch thc tng i rng dng dao phay a t hp gm 2 a mng ghp li, gia c lt tm phng m mng c th thay i chiu dy tng cng. - Dng dao phay a c chiu rng nh hn chiu rng ca rnh phay ph, sau m rng cho n khi t kch thc. - Dng dao c chiu rng nh hn rnh chng 0,1 0,15 mm, lp trn trc g dao vi nghing nht nh (1 gc rt nh) bng cch dng vng lt vt u khi quay dao s o v ct thnh rnh rng vi kch thc theo nghing ca dao.

2 Phay rnh vung bng dao phay tr ng - Thng thng c th dng dao phay tr ng tiu chun c chui cn hoc tr trong cc rng dao thng cch nhau khng u nhn b mt gia cng khng b vt dao (v nu khng mt rng no lm xc th rng khc xo i v vng quay tip sau khng b lp li hin tng ). - ng knh ca dao phi nh hn hoc bng chiu rng ca rnh vung cn phay v chiu di phn lm vic ca dao phi di hn chiu su ca rnh cn phay. - Dao phay tr ng loi c chui cn c lp trn my bng cch cm chui cn vo l trc chnh ca my v trc rt ln pha cui trc my. - Dao phay trc ng c chui tr c kp thng qua ng kp xen ga.

* Cch iu chnh my: - Cho mt tr ngoi ca dao chm vo mt bn ca chi tit, h bn my xung cho dao khi phi v dch vo mt khong a. a=d+T Vi: d: l ng knh ca dao. T: Khong cch t mt bn ti rnh a: Khong dch chuyn Nng bn my ln cho mt u ca dao chm vo mt trn ca chi tit. Sau li bn my ra theo trc X ta ly chiu su cho mi lt ct.

3.2.3 Cc dng sai hng, nguyn nhn, bin php khc phc * Cc dng sai hng: - Sai s v kch thc - y rnh khng vung gc vi thnh rnh - Thnh rnh khng song song vi mt bn - nhn b mt khng t * Nguyn nhn. - Do qu trnh iu chnh my sai, o kim khng chnh xc, dao b o, chn dao sai. - Do u g dao b nghing, dao cn, dao b y. - Do khng r cho mt bn ca phi song song vi hng chy dao - Do dao cn, ch ct khng hp l, khng ti dung dch trn ngui. * Bin php khc phc - iu chnh li my, thao tc o kim chnh xc. kim tra dao- Kim tra li u g dao, dao.- Dng ng h xo r m bo song song- Kim tra li ch ct, ti dung dch lm mt, thay dao nu

3.3 Phay rnh then 3.3.1 Khi nim chung v rnh then. Trong ngnh ch to my mi ghp then rt ph bin, then c cc loi nh: then hnh ch nht, then hnh chm, then bn nguyt - Rnh then c chia lm 3 loi: rnh then thng sut, rnh then h v rnh then kn. * Cc yu cu k thut i vi rnh then - Chiu rng ca rnh phi t cp chnh xc 2, 3. - Chiu su ca rnh t cp chnh xc 5. - Chiu di ca rnh t cp chnh xc 3. Ngoi ra: Rnh then cn yu cu cc mt bn ca rnh phi i xng nhau qua mt phng i qua tm ca trc cn bng phi t cp chnh xc 5.

3.2.2 Dao phay rnh then phay rnh then ngi ta s dng cc loi dao: - Dao phay a: c dng phay cc rnh nng. - Dao phay rnh ht lng: Loi dao ny ch c mi mt trc. u im l kch thc chiu rng ca dao khng b thay i sau khi mi. ng knh ca chng t 50 100 v chiu rng t 4 16 mm. - Dao phay rnh then: c chui tr hoc chui cn. Dao phay rnh then c hai rng ct vi cc li ct mt u thc hin cng vic chnh trong qu trnh gia cng. - Dao phay rnh then c hnh bn nguyt c ui dng phay rnh then hnh bn nguyt c ng knh t 4 50. 3.2.3 Kp cht chi tit gia cng.

- Nu chi tit c dng hnh tr th tin nht khi phay rnh l kp trn
khi trn khi V. i vi cc chi tit ngn th ch cn mt khi, cc chi tit di cn 2 khi V.

Kp chi tit bng t my, mm cp...

3.3.4 Phng php phay rnh then. 1. Phay rnh then thng sut. - Rnh then thng sut v rnh then h c gia cng bng dao phay a trn my phay nm ngang - Chn dao: B rng dao phi nh hn hoc bng b rng rnh

- Khi g dao trn trc g phi m bo cho dao c o mt u nh nht. - Dao phi i xng so vi mt phng i qua tm ca chi tit.

- m bo i xng ta phi dng phng php r b i. Cch r: - Dng ke 900 p mt cnh xung mt bn my v mt cnh p vo ng sinh ca chi tit . Dng thc cp o khong cch S ri di chuyn bn my ngang iu chnh sao cho.

Kim tra nh vy hai u chi tit ri g x dch g cho n khi kch thc S hai u u bng nhau l t yu cu song song. Nu i ke sang pha bn kia ca chi tit kim tra v x dch bn my sao cho kch thc S hai bn u bng nhau l t yu cu i xng vi ng tm chi tit. - Ngoi ra ngi ta c th dng ng h l xo kim tra song song.

* iu chnh my ly chiu su ct - Sau khi g dao, ta nng t t bn my ln dao chm nh vo b mt chi tit, ta dch chuyn bn my theo phng dc li dao ra khi phi, sau ly chiu su ct cho tng lt 2 Phay rnh then kn. - Thng dng dao phay tr (dao ngn) trn my phay ng. - r t song song v i xng ta cng c th p dng nh i vi dao phay a. Ngoi ra ta cn c cch r sau: Cho cnh dao tip xc vo ng sinh ca chi tit sau h bn my v dch dao vo mt khong S.

- Nu phay rnh kn mt u th phi li dao ra khi mt u ri ly chiu su ct v ct ht chiu di rnh then cn phay. - Nu phay rnh kn hai u th cn phi so dao t mt u ca chi tit ti rnh. Ta cn dch chuyn bn my mt khong: A=H+D Trong : H: L khong cch t mt u ti rnh D: L ng knh dao phay Sau ly chiu su ct cho tng lt ti khi t chiu su ca rnh. Ngoi ra : Ta cn c th cho mt u ca dao chm vo chi tit nu trn chi tit hnh thnh vt ct trn th tm dao trng vi tm chi tit, cn nu hnh thnh vt ct khng trn th tm dao b lch so vi tm chi tit

3. Phay rnh then bn nguyt. - Rnh then hnh bn nguyt c gia cng bng dao phay rnh then chp hoc dao phay rnh then c ui m ng knh ca chng ln hn 2 ln bn knh ca rnh.- Dao v phi c g bnh thng - Chy dao c thc hin theo phng ng vung gc vi tm ca trc. 3.3.4. Kim tra kch thc rnh - Kch thc ca rnh c kim tra bng cc dng c o nh thc cp, thc o su, Pan me o trong. - Khi kim tra kch thc chiu su ca rnh phay nu o t mp rnh ti y rnh s c kt qu sai. Ta phi o ng knh ca chi tit ri tr i kch thc phn cn li. h=d-t Trong : h: L chiu cao rnh d: ng knh phi t: Kch thc phn cn li

3.3.5 Cc dng sai hng, nguyn nhn, bin php khc phc. * Cc dng sai hng: - Kch thc b rng ca rnh b sai - Tm ca rnh khng trng vi ng tm ca chi tit - nhn b mt khng t * Nguyn nhn: - Do dao b o, thao tc o sai, ly du xch sai. - Do so dao b sai khng ng tm - Do khng ti dung dch trn ngui, ch ct sai, lng chy dao qu ln * Bin php: - Kim tra li dao, thao tc o kim chnh xc - R chnh xc tm dao trng vi ng tm ca chi tit - Kim tra li ch ct, lng chy dao, ti dung dch trn ngui

3.4.1 Phay rnh ch V Cc rnh ch V c dng thng l rnh ch V i xng v c tr s gc bng 90. Dng lm mt dnh v cho cc chi tit hnh tr trn.

3.4.1.1 Trnh t khi phay rnh ch V 1. Phay ln lt cc cnh ca chi tit: m bo song song - vung gc, v m bo kch thc. - C th gia cng trn my phay ngang hoc my phay ng, dng dao phay mt u hoc dao phay tr nm. - Ch ct, phng php phay tng t nh khi phay mt phng song song - vung gc.

2. Phay rnh nh tm. - Chi tit c g trn my phay nm hoc my phay ng. Phi r sao cho ng tm ca chi tit song song vi hng chy dao - Dng dao phay a mng ( c b dy t 2 - 3mm ) hoc dao tr c ng knh nh. Ta iu chnh cho dao ct vo ng ng tm ca rnh ch V cn gia cng ( R theo ng ly du hoc dng thc cp o tng bn cho i xng) - Phay rnh nh tm theo cch thc phay rnh thng sut. V dao c b dy nh nn phi s dng ch ct thp, chiu su ct nh v phi ti dung dch trn ngui y .

3. Phay rnh ch V.

- Dng dao phay gc kp 90 gia cng . R cho mi dao ng ng tm ca rnh ( Da vo rnh nh tm phay trong bc trc ). Cch r: Dng Ke vung p vo tng bn ca chi tit sau o khong cch t ke vung n mt bn ca dao, dch chuyn bn my n khi kch thc hai bn bng nhau l t trng tm.

- Sau khi r xong ta tin hnh phay t t thnh rnh ch V cho n khi t kch thc cn c. Do phn ln b mt ca dao tip xc vi b mt phi nn ta phi chn ch ct thp - Mun m bo b mt rnh ch V chnh xc, phi chn dao c chiu rng li ct ln hn chiu rng ca ming rnh. Ngoi ra ngi ta cn c th phay rnh ch V bng dao phay gc n hoc dao phay tr . Tu theo tr s gc ch V m ta chn tr s gc ca dao phay gc n cho ph hp. Sau khi iu chnh cho mi dao trng vi ng tm chi tit ta tin hnh phay tng bn mt - i vi dao tr c gia cng trn my phay ng bng cch xoay nghing u my theo gc ca rnh ch V. Ta cng tin hnh phay tng bn ca rnh. 4. Cc dng sai hng - Nguyn nhn - Bin php khc phc - Kch thc sai: Do o kim khng chnh xc - Sai s v gc : Do chn dao sai, xoay u my khng ng - Rnh khng i xng: Do iu chnh tm dao khng trng vi tm rnh

3.4.2 Phay rnh ch T 3.4.2.1 Khi nim. 3.4.2.2 Cng dng 3.4.2.3 Phng php phay. 1. Phay rnh vung: - Ta c th s dng dao phay tr ng (dao ngn) hoc dao phay a ba mt ct gia cng rnh vung. - Trong khi phay tu theo hng n dao m ta hm cc chuyn ng khng cn thit. Nu khng s xy ra hin tng rung ng, gim cht lng b mt ca rnh gy m hoc gy dao. Qu trnh phay c tin hnh bnh thng nh khi phay rnh vung.

2. Phay rnh ch T - Phay rnh ngang bng dao phay c bit (thng gi l dao phay rnh ch T) c kch thc ph hp. - Sau khi phay rnh vung xong ta khng dch chuyn bn my theo phng ngang m phi lp dao vo trc chnh ca my v tin hnh iu chnh my phay rnh ch T. Lc ny tm ca rnh vung phi trng vi tm ca dao phay. - Chiu cao ca rnh c thc hin bng cch: Dch chuyn bn my cho mt trn ca chi tit chm nh vo mt u ca dao sau dch cho phi ra khi dao v nng bn my ln mt khong H bng chiu cao ca rnh.

- Khi chiu rng ca rnh bng chiu rng ca dao th phay bnh thng. - Cn nu chiu rng ca rnh ch T ln hn chiu rng ca dao th ta phi dch chuyn dao sang hai bn ct ht chiu rng ca rnh. Ch : Loi ny rt yu, d gy c dao do phi ly lng chy dao nh v phay tht thn trng, tc ct ly nh

3. Phay vt mpC x - phay vt mp C x 450 ta c th dng dao phay c gc hoc dao phay tr xoay u my i mt gc .

3.4.2.4 Dng sai hng, nguyn nhn, bin php khc phc. * Dng sai hng:

- Sai s v kch thc ca rnh

- Sai s v v tr tng quan, ng tm ca rnh khng i xng - nhn b mt khng t:

* Nguyn nhn: - Thao tc o khng chnh xc, sai s dng c o - Do ly du khng ng, iu chnh my sai - Ch ct khng hp l, khng ti dung dch trn ngui, dao b cn * Bin php khc phc: - o kim chnh xc, kim tra li dng c trc khi o - Ly du chnh xc, kim tra li trc khi phay tinh - Ly ch ct hp l, kim tra li dao, ti dung dch trn ngui

3.4.3 Phay rnh ui n: 3.4.3.1 Khi nim chung. - L rnh hp bi 2 mt phng nh hn 900 thng l cc gc: 450, 500, 550, 600, 650 - Rnh ui n c dng nhiu trong qu trnh tho lp nhanh cc c cu vi cc thit b i hi chnh xc cao nh cc rnh trt, sng trt mang c, rnh lp khun dp vo e u my

3.4.3.2. Cc thng s c bn Trong : H: L chiu su ca rnh L: L chiu rng ca rnh : Gc ca rnh

3.4.3.3 Phng php phay rnh ui n 1. Phay rnh vung - C th s dng dao phay a hoc dao phay tr ng sao cho rnh vung c chiu rng phi nh hn chiu rng ca ming rnh ui n v chiu su ca rnh vung phi nh hn chiu su ca rnh ui n khong 0,1 0,2 mm. - Ch ct, phng php phay, cch iu chnh my tng t nh khi phay rnh vung.

2. Phay rnh ui n - Chn dao: Ta s dng dao phay gc n c gc () tng ng vi gc yu cu ca chi tit gia cng v chn ng knh ca dao (D) ph hp vi chiu rng ca rnh - Ch ct: Do iu kin lm vic ca dao kh khn ( dao nh hnh), dao d b gy nn chn VC = 2/3 VC khi phay rnh vung. Khi phay phi lun phay nghch vi lng d nh v lng chy dao nh S = 0.02 - 0.04

3. Kim tra rnh ui n - Vic kim tra chnh xc ca rnh ui n c thc hin bi cc dng chuyn dng. Cc dng ny cho php kim tra gc nghing ca cnh bn, v tr i xng ca chng v chiu cao ca rnh. - Ngoi ra ta c th kim tra bng phng php o: Nhng y khng o trc tip c m phi o gin tip thng qua con ln. Theo hnh v ta c:

Trong :

D: L ng knh ca con ln (mm) : L gc ca rnh ui n () L: Chiu rng ca y rnh cn kim tra Y: L kch thc o c bng thc cp 4. Cc dng sai hng, nguyn nhn, bin php khc phc. * Dng sai hng: - Sai s v gc Sai s v kch thc - Sai s v v tr tng quan - nhn b mt khng t * Nguyn nhn: - Do chn dao sai, khng ng gc - Do tnh ton khong Y sai - Chn con ln khng ng, khng u - Thao tc o kim sai - Do khng iu chnh cho ng tm ca rnh trng vi ng tm chi tit Do ch ct khng hp l, dao cn, khng ti dung dch trn ngui

* Bin php khc phc - Kim tra gc ca dao trc khi gia cng - Tnh ton li khong Y - Kim tra ng knh con ln - Thao tc o kim chnh xc - Kim tra trc khi phay tinh - iu chnh li ch ct, kim tra li dao

3.4.4 Phay cht ui n

4.4.4.1 Cc thng s c bn ca cht ui n

Trong :

L: L b rng ca cht. : L gc nghing ca cht h: L chiu cao 4.4.2. Phng php phay 1. Phay bc thng gc

- Dng dao phay tr hoc dao phay a 3 mt ct phay bc thng gc sao cho kch thc cn li ca bc phi ln hn kch thc ln nht ca cht v chiu cao ca bc phi nh hn chiu cao ca cht. - Ch ct, phng php phay tng t nh khi gia cng mt bc.

2. Phay mt nghing - S dng dao phay gc n c gc tng ng ph hp vi gc yu cu ca chi tit gia cng. - Phng php phay tng t khi phay rnh ui n.

3. Kim tra cht - Cng nh khi kim tra rnh ui n khi kim tra cht ta phi kim tra thng qua hai con ln

3. Cc dng sai hng - Nguyn nhn - Bin php khc phc

* Cc dng sai hng . Sai s v gc Sai s v kch thc Sai s v v tr tng quan nhn b mt khng t * Nguyn nhn : - Do chn dao sai, khng ng gc - Do tnh ton khong Y sai - Chn con ln khng ng, khng u - Thao tc o kim sai - Do khng iu chnh cho tm rnh trng vi ng tm chi tit - Do ch ct khng hp l, dao cn *Bin php khc phc

Chn li dao Kim tra gc ca dao trc khi phay Tnh ton cn thn Kim tra ng knh con ln o kim chnh xc Kim tra trc khi phay tinh iu chnh li ch ct, kim tra lo dao