I HOC QUC GIA THANH PH H CHI MINH

I HOC BACH KHOA TP HCM

KHOA CNG NGH VT LIU
B MN KIM LOI HP KIM

N MN HC THIT K C

THIT K C CHI TIT BANH

AI S DNG TRONG MAY NN KHI
GVHD:

L Quc Phong

SVTH:

Cao Minh Tr

MSSV: V1003567

TPHCM, thang 04/2014

MC LC
LI NI U..........................................................................................................3
TRNH T THIT K C...................................................................................5

 N MN HC THIT K C

GVHD: L QUC PHONG

PHN 1: NGHIN CU CHI TIT C............................................................6

1. Quan st chi tit cn c..........................................................................................6
2. Nghin cu iu kin lm vic ca chi tit...............................................................6
3. Tnh cht hp kim c:............................................................................................7
4. Nghin cu tnh cng ngh ca chi tit:...................................................................7
5. Phn tch, ti u kt cu c (thay i nu cn).......................................................8
6. Xc nh loi hnh sn xut c.............................................................................10

PHN 2: THIT K BN V PHI..................................................................12

1. Chn v tr vt c trong khun..............................................................................12
1.1

Chn mt phn khun......................................................................................12

1.2

B tr rut........................................................................................................13

2. V tr ca chi tit Puli trong khun.........................................................................13

3. Sai lch cho php...................................................................................................16
4. Lng d gia cng c kh......................................................................................16
4.1

Lng d l trc..............................................................................................16

4.2

Lng d rnh hnh thang...............................................................................17

5. Lng tr co..........................................................................................................17
6. Lng d cng ngh..............................................................................................18
7. Kch thc phi......................................................................................................18
8. Chn chun gia cng..............................................................................................19
9. Lp bn v phi......................................................................................................19

PHN 3: THIT K BN V CNG NGH C..........................................20

1. Thit k h thng rt..............................................................................................20
1.1

Chn kiu h thng rt....................................................................................20

1.2

Chn v tr t h thng rt..............................................................................21

2. Tnh ton h thng rt............................................................................................22

2.1

Xc nh thi gian rt hp l:..........................................................................22

 N MN HC THIT K C

GVHD: L QUC PHONG

2.2

Kim tra li thi gian rt hp l......................................................................24

2.3

Tnh ton tit din hp nht ca h thng rt...................................................25

2.4

Tnh ton tit din rnh lc x v ng rt.........................................................27

2.5

Xc nh hnh dng v kch thc cc thnh phn ca h thng rt:...............28

3. Thit k rut...........................................................................................................33
3.1

Rut li...............................................................................................................33

3.2

Rut vng...........................................................................................................35

3.3

Lp bn v rut...................................................................................................37

4. Lp bn v cng ngh............................................................................................37

PHN 4: PHI LIU VA NU LUYN GANG XAM MAC GX 15 32......38

1. Gang xm............................................................................................................... 38
2. Thnh phn ha hc...............................................................................................38
3. T chc t vi:.........................................................................................................38
4. C tnh v bin php nng cao c tnh...................................................................39
4.1.

C tnh............................................................................................................. 39

4.2.

Cc bin php nng cao c tnh.......................................................................39

5. Mc gang xm GX 15 32....................................................................................39
6. Chi tit Puli............................................................................................................40
7. Tnh hnh s dng cc loi l nu gang TP H Ch Minh...................................41
8. Tnh ton phi liu.................................................................................................43

TAI LIU THAM KHO:...................................................................................46

TAI LIU INH KM:........................................................................................46

 N MN HC THIT K C

GVHD: L QUC PHONG

LI NI U
Ngnh ch to my gi mt vai tr quan trng trong s nghip xy dng t nc.
Mc d c nhiu tin b v khoa hc k thut khu ch to phi, song cho n nay
phn ln chi tit my mc (khong 40 60%) vn c ch to bng phng php c.
Khi thit k mt chi tit c, phi tha mn yu cu v c tnh v cc tnh cht lm
vic khc ng thi phi m bo tnh d c cho chi tit. Ngc li khi thit k mt
cng ngh c cn phi ch n qu trnh gia cng c kh v sau ny, nht l trong sn
xut ln. Tng cng mi quan h gia c v ch to c kh s to iu kin nng cao
cht lng v h gi thnh sn phm
sn xut ra vt c phi quan tm n ton b qu trnh sn xut t nguyn liu
n thnh phm: khng nhng ch n cc qu trnh cng ngh chnh (lm mu, lm
khun, nu rt, chun b hn hp, lm sch, x l hn hp s dng ) m cn phi
ch n hng lot cc vn khc (vn chuyn trong xng, kim nghim nguyn liu
v thnh phm, bo quan kho, sa cha my ).
mi khu ca sn xut u phi c thit k, hng dn hoc quy nh k thut.
Trong qu trnh thc hin n mn hc vi s gip tn tnh ca GVHD l thy
L Quc Phong, em hon thnh c ti c giao. Tuy nhin do vn kin thc
cn hn ch v cha c nhiu kinh nghim trn thc t, nn n c th c nhiu sai st
v ni dung ln hnh thc trnh by. Rt mong thy v cc bn gp em c th khc
phc.
Qu trnh thc hin n c s dng s tr gip ca hai phn mm chnh l:
-

PTC Creo Parametric 2.0

AutoCad 2007

 N MN HC THIT K C

GVHD: L QUC PHONG

TRNH T THIT K C
1.
2.
3.

Nghin cu bn v v chi tit c

Tm hiu iu kin lm vic ca chi tit c.
Nghin cu c im ca vt liu ch to v yu caaif tnh cht c l ca chi tit.
Phn tnh tnh cng ngh ca kt cu c
Nghin cu cc vn lin quan n hnh dang vt c
V tr vt c khi lm khun v khi rt.
Mt phn khun v mt phn mu.
Hnh dng rut, cch c nh v lp rp rut.
Lng d gia cng, lng d cng ngh, lng co.
Tnh ton, chn kiu b tr h thng rt, ngt, phn tch cc hin tng v
nhit xy ra khi vt c ng c.
4. Chn phng php lm khun, kch thc khun ph hp vi chi tit v s
lng mu khi c.
5. Thit k b mu, khun c
6. Lp cc h s k thut
- Bn v chi tit.
- Bn v phi.
- Bn v rut.
- Bn v cng ngh.
Cc bng tra s dng trong qu trnh tnh ton u ly ti liu tham kho [1]

 N MN HC THIT K C

GVHD: L QUC PHONG

PHN 1: NGHIN CU CHI TIT C

Mc tiu:
- iu chnh kt cu ca chi tit
- Lp bn v chi tit
- Chn phng php c ph hp.
1. Quan st chi tit cn c
Mc tiu: Hnh dung chi tit mt cch y phc v cho qu trnh lp bn v
chi tit, chn mt phn khun, thit k li, h thng rt, phng php c ph hp
Chi tit bnh ai truyn ng (Puli) trong my nn kh c dng trn xoay s dng
h thng nan nghing dng cnh qut gm 6 nan gip to gi trong qu trnh quay nhm
gp phn gii nhit ng c ca my. c c nh vi trc truyn ng bng mt then
bng. Truyn ng bng h thng hai ai thang vnh.

Hnh 1.1 Hnh dng chi tit c

2. Nghin cu iu kin lm vic ca chi tit.

Nghin cu iu kin lm vic ca chi tit l rt cn thit cho qu trnh thit k c, t

c th ra cc phng php ch to vt c ph hp.
6

 N MN HC THIT K C

GVHD: L QUC PHONG

Chu ti trng khng ng u trong qu trnh lm vic (xoay).

B ma st nhiu vi dy ai khi lm vic, nhng do chi tit Kim loi nn lng hao
mn vi dy ai (cao su) gn nh khng ng k
Do b ma st nhiu khi lm vic nn nhit b mt tip xc c th ln n trn
50 C.
o

3. Tnh cht hp kim c:

Vt liu dng ch to chi tit l gang xm c mc: GX 15-32 c thnh phn c
im:
-

T trng 7,2Kg/dm3.

Gn nh khng gim th tch trong qu trnh kt tinh => gim c khi

lng u ngt ph phm vt c.

Thnh phn ha hc:

Si

Mn

3,5 3,7%

2,0 2,4%

0,5 0,8%

<0,3%

<0,5%

C tnh ca mc gang xm GX 15-32:

Gii hn bn ko: K = 15N/mm.
Gii hn bn un: U = 32N/mm.
cng: 173 229 HB.

Nhit nng chy: 1180 1250oC (ty thuc vo thnh phn nu luyn).

Nhit rt 1280 1350oC ty vo khi lng vt c, cng ngh lm

khun

4. Nghin cu tnh cng ngh ca chi tit:

Chi tit c mt l trung tm 34, mt rnh then 2 rnh thang c yu cu gia cng
nhm b mt. Khi c ta s c l trc v hai rnh thang v gia cng li sau khi c
cn i vi then s khng c ny m gia cng sau ny.
Da vo iu kin lm vic v tnh cng ngh ca chi tit ta chn c:

 N MN HC THIT K C

GVHD: L QUC PHONG

Dung sai gia song song ca hai b mt trc quay l 0.1mm.

nhm yu cu b mt ca trc l Rz 6,3.

nhm yu cu b mt lm vic ca rnh thang l Rz 0,8.

Dung sai vung gc gia ng tm ca l trc v 2 mt u trc

0.03mm, dung sai ny l rt nh m bo yu cu lm vic khi quay ca
chi tit.

B mt gia cng quan trng ca chi tit l b mt tip xc gia rnh thang v ai.

Hnh 1.2 Mt ct th hin yu cu nhm rnh gia cng ca chi tit.

5. Phn tch, ti u kt cu c (thay i nu cn)
Da vo cc yu cu v thit k c:
-

B dy thnh nh nht l 7mm, tha yu cu dnh do vt c gang xm

(thnh nh nht 5mm).

 N MN HC THIT K C

GVHD: L QUC PHONG

B dy thnh vt c khng nn chnh lch nhiu t gy lm co, xp co.

Nu c ta nn to cc gc lng ti v tr tip gip gia hai thnh vt c. V
tr cc gc lng c th hin hnh 1.3

Hnh 1.3 V tr cc gc c
i vi cc v tr 1 v 2 ta bo trn vi bn knh gc bo R5.
i vi v tr 3 v 4 c th thc hin bo trn nu thm lng d gia cng v thay
i hnh dng l.

 N MN HC THIT K C

GVHD: L QUC PHONG

Nan qut c tit din hnh thang ( m bo kh nng rt vt c hoc mu ra khi

khun) nghing 1 gc 30o so vi mt phng ngang, tng cng c 6 nan cch nhau u
mt gc 60o , ta cng to cc gc lng vi bn knh R5 cc gc trn ca cnh.

Hnh 1.4 Tit din ngang ca nan.

6. Xc nh loi hnh sn xut c
Chi tit Puli c s dng rt rng ri trong c kh ch to my, c s dng ch
yu truyn ng trong cc loi my nh my nn kh. Nn ta s chn loi hnh sn
xut ln vi mc ch chnh l s dng ch to my v thay th sa cha.
Sn lng c tnh vo khong 3000 5000 tn/nm.
Da vo sn lng v kt cu chi tit ta thy chi tit ph hp vi phng php c
bng khun kim loi bn vnh cu.

u im:
-

sch v chnh xc c nng cao ng k. iu ny s lm gim khi

lng gia cng c kh.

Nng cao bn c hc ca vt c, c bit l bn lp b mt tip gip

vi khun kim loi.

Nng cao sn lng hng nm do gim c kch thc u ngt v ph

phm c.
Nng cao nng sut lao ng.
Tit kim din tch nh xng do khng cn ch to hn hp lm khun v
qu trnh lm khun.

10

 N MN HC THIT K C

GVHD: L QUC PHONG

Kh nng gii nhit ca khun ln nn trnh c cc khuyt tt nh xp co,

lm co v to iu kin d dnh cho kim loi lng ng c c hng.
Sn lng ln => gim gi thnh sn phm.
D c kh v t ng ho, iu kin v sinh lao ng tt.

Nhc im:
-

bn khun hn ch khi c thp (khng nh hng nhiu do chi tit bng

gang xm).

Kh c nhng vt thnh mng v hnh dng phc tp (Chi tit n gin)

Vt c c ng sut ln do khun kim loi cn co mnh ( Khc phc bng

cng on , nhit luyn sau c).

Ch to khun kim loi phc tp v t tin (do sn lng ln nn ph

hp iu kin kinh t).

Vt c gang d b bin trng (khng nh hng n tnh cng ngh ca chi

tit Puli).

Quy trnh c phi cht ch.

Kt Lun: Chi tit s dng cng ngh c trong khun kim loi bn vnh cu
vi cc yu cu sau:
-

Thm lng d phn l trc v phn rnh thang m bo dung sai.

C th bo trn cc v tr 3 v 4 (Hnh 1.3).

L trc v rnh thang c to hnh bng rut.

T cc thng s kho st, o c v chn la c da vo iu kin lm vic

v yu cu cng ngh ta tin hnh lp bn v chi tit.
(Xem ti liu nh km [1])

PHN 2: THIT K BN V PHI

1. Chn v tr vt c trong khun
1.1 Chn mt phn khun
11

 N MN HC THIT K C

GVHD: L QUC PHONG

Khi chn v tr vt c trong khun khi rt cn ch :

Nhng phn quan trng ca chi tit cn st cht, nhng b mt gia cng quan trng,
ln nn t phn di ca khun (v d phn sng trt ca thn my tin, cc b mt
rng ca bnh rng... ).
Nu khng th thc hin c iu nu trn th t cc mt ny dng ng hoc
nghing trnh khuyt tt r x, r kh...
Nu v nguyn nhn no nhng mt gia cng quan trng bt buc phi t quay
v pha trn th phi to mi iu kin nhng khuyt tt c (r co, r x r kh... ) ch
sinh ra nhng phn ca vt c m sau khi c c th ct b i (u nhng phn ca
vt c m sau khi c c th ct b i (u hi, u ngt, phn gia cng c kh...).
Nhng vt c bng hp kim c co ln khi ng ngui th khi rt phi t v tr
c th m bo cho hng ng ca kim loi trong khun vpha b ngt cho u ngt.
t nhng phn vt c c thnh mng v rng pha di ca khun hoc nm
nghing lc rt trnh cc khuyt tt nh thiu, khp... ca vt c.
Mt rp khun trong khun nn chn sao cho khun ch c mt mt rp khun ,iu
lm cho cu to khun c n gin, vt c t chnh xc. thc hin ch dn
ny c trng hp ngi ta dng thm cc li to hnh b mt bn phc tp ca vt
c.

12

 N MN HC THIT K C

GVHD: L QUC PHONG

Hnh 2.1 M phng mt phn khun bn trong bnh ai.

Do chi tit puli c phn nan nghing khng phi dng trn xoay v khng lin tc
nn mt phn khun bn trong tng i phc tp, s dng s tr gip ca phn mm
Creo Parametric ta to c mt phn khun (mu xanh) ca phn nan qut bn trong
Puli.
Do chi tit c trong khun kim loi nn m bo tnh cng ngh ta chn mt
phn khun l mt phn khun ng.
1.2 B tr rut
Nn b tr li sao cho v tr ca li l thng ng. nh v li chnh xc, trnh c
tc dng lc ca kim loi lng lm bin dng thn li v d kim tra khi lp rp.
i vi chi tit Puli c trong khun kim loi, khun gm 2 loi li l li gia
to phn l trung tm v h thng rut vng to rnh thang bn ngoi vnh ca bnh
ai (Thng s chi tit tnh by phn tnh ton rut).
2. V tr ca chi tit Puli trong khun
Da vo cc nguyn tt trnh by bn trn, ta c th chn c cch b tr vt
c trong khun mt cch ti u nht

13

 N MN HC THIT K C

GVHD: L QUC PHONG

Hnh 2.2 B tr vt c v h thng rut bn trong hm khun.

u im ca phng php b tr ny l:
Mt phn khun nm ngang gip cho qu trnh thot kh din ra d dng qua mt
phn khun
H tr gip cho qu trnh rt vt c ra khi khun kim loi
D dng b tr h thng rt sau ny.
Gip vt c d ng c c hng.
D c kh ha, nng sut cao.
Nhc im ca cch b tr ny:
Rut phn li nm ngang d b ni rut gy sai lch.
Kh t rut.

14

 N MN HC THIT K C

GVHD: L QUC PHONG

Khun d cng vnh.

Hnh 2.3 M phng tch khun bng phn mm Creo Parametric.

15

 N MN HC THIT K C

GVHD: L QUC PHONG

3. Sai lch cho php

Do ta s dng phng php c trong khun kim loi vi sn lng ln nn cp
chnh xc ca vt c l cp ln nht cp I, tra bng Sai lch cho php v kch thc i
vi vt c bng gang xm ta c:

Kch thc o ca vt c

Cp chnh xc I

(mm)

Sn xut ln

300 500

Trn

Di

(+)

(-)

1,5

Bng 2.1 Sai lch cho php () i vi vt c bng gang xm, mm.
4. Lng d gia cng c kh
Lng d gia cng c kh c chn theo:
-

Loi vt liu.

Phng php c.

Cp chnh xc.

Kch thc vt c

V tr b mt vt c trong khun.

Do chi tit c c trong khun kim loi, sau khi c chi tit c chnh xc b
mt cao nn ch c mt vi b mt phi gia cng li sau khi c, ta ch ly lng d cho
nhng b mt ny.
4.1 Lng d l trc
Chi tit c l 34 l l c, lng d ca b mt l ny c ly theo bng tra 21:

Kch thc ln nht ca vt c

16

Nhm lng d

 N MN HC THIT K C

GVHD: L QUC PHONG

(mm)

Sn xut ln

300 500

Bng 2.2 Lng d gia cng ln nht gia cng c kh i vi nhng l lp ghp
trong vt c bng gang xm, mm.
4.2 Lng d rnh hnh thang
Rnh thang l b mt c c yu cu nhm sau gia cng nn ta tnh ton lng
d cho b mt ny. Lng d c ly theo bng tra 19:

Kch thc chon ch

ln nht ca chi tit

V tr b mt khi c

Lng d i vi cc
khong kch thc danh
ngha
50

260 500

Pha bn

2,5

Bng 2.3 Lng d cho gia cng c ca vt c bng gang xm.

(i vi vt c c cp chnh xc I), mm
5. Lng tr co
Lng tr co khi c ph thuc vo:
-

Loi hp kim c

Hnh dng kch thc vt c

Chiu dy thnh vt c

cng ca khun

17

 N MN HC THIT K C

GVHD: L QUC PHONG

Nhit kim loi rt vo khun

i vi chi tit Puli c trong khun kim loi c cn co cao, dng hnh tr trn,
tra bng 23 xc nh cn tr
co,%

Nhm vt c

B cn tr

Gang xm:
Vt c hnh tr trn
-Theo chiu di

0,8

-Theo ng knh

0,5

Bng 2.4 Lng c theo chiu di ca vt c bng gang xm, mm.

6. Lng d cng ngh
Trn chi tit Puli c mt rnh hnh ch nht dng ci cht c nh Puli vi
trc quay, rnh ny ta khng c m s gia cng c sau khi c
7.Kch thc phi
Sau khi chn lng d, ta s dng thng s tra c tnh ton lng d t
lp c bn v phi:
- ng knh l trc c: c = (34 6) 100,5% = 28,1 (mm)
- rng ca rnh thang:

y ln:

(12 - 2,5) 100,8% = 9,6

y b:

(8 2,5) 100,8% = 5,5 (mm)

Chiu cao rnh thang :

(10 2,5) 100,8% = 7,6

8. Chn chun gia cng

18

(mm)

(mm)

 N MN HC THIT K C

GVHD: L QUC PHONG

Sau khi loi b h thng rt, ta tin hnh thc hin gia cng cho chi tit t
c kch thc ng theo yu cu.
u tin ta chn chun th gia cng, ta chn chun th u tin cho chi tit Puli
l b mt l trc gia cng cho cc b mt rnh, b mt l lc ny s dng g t
phi trong lc tin hnh gia cng rnh. Sau khi gia cng rnh thang ta chn b mt
rnh thang lm chun gia cng tinh, t gia cng li l trc v phn rnh then.
(xem chi tit bn v phi)
9. Lp bn v phi
T cc thng s tnh ton c v quy trnh gia cng ta tin hnh lp bn v phi
ca chi tit.
(Ti liu nh km [2])

PHN 3: THIT K BN V CNG NGH C

19

 N MN HC THIT K C

GVHD: L QUC PHONG

1. Thit k h thng rt
Yu cu chung:
-

m bo ngn khng cho x c cc tp cht khc ln vo vt c cng vi

kim loi lng.

Cung cp kim loi lng v iu chnh lng nhit cho vt c trong thi
gian ng c v lm ngui.

Dng kim loi lng chy m, u v lin tc.

Khi lng b, t chim ch.

Cc im cn lu khi thit k h thng rt cho vt c bng gang:

-

m bo dng kim loi chy t ri trong rnh.

trnh x bn cun thng vo h thng rt nn, cc thnh phn ca h

thng rt nn lm nh dn.

Khi vt c c th tch b, t to r ngt ( Vd: gang xm nhiu graphit) nn

dn kim loi vo ch thnh mng ca vt c m bo ng c ng
thi.

Khi vt c c xu hng to r ngt (Vd: gang cu) nn dn kim loi vo

thnh dy hay bn trn b sung kim loi cho vt c.

1.1 Chn kiu h thng rt

i vi vt c l Puli bng gang xm GX 15 32, do c trong khun kim loi
nn thun tin cho vic b tr h thng rt v d rt vt c ra khi khun sau ny ta
chn h thng rt kim loi khuyt:
-

Khng c rnh lc x

Rt kim loi t trn xung qua phu rt c mng lc x.

u im:
-

Nhit phn vt c pha trn cao hn cc phn nhit cn li, to

hng ng thun li b ngt cho vt c, nht l khi c cc hp kim
c co ln.

20

 N MN HC THIT K C

GVHD: L QUC PHONG

H thng rt loi ny thng c khi lng b hn cc kiu HTR khc.

Nhc im:
-

Nu lng khun cao th khun c rt d b v do tc dng ca dng kim

loi ri t trn cao vo khun. V th kiu h thng rt ny ch nn dng
c cc vt c chiu cao khng ln lm v khng c yu cu cao v cht
lng v yu cu gia cng c kh t (cc loi a, t... ). khc phc mt
nhc im ca kiu h thng rt ny, ngoi kt cu thng thng c th
dng cc kt cu h thng rt rt qua mt vi ng rt, rt qua mng lc
gim nguy c xi l khun v gn gi c x.

1.2 Chn v tr t h thng rt

Da vo cc yu cu ca h thng rt ta b tr h thng rt nh hnh 3.1

21

 N MN HC THIT K C

GVHD: L QUC PHONG

Hnh 3.1 H thng rt t trn xung v rnh dn kim loi.

2. Tnh ton h thng rt
2.1 Xc nh thi gian rt hp l:
tnh ton h thng rt cho vt c bng gang xm, u tin ta xc nh thi gian
rt c li nht cho vt c t tnh tit din ca cc thnh phn h thng rt m bo
thi gian rt quy nh.
Thi gian rt hp l c tnh theo cng thc thc nghim sau:

22

 N MN HC THIT K C

GVHD: L QUC PHONG

t=s

trong :
g: chiu dy thnh trung bnh ca vt c, mm
G: khi lng vt c cng h thng rt, Kg
s: h s i vi vt c bng gang khi lng < 1 tn, s = 1,4 ~ 1,6

Hnh 3.2 Cc thng s ca phi c tnh ton bng phn mm.

S dng phn mm Creo Parametric ta tnh c khi lng ca chi tit G v ~
13,7(Kg).
Gi s h thng rt chim 30% trng lng ca vt c:

23

 N MN HC THIT K C

GVHD: L QUC PHONG

G = Gv 130% = 17,8 (Kg).

i vi vt c bng gang xm, rt t trn xung tra bng 34, ta chn c h s s
= 1,5.
Chi tit Puli c thnh vt c khng ng u nn ta tac lng chiu dy trung
bnh ca vt c bng mt ct ca phi c (bn v phi). Chiu dy trung bnh c
lng vo khong 14 mm.
Thi gian rt hp l:

t=1,5 3 17,8 14=9,4( s)

2.2 Kim tra li thi gian rt hp l

Xc nh thi gian rt kim loi vo khun cn tnh n tc dn ca kim loi khi
rt. Tc ny khng c qu b v s lm thnh vt c nhn nheo do kim loi b
ngui, cng nh b bn do oxy hay tp cht phi kim loi to thnh trn b mt kim loi.
Tc dn b nht cho php tnh bng cm/s ph thuc vo chiu dy thnh vt c.
i vi vt c c chiu cao C tnh bng cm, o t im thp nht n im cao
nht khi rt, tc dn kim loi s l:
v=

C
t

Tr s v b nht cho php, tra bng 35

Chiu dy thnh vt c

Vt c gang

Vt c thp

n 4

3-10

__

4-10

2-3

10-40

1-2

Trn 40

0.8-1

0,8

24

 N MN HC THIT K C

GVHD: L QUC PHONG

Bng 3.1 Tr s v b nht cho php (cm/s).

Kim tra li tc dng ca kim loi:
v=

40
=4,3 (cm/s)
9,4

v >vmin : tha iu kin

2.3 Tnh ton tit din hp nht ca h thng rt
Sau khi tnh ton thi gian rt hp l ta tnh ton tit din hp nht ca h thng rt
Fmin, xc nh lng kim loi chy qua h thng rt trong mt n v thi gian theo cng
thc:

Fmin =

G
1
G
=

0,31 h tb . t 0,31 htb t

trong :

G Khi lng vt c k c h thng rt, Kg

h s tr lc ca khun
htb ct p thy tnh trung bnh ca kim loi, cm
G
t

tc cung cp kim loi t thng rt, kg/s

i vi vt c gang th tit din b nht ny chnh l tit din rnh dn.

Tr lc ca khun ph thuc vo mc phc tp ca vt c, tra bng 36 ta
chn c h s tr lc = 0,41.
Ct p thy tnh trung bnh ca kim loi htb tnh theo biu thc:
P2
htb =H 0
2C

trong :

H0 p sut thy tnh ban u ln nht, cm

P Chiu cao vt c trn rnh dn, cm
C Chiu cao ca vt c v tr khi rt, cm

25

 N MN HC THIT K C

GVHD: L QUC PHONG

Hnh 3.3 Cch xc nh cc h s H0, P, C.

Hnh 3.4 Chiu cao ct p thy tnh H0.

i vi cch b tr h thng rt nh hnh 4.3, ta c H 0 =160 mm = 16 cm. Cc b tr
ny khng to ra P nn P = 0.
Do theo cng thc tnh htb ta c htb = 16 cm.

26

 N MN HC THIT K C

GVHD: L QUC PHONG

Th vo cng thc tnh Fminta tnh c Fmin = 5cm2

Ta c vt c khi lng 17,8 Kg, thnh dy trung bnh 14 mm, ct p trung bnh
16 cm, vy tng tit din rnh dn tng ng theo ton XbievFd= 1,9 cm2.
Tra bng 37 xc nh s lng rnh dn, di rnh dn v tit din rnh dn b
nht cho php i vi vt c Puli kt cu n gin:

Chiu dy thnh vt
c (mm)

Rnh dn
Khi lng vt
c(Kg)

17,8

Tit din 1
rnh dn (cm2)

Chiu di

14

(mm)

S lng rnh dn

0,65 0,85

25 30

23

Bng 3.2 Tit din b nht v s lng rnh dn i vi vt c bng gang xm

khi lng di 200 Kg.
i vi Fd = 1,9 cm2, m bo tit din rnh dn v gim phc tp ca khun
ta chn s rnh dn l 2, chiu di rnh dn l 25 mm
Tit din ca mt rnh dn = Fd/2 = 0.95 cm2
2.4 Tnh ton tit din rnh lc x v ng rt
i vi vt c bng gang xm th ta c t l cc rnh dn (F d) , rnh lc x (Fx), ng
rt (Fr) nh sau:
Fd : Fx : Fr = 1 : 1,2 : 1,4
Nhng do vt c trong khun kim loi ng, m bo tnh cng ngh ta s
khng b tr rnh lc x trong h thng rt m s b tr mng lc x phu rt.
Tit din ng rt Fr = 1,4 1,9 = 2,7 (cm2) => ng knh ng rt dr = 18,5 (mm)
2.5 Xc nh hnh dng v kch thc cc thnh phn ca h thng rt:

27

 N MN HC THIT K C

GVHD: L QUC PHONG

Dung tch phu rt i vi vt c bng gang c xc nh theo bng 38, vi mc

tiu th kim loi = G/t = 17,8/9,4 = 1,9 (Kg/s)

Phu rt cho mt ng rt
Tiu th kim loi

Dung tch phu rt

Kg/s

(Kg)

1,3 2

Bng 3.3 Dung tch phu rt theo lng tiu th kim loi i vi vt c bng
gang.
T khi lng phu rt, ta tnh c th tch phu rt: V r = 2/7,2 = 0,27(dm3) =
270(cm3).
T ng knh ng rt tra bng 39 v s dng phng php ni suy xc nh cc
kch thc ca phu rt v mng lc x:

Kch thc

ng knh ng
rt

(mm)

(mm)

D1

D2

D3

D4

h1

18,5

93,5

78,7

57

49

77

78,7

11,1

Bng 3.4 Cc kch thc ca phu rt c mng lc x theo ng knh ng rt.

28

 N MN HC THIT K C

GVHD: L QUC PHONG

Hnh 3.5 Cc thng s ca phu rt c mng lc x.

T cc kch thc ca phu rt, tra bng v s dng phng php ni suy tnh
ton cc thng s ca mng lc x:

Kch thc
S l
20

Tng tit
din cc l

(mm)
D

D0

D1

D2

D3

d1

d2

(cm2)

78,7

74,7

51,9

36,4

16,4

5,5

6,5

4,7

Bng 3.5 Cc kch thc ca mng lc x.

29

 N MN HC THIT K C

GVHD: L QUC PHONG

Hnh 3.6 Cc thng s kch thc ca mng lc x.

Do vt c hnh trn, b dy thnh trung bnh tng i mng nn ta chn rnh dn

dng hnh thang cao m bo kh nng in y ca kim loi lng vo khun.

30

 N MN HC THIT K C

GVHD: L QUC PHONG

Tra bng 39 kt hp s dng phng php ni suy cho tit din rnh dn l 0,95 cm2
xc nh cc kch thc ca rnh dn:

Chiu cao h
(mm)

(cm2)

0,95

12,5

9,5

Bng 3.6 Cc kch thc ca rnh dn.

Hnh 3.7 Cc thng s kch thc ca rnh dn hnh thang cao

Do phi c hnh trn nn ta s b tr rnh dn dng tip tuyn nghing 1 gc
khong 10o so vi phng thng ng m bo kh nng in y kim loi vo khun
cng nh hn ch va chm ca dng chy vo nhau dn n s ha tan kh vo kim loi
lng tng ln.

31

 N MN HC THIT K C

GVHD: L QUC PHONG

Hnh 3.8 B tr h thng rt v dng chy ca kim loi lng trong lng khun.

32

 N MN HC THIT K C

GVHD: L QUC PHONG

3. Thit k rut
Yu cu ca rut: n gin, d lm, m bo thng hi, thng kh ca rut, chu
c trng lng ca bn thn rut v lc tc dng ca kim loi lng ln rut.
S lng: 4 rut trn mt b khun, bao gm 1 rut li v 3 rut vng.
Hn hp lm rut: s dng hn hp ct nc thy tinh (thi CO 2) lm rut, lm
nhanh v rut chc chn.
3.1 Rut li
Kiu t rut: t nm ngang c 2 u gc rut
Cc thng s ca rut c tra bng 28
ng
knh u
gc
(mm)

Di 30

Chiu di u
gc

Khe h gia du gc
v gc mt pha

(mm)

(mm)

Bn knh
ln
chn u
gc

xin ca
u gc

Rut khng
c u gc
di

Phn
di ca
khun

Phn
trn ca
khun

a1

a2

25

Khng
c khe
h

10o

(mm)

Bng 3.7 Cc thng s u gc rut nm ngang.

33

 N MN HC THIT K C

GVHD: L QUC PHONG

Hnh 3.9 Cc thng s u gc rut nm ngang.

Do chi tit c mt phn khun nm ngang, m bo kh nng lp rut vo
khun, ta s b tr 1 u gc rut c cn nm phn khun di ng m bo phn
rut ny s d dng khp vo khun.
Cc thng s u gc rut ny s c m bo nh bng 3.7

Hnh 3.10 Hnh dng 2 u gc rut ca ca chi tit Puli.

3.2 Rut vng

34

 N MN HC THIT K C

GVHD: L QUC PHONG

Gm 3 rut c kch thc ghp li vi nhau, mi rut l 1 cung 120o.

Do c cu to dng trn v c lp quanh phn ai ca Puli nn u gc rut ca
rut vng cng s c dng u gc rut ng.

Hnh 3.11 u gc rut vng

Tra bng 29 ly cc thng s v kch thc ca u gc rut ng:
Chiu cao u
ng knh
gc
u gc
(mm)
(mm)
Rut khng
vng
D

Khe h gia du gc
v gc mt pha
(mm)
Phn
di ca
khun

Phn trn
ca
khun

a1

a2

35

Bn knh
ln chn
u gc

xin ca
u gc

(mm)
r

 N MN HC THIT K C

31-50

30

GVHD: L QUC PHONG

Khng
c khe
h

1,5

Bng 3.8 Cc thng s u gc rut ng.

Hnh 3.12 Cu to v hnh dng ca 3 rut vng.

36

15

 N MN HC THIT K C

GVHD: L QUC PHONG

3.3 Lp bn v rut
T cc thng s kch thc tra c ta tin hnh lp bn v rut.
Quy trnh lm rut: do rut c kch thc nh, tng i n gin nn ta c th thc
hin lm rut hng lot. Lm rut bng hn hp ct nc thy tinh ha bn bng thi
CO2 bn ngoi b mt rut m khng cn thi vo bn trong. Rut c lm bng hp
rut bng g.
4. Lp bn v cng ngh
Sau khi tnh ton y cc thng s ca h thng rt v h thng rut bn trong
khun ta tin hnh lp cc bn v cng ngh.
(xem ti liu nh km [3] [4] [5] [6])

37

 N MN HC THIT K C

GVHD: L QUC PHONG

PHN 4: PHI LIU VA NU LUYN GANG XAM MAC

GX 15 32
1. Gang xm
Gang xm l loi gang m phn ln hay ton b cacbon tn ti di dng t do
graphit. Graphit ca n dng tm, phin, chui Mt gy ca n c mu xm, l
mu ca graphit. y l loi gang ph bin nht v c s dng rng ri trong k thut,
thng thng khi ni ti gang ngi ta hiu rng l gang xm.
2. Thnh phn ha hc
Cacbon:Lng cacbon cng nhiu nhit nng chy ca gang cng thp, nhng
s lm cho graphit tng ln c tnh s cng thp. Xu hng ngy nay dng gang c
cacbon thp c bn cao. V vy lng cacbon trong gang xm t 2.8 3.5%.
Silic:L nguyn t hp kim quan trng nht trong gang xm, silic cng nhiu vic
to thnh graphit cng d dng. Lng silic trong gang xm t 1.5 3%.
Manga:L nguyn t cn tr vic to thnh graphit, nhng c tc dng nng cao c
tnh. Nu trong gang xm lng mangan tng ln th silic cng phi tng ln tng ng.
Lng mangan t 0.5 1.0%.
Photpho:Photpho khng nh hng n s to thnh graphit nhng c tc dng
lm tng chy long v nng cao tnh chng mi mn (to ra cng tinh Fe + Fe3P v
Fe + Fe3P + Fe3C). Lng photpho t 0.1 0.2%, khi cn tnh chng mi mn cao c th
n 0.5%. Khng s dng cao hn v lm gang b dn.
Lu hunh:L nguyn t c hi v lm gim nhit chy long ca gang v cn
tr qu trnh to graphit. Lng lu hunh t 0.08 0.12%.
3. T chc t vi:
T chc t vi ca gang xm c phn ra lm hai phn: nn kim loi (c bn) v
graphit. Ty theo mc graphit ha gang xm c ba loi.
Gang xm pherit: t chc ca n gm nn kim loi l st nguyn cht k thut
(pherrit) v graphit. Loi gang ny c bn thp nht.
Gang xm pherit peclit: gm kim loi l thp trc cng tch v graphit, lng
cacbon trong nn kim loi < 0.8%.

38

 N MN HC THIT K C

GVHD: L QUC PHONG

Gang xm peclit: gm c nn kim loi l thp cng tch v graphit, lng cacbon
trong nn kim loi l 0.8%, loi gang ny c bn cao nht.
4. C tnh v bin php nng cao c tnh
4.1.

C tnh

Do c graphit dng tm nn lm gim mnh bn ko ca gang, ch bng khong

1/3 1/5 so vi thp tng ng. Do graphit tm, b mt ln chia ct mnh nn kim loi
v c hai u nhn l ni tp trung ng sut.
Tuy nhin graphit c tnh bi trn tt lm gim ma st, tng tnh chng mi mn, c
tc dng lm tc rung ng v dao ng cng hng.
cng thp 150 250 HB, phoi d gy, ct gt tt. do xp x khng, khng
bin dng do c.
4.2.

Cc bin php nng cao c tnh.

Cc yu t nh hng n c tnh ca gang xm: nn kim loi, hnh dng, s lng

v kch thc graphit. Trong nn kim loi nh hng quyt nh nht, nn kim loi
cng bn th c tnh ca gang cng cao, ta c cc bin php sau:
-

Gim lng cacbon ca gang: do gim c lng graphit t do. Ngy nay xu
hng dng gang c lng cacbon thp t 2.2 2.5%. Tuy nhin phi dng l c
nhit cao (l in) mi nu chy c do nhit nng chy ca gang b nng
cao.

Bin tnh: lm nh mn graphit, cht bin tnh gm 65% pherosilic v 35% Al

trc khi rt gang lng vo khun.

Hp kim ha: cho thm cc nguyn t hp kim cn thit khi nu luyn ha

bn nn kim loi, nng cao thm ti, tnh chng n mn, mi mn, chu
nhit

Nhit luyn: to ra cc nn kim loi ph hp vi yu cu s dng.

5. Mc gang xm GX 15 32.
-

Thnh phn ha hc:

39

 N MN HC THIT K C

GVHD: L QUC PHONG

C: 3.5 3.7%
Si: 2.0 2.4%
Mn: 0.5 0.8%
P: 0.3%
S: 0.15%
-

T chc: Graphit dng tm trung bnh, phn b trn nn kim loi pherit peclit.

Tnh cht c hc:

o Gii hn bn ko: 15 N/mm2.
o Gii hn bn un: 32 N/mm2.
o cng: 163 229 HB.
o vng f, mm khi khong cch gia hai im ta l:
600mm : 8mm.
300mm : 2.5mm.

Nhit nng chy: ty theo thnh phn nu luyn nhit nng chy dao
ng trong khong 1180 1250oC.

Nhit lc rt: 1280 - 1350oC ty theo mac gang, chiu dy c trng,

phc tp, khi lng ca vt c, cng ngh lm khun.

ng dng: Chi tit t quan trng, chu ti trung bnh b dy 8 15mm. Chi
tit chu mi mn, cc loi chi tit yu cu khng cong vnh.

6. Chi tit Puli.

40

 N MN HC THIT K C

GVHD: L QUC PHONG

c im chi tit: trn ton b chi tit vt c, chiu dy thnh tng i

ng u v mng.
c im lm vic: chu ti nng khng ng u, chu ma st n mn

cao.
7. Tnh hnh s dng cc loi l nu gang TP H Ch Minh.
i vi gang xm th l ng chim phn ln s lng l dng nu luyn gang
xm do c hiu sut cao (so vi cc loi l nhin liu), nng sut cao nu c cc m
ln, vn u t thp, hon ton c th ch to trong nc Tuy nhin ch nu luyn
c cc loi gang thng thng.
L cm ng ngy cng c s dng nhiu, ch yu l l do Trung Quc sn xut
v ph bin l loi l 500kg/m. Vi l cm ng ta c th s dng nu luyn c
nhiu mac gang v thp c cht lng cao, thi gian nu nhanh, thnh phn ha n nh
v c th iu chnh cTuy nhin do chi ph u t ln v tn hao in nng nn t
c cc doanh nghip s dng nu gang xm.
So snh nu gang trong l ng v l in cm ng.
Ni dung

L ng t than

L in cm ng

so snh
Khi

L loi l lin tc.

L lo chu k.

nim

Nhin liu l than.

Dng nng lng l in.

Kim loi rn tip xc vi nhin liu -

Kim loi c cch ly trong ni

v sn phm chy.

l.

C th cung cp c lng nc -

Nu c cc loi gang cht

gang ln, lin tc thch hp cho

lng cao, t cacbon.

hot ng sn xut theo dy chuyn. -

D dng iu chnh hm lng

Nng sut cao.

m nu theo mun, thch hp

Hiu sut cao so vi cc loi l s

cho vic tinh luyn.

u im

41

 N MN HC THIT K C

GVHD: L QUC PHONG

dng nhin liu thng thng (30 - -

C th iu chnh nhit chnh

40% vi gi ngui; 45% vi gi

xc theo mun.

nng)
-

Nh c s khuy trn ca dng

Gi thnh chi ph cho l kh thp, c

in ng m thnh phn gang

th ch to trong nc.

ng u.

Cng tc np liu v ra gang tch -

Cht lng nu luyn khng

bit hn nhau, khng l thuc vo

ph thuc nhiu vo thnh phn

nhau.

v tnh cht ca cc nguyn liu.

-

Thi gian chun b ngn, thi

gian nu luyn ngn.

t ha tan cc cht kh.

So vi cc loi l khc th mi
trng lm vic ca l in sch
hn, nh nhng hn.

C th nu luyn trong chn

khng hoc kh quyn thch
hp.

Nhc

im

V kim loi lng tip xc vi than -

Nhit ca x thp.

nhin liu nn gang nu ra bn hn, cha nhiu tp cht hn so vi nu

Tui th ca lp lt bazit khng

l in.
-

cao.
Gi thnh u t ban u cao,

Qu trnh nu luyn khng n nh

cha t sn xut phi c nhp

v: thnh phn ha hc ca gang

t nc ngoi.

lng; nhit ca gang lng; nng

sut ca l.

42

 N MN HC THIT K C

GVHD: L QUC PHONG

Mi trng lm vic c nhiu khi

bi

Vn hnh l phc tp, cn nhiu

cng nhn hn nu l cha c c
kh ha.

Thnh phn v tnh cht gang lng

nu c ph thuc kh nhiu vo
vic chun b nguyn liu v nhin
liu, v vy gi nguyn liu cho m
liu cao hn.

Kh nng kh cc tp cht km.

Bng 8.1: So snh nu gang trong l ng v l in cm ng.

8. Tnh ton phi liu.
Tng khi lng vt cn c:
-

Khi lng mt chi tit c: G = 18 kg.

S lng chi tit c: N = 350 chi tit/ngy

Tng khi lng vt c:

G=6300 Kg

= 6,3 tn.

Tng khi lng gang lng:

-

Tht thot gang lng trong qu trnh rt : 5%.

Khi lng ring ca gang lng v gang khng chnh lch nhiu ta xem nh b
qua.

Tng khi lng gang lng:

gl

= 6000 x 105% = 6615Kg.

Da vo s liu trn ta thy rng khi lng gang nu ln, ti Vit Nam cha c loi l
no c th nu lng gang ln nh vy nn ta c th chn gii php nh sau:
43

 N MN HC THIT K C

GVHD: L QUC PHONG

Gii php 1: Nu gang trong l t than vi yu cu v chi tit khng cao lm v

cht lng gang nu ra kh m bo c thnh phn v yu cu so vi l thuyt.
Nhng li gii quyt c tnh lin tc ca qu trnh sn xut.

Gii php 2: Nu tng m gang nh trong l cm ng trung tn nng sut

500kg/m (a s c s dng ti cc doanh nghip VN). u im ca gii
php ny c th iu chnh tt thnh phn v cht lng gang lng ra l. Nhng
kh lm vic lin tc do thi gian nu mt m trong thc t mt 4 - 5h.
Tng khi lng liu np vo:

Chy hao:

Nguyn t hp kim
Mangan

Silic

Dng a vo l

Mc chy hao (%)

Ph liu

Kim loi

Ph liu

Kim loi

10 - 12

Bng 8.2: Chy hao.

-

X: Chim 5 10% khi lng, ty vo loi liu ta np vo l.

Tng khi lng liu np vo l:

liu

= 6615 x 120% = 7938Kg.

Ta chn gii php kh thi hu ht cc doanh nghip trong iu kin sn

xut ti Vit Nam: Gii php 1.
-

Gi s ta chn l c kch thc c bn nh sau:

Chiu cao l: 4m.
Chiu cao hu ch ca l: 2.5m.
ng knh ngoi l: 1m.

44

 N MN HC THIT K C

GVHD: L QUC PHONG

ng knh trong: 0.55m.

L chy gi mt do mt qut gi kiu tua bin vi p lc gi 600mm H2O.
S lng hng mt gi: 2 hng.
S lng mt gi mi hng: 4 mt gi.
S lng ng dn gi: 1 ng.
Khi lng nu mt m vo khong2,7 tn
-

Phi liu:
V hm lng tro trong than cc cao nn mun m bo nhit nng chy nc
gang th t l gang/than = 20%, v vi t l gang than nh vy th cn phi s dng
vi bng 30% khi lng than to x.
Nguyn vt liu 1 m bao gm:
2,1 tn gang ph liu
540 Kg gang hi liu.
156 kg vi.
20 kg ferosilic.
Nhin liu bao gm:

520 kg than cc.

Nhit ra v nng sut l:
Nhit ra gang khong 1350oC.

45

 N MN HC THIT K C

GVHD: L QUC PHONG

TAI LIU THAM KHO:

[1] Thit k c Nguyn Xun Bng, Phm Quang Lc NXB Khoa Hc K Thut H
Ni 1987.
[2] Cng ngh c ng Mu Chin NXB i Hc Quc Gia TP.HCM 2003.
[3] Cc phng php c c bit Nguyn Ngc H NXB i Hc Quc Gia
TP.HCM 2006.

TAI LIU INH KM:

[1] - 1 bn v chi tit PULI (A3).
[2] - 1 bn v phi PULI (A3).
[3] - 1 bn v phu rt (A3).
[4] - 1 bn v mng lc x (A3).
[5] - 1 bn v h thng rt (A3).
[6] - 1 bn v tng th (A0).

46