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Chng 1
Phi kim
Ti nguyn
thin nhin
Ch to vt
liu
Luyn kim
Ch to phi
c, cn, rn dp,
hn...
Gia cng ct
gt
X l v bo
v
Nhit luyn, ho
nhit luyn, m,
sn...
Ph phm v
ph liu
Ph phm v
ph liu
Chi tit my
nng - 2002
nng - 2002
nng - 2002
Ra =
1
y dx
L 0
Ra =
n
1
( y1 + y 2 + y3 + ... + y n ) = 1 yi .
n
n i =1
(h
+ h2 + + h9 ) ( h2 + h4 + + h10
5
.
Rz20
2,5
a/
b/
Trong thc t sn xut, tu theo cc phng php gia cng khc nhau ta
c cc cp bng khc nhau. V d:
B mt rt th, th t cp 1 3 (Rz = 320 40): c, rn
nng - 2002
nhm
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Tr s nhm (m)
Ra
Rz
2,5-1,25
1,25-0,63
0,63-0,32
0,32-0,16
0,16-0,08
0,08-0,04
0,04-0,02
-
320 - 160
160 - 80
80 - 40
40 - 20
20 - 10
0,1 - 0,05
0,05 - 0,025
Chiu di
chun
L(mm)
8
8
8
2,5
2,5
2,5
0,8
0,8
0,8
0,25
0,25
0,25
0,08
0,08
Phng php
gia cng
Tin th, ca,
da, khoan ...
Tin tinh, da
tinh, phay...
Doa, mi, nh
bng v.v...
Mi tinh mng,
nghin, r, gia
cng c bit,
ph. php khc
ng dng
Cc b mt khng tip
xc, khng quan trng:
gi , chn my v.v...
B mt tip xc tnh,
ng, trc vt, b. rng ...
B mt tip xc ng:
mt rng, mt pittng,
xi lanh, cht v.v...
B mt mt, van, bi, con
ln, dng c o, cn
mu v.v...
B mt lm vic chi tit
chnh xc, dng c o
HB
3
h
H.1.4. Tnh cht c l lp b mt
nng - 2002
1- Mt ngoi b ph hu
2- Lp cng ngui
3- Kim loi c bn
h- Chiu su kim loi
HB- cng
>3
>6
10
> 10
18
> 18
30
> 30
50
> 50
80
> 80
120
> 120
180
>180
250
4
6
10
14
25
40
60
100
6
8
12
18
30
48
75
120
8
9
15
22
36
58
90
150
8
11
18
27
43
70
110
180
9
13
21
33
52
84
130
210
11
16
25
39
62
100
160
250
13
19
30
46
74
120
190
300
15
22
35
54
87
140
220
350
18
25
40
63
100
160
250
400
20
29
46
72
115
185
290
460
nng - 2002
dmin
dmax
ITt
es
ei
Dmax
Dmin
ITl
ES
EI
nng - 2002
Dung sai tr
Sai s v tr tng i cc b mt
K hiu
TT
1
2
3
4
5
6
7
Tn gi
Dung sai song song
Dung sai vung gc
Dung sai ng tm
Dung sai i xng
Dung sai giao nhau
D. sai o mt u
D. sai o hng knh
nng - 2002
K hiu
10
25
25
H7
e8
a/
+ 0,021
+ 0,028
+ 0,015
b/
H.1.7. S v cch ghi k hiu lp ghp
a/ Cch ghi k hiu trn bn v thit k
b/ Cch ghi k hiu trn bn v lp
nng - 2002
11
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12
Chng 2
2.1.1. C tnh
C tnh l c trng c hc biu th kh nng ca kim loi hay hp kim
khi chu tc dng ca cc ti trng. Chng c trng bi:
a/ bn: l kh nng ca vt liu chu tc dng ca ngoi lc m khng b
ph hu. bn c k hiu . Tu theo cc dng khc nhau ca ngoi lc ta
c cc loi bn: bn ko (k); bn un (u); bn nn (n). Gi tr
bn ko tnh theo cng thc :
k =
P
(N/mm2).
F0
F0
P(N)
P(N)
H.2.1.S mu o bn ko
P
F
(kG/mm2).
nng - 2002
13
d
a/
b/
c/
Thang o
Rcoen
(mu)
B ()
C (en)
A (en)
Mi th
Ti trng
chnh P (N)
K hiu
cng Rcoen
Vin bi thp
Vin bi thp
Mi kim cng
1000
1500
600
HRB
HRC
HRA
Gii hn cho
php thang
Rcoen
25100
2067
> 70
P
.
d2
l1 l0
* 100% .
l0
nng - 2002
14
A
F
(J/mm2).
2.1.2. L tnh
L tnh l nhng tnh cht ca kim loi th hin qua cc hin tng vt l
khi thnh phn ho hc ca kim loi khng b thay i. N c c trng
bi: khi lng ring, nhit nng chy, tnh dn n, tnh dn nhit, tnh dn
in v t tnh...
2.1.3. Ho tnh
Ho tnh l bn ca kim loi i vi nhng tc dng ho hc ca cc
cht khc nh xy, nc, axt v.v... m khng b ph hu.
a/ Tnh chu n mn: l bn ca kim loi i vi s n mn cc mi trng
xung quanh.
b/ Tnh chu nhit: l bn ca kim loi i vi s n mn ca xy trong
khng kh nhit cao.
c/ Tnh chu axt: l bn ca kim loi i vi s n mn ca axt.
nng - 2002
15
2.2. Thp
2.2.1. Thp ccbon
a/ Khi nim chung v thp ccbon
Thp ccbon l hp cht ca Fe-C vi hm lng ccbon nh hn 2,14%.
Ngoi ra trong thp ccbon cn cha mt lng tp cht nh Si, Mn, S, P ...
Cng vi s tng hm lng ccbon, cng v bn tng ln cn
do v dai li gim xung. Si, Mn l nhng tp cht c li cn S v P th c
hi v gy nn dn nng v dn ngui nn cn hn ch < 0,03%.
Thp ccbon c c tnh tng hp khng cao, ch dng trong xy dng, ch
to cc chi tit chu ti trng nh v va trong iu kin p sut v nhit thp.
b/ Phn loi thp ccbon
C nhiu cch phn loi thp ccbon nhng c bn c mt s cch nh sau:
a/ Phn loi theo hm lng ccbon
Thp ccbon thp C < 0,25%.
Thp ccbon trung bnh C = 0,250,5%.
Thp ccbon cao C > 0,50%.
b/ Phn loi theo cng dng
Thp ccbon cht lng thng: loi ny c tnh khng cao, ch dng
ch to cc chi tit my, cc kt cu chu ti trng nh. Thng dng trong
ngnh xy dng, giao thng. Nhm thp thng dng ny hin chim ti 80%
khi lng thp dng trong thc t, thng c cung cp dng qua cn
nng (tm, thanh, dy, ng, thp hnh: ch U, I, thp gc, ...). Nhm thp ny
c cc mc thp sau:
Mc thp
LX
CT0
CT1
CT2
CT3
CT4
CT5
CT6
Mc thp
VN
CT31
CT33
CT34
CT38
CT42
CT51
CT61
k (kG/mm2)
31
3242
3444
3849
4254
5064
60
nng - 2002
0,2
(kG/mm2)
20
21
24
26
30
(%)
20
31
29
23
21
17
12
16
2.2.2.Thp hp kim
a/ Khi nim v thp hp kim
Thp hp kim l loi thp m ngoi st, ccbon v cc tp cht ra, ngi
ta cn c a vo cc nguyn t c bit vi mt lng nht nh lm thay
i t chc v tnh cht ca thp hp vi yu cu s dng. Cc nguyn t a
nng - 2002
17
vo gi l nguyn t hp kim thng gp l: Cr, Ni, Mn, Si, W, V, Mo, Ti, Nb,
Cu,...vi hm lng nh sau:
Mn: 0,8 - 1,0%; Si: 0,5 - 0,8%; Cr: 0,2 - 0,8%; Ni: 0,2 - 0,6%;
W: 0,1 - 0,6%; Mo: 0,05 - 0,2; Ti, V, Nb, Cu > 0,1%; B > 0,002%.
Trong thp hp kim, lng cha cc tp cht c hi nh S, P v cc kh
xy, hyr, nit l rt thp so vi thp ccbon. V c tnh thp hp kim c
bn cao hn hn so vi thp ccbon dc bit l sau khi nhit luyn. V tnh chu
nhit: Thp hp kim gi c cng cao v tnh chng do ti 6000C (trong
khi thp ccbon ch n 2000C), tnh chng xy ho ti 800-10000C. V cc tnh
cht vt l v ho hc c bit: thp ccbon b g trong khng kh, b n mn
mnh trong cc mi trng axit, baz v mui,...Nh hp kim ho m c th to
ra thp khng g, thp c tnh gin n v n hi c bit, thp c t tnh cao v
thp khng c t tnh, ...
b/ Phn loi thp hp kim
C nhiu cch phn loi thp hp kim nhng n gin v thng dng nht
l phn loi theo cng dng:
a/ Thp hp kim kt cu
Trn c s l thp ccbon kt cu cho thm cc nguyn t hp kim.
Thp hp kim kt cu c hm lng ccbon khong 0,10,85% v lng
phn trm nguyn t hp kim thp. Thp ny phi qua thm than ri nhit luyn
c tnh mi cao. Loi thp ny c dng ch to cc chi tit chu ti trng
cao, cn cng, chu mi mn, hoc cn tnh n hi cao v.v...
Cc mc thp hp kim kt cu thng gp: 15Cr, 20Cr, 40Cr, 20CrNi,
12Cr2Ni4, 35CrMnSi; cc loi c hm lng ccbon cao dng lm thp l xo
nh 50Si2, 60Si2CrA v.v...
K hiu mc thp biu th ch s u l hm lng ccbon tnh theo phn
vn, cc ch s t sau nguyn t hp kim l hm lng ca nguyn t , ch
A l loi tt. V d: thp 12Cr2Ni4A trong c 0,12% C, 2% Cr, 4% Ni v l
thp tt.
b/ Thp hp kim dng c
L loi thp dng ch to cc loi dng c gia cng kim loi v cc
loi vt liu khc nh g, cht do v.v...
Thp hp kim dng c cn cng cao sau khi nhit luyn, chu nhit
v chu mi mn cao. Hm lng ccbon trong thp hp kim dng c cao t
0,71,4%; cc nguyn t hp kim cho vo l Cr, W, Si v Mn.
Thp hp kim dng c sau khi nhit luyn c cng t 6062 HRC. C
mt s mc thp chuyn dng nh sau:
nng - 2002
18
Thp dao ct dng ch to cc loi dao ct nh dao tin, dao bo, dao phay,
mi khoan v.v...nh 90CrSi, 140CrW5, 100CrWMn, hoc mt s thp gi
nh 80W18Cr4VMo, 90W9V2, 75W18V cc loi thp gi c cng cao,
bn, chu mi mn v chu nhit n 6500C.
Thp lm khun dp: i vi khun dp ngui thng dng 100CrWMn,
160Cr12Mo, 40CrSi. i vi khun dp nng hay dng cc mc thp:
50CrNiMo, 30Cr2W8V, 40Cr5W2VSi.
Thp ln: l loi thp dng ch to cc loi bi hay a l loi thp
chuyn dng nh OL100Cr2, OL100Cr2SiMn. Cc ln lm vic trong mi
trng nc bin phi dng thp khng g nh 90Cr18 v lm vic trong iu
kin nhit cao phi dng thp gi loi 90W9Cr4V2Mo.
Cc k hiu ca thp hp kim dng c cng c biu th nh cc loi
thp hp kim khc tr thp ln l c thm ch OL ban u.
c/ Thp hp kim c bit
Trong cng nghip c nhiu chi tit my phi lm vic trong nhng iu
kin c bit v vy chng cn phi c nhng tnh cht c bit p ng yu
cu ca cng vic.
Thp khng g: l loi thp c kh nng chng li mi trng n mn.
Thng dng cc mc thp: 12Cr13, 20Cr13, 30Cr13, 12Cr18Ni9,
12Cr18Ni9Ti,...
Thp bn nng: l loi thp lm vic nhit cao m bn khng gim,
khng b xy ho b mt. V d 12CrMo, 04Cr9Si2 chu c nhit
3005000C; loi bn nng 10Cr18Ni12, 04Cr14Ni14W2Mo chu c nhit
5007000C; hoc l thp NiCrm chuyn ch to dy in tr
10Cr150Ni60.
Thp t tnh: l loi thp c nhim t cao. Thp hp kim t cng thng
dng cc thp Cr, Cr-W, Cr-Co hoc dng hp kim h Fe-Ni-Al, Fe-Ni-AlCo ch to cc loi nam chm vnh cu bng phng php c v qua mt
qu trnh nhit luyn c bit trong t trng. Thp v hp kim t mm c
lc kh t nh t thm ln dng lm li my bin p, stato my in, nam
chm in cc loi,...Thng dng: st ty nguyn cht k thut (<0,04% C),
thp k thut in (thp Si) c 0,010,1% C v 24,4% Si; c th dng hp
kim permaloi c thnh phn 79% Ni, 4% Mo cn li l Fe.
Thp khng t tnh: l loi vt liu khng nhim t nh 55Mn9Ni9Cr3.
nng - 2002
19
2.3. Gang
2.3.1. Khi nim chung
Gang l hp kim Fe-C, hm lng ccbon ln hn 2,14% C v cao nht
cng < 6,67% C. Cng nh thp trong gang c cha cc tp cht Si, Mn, S, P v
cc nguyn t khc. c tnh chung ca gang l cng v dn, c nhit nng
chy thp, d c.
nng - 2002
20
2.4.1.ng v hp kim ng
a/ ng
ng l mt kim loi c nhiu tnh cht qu nh: do cao, kh nng
chng n mn tt trong nhiu mi trng, c bit l dn nhit v dn n rt
cao. ng c khi lng ring: 8,94 G/cm3; nhit nng chy: 10830C;
bn: b= 16 kG/mm2. Theo TCVN 1659-75 ng c 5 loi sau y: Cu99,99,
Cu99,97, Cu99,95 dng lm dy dn in; Cu99,90, Cu99,0 dng ch to brng
khng Sn.
b/ Hp kim ng Latng
La tng l hp kim ng, trong km l nguyn t hp kim chnh. La
tng c mu sc p, do, d bin dng, m tt, gi thnh thp hn ng , ph
bin nht trong thc t.
nng cao mt s tnh cht c bit ca latng ngi ta a vo hp
kim mt s nguyn t nh thic tng kh nng chng n mn trong nc
bin. Latng vi thnh phn 29%Zn-1%Sn-70%Cu rt thng dng trong ngnh
ng tu; hoc thm nhm, Mn v st tng c tnh v kh nng chng n mn
ca latng.
Hp kim ng c 17-27%Zn, 8-18%Ni gi l mayxo dng lm dy in
tr.
C cc mc Latng thng dng: LCuZn30, LCuZn40, LCuZn29Sn1,
LCuZn27Ni18,...Latng c k hiu bng ch L ri ln lt cc ch Cu, Zn,
sau l cc nguyn t hp kim khc nu c. Cc con s ng pha sau mi
nguyn t ch hm lng trung bnh ca nguyn t theo phn trm.
nng - 2002
21
c/ Hp kim ng Brng
Brng l hp kim ca ng vi cc nguyn t hp kim khc nh Sn, Al,
Pb,...ng thanh c mt s loi sau:
Brng thic: Cu-Sn (8-10%Sn) c c tnh cao v kh nng chng n mn
trong nc bin tt. Chng c s dng lm cng tc in, a ly hp, l xo,
bnh rng v i khi lm bc lt. C cc mc sau: BCuSn5P0,15;
BCuSn5Zn5Pb5, ...
Brng nhm: Cu-Al c cha khong <13% Al c tng hp c tnh cao, kh
nng chng mi mn v gii hn mi tng i ln thng dng ch to
h thng trao i nhit, cc chi tit my bm. Cc mc Brng nhm nh:
BCuAl5, BCuAl9Fe4, ...
Brng ch: Cu-Pb c s dng nhiu ch to trt, thng dng nht l
hp kim BCuPb30.
Brng berili: l mt th h hp kim mi c bn, kh nng chng mn,
chng mi, bn nng cao. c bit l gii hn n hi rt cao. Brng
berili thng cha khong 2% Be. N c s dng lm l xo, mng n hi
v cc chi tit i hi chu nhit, n hi v dn in cao. V d: BCuBe2.
nng - 2002
22
H Al-Mn: chu gia cng bin dng nng v ngui tt, c tnh hn v chng
n mn trong kh quyn cao. Chng c s dng thay cho nhm nguyn
cht k thut khi c yu cu cao hn v c tnh.
H Al-Mg: c tnh hn tt, kh nng chng n mn trong kh quyn cao, gii
hn bn mi cao, b mt sau khi gia cng p nn c dng nhiu trong
cng nghip ch to t v xy dng cng trnh.
H Al-Cu v Al-Cu-Mg: chng c hiu ng ho bn cao c gi l uyra.
V d: AlCu4,5Mg0,5MnSi - dng trong t v hng khng.
H Al-Mg-Si: c dng ch to cc chi tit chu hn, cc cu kin tu
thu. V d: AlMgSi1,5Mn.
Hp kim h Al-Zn-Mg v Al-Zn-Mg-Cu: c s dng trong hng khng,
ch to v kh, dng c th thao, v.v... V d: AlZn5,5Mg2,5Cu1,5Cr.
c/ Hp kim nhm c
Hp kim nhm c cn tnh c tt d dng to hnh cc chi tit,
chng cha lng nguyn t hp kim ln hn. C cc dng hp kim nhm c
in hnh v thng dng:
Hp kim Al-Si: cho thm mt s nguyn t khc na ta s c mt loi hp
kim c tnh c tt, h s dn n nhit nh, chng mn tng i dng ch
to pittng ng c t trong nh: AlSi12CuMg1Mn0,6Ni.
Hp kim Al-Cu v mt s nguyn t khc c kh nng bn nng cao v gii
hn mi kh ln rt thch hp ch to cc chi tit nh, hnh dng phc tp
lm vic nhit cao nh: AlCu5Mg1Ni3Mn0,2.
Mt s h hp kim nhm c khc nh Al-Mg; Al-Zn-Mg c s dng
nhiu trong nc bin v mt s mi trng in ly khc.
Ch : Cc k hiu ca hp kim nhm c pha sau cng c ch phn bit
vi hp kim nhm bin dng.
nng - 2002
23
nng - 2002
24
chng 3
k thut c
3.1. khi nim chung
3.1.1. Thc cht ca sn xut c
c l phng php ch to chi tit bng cch nu chy v rt kim loi
lng vo khun c hnh dng nht nh, sau khi kim loi ho rn trong khun ta
thu c vt c c hnh dng ging nh khun c.
Nu vt phm c a ra dng ngay gi l chi tit c, cn nu vt phm
c phi qua gia cng ct gt nng cao chnh xc kch thc v bng
b mt gi l phi c.
c c nhng phng php sau: c trong khun ct, c trong khun
kim loi, c di p lc, c li tm, c trong khun mu chy, c trong
khun v mng, c lin tc v.v... nhng ph bin nht l c trong khun ct.
3.1.2. c im
c c th gia cng nhiu loi vt liu khc nhau: Thp, gang, hp kim mu
v.v... c khi lng t mt vi gam n hng trm tn.
Ch to c vt c c hnh dng, kt cu phc tp nh thn my cng c,
v ng c v.v...m cc phng php khc ch to kh khn hoc khng ch
to c.
chnh xc v hnh dng, kch thc v bng khng cao (c th t cao
nu c c bit nh c p lc).
C th c c nhiu lp kim loi khc nhau trong mt vt c.
Gi thnh ch to vt c r v vn u t t, tnh cht sn xut linh hot,
nng sut tng i cao.
C kh nng c kh ho v t ng ho.
Hao tn kim loi cho h thng rt, u ngt, u hi.
D gy ra nhng khuyt tt nh: thiu ht, r kh, chy ct v.v...
Kim tra khuyt tt bn trong vt c kh khn, i hi thit b hin i.
nng - 2002
25
c trong khun ct
c trong
hm khun
c trn
nn xng
c bng
dng gt
khun
kim loi
c p
lc
c ly
tm
c
lin tc
B phn mc
mu
Ch to hn hp
lm li
Nu kim loi
Sy khun
Lm li
Sy li
Lp rp khun v
rt kim loi
Ph khun ly
vt c
Ph li khi
vt c
Lm sch vt
c
nng - 2002
26
10
1234567891011-
1
2
4
5
nng - 2002
Hm khun trn
Cht nh v
Mt phn khun
Ct khun
Xng khun
Lng khun
Li
Rnh thot kh
Hm khun di
H thng rt
u hi (hoc u ngt)
27
nng - 2002
28
tnh ln tt. Khi rt kim loi n b chy, do tng tnh xp, tnh ln, thot kh
v d ph khun nhng ht m nn sy xong phi dng ngay.
Bt h: (nng 2,53%) ht nc nhiu, tnh cht nh nc ng,
dng lm khun ti rt tt.
Cc cht dnh kt ho cng: Nha thng, ximng, hc n, nha ng.
Khi sy chng chy lng ra v bao quanh cc ht ct. Khi kh chng t ho
cng lm tng bn, tnh dnh kt cho khun. Thng dng loi ximng pha
vo hn hp khong 12%, m ca hn hp 68%, trong khng kh 2427
gi c kh nng t kh, loi ny rt bn.
Nc thu tinh: chnh l cc loi dung dch silicat Na2O.nSiO2.mH2O
hoc K2O.nSiO2.mH2O sy 2002500C, n t phn hu thnh nSiO2.(m-p)H2O
l loi keo rt dnh. Khi thi CO2 vo khun lm xong, nc thu tinh t phn
hu thnh cht keo trn, hn hp s cng li sau 1530 pht.
d/ Cc cht ph:
L cc cht a vo hn hp khun v li c mt s tnh cht c bit
nh nng cao tnh ln, tnh thng kh, lm nhn mt khun, li v tng kh nng
chu nhit cho b mt khun li, gm 2 loi:
Trong hn hp thng cho thm mn ca, rm vn, phn tru b kh, bt
than... Khi rt kim loi lng vo khun, nhng cht ny chy li trong
khun nhng l rng lm tng tnh xp, thng kh, tnh ln cho khun li. T
l khong 3% cho vt c thnh mng v 8% cho vt c thnh dy.
Cht sn khun: mt khun nhn bng v chu nng tt, ngi ta thng
qut ln b mt lng khun, li mt lp sn, c th l bt than, bt grafit, bt
thch anh hoc dung dch ca chng vi t st. Bt than v grafit qut vo
thnh khun, khi rt kim loi vo n s chy to thnh CO, CO2 lm thnh
mi trng hon nguyn rt tt, ng thi to ra mt lp kh ngn cch gia
kim loi lng vi mt lng khun lm cho mt lng khun khng b chy ct
v to cho vic ph khun d dng.
3.2.4. hn hp lm khun
Hn hp lm khun c hai loi:
a/ Ct o:
Dng ph st mu khi ch to khun nn cn c bn, do cao, ng
thi n trc tip tip xc vi kim loi lng nn cn phi c chu nhit cao,
ht cn nh hn b mt c nhn bng, thng thng ct o lm bng vt liu
mi, n chim khong 1015% tng lng ct khun.
nng - 2002
29
b/ Ct m:
Dng m cho phn khun cn li, khng trc tip tip xc vi kim
loi lng nn tnh chu nhit, bn khng cn cao lm, nhng phi c tnh
thng kh tt chim 8590% lng ct.
Vt c cng ln yu cu ht ca hn hp lm khun cng ln tng
tnh thng kh.
3.2.5. Ch to b mu v hp li
B mu l cng c chnh dng to hnh khun c. B mu bao gm :
Mu, tm mu, mu ca h thng rt, u hi, u ngt.Tm mu kp mu
khi lm khun, dng kim tra.
a/ Vt liu lm b mu v hp li
Yu cu:
Bo m bng, chnh xc khi gia cng ct gt.
Cn bn, cng, nh, khng b co, trng, nt, cng vnh trong khi lm vic.
Chu c tc dng c, ho ca hn hp lm khun, t b mn, khng b r v
n mn ho hc. R tin v d kim.
b/ Cc loi vt liu lm mu v hp li
Vt liu thng dng: G, kim loi, thch cao, ximng, cht do. Ch yu
l g, kim loi.
G: u im l r, nh, d gia cng, nhng c nhc im l bn, cng
km; d trng, nt, cong vnh nn g ch dng trong sn xut n chic, lot
nh, trung bnh v lm mu ln. Thng dng cc loi sau: g lim, g, sn, m,
d, thng, b , v.v...
Kim loi: c bn, cng, nhn bng, chnh xc b mt cao, khng
b thm nc, t b cong vnh, thi gian s dng lu hn, nhng kim loi t kh
gia cng nn ch s dng trong sn xut hng khi v hng lot. Thng dng:
hp kim nhm, gang xm, hp kim ng.
Thch cao: Bn hn g (lm c 1000 ln) nh, d ch to, d ct gt.
Nhng gin, d v, d thm nc. Nn lm nhng mu nh khi lm bng tay,
tin li khi lm mu ghp v dng trong c m ngh (v d sa).
Ximng: Bn, cng hn thch cao, chu va chm tt, r, d ch to, nhng
nng tuy khng ht nc, kh gt, sa nn ch dng lm nhng mu, li phc
tp, mu ln, mu lm khun bng my.
nng - 2002
30
b/
a/
c/
d/
nng - 2002
31
8
9
123456789-
si (hoc x)
ng nghim
Ct o
Hm khun trn
u hi
Ti trng
Cc rt
Rnh dn
Cht nh v
nng - 2002
32
a/ Dm cht khun c
Dm cht khun c bng cch p: C nhiu kiu dm cht hn hp lm
khun c bng cch p: p trn xung, p di ln v p c 2 pha. My p lm
khun c nng sut cao, khng n nhng dm cht thay i mnh theo chiu
cao. Khi p trn dm cht mt di khun thp nn chu p lc kim loi lng
km. My p ch thch hp vi hm khun thp.
6
5
h, mm
1233 4g/cm
56789-
h, mm
4
3
2
1
8
g/cm3
7
a/
b/
H.3.7. Dm cht khun c bng cch p
a/ p trn xung; b/ p di ln
nng - 2002
bn my
mu
hm khun chnh
hm khun ph
chy p
x ngang
van kh
phttng y
xilanh
33
4
3
h, mm
2
1
h, mm
2
1
8
g/cm3
6
7
8
7
6
g/cm3
9
11
10
a
nng - 2002
34
Ly mu bng c cu y hm khun:
3
2
1
2
4
4
5
b
a
H.3.10. Ly mu bng bn quay
nng - 2002
35
1
4
a
H.3.11. Ly mu bng bn lt
2
3
4
1- Phu rt
2- ng rt
3- Rnh lc x
4- Rnh dn
H.3.12. H thng rt
b/ u hi: Dng kh trong lng khun thot ra, i khi dng b sung
kim loi cho vt c. C 2 loi u hi: u hi bo hiu v u hi b sung
chng thng c t v tr cao nht ca vt c.
nng - 2002
36
3.3. c gang xm
Gang c nhiu loi, nh gang trng, gang do, gang bin tnh, gang cu,
song trong k thut c ngi ta ch yu s dng gang xm. Gang xm c k
hiu: Gx. v d: Gx15-28. Thnh phn ho hc: 2,53,5% C; 0,83% Si;
0,61,3% Mn; 0,21% P; < 0,12%S. Trong C trng thi t do gi l graft.
b/ Nhin liu:
Trong thc t thng dng cc loi nhin liu sau:
Than cc: (1016)% khi lng kim loi/ M liu.
Than gy (than c mc cc bon ho cao): nc ta thng dng than
gy ng triu, Mo kh. Trong thc t thng dng: 20 22% khi lng
kim loi/ M liu.
Than : t dng v nhit tr thp, bn c hc khng cao.
nng - 2002
37
c/ Cht tr dung:
Cht tr dung dng lm long x cho d ni ln trn b mt v d dng
loi b chng cng vi tp cht. Thng dng vi (45% khi lng kim
loi/M liu); hunh thch (cha CaF2): (<8% khi lng kim loi/M liu)
hoc x l Mctanh.
3.3.2. L nu gang
Thng dng l ng, l ch, l in. Nhng ch yu l dng l ng v
l ch. L ng c s dng rng ri v cu to n gin, tiu hao nhin liu t,
vn u t thp, d thao tc, cng sut cao (50025.000 kG gang lng/ gi).
Song nhit gang ra l khng cao (14500C), thnh phn ho hc ca gang
khng n nh. Cc gang hp kim cn cht lng cao thng c nu bng l
in hoc l ni.
a/ L ng nu gang
L l loi l ng, hnh tr gm cc b phn ch yu l: b phn l,
thn l, thit b tip liu v thit b gi nng, h thng gi v thit b lm ngui,
ng khi c thit b dp la, l tin v ng dn gang v.v..
H.3.14. S cu to ca l ng nu gang
nng - 2002
38
Q. L. K
4,71. L1
b/ L ch nu gang
Hin nay cc xng c nh u dng l ch nu gang. u im c
bn l cu trc rt n gin d ch to, vn u t rt t. Nhin liu d kim, ch
cn than c nh 20-30 mm, c th nu bng nhiu loi than .
Song l ch c nng sut thp v thnh phn ho hc ca gang khng n
nh. L ch ch ph hp cho cc xng c nh, mt hng c c nh (<60
kG), iu kin c kh ho thp.
nghing l
ra gang
Hp gi
Mt gi
D
L x
L ra gang
H.3.15. L ch nu gang
a/ L ch quay; b/ L c nh
nng - 2002
b/
39
a/ Vt liu nu:
Vt liu chnh: Gm ng k thut, ng thanh v ng thau, hi liu.
Hp kim ph: Hp kim ng + 1 nguyn t kim loi khc (50%Cu + 50%Al
hoc 80%Cu + 20%Mn)
Cht kh oxy: Dng hon nguyn oxyt kim loi trong hp kim (90%Cu +
10%P) v: 5Cu20 + 2P = 10Cu + P205; P205 to thnh x ni ln.
Cht tr dung: Dng kim loi lng khi b oxy ho v tch tp cht ra
thnh x. Thng dng: Than ci hoc thu tinh lng, thch cao, mui n.
c/ Qu trnh nu ng:
Nu ng : Sy l n 90010000C, ri cht mt lp than ci vo y ni
v ph mt lp than ci ln trn. Tip tc nung n khi Cu nng chy.
kh tt oxy sau khi Cu nng chy, cho dn Cu + P vo kh. Kh xong rt ly
nng - 2002
40
nng - 2002
41
Tinh luyn bng kh: Nu chy 1/3 m liu ri cho hp kim ph v phn cn
li ca m liu vo l. Khuy u ri thi kh clo (hoc N2) vo kim loi
lng, khong 5 15 pht tinh luyn:
3Cl2 + 2Al = 2AlCl3 + Q
Cl2 + H2 = 2HCl + Q
AlCl3 v HCl bay ln to thnh s si mang theo cc tp cht (Al2O3, SiO2
v cc kh khc thot ra ngoi. sau cng lm bin tnh, th v rt vo khun.
nng - 2002
42
3.5.2. c di p lc
a/ c im
b/ My c p lc
Kim loi lng c vo xi lanh, Piston trn nn xung, piston di I
xung, kim loi lng theo rnh dn vo khun c, sn phm c y ra nh c
cu bn y.
3.5.3. c ly tm
a/ c im:
c ly tm l rt kim loi vo khun quay, nh lc ly tm m kim loi
lng c phn b u trn b mt bn trong ca khun to thnh vt c.
Lc ly tm: P = m.r.2 .
c c nhng chi tit hnh trn xoay, rng m khng cn li.
nng - 2002
43
b/ Cc phng php c ly tm
c ly tm ng: Khun quay theo trc thng ng. Vt c thng c dng
mt Parabonloit. Phng php ny dng c cc chi tit ngn.
c ly tm nm ngang: Khun quay theo phng nm ngang. Vt c l mt
ng hnh tr c chiu dy nh nhau. kim loi chy u vo khun nn t
trc quay nghing mt gc 50.
1
2
1
2
3
b/
a/
nng - 2002
44
chng 4
b/ c im
Kim loi gia cng th rn, sau khi gia cng khng nhng thay i hnh
dng, kch thc m cn thay i c c, l, ho tnh ca kim loi nh kim
loi mn cht hn, ht ng u, kh cc khuyt tt (r kh, r co v.v ...) do
c gy nn, nng cao c tnh v tui bn ca chi tit v.v ...
GCAL l mt qu trnh sn xut cao, n cho php ta nhn cc chi tit c kch
thc chnh xc, mt chi tit tt, lng ph liu thp v chng c tnh c hc
cao so vi cc vt c.
nng - 2002
45
nng - 2002
46
A
T
T
ho
A C
A I B
l B
A
h1
A B
l1 F0
=
l 0 F1
(mm).
Lng p tuyt i:
h = (ho - h1)
Quan h gia lng p v gc n:
h = D(1 - cos ) (mm).
S thay i chiu di trc v sau khi cn gi l lng gin di:
l = l1 - lo
S thay i chiu rng trc v sau khi cn gi l lng gin rng:
b = b1 - bo
Cn c th tin hnh trng thi nng hoc trng thi ngui. Cn nng c
u im: tnh do ca kim loi cao nn d bin dng, nng sut cao, nhng cht
lng b mt km v c tn ti vy st trn mt phi khi nung. V vy cn nng
dng cn phi, cn th, cn tm dy, cn thp hp kim. Cn ngui th ngc li
nng - 2002
47
4.2.2. Sn phm cn
Sn phm cn rt a dng, c phn ra bn nhm chnh: dng hnh, dng
tm, dng ng v dng c bit.
a/ Loi hnh:
Cc sn phm dng hnh c chia ra dng hnh n gin (a), gm c
thanh, thi tit din trn, vung, ch nht, lc gic, bn nguyt ... v dng hnh
phc tp (b) c tit din ch V, U, I, T, Z ...
b/ Loi tm:
Cc sn phm dng tm c phn loi theo chiu dy ca tm thnh:
Mng: s = 0,23,75 mm; b = 6002200 mm.
Dy: s = 460 mm; b = 6005000 mm; l = 400012000mm.
Cun: s = 0,22 mm; b = 2001500 mm; l = 400060.000 mm.
nng - 2002
48
c/ Loi ng:
Cc sn phm dng ng c phn ra: ng khng hn v ng c mi hn.
ng khng hn c cn t phi thi c = 5426 mm, chiu dy thnh ng
S = 0,540 mm.
ng c mi hn c ch to bng cch cun tm thnh ng sau cn
hn gip mi vi nhau. Loi ny c ng knh ngoi n 720 mm v chiu
dy n 14 mm.
4.2.3. Thit b cn
a/ Cc b phn ch yu ca my cn
2
3
4 5 6
5 4
7
H.4.3. S cu to my cn
1. Trc cn
2. Trc cc ng
3. Hp phn lc
4. Khp ni 5. Bnh 6. Hp gim tc 7. ng c
1 2
a. Trc cn thng
nng - 2002
49
b/ Phn loi my cn
Cn c theo s lng trc cn:
a/
b/
c/
d/
e/
nng - 2002
50
b.
c
e
d
d
b
a
a.
b.
a) Cn rng b) Cn di
nng - 2002
51
b/ Cn thp hnh
Cn thp hnh n gin: Qu trnh cn cc loi thp hnh n gin
thng qua nhiu ln cn vi trc cn hnh, cc bc cn th tin hnh vi cc l
hnh c bin dng khc nhau nh: l hnh vung, l hnh ch nht, l hnh thoi,
l hnh -van,... cn cn tinh, l hnh c bin dng ca sn phm. Hnh sau trnh
by s cn mt s loi thp hnh n gin.
90o
90o
b
90o
90o
c
H.4.7. S cn mt s thp hnh
a) Cn thp trn b) Cn thp vung c) Cn thp gc
c/ Cn ng:
Khi cn ng khng c mi hn (a), phi ban u l thp trn, my cn
c hai trc cn, mi trc c hai phn hnh nn ct ngc nhau, quay cng chiu
v t cho nhau trong khng gian mt gc = 4 6o.
Trong qu trnh cn, phi va chuyn ng quay, va chuyn ng tnh
tin dc trc ca n. vng bin dng, tm ca phi b bin dng nhiu v chu
ng sut ko nn thay i lin tc lm xut hin cc vt nt v to thnh l, sau
l c mi xoy sa li bin dng. Sau khi cn th, ng c a qua
nguyn cng tu chnh sa chnh xc ng knh trong v ngoi.
K
nhn theo K
2
1
H.4.8. S cn ng khng c mi hn
1) Trc cn 2) Mi xoy 3) Phi
nng - 2002
52
P
4
b)
a)
H.4.9. S ko si
a/ Ko si b) Ko ng
1) Phi 2) Khun ko 3) Sn phm 4) Li sa l
Khi ko si, phi (1) c ko qua khun ko (2) vi l hnh c tit din
nh hn tit din phi kim loi v bin dng theo yu cu, to thnh sn phm
(3). i vi ko ng, khun ko (2) to hnh mt ngoi ng cn l c sa
ng ng knh nh li (4) t trong.
4.3.2. Qu trnh ko si
Ty theo tng loi kim loi, hnh dng l khun, mi ln ko tit din c
th gim xung 15% 35%. T l gia ng knh trc v sau khi ko gi l
h s ko di:
K=
d0
= 1+
d1
P(1 + f cot g )
nng - 2002
53
d0
d
d
d
d
; d 2 = 1 = 02 ; d n = n 1 = 0n
k
k
k
k
k
d0
lg d 0 lg d n
n lg k = lg d 0 lg d n ; ta c: n =
dn
lg k
Lc ko si phi m bo:
ln thng lc ma st gia kim loi v thnh khun, ng thi kim
loi bin dng.
ng sut ti tit din ra khi khun phi nh hn gii hn bn cho php ca
vt liu nu khng si s b t.
Lc ko si c th xc nh:
P = . F1 .lg
F0
(1 + f cot g )
F1
(N)
4.3.3.Dng c v thit b ko si
a/ Khun ko:
Khun ko si gm khun (1) v khun
(2), bin dng l hnh ca khun gm 4 phn: on
cn (I) l phn lm vic chnh ca khun c gc
cn = 24o360 (thng dng nht l 260), on
cn vo (II) c gc cn 90o l ni phi vo v
cha cht bi trn, on thng (III) c tc dng
nh knh v on cn thot phi (IV) c gc cn
Vt
600 si ra d dng khng b xc.
liu ch to khun l thp cc bon dng c, thp
hp kim hoc hp kim cng, thng dng cc loi
sau: CD80, CD100, CD130, 30CrTiSiMo, Cr5Mo.
nng - 2002
II I
IV
III
Khun ko
1) Khun 2) khun
54
b/ My ko si
My ko si c nhiu loi, cn c vo phng php ko c th chia lm 2
loi: my ko thng hay my ko c tang cun. Cng c th c phn loi theo
s lng khun ko, s si c ko ng thi.
My ko thng dng khi ko cc si hoc ng c ng knh ln khng
th cun c ( = 610 mm hoc ln hn). Lc ko ca my t 0,275 tn, tc
ko 1545 m/ph. tu kt cu ca my c th ko 1 hoc 3 sn phm cng mt
lc. to chuyn ng thng c th dng xch, vt v cu, thanh rng v bnh
rng, du p v.v...Trn hnh sau trnh by my ko si bng xch si c kp
cht nh c cu kp (3), c ko nh hai xch ko (4) ni chuyn ng vi h
thng dn ng.
2
H.4.10. S my ko si ko thng
1) Kim loi 2) Khun ko 3) C cu ko 4) Xch ko
a
1
b.
H.4.11. My ko c tang cun
a-My ko mt khun; b- My ko nhiu khun
nng - 2002
55
3 4
a/
2 4
b/
4
5
c/
Khi p thanh, thi ngi ta c th tin hnh bng phng php p thun
hoc p nghch. Vi p thun (a), khi pistng (1) p, kim loi trong xi lanh (2) b
p qua l hnh ca khun p (4) chuyn ng ra ngoi cng chiu chuyn ng
ca pistng p. Vi p nghch (b), khi pistng (1) p, kim loi trong xi lanh (2)
b p qua l hnh ca khun p (4) chuyn ng ra ngoi ngc chiu chuyn
ng ca pistng p. Vi p thun kt cu n gin, nhng lc p ln v ma st
gia kim loi v thnh xi lanh lm tng lc p cn thit, ng thi phn kim loi
trong xi lanh khng th p ht ln (1012%). p nghch lc p thp hn, lng
kim loi cn li trong xi lanh t hn (68%), nhng kt cu p phc tp.
S hnh (c) trnh by nguyn l p ng, y l ng c to thnh
nh li (5). Phi p c l rng t li (5), khi pistng (1) p, kim loi b y
qua khe h gia l hnh ca khun (4) v li to thnh ng.
4.4.2. Khun p
V kt cu, khun p c ba dng: hnh cn (a), hnh phu (b) v hnh tr (c).
H.4.13. Kt cukhun p
nng - 2002
56
4.4.3. c im v ng dng
p l phng php sn xut cc thanh c tit din nh hnh c nng sut
cao, chnh xc v nhn b mt cao, trong qua trnh p, kim loi ch yu
chu ng sut nn nn tnh do tng, do c th p c cc sn phm c tit
din ngang phc tp. Nhc im ca phng php l kt cu p phc tp,
khun p yu cu chng mn cao. Phng php ny c ng dng rng ri
ch to cc thanh kim loi mu c ng knh t 5200 mm, cc ng c
ng knh trong n 800 mm, chiu dy t 1,58 mm v mt s prfin khc.
nng - 2002
57
4.5. Rn t do
4.5.1. Thc cht, c im v dng c rn t do
Rn t do l mt phng php gia cng p lc m kim loi bin dng
khng b khng ch bi mt mt no khc ngoi b mt tip xc gia phi kim
loi vi dng c gia cng (ba v e). Di tc ng ca lc P do ba (1) gy ra
v phn lc N t e (3), khi kim loi (2) bin dng, s bin dng ch b khng
ch bi hai mt trn v di, cn cc mt xung quanh hon ton t do.
1
P
2
3
N
H.4.14. S rn t do
a/ c im
chnh xc, bng b mt chi tit khng cao. Nng sut thp
Cht lng v tnh cht kim loi tng phn ca chi tit kh m bo ging
nhau nn ch gia cng cc chi tit n gin hay cc b mt khng nh hnh.
Cht lng sn phm ph thuc vo tay ngh ca cng nhn.
Thit b v dng c rn t do n gin.
Rn t do c dng rng ri trong sn xut n chic hay hng lot nh. Ch
yu dng cho sa cha, thay th.
b/ Dng c
Nhm1: L nhng dng c cng ngh c bn nh cc loi e, ba, bn l, bn
tp, sn, cht, mi t.
Nhm 2: L nhng dng c kp cht nh cc loi km, t v cc c cu kp
cht khc.
Nhm 3: L nhng dng c kim tra v o lng: ke, thc cp (o trong o
ngoi, o chiu su, cc loi compa.
nng - 2002
58
4.5.2. Thit b rn t do
Thit b rn t do bao gm: Thit b gy lc, thit b nung, my ct phi,
my nn thng, my vn chuyn.v.v...
Rn t do c th tin hnh bng tay hoc bng my. Rn tay ch yu dng
trong sn xut sa cha, trong cc phn xng c kh ch yu l rn my. Theo
c tnh tc dng lc, cc my dng rn t do c chia ra: my tc dng lc
va p (my ba), my tc dng lc tnh (my p). Trong , my ba hi l
thit b c s dng nhiu nht.
Hnh sau trnh by s ca mt my ba hi. My ba hi c hai xi
lanh, mt xi lanh kh (5) v mt xi lanh ba (9). Gia hai xi lanh c van phn
phi kh (7) iu khin s cp kh nn t xi lanh nn sang xi lanh u ba.
7
6
5
9
10
4
3
11
12
13
2
1
14
H.4.15. S nguyn l my ba hi
1- ng c in 2- B truyn ai 3- Trc khuu 4- Tay bin 5- Xi lanh p
6-Pistng p 7- Van phn phi kh 8- Pistng ba 9- Xi lanh ba 10- e
trn 11- e di 12- gi e 13-B e 14- bn p iu khin
nng - 2002
59
h
h0
s
h
L
B
nng - 2002
60
Khi mun chuyn i phi c tit din vung thnh chi tit c tit din trn
vi chiu di thay i khng ng k th chn cnh ca phi b hn ng
knh ca chi tit 23%.
Khi phi c tit din hnh trn m chi tit c tit din hnh ch nht m
mun chiu di khng thay i ng k th ng knh ca phi D c
tnh:
D=
2a + b
3
nu
a
2 ; D = 1,3a
b
nu
a
2
b
ba
l
a
nng - 2002
61
Trng hp 1: khi
h0
2,5 vt chn d b cong, cn nn thng ri chn tip ().
d0
d0
h0
Chn cc b
Ch cn nung nng vng cn chn hay lm ngui trong nc phn khng
cn chn ri mi gia cng. Cng c th nung nng ton b ri gia cng trong
nhng khun m thch hp.
H.4.20. Chn cc b
nng - 2002
62
c/ nguyn cng t l
t lthng sut:
Nu chi tit t mng v rng th khng cn lt phi trong qu trnh t. Cn
phi c vng m d thot phoi. Nu chiu dy vt t ln th t n
7080% chiu su l, lt phi 1800 t phn cn li.
h
d
nng - 2002
63
4.6. Dp th tch
4.6.1. Khi nim chung
a/ nh ngha
Dp th tch l phng php gia cng p lc trong kim loi bin dng
trong mt khng gian hn ch bi b mt lng khun.
Qu trnh bin dng ca phi trong lng khun phn thnh 3 giai on:
giai on u chiu cao ca phi gim, kim loi bin dng v chy ra xung
quanh, theo phng thng ng phi chu ng sut nn, cn phng ngang chu
ng sut ko.
p
1
3
6
5
H.4.20. S kt cu ca mt b khun rn
1-khun trn; 2- rnh cha ba-via;
3- khun di; 4- chui ui n;
5- lng khun; 6- ca ba-via
b/ c im
chnh xc v bng b mt phi cao (cp 6 - 7; RZ = 80 20)
Cht lng sn phm ng u v cao, t ph thuc tay ngh cng nhn.
C th to phi c hnh dng phc tp hn rn t do.
Nng sut cao, d c kh ho v t ng ha.
Thit b cn c cng sut ln, cng vng v chnh xc cao.
Chi ph ch to khun cao, khun lm vic trong iu kin nhit v p lc
cao. Bi vy dp th tch ch yu dng trong sn xut hng lot v hng khi.
nng - 2002
64
a/ My p thy lc
Cc my p thu lc l cc loi my rn truyn dn bng dng cht lng
(du hoc nc) c p sut cao. My c ch to vi lc p t 300 - 7.000 tn.
to p lc p ln, trong cc my p thy lc
n u p
thng dng b khuch i p sut vi hai xi lanh: xi
P2
lanh hi (1) v xi lanh du (3). Pittng (2) c hai
3
phn ng knh khc nhau, phn nm trong xi lanh
hi c ng knh ln (D) v phn nm trong xi lanh
du c ng knh b (d). Vi p sut hi p1, p sut
d
2
du (p2) c tnh theo cng thc sau:
p 2 = p1
D2
d2
b/ My p trc khuu
Hi
B khuyt i p sut
My p trc khuu c lc p t
1610.000 tn. My ny c loi hnh trnh u
con trt c nh gi l my c hnh trnh cng;
c loi u con trt c th iu chnh c gi
l hnh trnh mm. Nhn chung cc my ln u
c hnh trnh mm. Trn my p c kh c th
lm c cc cng vic khc nhau: rn trong
khun h, p phi, t l, ct bavia v.v... S
nguyn l c trnh by trn hnh sau:
Nguyn l lm vic ca my nh sau:
ng c (1) qua b truyn ai (2) truyn
chuyn ng cho trc (3), bnh rng (4) n
khp vi bnh rng (7) lp lng khng trn trc
khuu (5).
nng - 2002
P1
3
4
5
6
7
8
10
9
65
Khi ng li hp (6), trc khuu (8) quay, thng qua tay bin (8) lm cho
u trt (9) chuyn ng tnh tin ln xung, thc hin chu trnh dp. e di
(10) lp trn b nghing c th iu chnh c v tr n khp ca khun trn v
khun di.
c im ca my p trc khuu: chuyn ng ca u trt m hn
my ba, nng sut cao, tn hao nng lng t, nhng c nhc im l phm vi
iu chnh hnh trnh b, i hi tnh ton phi chnh xc v phi lm sch phi
k trc khi dp.
a/ Khi dp s b
Qu trnh dp c tin hnh vi cc lng khun sau:
Lng khun vut: lng khun lm gim tit din ngang mt phn phi ng
thi lm tng chiu di phi (H.3.22a).
Lng khun p t: lng khun lm tng tit din ngang ca phi mt s
ch nh gim tit din cc ch khc, chiu di phi c gi nguyn
(H.3.22b).
Lng khun un: lng khun lm thay i hng trc ca mt phn phi so
vi phn khc ph hp vi dng ca vt dp (H.3.22c) .
a/
b/
c/
b/ Khi dp bn tinh
S dng lng khun thnh hnh: lng khun to hnh gn ging vi hnh
dng vt dp (H.3.23d), nhng cn, gc ln ln hn khun dp tinh v
khng c rnh bavia.
nng - 2002
66
c/ Khi dp tinh
S dng lng khun tinh: lng khun to hnh chnh xc vt dp c rnh
bavia (H.3.23e).
d/
e/
4.7. k thut Dp tm
4.7.1. Khi nim chung
a/ Thc cht
Dp tm l mt phng php gia cng p lc tin tin ch to cc sn
phm hoc chi tit bng vt liu tm, thp bn hoc thp di.
Dp tm c tin hnh trng thi ngui (tr thp ccbon c S > 10mm)
nn cn gi l dp ngui.
Vt liu dng trong dp tm: Thp ccbon, thp hp kim mm, ng v
hp kim ng, nhm v hp kim nhm, niken, thic, ch vv...v vt liu phi kim
nh: giy cctng, bnt, fp, aming, da, vv...
b/ c im
Nng sut lao ng cao do d t ng ho v c kh ho.
Chuyn ng ca thit b n gin, cng nhn khng cn trnh cao, m
bo chnh xc cao.
C th dp c nhng chi tit phc tp v p, c bn cao..v.v...
c/ Cng dng
Dp tm c dng rng ri trong cc ngnh cng nghip c bit ngnh ch to
my bay, nng nghip, t, thit b in, dn dng v.v...
nng - 2002
67
4.7.2.Thit b dp tm
Thit b dp tm thng c hai loi: my p trc khuu v my p thu
lc. My dp c th tc dng n (my ch c mt con trt chnh dng t,
ct, to hnh) tc dng kp (my c 2 con trt: 1 con trt dng p phi, con
trt kia dng dp su) 3 tc dng (ngoi 2 con trt nh my trn cn c b
phn y sn phm ra khi khun).
1
1234-
2
3
c cu cam
con trt ngoi
con trt trong
phi kim loi
H.4.24. My p tc dng kp
a/ My p trc khuu
Truyn ng ca trc khuu l truyn ng cng, khong hnh trnh ca
my khng ch chnh xc nn sn phm dp tm c cht lng cao v ng u.
Khi ng c quay, trc khuu c th c iu khin bng bn p, khi khng
lm vic con trt v tr cao nht d tho sn phm v a phi vo.
Phn ln cc my p trc khuu u c th iu chnh hnh trnh ca con
trt ph hp vi kch thc ca chi tit. Ngoi ra cn c nhiu c cu cp
phi v ly sn phm t ng trong sn xut hng lot.
1
3
x
x
x
6
x
8
10
12345678-
mt in
b truyn ai
b ly hp
phanh hm
trc khuu
bin truyn ng
b gim chn
b thay i hnh trnh v
cn bng con trt.
9- con trt cng tc
10- bn my
nng - 2002
68
a/ Ct t
L nguyn cng ct phi thnh tng ming theo ng ct h, dng ct
thnh tng di c chiu rng cn thit, ct thnh ming nh t nhng phi thp
tm ln. C cc loi my ct t sau:
My ct li dao song song:
Gc trc =230
Ct c cc tm rng B 3200
mm, chiu dy S n 60 mm.
+
+
+
+
Ch ct c ng thng, chiu
rng tm ct phi nh hn chiu
B
S
di dao.
ng ct thng, p, hnh trnh
dao nh; Lc ct tng i ln:
P = 1,3.B.S. c (N).
B - chiu rng ct ca phi (mm); S - chiu dy phi ct (mm).
c - Gii hn bn ct ca phi c = (0,60,8)b (N/mm2).
My ct dao nghing:
Li dao di nm ngang, li
260.
+
+
+
+
0
Gc ct = 7585 ; gc sau =
230. n gin khi mi dao
S
cho php = 900; gc sau = 0.
Z
h gia 2 dao Z = 0,05
0,2mm
Lc ct khng ln, ct c cc tm dy; Ct c cc ng cong; ng
ct khng thng v nhn. Hnh trnh ca dao ln.
P = 1,3
0,5. S 2 . c
tg
(N)
nng - 2002
69
My ct chn ng:
My c 2 li dao nghing to
thnh mt gc = 24300; gc trc
= 670, khi ct li ct trn ln
xung rt nhanh (20003000
ln/pht) v vi hnh trnh ngn 23
mm. Ct c tm c S 10 mm.
My ct dao a mt cp dao:
D
h
D
h
B
b/ My ct dao di nghing
My ct nhiu dao a.
B
Li ct l 2 a trn quay ngc chiu
nhau; my c th c hai hoc nhiu cp a
D
ct.
Gc ct 900; Z = (0,1 0,2)S
ng knh dao a: D =(40 125)S (mm).
Chiu dy dao: B = 15 30 (mm)
Z
Vn tc ct: v = 1 5 m/s
Vt liu lm dao: 5XBC
My ny dng ct cc ng thng v ng cong chiu di tu . Cc
tm ct mng < 10 mm.
b/ Dp ct v t l
y l nguyn cng ct m ng ct l mt chu vi kn. V nguyn l dp
ct v t l ging nhau ch khc nhau v cng dng.
t l l qu trnh to nn l rng trn phi, phn vt liu tch khi phi
gi l ph liu, phn cn li l phi i qua nguyn cng to hnh. i vi dp
ct th phn ct ri l phi phn cn li l ph liu .
Mt s thng s k thut cn lu :
Chy v ci phi c cnh sc to thnh li ct,
gia chy v ci c khong h Z = (5% 10%)S.
Khi t mun c kch thc l t cho th kch
Cc loi u chy
thc ca chy chn bng kch thc ca l, cn
nng - 2002
70
x.S
Ci
nng - 2002
71
Kch thc phi: Nu S < 0,5 mm th din tch phi bng din tch mt trong
hoc din tch mt ngoi ca chi tit, cn nu S > 0,5mm th ly bng din
tch lp trung ho ca chi tit (k c y). Trong thc t din tch phi (k c
lng d ct mp) c tnh:
D = 113
,
F = 113
,
f (mm)
Trong : F - din tch b mt ca chi tit, mm2.
f - tng din tch cc phn t ring ca b mt chi tit, mm2.
Xc nh s ln dp vut:
Khi dp vut tu theo tnh do ca vt liu mi ln dp cho php dp
thnh chi tit c ng knh nht nh. H s dp cho php c tnh nh sau:
m=
d ct
D ph
d1
D
d2
d1
d
mn = n
d n1
m2 =
d1 = m1.D
d2 = m2.d1 = m1.m2.D
dn = m1.m2.m3...mn.D
dct
d3
Ta c th vit: dn = m1.mtb(n-1).D
d2
d1
Ly lg c hai v ta s c :
n = 1+
lg d n lg(m1 . D)
lg mtb
Qu trnh dp vut:
Nhng chi tit c phi l tm dy
th tin hnh trn khun khng cn vnh
p, nhng nu phi l tm mng s xy ra
hin tng nhn xp thnh sn phm
nn dng thm vnh p.
nng - 2002
1
4
3
2
d1
D
1 - chy p; 2 - khun p
3 - phi k.loi; 4 - vnh p
72
ch
S0 S
100% = (40 60)%
S0
z =( 0,3-0,8)S
c/ Un vnh
L phng php ch to cc chi tit c g, ng knh D chiu cao H, y
chi tit rng. Phi un vnh phi t l vi d trc, sau dng chy v khun
to vnh.
d
d/ Tp ming
d0
nng - 2002
73
e/ Mit
Mit l phng php ch to cc chi tit trn xoay mng. c bit mit
c dng ch to nhng chi tit c ng knh ming thu nh vo v thn
phnh ra nh bi ng, l hoa...k tip sau nguyn cng dp vut.
Cng ngh mit c ng dng
Khun
Phi
i vi cc chi tit bng thp mm hay
kim loi mu. Mit khng bin mng
thnh i vi thp chiu dy khng qu
Ta
1,5mm, i vi kim loi mu khng qu
2mm, cn mit mng thnh th ng dng
vi vt liu c chiu dy ln hn
Cn p
(20mm).
S vng quay ca trc chnh ph thuc
vo vt liu: thp mm 400 - 600 v/ph;
nhm 800 - 1200 v/ph; uara 500 - 900
S mit
v/ph; ng 600 - 800 v/ph.
d min
= 0,2 0,3 (dmin- ng knh nh
D
d
nht ca hnh cn); mit nhng chi tit hnh tr: = 0,6 0,8 .
D
nng - 2002
74
chng 5
k thut hn
5.1. Khi nim chung
a/ Thc cht
Hn l phng php ni hai hay nhiu chi tit kim loi li vi nhau m
khng th tho ri bng cch nung nng kim loi vng tip xc n trng thi
nng chy, sau ngui t do v ng c hoc nung n trng thi do, sau
tc dng lc p ln.
nng - 2002
75
2
l1
l3
l2
L
a/ Que hn nng chy
1- li kim loi; 2- thuc bc
nng - 2002
76
a- u dy trc tip
b- u dy gin tip
c- u dy 3 pha
5.2.3 Ngun in v my hn
a/ Yu cu:
Ngun in hn trong hn h quang tay c th l ngun in xoay chiu hoc
mt chiu. Nhn chung ngun in hn v my hn phi m bo cc yu cu
chung sau:
u (V)
in p khng ti U0 phi < 80 v.
2
i vi my hn xoay chiu:
A
1
U0= 5580 V, Hh = 3055 V.
B
i vi my hn mt chiu:
U0= 2545 V, Hh = 1635 V.
I (A)
ng c tnh ng V-A ca my
hn phi l ng dc lin tc.
1- ng c tnh tnh ca h quang
C kh nng chu qu ti khi ngn
2- ng c tnh ng ca my hn
mch I= (1,31,4)Ih.
C kh nng iu chnh dng in hn trong phm vi rng.
My hn phi c khi lng nh, h s hu ch ln, gi thnh r, d s dng
v d sa cha.
nng - 2002
77
b/ My hn h quang mt chiu
My pht hn h quang: Hnh sau trnh by s nguyn l ca mt my hn
mt chiu dng my pht c cun kch t ring v cun kh t mc ni tip.
nng - 2002
78
My hn gm my pht in
mt chiu (M) c cun dy kch t
ring (2) c cp in ring t
ngun in xoay chiu qua b chnh
lu (1). Trn mch ra ca my pht
t cun kh t (3). Ngi ta b tr
sao cho t thng (c) sinh ra trn
cun kh t lun lun ngc hng
vi t thng (kt) sinh ra trong cun
kch t.
ch khng ti, dng
in hn Ih = 0 nn t thng c = 0,
my pht c kch t bi t thng
(kt) do cun dy kch t (2) sinh
ra: kt = I kt .
1
2
kt
M
n p
W
Rk
c
K
H.5.3. S my
pht hn
H.5.3. S my hn
chnh lu 1 pha
nng - 2002
79
5.2.4. Ch hn h quang in
a/ ng knh que hn:
ng knh que hn ph thuc vo vt liu hn, chiu dy vt hn, v tr
mi hn trong khng gian, kiu mi hn... chn c th tra theo s tay cng
ngh hn hoc xc nh theo cc cng thc kinh nghim i vi cc vt hn
mng:
S
+ 1 [mm]
2
K
Hn gc, hn ch T: d = + 2 [mm]
2
Hn gip mi:
d=
Fd F0
+ 1 . Trong Fd l din tch
Fn
/ Tc hn (Vh):
Tc hn ph thuc vo cng dng in hn v tit din mi hn,
c th tnh theo cng thc kinh nghim sau:
Vh =
d .Ih
3600 Fd
[cm/s]
nng - 2002
80
b
c
a
nng - 2002
81
5.3. Hn h quang t ng v
bn t ng
5.3.1 Thc cht v c im
a/ Thc cht:
Hn h quang t ng l qu trnh hn trong cc khu ca qu trnh
c tin hnh t ng bi my hn, bao gm: gy h quang, chuyn dch in
cc hn xung vng hn duy tr h quang chy n nh, dch chuyn im
hn dc mi hn, cp thuc hn hoc kh bo v.
Khi mt s khu trong qu trnh hn c t ng ha ngi ta gi l hn
bn t ng. Thng khi hn bn t ng ngi ta ch t ng ha khu cp in
cc hn vo vng hn cn di chuyn in cc thc hin bng tay.
b/ c im:
c/ Phn loi
Hn h quang t ng v bn t ng c tin hnh vi in cc hn
dng dy khng c thuc bc, bi vy trong qu trnh hn thng phi s dng
cc bin php bo v mi hn.
Theo phng php bo v kim loi mi hn phn ra: hn h, hn di lp
thuc, hn trong mi trng kh bo v.
Theo mi trng kh bo v c th phn ra:
Hn TIG (Tungstene Inert Gas): Hn h quang dng in cc khng nng
chy, bo v bng kh tr (Ar, He ...).
Hn MIG (Metal Inert Gas): Hn h quang dng in cc nng chy, bo v
bng kh tr.
Hn MAG (Metal Active Gas): Hn h quang dng in cc nng chy, bo
v bng kh hot tnh (CO, CO2, H2 ...)
nng - 2002
82
5.3.2. Hn h quang t ng
Hn h quang t
ng c s dng trong
sn xut hng lot cc
kt cu hn bng thp v
kim loi mu, hn cc
mi hn n (ng
thng, ng trn... ), v
tr mi hn khng phc
tp. Hn h quang t
ng c th c thc
hin trong mi trng
kh bo v (kh tr: Ar,
He; kh hot tnh: CO,
CO2, H2 ...) hoc bo v
bng tr dung (thuc hn
ri).
5.3.3. Hn h quang bn t ng
i vi cc ng
hn phc tp, v tr hn
khng thun li trong sn
xut hng lot thng s
dng hn h quang bn
t ng. Khi hn h
quang bn t ng vic
dch chuyn dy hn dc
ng hn c thc
hin bng tay. Hnh bn
trnh by s thit b
hn bn t ng trong
mi trng kh CO2.
nng - 2002
83
b/ Kh hn
xy k thut xy dng hn kh l xy k thut cha t 98,599,5 % xy v
khong 0,51,5 % tp cht (N2, Ar).
Trong cng nghip, sn xut xy dng phng php in phn nc
hoc lm lnh v chng ct phn on khng kh . xy hn ch yu dng
phng php lm lnh khng kh. Nh chng ta bit, trong thnh phn khng
kh cha khong 78,03 % N2, 0,93 % Ar v 20,93 % O2, nhit ho lng ca
chng tng ng l -195,8 oC, -185,7 oC v -182,06oC. Bng phng php lm
lnh khng kh xung nhit di -182,06 oC nhng trn nhit ha lng ca
N2 v Ar, sau cho N2 v Ar bay hi ta thu c xy lng. xy k thut c th
bo qun th lng hoc kh. th lng, xy c cha bng cc bnh thp v
gi nhit thp, khi hn cho xy lng bay hi, c 1 lt xy th lng bay hi
cho 860 lt th kh iu kin tiu chun.
Axtylen
Axtylen l hp cht ca ccbon v hyr c cng thc ha hc l C2H2,
khi lng ring iu kin tiu chun 1,09 kg/m3, nhit tr 11.470 Cal/m3.
Axtylen c sn xut t t n CaC2. Khi cho t dn tc dng vi nc ta
thu c Axtylen theo phn ng:
CaC2 + 2H2O C2H2 + Ca(OH)2 + 30.400 Cal/mol
Kh Axtylen c cc tnh cht sau:
Nhit t bc chy khong 420oC ( p sut 1 at).
nng - 2002
84
nng - 2002
85
Bnh iu ch axtylen:
Bnh iu ch dng iu ch kh axtylen t t n. Trong thc t,
ngi ta dng nhiu loi bnh iu ch kh khc nhau. Theo nguyn tc tc dng
gia t t n v nc ta c cc loi ri vo nc, nc ri vo v
tip xc vi nc.
S nguyn l ca mt s bnh iu ch kh in hnh:
6
C2H2
3
4
C2H
5
1
5
1 1
C2H2
2
b) Kiu nc ri
a) Kiu ri vo
c) Kiu tip xc nc
Van gim p: l dng c dng gim p sut kh trong bnh cha xung p
sut lm vic cn thit v t ng duy tr p sut mc n nh. i vi kh
oxy p sut kh trong bnh ti 150 at, p sut kh lm vic khong 34 at, cn
kh axtylen p sut trong bnh ti 1516 at, p sut lm vic 0,11,5 at.
Trn hnh sau trnh by s nguyn l ca mt s van gim p:
1
3 4
p1
p2
p1
p2
10
6
9
8
nng - 2002
86
H.5.9. S nguyn l cu to ca m hn kh
1. u m hn; 2. ng dn hn hp kh chy; 3. Bung ht;
4. Van iu chnh xy; 5. Van iu chnh C2H2
nng - 2002
87
O2
= 1,11,2.
C2 H 2
nng - 2002
88
Vng chy hon ton: trong vng ny xy ra phn ng chy hon ton:
CO + H2 + O2kk CO2 + H2O + Q
Ngn la vng ny c mu vng sm, cha nhiu CO2 v H2O v nhit
thp hn vng gia. Vng ny khng hn c v c nhiu cht xy ho.
b/
nng - 2002
89
S
+ 1 [mm]; Hn phi:
2
d=
S
[mm]
2
nng - 2002
90
b/ M ct
ct bng kh ch yu s dng cc m ct dng nhin liu kh. S
cu to chung ca chng c trnh by trn hnh sau:
6
H.5.12. S m ct kh
1. ng dn kh axtylen 2. ng dn kh xy 3. van axtylen 4. van xy 5.
van kh xy 6. ng dn kh xy. 7. ng dn hn hp kh C2H2- O2
nng - 2002
91
5.5. Hn in tip xc
5.5.1. Thc cht, c im
Hn in tip xc l mt phng php hn p lc, s dng nhit do bin
i in nng thnh nhit nng bng cch cho dng in c cng ln i qua
mt tip xc ca hai chi tit hn nung nng kim loi.
Khi hn, hai mp hn c p
3
st vo nhau nh c cu p, sau cho
P
dng in chy qua mt tip xc, theo
nh lut Jun-Lenx nhit lng sinh
1
ra trong mch in hn xc nh theo
2
2
cng thc: Q = 0,24. R. I . t . Nhit ny
4
nung nng hai mt tip xc t n
trng thi do, sau cho lc tc dng
5
lm cho hai mt tip xc ca hai vt
H.5.13. S hn in tip xc gip mi
hn tip cn nhau, xut hin mi lin
1,2/
Vt hn ; 3/ C cu kp phi; 4/ Bn my;
kt kim loi v s khuych tn ca cc
5/ My bin p
nguyn t hnh thnh nn mi hn.
Hn tip xc c nhng c im sau:
Thi gian hn ngn, nng sut cao do d c kh ha v t ng ha.
Mi hn bn v p.
Thit b t, vn u t ln. i hi phi c my hn cng sut ln.
nng - 2002
92
b/ Hn im:
Hn im l phng php hn tip xc m mi hn c thc hin theo
tng im trn b mt tip xc ca hai chi tit hn.
a/
b/
c/
nng - 2002
93
4
P
P
2
H.5.15.S hn ma st
1. Gi kp; 2,3. Chi tit hn; 4. Mi hn
5.6.2. Hn siu m
Hn siu m l phng php hn p
lc, di tc dng ng thi ln vt hn
cc dao ng c hc vi tn s siu m
vi lc nn thch hp mi hn t n
trng thi do v to thnh mi hn.
Dng cao tn t my pht siu m
truyn vo bin t 1 to ra tn s siu m
H.5.16.S hn siu m
(dao ng siu m) truyn qua b truyn
1.Bin
t; 2.B truyn dao ng;
2, n dng c 3 vo vt hn 4 lm cho
3.Dng c; 4.Tm hn; 5.n by
mi hn t n trng thi do.
Ti trng P qua n by v dng c 5 to lc nn lm cho cc phn t hn
thm thu vo nhau to thnh mi hn.
Hn siu m dng hn cc vt nh, mng (< 0,1 mm), nhng kt cu
phc tp khng cn lm sch ch hn, thi gian hn ngn, cc phng php khc
kh thc hin c.
nng - 2002
94
5.6.4. Hn x in
Hn x in l phng php hn nng chy nh nng lng nhit ca vng
x hn chy lng c in tr rt ln. Khi dng in i qua vng x lng, nhit
lng to ra theo nh lut Jun-Lenx rt ln lm cho kim loi vt hn v in
cc hn nng chy.
in cc trong hn x in c nhim v gy h quang lm nng chy
x hn v b sung kim loi cho mi hn. Hn x in l phng php ti u
hn vt hn c chiu dy ln, hn p, hn phc hi cc chi tit my mn.
Vng x lng 4 c in tr ln cung
cp nhit lng nung nng chy mp
hn ca cc vt hn 1 v cc hn 3. Khi
ng c to thnh mi hn 8. Cc tm
chn 2 km cc ng dn nc lm ngui
v ng c kim loi lng vng hn to
thnh mi hn 8. Gi in cc c ng
dn in cc, c nhim v a in cc 3
H.5.18.S hn x in
vo vng hn 5 v to ra h quang 6.
1.Tm hn; 2.Tm chn; 3.Dy hn;
4.X lng; Kim loi lng; 6.H quang;
Trong qu trnh hn thuc hn c phu
7.Phu thuc; 8.Mi hn
7 cung cp vo bo v mi hn.
Ngoi ra cn nhiu phng php hn c bit khc nh hn bng chm tia
in t, hn cm ng, hn bng lade v.v...cng c ng dng trong cng nghip
tin tin.
nng - 2002
95
chng 6
b/ Chuyn ng c bn khi ct gt
Trong qu trnh gia cng c kh, phi v dng c ct gt di chuyn tng
i vi nhau nh nhng c cu my. C hai dng chuyn ng: Chuyn ng c
bn l chuyn ng sinh ra vic ct gt v chuyn ng ph. Chuyn ng c
bn c th chia ra:
Chuyn ng chnh (chuyn ng ct): c tc ln hn tt c cc chuyn
ng khc. Chuyn ng chnh ch yu thc hin qu trnh ct to ra phoi,
k hiu l V hoc n.
Chuyn ng bc tin (chuyn ng chy dao): c tc nh hn chuyn
ng chnh. y l chuyn ng thc hin qu trnh ct tip tc v ct ht
chiu di chi tit.
Vic ct gt c tin hnh thng qua hai chuyn ng ny thng qua
cc phng php ct gt thng dng nhiu l tin, phay, bo, mi, khoan:
nng - 2002
96
6.1.2. Cc thng s c bn ca ch ct
Nhng thng s c bn ca ch ct gt: vn tc ct, lng chy dao,
chiu su ct.
a/ Tc ct V:
Tc ct l khong dch chuyn ca mt im trn li ct hoc mt
im trn b mt chi tit gia cng sau mt n v thi gian.
i vi my c phi hoc dng c ct quay trn (tin):
V =
. D. n
1000
(m/pht)
L
(m/pht)
1000. t
nng - 2002
97
c/ Chiu su ct t:
l khong cch gia b mt cn c gia cng v mt gia cng sau
mt ln dao ct chy qua.
bc tin S
phi
- Khi tin ngoi, chiu su ct o theo
ng vung gc vi trc phi v c tnh
d D
theo cng thc:
t=
Dd
(mm) .
2
chiu su ct t
D
(mm). D - ng knh mi khoan.
2
6.1.3. Dng c ct gt
a/ Cu to ca dng c ct:
Dao ct (dao tin, dao bo, dao phay...) l loi dng c ct dng rt rng
ri gia cng kim loi. Dao gm u dao I v thn dao II. Thn dao dng
kp trong gi dao.
mt thot
I
li ct ph
II
mt sau ph
mi
li ct chnh
H.6.3.Cc b phn chnh ca dao tin
nng - 2002
mt sau chnh
98
nng - 2002
99
b/ K hiu my
d dng phn bit cc nhm my khc nhau, ngi ta t k hiu
cho cc my. Cc nc c k hiu khc nhau. Cc my sn xut Vit nam
c k hiu nh sau:
Ch u tin ch nhm my: T - tin; KD - khoan doa; M - mi; TH - t hp;
P - phay; BX - bo xc; C - ct t ...
Ch s tip theo biu th kiu my, c trng cho mt trong nhng kch thc
quan trng ca chi tit hay dng c gia cng.
Cc ch ci sau cng ch r chc nng, mc t ng ho, chnh xc v
ci tin my.
nng - 2002
100
D1
n
1 ) = 2
(
D2
n1
n2 D2
n1 D1
Z 1 n2
=
Z 2 n1
nng - 2002
Z1; n1
X
Z2; n2
Z2; n2
101
Zbv
b/
H.6.4. Truyn ng trc vt-bnh vt
a/ 1- Vt v tn; 2- Bnh rng vt v
tn
Truyn ng xch
Z
n
T s truyn: i = 1 = 2
Z 2 n1
n1; Z1
n2; Z2
Truyn ng trc vt me - ai c:
y l mt dng truyn chuyn ng bin chuyn ng quay trn
thnh chuyn ng tnh tin.
Khi trc vt quay trn ti ch, ai c tnh tin ; khi ai c c nh, trc vt
quay trn v tnh tin. Sau n vng quay ca trc vt vi bc vt tx ai c tnh
tin c mt on S = tx.n:
nng - 2002
102
D1
I
n1
y l truyn ng cho ta tc
bt k gia 2 tc gii hn nmin v
nmax. Trong my ct kim loi c mt s
c cu truyn dn v cp sau:
cn gt
n2
Bnh ai cn - ai dt (a):
D
n
i = 1 (1 ) = 2
D2
n1
n1
D2
D1
n2
D2
II
b
nng - 2002
103
D1
n
1 ) = 2
(
D2
n1
n1
D1
n2
D2
II
Zi Z a Zi
*
=
Z a Zb Zb
Thng cc gi tr s rng ca mi
bnh rng chnh lch khng nhiu nn
vng quay nII cng chnh lch rt t. C
cu ny thch hp thc hin thay i
lng chy dao S my tin.
nng - 2002
Za
n2
Zb
A
B C D
H.6.8. C cu Nooctong
II
104
C cu o chiu
Trong my ct kim loi thng s dng 2 loi c cu o chiu c kh:
o chiu bng ly hp (a) v o chiu bng bnh rng di trt (b).
Theo nguyn tc nu s trc chn th trc b ng quay ngc chiu vi
trc ch ng. Nu s trc l s l, trc b ng v trc ch ng quay cng
chiu.
b/
I
Z1
Z2
X
II
nI
Z1
b/
I
Z2
Za
II
III
Za
III
nIII
Z3
nI
nIII
Z3
Z4
a/
Z4
b/
1
H.6.9. C cu o chiu
a/ o chiu bng ly hp vu; b/ o chiu bng bnh rng di trt
c/ Truyn ng gin on
Trong my ct kim
loi thng s dng c
cu Cult truyn
chuyn ng ti - lui cho
chuyn ng chnh dao
ct (my bo ngang).
Bnh rng 1, 2 v
a 3 quay lm con trt 8
s trt ti-lui trong rnh
trt ca tay quay 10 lm
cho tay quay 10 lc xung
quanh tm 0. Nh vy bn
trt 4 c g dao 5 nhn
c chuyn ng qua-li
trn chi tit 6 c g trn
bn g.
d/ Xch truyn ng
Xch tc : gii thiu
mt b truyn nhiu cp tc
cho trc chnh. Phng
trnh xch ng c tnh:
nc.i1.i2.i3.i4...in = nc
6
2
8
9
0
10
z1
X
z3
z4
nc
z
k
z2 nc
X
z5
H.6.11. Xch tc
nng - 2002
z6
105
6.2.4. My tin
a/ Cng dng
My tin l loi my gia cng ct gt ph bin nht trong cc nh my c
kh (4050%) bi v n c th gia cng c nhiu b mt:
Mt trn xoay ngoi v trong.
Cc mt tr, cn, hay nh hnh.
Cc loi ren (tam gic, thang, vung...).
Mt phng mt u hay ct t.
Ngoi ra trn my tin c th dng khoan l, doa l, mi, thm ch gia
cng cc mt khng trn xoay nh cc g...
nng - 2002
106
b. Tin trc bc
Dd
2l
y D, d - ng knh u ln v u nh ca on cn.
l - chiu di ca on cn.
l
n
S.n
nng - 2002
107
L Dd
h=
mm.
l 2
Tm mi
D
Tm c
L
c/ nh lch ng
Tin ren:
Tu theo dng ren v yu cu, ngi ta s dng 3 cch tin dao khc
nhau. Phng php (a) ch dng ct ren nh, hai li cng ct s chu lc ln,
nhng c hai mp u nhn. Phng php (b) v (c) khi n dao nghing theo
mt mp, th ch c mt li tham gia ct, s gim lc nhng mp bn phi km
nhn bng. Phng php ny c dng khi ct th c kch thc ln.
Ch : cc loi ren vung hay hnh thang, giai on u cng thng ct
tam gic, sau dng dao nh hnh sa ng .
s
a.
b.
s
c.
Gia cng b mt lch tm: c 2 phng php gia cng cc b mt lch tm:
Phng php dng mi chng
tm: Trn mt u phi khoan 2
2
l tm trng vi ng trc ca
1
mt lch tm v ng trc ca
I
ngng trc. Khi g l tm I-I ta
II
gia cng mt lch tm 2, khi g
l tm II-II gia cng ngng trc
1.
nng - 2002
I
II
108
Phng php gia cng trn mm cp: ngi ta to mt lch tm bng cch
m mt ming kim loi c chiu dy A nht nh di mt vu ca mm
cp. Chiu dy A c xc nh theo cng thc:
e
A = 1,5e 1
2d
d - ng knh ca b mt c kp cht
e - khong lch tm .
O2
d
e
O1
/ Cc dng c ch yu ca my tin
Mm cp: l b phn kp cht v t nh v phi khi gia cng. C cc loi
mm cp chnh sau:
H.6.12.Cc loi mm cp
a/ Mm cp 3 chu; b/ Mm cp 4 chu; c/ Mm cp hoa
nng - 2002
109
nng - 2002
110
6.2.5. My khoan-doa
a/ Cng dng v phn loi
My khoan-doa dng gia cng l hnh tr bng cc dng c ct nh:
mi khoan, mi khot v dao doa.
My khoan to ra l th t chnh xc, bng b mt gia cng thp
Rz160 Rz40. nng cao chnh xc v bng b mt l phi dng khot
hay doa trn my doa. Sau khi doa, chnh xc t cp 4 hoc 5 v bng c
th t Ra = 1,25 0,32.
My khoan-doa c chuyn ng chnh l chuyn ng quay trn ca trc
mang dao, chuyn ng chy dao l chuyn ng tnh tin ca dao. Trn my
khoan c th dng dng c tar, bn ren gia cng ren.
My khoan c cc loi sau:
My khan in cm tay Cho php
khoan cc l trn nhng chi tit m
khng cho php cc loi my
khoan c trc chnh c nh thc
hin.
My khoan bn: l loi my n
gin, nh, t trn bn ngui. L
khoan ln nht d 10 mm. My
thng c 3 cp vng quay vi s
vng quay ln.
nng - 2002
111
dn
1000
m/pht
H.6.16. Mi khoan
a/ Tit din lp phoi; b/ Mi khoan tm; c/ Mi khoan rut g
d
(mm).
2
nng - 2002
112
Tar v bn ren:
Ta r l dng c gia
cng ren trong c th lp trn
trc khoan hoc thao tc bng
tay. ng vi mt kch thc,
mt b tar c t 23 chic
ct t th n tinh.
Bn ren dng gia
cng ren ngoi vi kch thc
khng qu ln.
H.6.15. g/ Ta r; h/ Bn ren
6.2.6. my bo, xc
a/ c im, phn loi v cng dng
My bo, xc l nhm my c chuyn ng tnh tin kh hi, dng gia
cng cc mt phng ngang, ng hay nm nghing; gia cng cc rnh thng vi
tit din khc nhau: mang c, ch T, dng rng thn khai...My cng c kh
nng gia cng chp hnh to ra cc mt cong mt chiu.
Chuyn ng chnh ca my l chuyn ng tnh tin kh hi: gm mt
hnh trnh c ti v mt hnh trnh chy khng. Chuyn ng chy dao thng
l chuyn ng gin on. Gia cng trn my bo, xc c nng sut thp,
chnh xc thp v nhn km.
b/ Cc loi My bo, xc
Tu theo nhng c trng v cng ngh,
my bo c chia thnh: my bo ngang, my
bo ging, my xc (bo ng) v cc my
chuyn mn ho.
My bo ngang: dng gia cng nhng phi
khng ln (< 600 mm). Bn my cng vi phi
di chuyn theo chiu ngang trn mt bng ca
thn my, cn u trt ca my cng vi bn
dao v dao bo chuyn ng ti-lui trn mt
bng c dng ui n. Hp tc v c cu
Cult dng di chuyn bn trt.
nng - 2002
H.6.18. My bo ngang
113
H.6.19. My xc
c/ Dao bo v K thut bo
Tu theo v tr ca li
ct m dao bo c phn
thnh dao bo phi v dao
bo tri; tu theo v tr ca
u dao so vi thn dao chia
thnh dao bo ngoi, dao
bo mt mt, dao bo ct,
dao bo nh hnh, dao bo
thng, dao bo cong. Dao
bo c ch to bng thp
hp kim dng c (thp gi)
H.6.20. Dao bo v nguyn cng bo, xc
hoc hp kim cng.
Nhng nguyn cng thng c thc hin trn my bo l gia cng cc
mt phng ngang, mt phng thng ng, mt phng nghing, mt c bc, mt
nh hnh; gia cng cc loi rnh thng thng, rnh ch T, rnh ui n v.v...
nng - 2002
114
6.2.7. my phay
a/ c im, cng dng
My phay l loi my c nhiu chng loi v c t l ln trong cc nh
my c kh. Phay trn my phay l phng php khng ch t nng sut cao m
cn t c nhn b mt tng i (Ra2,5 Rz40), chnh xc xp x vi
khi gia cng trn my tin (cp 6 cp 11).
My phay dng ph bin gia cng mt phng, mt nghing, cc loi
rnh cong v phng, rnh then, l, mt ren, mt rng, cc dng b mt nh hnh
(cam, khun dp, mu, dng, chn vt tu thu, cnh qut, cnh tucbin...), ct
t v.v... Trong sn xut hng lot v hng khi, phay c th thay th cho bo v
phn ln cho xc. Trong sn xut n chic v hng lot nh phay c nhiu
cng dng, c th thay th cho bo - xc, do dao phay c nhiu li cng ct,
tc phay cao v c nhiu bin php cng ngh, nn nng sut ca phng
php phay cao hn hn bo - xc v gi thnh sn phm thp.
nng - 2002
H.6.22.My phay ng
115
c/ Dao phay
Trong my phay, chuyn ng chnh l chuyn ng quay trn ca dao
phay nn cu to ca dao thng ph hp vi s quay trn ca trc dao nm
ngang hay thng ng.
Tu theo dng b mt gia cng c cc loi dao sau:
Loi dao gia cng mt phng gm dao phay tr, dao phay mt u.
Loi dao gia cng rnh gm dao a, dao phay 3 mt ct, dao phay ngn...
Loi dao gia cng bnh rng nh dao phay mun, dao phay ln rng ...
d/ S ct khi phay
Khi dao phay quay trn theo tc ca trc chnh c tnh theo cng
thc: v =
dn
1000
m/pht
nng - 2002
116
Chiu su phay t (mm): chiu su lp kim loi b ct trong mt hnh trnh phay.
Chiu rng phay B (mm): l chiu rng gia cng sau mt hnh trnh phay o
theo phng song song vi trc dao.
Chiu dy ct a (mm): l khong cch gia hai v tr k tip nhau ca qu o
chuyn ng ca mt im trn li ct o theo phng vung gc vi li ct
chnh.
Chiu dy ct thay i t amin n amax (hoc amax n amin).
nng - 2002
117
K
1 1 1 1
= ; ; ;
Z bv 40 60 90 120
N
(z - s rnh cn gia cng).
z
N
a
a. m
= A+ = A+
(vng)
Z
b
b. m
N 40
13 2
26
=
= 1+
= 1+
Z 27
27 2
54
nng - 2002
118
Vy sau khi gia cng xong mt rnh ta s quay tay quay (4) mt vng
trn, sau ta quay thm mt gc c cha 26 l trn vng l 54. Tip tc nh
vy ta s gia cng xong 27 rng c chia u khng c sai s. l trng hp
phn n gin. Khi khng th phn n gin v khng th chn m thch
hp ta dng phn vi sai. Lc ny phi s dng b bnh rng a, b, c, d ni
t trc chnh n tay quay b tr sao cho lng sai s l ti thiu.
6.2.8. my mi
a/ Khi nim
Mi l phng php gia cng m dng c ct l mi. Mi c th gia
cng th ct b lp th cng mt ngoi cc loi phi, nhng a s trng hp
l gia cng tinh cc b mt (mt tr, mt phng, rnh, l, mt nh hnh, ren,
rng, then, then hoa...). Mi dng gia cng cc vt liu cng nh thp ti,
gang trng ...cng c th gia cng th ct phi, ct bavia, mi th ...
Chuyn ng chnh khi mi l chuyn ng quay trn ca mi:
v=
. D. n
601000
.
(m/s)
b/ mi
Vt liu ht mi l thnh phn ch yu ca , chng gm cc loi kim
cng nhn to, cc xyt nh xyt nhm thng, xyt nhm trng, ccbit silic,
ccbit boric...
Ht mi c ch to vi kch thc ht khc nhau ch to cc loi
khc nhau.
Cht dnh kt lin kt cc vt liu ht mi thng dng cht dnh kt
v c nh keramit, hu c nh baklit hoc cao su.
Trong thc t thng s dng cc loi loi mi c hnh dng nh sau:
nng - 2002
119
c/ Cc chuyn ng c bn ca my mi
Tt c cc loi my mi u c chuyn ng chnh l chuyn ng quay
trn ca mi v (m/s), cn chuyn ng chy dao c th c hai, ba loi khc
nhau:
Chuyn ng chy dao vng Sv
(a) - l chuyn ng quay trn
ca chi tit vc (m/ph). Trng
hp chi tit ln khng quay
c (d) th chuyn ng chy
dao vng l chuyn ng quay
hnh tinh ca .
Chuyn ng chy dao dc Sd
(b) - l chuyn ng thng kh
hi ca bn my mang chi tit S
(m/ph).
Chuyn ng chy dao ngang
Sn(hay chy dao hng knh Sk
theo chu k ca bn my Sn
(mm/hnh trnh kp).
H.6.29.Cc chuyn ng c bn khi mi
nng - 2002
120
nng - 2002
121
chng 7
x l v bo v b mt kim loi
7.1. Khi nim chung
S ph hu kim loi, cc my mc thit b bng kim loi c th do nhiu
nguyn nhn khc nhau nhng ch yu l do tc dng ho hc, tc dng in
ho v tc dng c hc.
S ph hu kim loi do ho hc hay in ho gi l s n mn kim loi
hay s g. S ph hu kim loi do c hc gi l s mi mn kim loi.
7.1.2. Cc dng mi mn
S mi mn l s thay i khng mong mun v hnh dng v kch thc
ca b mt chi tit v mt i mt lng kim loi do tc dng c hc ca cc phn
t rn t b mt chi tit hoc t mi trng ngoi.
S mi mn c hc c th xut hin 2 dng sau:
Khi c chuyn ng tng i ca kim loi trn kim loi.
Khi c chuyn ng ca mi trng phi kim trn b mt kim loi.
nng - 2002
122
nng - 2002
123
b. Ho nhit luyn
Ho nhit luyn l phng php lm bo ho mt s nguyn t ho hc
trn lp b mt kim loi lm thay i thnh phn ho hc, do lm thay i
tnh cht ca lp b mt
a/ Thm cc bon
Mc ch ca thm ccbon l lm bo ho ccbon ln lp b mt kim loi
nhm lm tng cng cho lp b mt chi tit. Thng dng cho cc loi thp
ccbon v hp kim c hm lng ccbon thp. Thm ccbon c th tin hnh
th rn, lng, kh.
Thm ccbon th rn c dng nhiu vi nguyn liu ch yu l than C
= (8090)% + cht xc tc (BaCO3, CaCO3). Nung n nhit thm
9009500C, gi nhit mt thi gian ccbon nguyn t thm vo lm bo ho
ccbon ln b mt chi tit thm. Lp b mt thm c (0,52)mm.
b/ Thm nit
Thm nit l phng php lm bo ho nit vo lp b mt chi tit kim
loi nhm nng cao cng, dai va chm, tnh chng mi mn, chng mi...
Vt liu thm nit thng dng amniac (NH3) nhit thm 4806500
NH3 3H + Nng.t
Nit nguyn t c hot tnh mnh, thm vo b mt chi tit. Lp thm
mng (0,20,3)mm; cng t c 6772 HRC.
c/ Thm xianua
Thm xianua l qu trnh lm bo ho ng thi c ccbon v nit ln b
mt chi tit kim loi, nhm nng cao cng, tnh chu mi mn v gii hn
mi ca lp b mt chi tit.
Qu trnh thm nit c th nhit thp 5405600C hoc nhit
trung bnh 8408600C v nhit cao 9009500C.
Vt liu thm dng mui c gc CN nh NaCN, KCN...Chiu su lp
thm < 0,10,2 mm.
nng - 2002
124
7.2.3. Bo v chng g
a/ Khi nim
Bo v chng g nhm m bo cc yu cu k thut ca kt cu khi lm
vic lu di, nng cao hiu qu kinh t... c bit cc kt cu lm vic trong mi
trng c cc hot ng ho hc mnh (khng kh, nc bin, nh sng mt
tri...)
b/ Phng php bo v
- Bo v lu di: gm chn vt liu c kh nng chng g tt v chn
phng php to lp chng g nh phun bi, ln p, to bng cao v.v...
X l kt cu l chn kt cu n gin c bng b mt cao, c phn
chuyn tip, thun li cho vic bo qun, chng g, x l v.v..
X l mi trng g cn kh hoc hn ch kh nng xm thc ca mi trng
nh m, xy, xt...
Bo v bng lp ph kim loi, phi kim, xt bng ho hc, in ho (trng
ph men, m crm, trng km, ph xt nhm, phun kim loi, m in, ngm
dung dch, qut sn...)
Bo v chng g trong mi trng nhit i: cn kh thnh phn xm thc
ca mi trng, cc sn phm g, nc v m mi trng, cn m niken,
crm, sn tng hp, sn chng g c tnh kim, dng bao b ng gi...
- Bo v tm thi: l qu trnh bo qun trong qu trnh sn xut, trong
kho, khi vn chuyn nh lm sch bi trn du m, cht chng g, paraphin, bao
gi, ng hp v.v...
nng - 2002