LI NOI AU

Nh chung ta a biet, van e ma nha san xuat

quan tam nhat oi vi san pham cua mnh la: nang
suat chat lng gia thanh. Trong nganh c kh che tao
may noi rieng, co the xem qui trnh cong nghe gia cong
c la yeu to anh hng rat ln en nang suat chat
lng gia thanh, mot qui trnh cong nghe gia cong hp
ly cua mot chi tiet se rut ngan c thi gian gia cong
va am bao c chat lng san pham theo yeu cau
t o giam c gia thanh.
Vi kien thc a tiep thu c qua mon hoc cong
nghe che tao may va vi s hng dan tan tnh cua
thay Hoang Lanh, chung em a hoan thanh o an:
thiet ke qui trnh cong nghe gia cong chi tiet Gia Dan
Hng.
Trong qua trnh thc hien tat nhien khong the
tranh khoi nhng sai sot, rat mong nhng y kien ong
gop qu bau va chan thanh cua qu thay, co trong bo
mon Che Tao May va cac ban sinh vien.
TAI LIEU THAM KHAO
1. Hng dan thiet ke o an mon hoc cong nghe che
tao may Le Trung Thc ang Van Nghn.
2. Thiet ke o an cong nghe che tao may-Tran Van
ch-NXB KH-KT-HN 2000
3. So tay cong nghe che tao may. Tap I Nguyen ac
Loc Le Van Tien Ninh c Ton Tran Xuan Viet.
NXB KH-KT-HN 1999
4. So tay cong nghe che tao may. Tap I Nguyen ac
Loc Le Van Tien Ninh c Ton Tran Xuan Viet.
NXB KH-KT-HN 2001
5. So tay cong nghe che tao may. Tap II Nguyen ac
Loc Le Van Tien Ninh c Ton Tran Xuan Viet.
NXB KH-KT-HN 2001
6. Cong nghe che tao may, Tap 1&2. Nguyen ac Loc,
Le Van Tien (chu bien va hieu nh) HBKHN 2001
7. o ga gia cong c kh Tien Phay Bao Mai.
Ho Viet Bnh Le ang Hoanh, Nguyen Ngoc ao.
H SPKT TPHCM 2000
8. Cac phng phap gia cong kim loai. Chu bien : ang
Van Nghn
HBK TpHCM 2001
9. Giao trnh cong nghe kim loai ,Tap 1 Tran Hu
Tng(chu bien)
HBK TpHCM 1969
10. Giao trnh kim loai hoc va Nhiet Luyen- Nghiem Hung
H SPKT 1997
11. Dung sai lap ghep va o lng ky thuat Hoang
Xuan Nguyen Nha xuat ban
giao duc.
12. Che o cat gia cong c kh Nguyen Ngoc ao- Tran
The San-Ho Viet Bnh
13. So tay CNCTM Nguyen Ngoc Anh
1. PHAN TCH CHI TIET:
Ten chi tiet: Ga dan hng.
Cong dung va ieu kien lam viec cua chi tiet
gia cong:
Ga dan hng la chi tiet trung gian e lien ket hai
truc song song vi nhau, e truc nay di chuyen song
song vi truc kia.
Vat lieu va c tnh yeu cau
- Vat lieu: Gang xam (GX 32-52), theo sach kim
loai hoc va nhiet luyen ta co:
+
2
/ 120 mm N
b

,
2
/ 280 mm N
u

,
2
/ 500 mm N
n

+ 190 HB
+ Gang xam la hp kim sat vi cacbon va co cha
mot so nguyen to khac nh (0,5 4,5)%Si,
(0,4 0,6)%Mn, 0,8%P, 0,12%S, ngoai ra con co them
Cr, Cu, Ni, Al
+ Gang xam co o ben nen cao chu mai mon, tnh
uc tot, gia cong c de, nhe, re va giam rung
ong
Phan tch yeu cau ky thuat
Ta can quan tam en cac yeu cau ky thuat sau:
- Ve kch thc:
+
046 , 0
51
, co dung sai lo la H8
+
027 , 0
15
, co dung sai lo la H8
- Ve o nhan cua be mat gia cong:
+ Mat tru trong cua lo co ng knh 51 co o
nham be mat la Ra=2,5
+ Mat tru trong cua lo co ng knh 15
+0,027
co
o nham be mat la Ra=2,5
2. XAC NH DANG SAN SUAT
Muc ch:xac nh hnh thc to chc san xuat(n
chiec,hanh loat nho, hang loat va, hang loat ln hay
hang khoi) e t o cai thien tnh cong nghe cua chi
tiet ,chon phng phap che tao phoi,chon thiet b cong
nghe hp ly cho viec gia cong chi tiet.
Cac yeu to phu thuoc: + San lng che tao
+ Khoi lung chi tiet
1. San lung chi tiet can che tao trong mot
nam:

,
_

+
,
_

+
100
1 *
100
1 * *
0

m N N
Trong o:
- N
0
= 10.000 chiec, la so san pham trong mot nam
theo e bai yeu cau.
- m = 1 so lng chi tiet nh nhau trong mot san
pham.
- = 10..20% so % d tr lam phu tung cho chi tiet
may noi tren,chon =15%
- = 3..5% so % chi tiet phe pham trong qua trnh
che tao, chon =4%

11960
100
04 , 0
1
100
15 , 0
1 1 000 . 10
,
_

+
,
_

+ x x x N
chiec/nam
2. Khoi lng chi tiet:
Khoi lung chi tiet gia cong co the tnh gan ung nh
sau:
- The tch hnh tru ln
[ ]
3 2 2
4 1
8 0 ) 5 . 6 * 3 ( ) 5 1 6 4 ( m m V

- The tch hnh khoi cho bat bu long (ben trai chi tiet):
3
2 2
2
2
19
)
2
15
2
15
30 * 18 ( 2 mm V +

- The tch 2vanh phai cua chi tiet:
3
2 2 2
2
70
3
10
2
15
8
51
4
15
) 64 30 ( 2 mm V
1
]
1

+ +

- The tch 2 g loi:
3
4
6
2
20 18
2 mm V
,
_

=> The tch ac cua chi tiet:

4 3 2 1
V V V V V + + +
=157057.3 mm
3
Vay khoi lng cua chi tiet la:
M= *V
Vi khoi lng rieng cua chi tiet:

gang xam
=3,6 kg/dm
3
M=6,8*157057.3*10
-6
=1,068 kg
Theo bang 2 1, [1,trang 24 ], vi lng san xuat 23920
chiec/nam va khoi lng chi tiet la 1,068 Kg Ta c
dang san xuat la: Hang loat va.
V dang san xuat ay khong phai la san xuat hang
loat ln hay hang khoi, nen ta khong can xac nh nhp
san xuat.
3. CHON PHOI & PHNG PHAP CHE TAO PHOI
3.1 Dang phoi:
Trong gia cong c kh cac dang phoi co the la:
phoi uc, ren, dap, can.
Xac nh loai va phng phap che tao phoi
phai nham muc ch bao am hieu qua kinh te
ky thuat chung cua quy trnh che tao chi tiet, ong
thi tong ph ton che tao chi tiet ke t cong oan
che tao phoi cho ti cong oan gia cong chi tiet
phai thap nhat.
Khi xac nh loai phoi va phng phap che tao
phoi cho chi tiet ta can phai quan tam en ac
iem ve ket cau va yeu cau chu tai khi lam viec
cua chi tiet (hnh dang, kch thc, vat lieu, chc
nang, ieu kien lam viec)
San lng hang nam cua chi tiet
ieu kien san xuat thc te xet ve mat ky
thuat va to chc san xuat (kha nang ve trang
thiet b, trnh o ky thuat che tao phoi)
Mac khac khi xac nh phng an tao phoi cho
chi tiet ta can quan tam en ac tnh cua cac loai
phoi va lng d gia cong ng vi tng loai phoi.
Sau ay la mot vai net ve ac tnh quan trong cua
cac loai phoi thng c s dung:
Phoi uc:
Kha nang tao hnh va o chnh xac cua phng
phap uc phu thuoc vao cach che tao khuon,co
the uc c chi tiet co hnh dang t n gian en
phc tap (chi tiet cua ta co hnh dang kha phc tap)
. Phng phap uc vi cach lam khuon theo mau
go hoac dng n gian cho o chnh xac cua phoi
uc thap. Phng phap uc ap lc trong khuon kim
loai cho o chnh xac vat uc cao. Phng phap uc
trong khuon cat, lam khuon thu cong co pham vi
ng dung rong, khong b han che bi kch thc va
khoi lng vat uc, ph ton che tao phoi thap,tuy
nhien nang suat khong cao. Phng phap uc ap
lc trong khuon kim loai co pham vi ng dung hep hn
do b han che ve kch thc va khoi lng vat uc,
ph ton che tao khuon cao va gia thanh che tao
phoi cao,tuy nhien phng phap nay lai co nang
suat cao thch hp cho san suat hang loat va.
Phoi ren:
Phoi t do va phoi ren khuon chnh xac thng
c ap dung trong nganh che tao may. Phoi ren t
do co he so dung sai ln, cho o ben c tnh cao,
phoi co tnh deo va an hoi tot. phng phap
ren t do, thiet b, dung cu che tao phoi la van
nang, ket cau n gian,nhng phng phap nay ch
tao c cac chi tiet co hnh dang n gian ,nang
suat thap. Ren khuon co o chnh xac cao
hn,nang suat cao nhng phu thuoc vao o chnh
xac cua khuon .Mat khac khi ren khuon phai co
khuon chuyen dung cho tng loai chi tiet do o ph
ton tao khuon va che tao phoi cao. Phng phap
nay kho at c cac kch thc vi cap chnh xac
7-8 nhng chi tiet co hnh dang phc tap.
Phoi can:
Co profin n gian, thong thng la tron,
vuong, luc giac, lang tru va cac thanh hnh khac
nhau, dung e che tao cac truc trn, truc bac co
ng knh t thay oi, hnh ong, ong vat, tay gat,
truc then, mat bt. Phoi can nh hnh pho bien
thng la cac loai thep goc, thep hnh I, U, V c
dung nhieu trong cac ket cau lap. Phoi can nh
hnh cho tng lnh vc rieng, c dung e che tao
cac loai toa tau, cac may keo, may nang
chuyen Phoi can ong dung che tao cac chi tiet
ong, bac ong, then hoa, tang trong, cac tru rong
C tnh cua phoi can thng cao, sai so kch thc
cua phoi can thng thap, o chnh xac phoi can
co the at t 912. Phoi can c dung hp ly
trong trng hp sau khi can khong can phai gia
cong c tiep theo, ieu o ac biet quan trong khi
che tao cac chi tiet bang thep va hp kim kho gia
cong, at tien.
=>Chi tiet gia an hng co hnh dang kha
phc tap va co mot so mat co o chnh xac
kch thc kha cao (cap 7-8),nen ta khong dung
phng phap can e tao phoi.
Ngoai ra trong thc te san xuat ngi ta con dung
phoi han nhng quy mo san xuat nho n chiec.
Chon phoi
Da vao ac iem cua cac phng phap tao phoi
tren, ta chon phng phap uc v:
+ gia thanh che tao vat uc re
+ thiet b au t phng phap nay tng oi
n gian,cho nen au t thap
+ phu hp vi san xuat hang loat va
+ o nham be mat, o chnh xac sau khi uc co
the chap nhan e co the tiep tuc gia cong tiep theo
Phng phap che tao phoi:
Trong uc phoi co nhng phng phap sau:
1. uc trong khuon cat mau go
- Chat lng be mat vat uc khong cao, ga thanh
thap, trang thiet b n gian, thch hp cho dang san xuat
n chiec va loat nho.
- Loai phoi nay co cap chnh xac IT16 IT17.
- o nham be mat: R
z
=160 m.
=> Phng phap nay cho nang suat trung bnh, chat
lng be mat khong cao,gay kho khan trong cac
bc gia cong tiep theo.
2. uc trong khuon cat mau loai:
- Neu cong viec lam khuon c thc hien bang may
th co cap chnh xac kha cao, gia thanh cao hn so vi
uc trong khuon cat mau go,v gia tao khuon cao.
- Cap chnh xac cua phoi: IT15 IT16.
- o nham be mat: R
z
=80 m.=> Chat lng be mat
cua chi tiet tot hn phng phap uc vi mau go,uc
c cac chi tiet co hnh dang phc tap, nang suat phu
hp vi dang san xuat loat va va ln.
3. uc trong khuon kim loai:
- o chnh xac cao, gia thanh au t thiet b ln, phoi
co hnh dang gan giong vi chi tiet nen lng d nho,
tiet kiem c vat lieu nhng gia thanh san pham cao.
- Cap chnh xac cua phoi: IT14 IT15.
- o nham be mat: R
z
=40 m.
=>Phng phap nay cho nang suat cao,ac tnh ky
thuat cua chi tiet tot nhng gia thanh cao nen khong
phu hp vi tnh kinh te trong san suat loat va.
4. uc ly tam:
- Loai nay ch phu hp vi chi tiet dang tron xoay,
rong, oi xng, ac biet la cac chi tiet hnh ong hay
hnh xuyen.
- Kho nhan c ng knh lo ben trongvat uc chnh
xac v kho nh c lng kim loai rot vao khuon chnh
xac
- Chat lng be mat trong vat uc kem (oi vi vat
uc tron xoay) v cha nhieu tap chat va x.
5. uc ap lc:
- Dung ap lc e ien ay kim loai trong long khuon
- Hp kim e uc di ap lc thng la hp kim Thiec,
Ch, Kem, Mg, Al,Cu.
- uc di ap lc dung e che tao cac chi tiet phc
tap nh vo bm xang, dau, nap buong ep, van dan kh
- Trang thiet b at nen gia thanh san pham cao.ac
tnh ky thuat tot nhng oi vi dang san suat loat va
th hieu qua kinh te khong cao.
6. uc trong khuon vo mong:
- La dang uc trong khuon cat nhng thanh khuon
mong chng 6-8mm
- Co the uc c gang , thep, kim loai mau nh khuon
cat,khoi lng vat uc en 100 kg
- Dung trong san xuat loat ln va hang khoi.
7. uc lien tuc:
-La qua trnh rot kim loai long eu va lien tuc vao
moat khuon bang kim loai,xung quanh hoac ben trong
khuon co nc lu thong lam nguoi (con goi la bnh
ket tinh) .Nh truyen nhiet nhanh nen kim loai long sau
khi rot vao khuon c ket tinh ngay, vat uc c
keo lien tuc ra khoi khuon bang c cau ac biet nh
con lan
-Thng dung e uc ong, uc thoi, uc tam
Ket luan:
- Vi nhng yeu cau cua chi tiet a cho, tnh kinh te
cung nh dang san xuat ta se chon phng phap che
tao phoi uc trong khuon cat mau kim loai, lam
khuon bang may.
- Phoi uc at cap chnh xac la II.
- Cap chnh xac kch thc IT15 IT16.
- o nham be mat: R
z
=80 m.
3.2Xac nh lng d gia cong:
- Chi tiet c che tao bang gang xam, c uc trong
khuon cat mau go, lam khuon bang may, mat
phan khuon X-X (nam ngang).
- Lng d pha tren: 3,5mm
- Lng d pha di va mat ben: 3,5 mm
- Goc nghieng thoat khuon: 3
0
- Ban knh goc ln: 3 mm.
3.3 Ban ve long khuon:
4. TIEN TRNH GIA CONG CAC BE MAT
4.1. anh so cac be mat
4.2 Phng phap gia cong cac be mat
Gia cong mat phang( mat au cua hnh tru)
Giai oan ten Ma Cap chnh o
gia cong nguyen
cong
xac IT nham
Ra(Rz)
1 Phay tho
Tien tho
-2
-1
12->14
14
25-50 (Rz)
25(Rz)
2 Phay ban
tinh
Tien tinh
1
2
10
11
3,2
3,2
3 Phay tinh
Tien tinh
3
4
8-9
8
2,5
2,5
Gia cong mat tru trong
Giai oan
gia cong
Ten
nguyen
cong
Ma Cap chnh
xac
(IT)
Ra (Rz)
1 Tien tho
Khoet tho
Khoan
-3
-2
-1
12
12
14
40(Rz)
50 (Rz)
50 (Rz)
2 Tien ban
tinh
Khoet tinh
1
2
10
10
20 (Rz)
12,5 (Rz)
3 Tien tinh
Doa tinh
3
4
8
8
2,5
2,5
4.3 Cac be mat can gia cong:
Mat au 1&3
Mat 6&8
Mat tru trong 4
Mat lo 5
Mat lo bulong 11
Ranh 14
4.4 Chon chuan cong nghe:
Chon mat 9 lam chuan tho e gia cong mat
1&3
Chon mat 1 lam chuan tinh e gia cong cac
be mat con lai
5. THIET KE NGUYEN CONG
Chon chuan cong nghe
- Chuan tho: Do chi tiet dang khoi va chi tiet co dang
con nen ta chon be mat tru ln ngoai (64) lam chuan
tho
- Chuan tinh: Dung be mat 1 hoac 3 lam chuan tinh phu
thong nhat cho ca qua trnh thc hien qui trnh cong
nghe
5.1 Nguyen cong 1:Phay mat 1&3
5.1.1 S o ga at:
5.1.2 Phng an gia cong:
Phay tho mat 1&3 at cap chnh xac 14 ,Rz=50
m
Phay ban tinh mat 1&3 at cap chnh xac 11
,Rz=20 m
5.1.3 nh v:
- e tao c mat au 1,3 th can khong che
cac bac t do sau:
Can: T(Oz) , Q(Ox) , Q(Oy)
Phu: T(Ox) T(Oy)
- Dung khoi V dai se khong che c 4 bac t
do:
T(Ox) , T(Oy) , Q(Ox) , Q(Oy)
- Dung chot ty khong che 1 bac t do: T(Oz)
5.1.4 Phng an kep chat:
Dung c cau kep chat lien ong,tao lc kep ep be
mat tru ngoai cua chi tiet sat vao mat khoi V
5.1.5 Chon may:
- Do gia cong tho nen t,s can ln e lam giam
thi gian gia cong.
- Chon may phay ngang cong xon 6H12 [che o
cat GC CK,tr 221]
+ Be mat lam viec cua ban(mm
2
): 320x1250
+ Cong suat ong c: 7 Kw
+ Hieu suat may: =0,75
+ So vong quay truc chnh (v/ph): 30-1500
+ Bc tien cua ban: 5-1500 mm/ph
+ Lc ln nhat cho phep theo c cau tien cua
may: 1500 Kg
5.1.6 Chon dung cu cat: Bang 4.85 [3,tr333]
-Dao phay a ba mat rang gan manh hp kim cng
BK8
+ ng knh dao phay: D=200 mm
+ ng knh lo cua dao phay: d=60 mm
+ Be rong dao phay: B=16 mm
+ So rang: 14 rang
Viec chon nh vay la do dung hp kim cng tot
hn dung dao thep gio v am bao nang suat cat
cao hn, thi gian lam viec giam rat nhieu do viec
tang toc o cat.
5.1.7 Dung cu kiem tra: thc cap
5.1.8 Dung dch trn nguoi: Emunxi , chu yeu lam
mat
5.2 Nguyen cong 2: khoet-doa lo 51
+0,046
5.2.1 S o ga at:
5.2.2 Phng an gia cong:
- Khoet tho at cap chnh xac 12 , Rz=50 m
- Khoet tinh at cap chnh xac 10 , Rz=12,5 m
- Doa tinh at cap chnh xac 8 , Ra=2,5 m
5.2.3 nh v:
- e tao c mat tru trong 51 th can khong che
cac bac t do sau:
Can: T(Ox) , T(Oy) , Q(Ox) , Q(Oy)
Phu: T(Oz)
- Dung phien ty nh v mat au 1 khong che 3
bac t do
T(Oz) , Q(Ox) , Q(Oy)
- Dung khoi V ngan nh v mat tru ln
ngoai, khong che 2 bac t do:
T(Ox) , T(Oy)
5.2.4 Phng an kep chat:
Dung c cau kep lien ong tao ra lc kep
ay be mat 1 cua chi tiet ep vao phien ty.
5.2.5 Chon may:
Chon may khoan can 2A55 [che o cat GC CK ,tr
220]
- ng knh gia cong ln nhat (mm): 50 mm
- Con moc ttruc chnh: N
0
5
- So vong quay truc chnh: 5-1700 vg/ph
- Bc tien mot vong quay truc chnh: 0,05-2,2
(mm/vg)
- Moment xoan ln nhat: 75 Kgm
- Lc doc truc ln nhat: 2000 Kg
5.2.6 Chon dung cu cat:
* Mui khoet tho:
- Vat lieu: thep gio P6M5
- Goc trc:
0
=3
0
- Goc sau: =6
0
-8
0
- Goc nghieng li cat phu: =0
0
- Goc nghieng =45-60
0
- Goc nghieng cua ranh xoan vt: =20
0
- Kch thc ket cau: D=50.3 L=176 d=30
* Mui khoet tinh:
- Vat lieu: thep gio P6M5
- Goc trc:
0
=3
0
- Goc sau: =6
0
-8
0
- Goc nghieng li cat phu: =0
0
- Goc nghieng =45-60
0
- Goc nghieng cua ranh xoan vt: =20
0
- Kch thc ket cau: D=50,68 L=176 d=30
* Mui doa tinh:
- Vat lieu: thep gio P6M5
- Goc trc:
0
=0
0
- Goc sau: =6
0
- Goc nghieng =45-60
0
- Goc nghieng cua ranh xoan vt =20
0
- Kch thc ket cau: D=51 L=80
- Tr so mon cho phep tren mat sau cua mui doa thep
gio la
h
1
=0,5-0,6 mm
5.2.7 Dung cu kiem tra : thc cap
5.2.8 Dung dch trn nguoi: dung dch Emunxi
5.3 Nguyen cong 3: Phay mat 6&8
5.3.1 S o ga at:
5.3.2 Phng an gia cong:
Phay tho mat 6&8 at cap chnh xac 12 ,Rz=25
m
Phay ban tinh mat 6&8 at cap chnh xac 11
,Rz=12,5 m
Phay tinh mat 6&8 at cap chnh xac IT9 , Ra=2,5
m
5.3.3 nh v:
- e tao c mat au 6,8 th can khong che
cac bac t do sau:
Can: T(Oz) , Q(Ox) , Q(Oy)
Phu: T(Ox) , T(Oy) , Q(Oz)
- Dung phien ty nh v mat au 1 se khong
che c 3 bac t do:
T(Oz) , Q(Ox) , Q(Oy)
- Dung chot tru ngan nh v mat tru trong 4 (51)
khong che 2 bac t do: T(Ox) , T(Oy)
- Dung chot ty khong che 1 bac t do: Q(Oz)
5.3.4 Phng an kep chat:
Kep chat bang bulong ep be mat 1 cua chi tiet
vao be mat phien ty
5.3.5 Chon may:
- Chon may phay ngang cong xon 6H12 [che o
cat GC CK,tr 221]
Thong so may giong nguyen cong 1
5.3.6 Chon dung cu cat:
-Dao phay a ba mat rang gan manh hp kim cng
BK8
+ ng knh dao phay: D=200 mm
+ ng knh lo cua dao phay: d=60 mm
+ Be rong dao phay: B=16 mm
+ So rang: 14 rang
5.3.7 Dung cu kiem tra: thc cap
5.3.8 Dung dch trn nguoi: Emunxi , chu yeu lam
mat
5.4 Nguyen cong 4: Khoan khoet doa lo
15
+0,027
5.4.1 S o ga at:
5.4.2 Phng an gia cong:
Khoan lo at cap chnh xac IT14 ,Rz=50 m
Khoet tho at cap chnh xac IT12 ,Rz=50 m
Khoet tinh at cap chnh xac IT10 ,Rz=12,5 m
Doa tinh at cap chnh xac IT8 , Ra=2,5 m
5.4.3 nh v:
chot ty
- e tao c mat lo 5 th can khong che cac
bac t do sau:
Can: T(Ox) , T(Oy) , Q(Ox) , Q(Oy) , Q(Oz)
Phu: T(Oz)
- Dung phien ty nh v mat au 1 se khong
che c 3 bac t do:
T(Oz) , Q(Ox) , Q(Oy)
- Dung chot tru ngan nh v mat tru trong 4 (51)
khong che 2 bac t do: T(Ox) , T(Oy)
- Dung chot ty khong che 1 bac t do: Q(Oz)
5.4.4 Phng an kep chat:
Dung bulong kep chat, tao lc ep be mat 1 cua chi
tiet vao be mat phien ty
5.4.5 Chon may:
- Chon may khoan ng 2A125 [che o cat GC
CK,tr 220]
- ng knh gia cong ln nhat (mm): 25 mm
- Con moc ttruc chnh: N
0
3
- Cong suat ong c:2,8 Kw
- Hieu suat may: =0,8
- So vong quay truc chnh: 97-1360 vg/ph
- Bc tien mot vong quay truc chnh: 0,1-0,81
(mm/vg)
- Lc hng truc cho phep cua c cau tien dao:
P
max
=900 Kg
5.4.6 Chon dung cu cat:
Chon dung cu cat giong nguyen cong 2
5.4.7 Dung cu kiem tra: thc cap
5.4.8 Dung dch trn nguoi: Emunxi , chu yeu lam
mat
5.5 Nguyen cong 5: Khoan lo (15
+0,43
)
5.5.1 S o ga at:
5.5.2 Phng an gia cong:
Khoan lo at cap chnh xac IT14 ,Rz=50 m
5.5.3 nh v:
- e tao c mat lo 11 (15
+0,43
) (lo bat bulong)
th can khong che cac bac t do sau:
Can: T(Oz) , T(Ox) , Q(Ox) , Q(Oy) , Q(Oz)
Phu: T(Oy)
- Dung phien ty nh v mat au 1 se khong
che c 3 bac t do:
T(Oz) , Q(Ox) , Q(Oy)
- Dung chot tru ngan nh v mat tru trong 4 (51)
khong che 2 bac t do: T(Ox) , T(Oy)
- Dung chot tramnh v mat lo 5(15) se
khong che 1 bac t do: Q(Oz)
5.5.4 Phng an kep chat:
Dung bulong kep chat, tao lc ep be mat 1 cua chi
tiet vao be mat phien ty
5.5.5 Chon may:
- Chon may khoan ng 2A125 [che o cat GC
CK,tr 220]
- ng knh gia cong ln nhat (mm): 25 mm
- Con moc ttruc chnh: N
0
3
- Cong suat ong c:2,8 Kw
- Hieu suat may: =0,8
- So vong quay truc chnh: 97-1360 vg/ph
- Bc tien mot vong quay truc chnh: 0,1-0,81
(mm/vg)
- Lc hng truc cho phep cua c cau tien dao:
P
max
=900 Kg
5.5.6 Chon dung cu cat: Bang 4.40 [3,tr287], bang
4.41 [3,tr292]
Mui khoan gan manh hp kim cng,ruot ga
uoi tru,loai ngan
- ng knh mui khoan: d=15 mm
- Chieu dai ca mui khoan: L=111 mm
- Chieu dai phan lam viec: l=56 mm
5.5.7 Dung cu kiem tra: thc cap
5.5.8 Dung dch trn nguoi: khong can
5.6 Nguyen cong 6: Phay ranh 14
5.6.1 S o ga at:
5.6.2 Phng an gia cong:
Phay tho ranh at cap chnh xac IT , Rz=
m
5.6.3 nh v:
- e tao c mat 14 (ranh) th can khong che
cac bac t do sau:
Can: T(Oy) , Q(Oy) , Q(Ox)
Phu: T(Ox) , T(Oz) , Q(Oy)
- Dung phien ty nh v mat au 1 se khong
che c 3 bac t do:
T(Oz) , Q(Ox) , Q(Oy)
- Dung chot tru ngan nh v mat tru trong 4 (51)
khong che 2 bac t do: T(Ox) , T(Oy)
- Dung chot tram nh v be mat lo 15 khong
che 1 bac t do: Q(Oz)
5.6.4 Phng an kep chat:
Dung bulong kep chat, tao lc ep be mat 1 cua chi
tiet vao be mat phien ty
5.6.5 Chon may:
May phay ngang 6H12 , giong nguyen cong 1
5.6.6 Chon dung cu cat:
Dao phay cat ranh bang thep gio: Bang 4.68
[3,tr336]
D=160 mm
B=3
D=32
So rang la 64
5.6.7 Dung cu kiem tra: thc cap
5.6.8 Dung dch trn nguoi: khong can
6. XAC NH LNG D GIA CONG VA KCH
THC TRUNG GIAN
6.1 Xac nh lng d va
kch thc trung gian bang phng phap phan tch
_ Phng phap nay tnh cho 1 mat, cac mat khac tra
bang.
_ Chon mat tru trong 51
+0,046
,cap chnh xac : 8
+ Vat lieu: GX 32 52
+ Chieu dai danh ngha cua lo : 80 mm
+ Kch thc ln nhat cua chi tiet : 150 mm
_ Trnh t cac bc gia cong:
0_ Phoi uc : + Cap chnh xac phoi : II
+ Rz
0
= 80 m , IT 16
PhuLuc 11a [1, tr 147] : Rz
0
+ T
0
= 700 m
1_ Khoet tho : + IT 12
+ Rz
1
= 50
2_ Khoet tinh : + IT 10
+ Rz
2
= 12,5
3_ Doa tinh : + IT 8
+ Rz
3
= 10 ( Ra = 2,5 m)
V vat lieu la gang xam nen chieu sau lp bien
cng sau bc gia cong au tien la khong co
T
1
=T
2
=T
3
=0
Sai lech khong gian cua lo uc :

2 2
0 x v
+
Vi : P
v
: o cong venh cua phoi
P
x
: o xien lech cua lo uc
Phu luc 11a. [1, tr 147] : . P
v
=
k
.L
= 2. 150 = 300 m
. Px =
x
.l
= 3. 80 = 240 m
Vi : L : chieu dai ln nhat cua chi tiet
l : chieu dai lo

2 2
0
240 300 +
=384 m
Sai so ga at :

2 2 2
dg k c gd
+ +
Vi
c
: Sai so chuan

k
: Sai so kep chat

dg
: Sai so o ga
nh v lo bang khoi V =>
c
=0
Sai so kep chat theo phng hng truc:
Bang 22 [2,tr44]:
k
=90 m
Bo qua sai so o ga :
dg
=0 m
Vay
gd
=90 m
Sai lech khong gian sau khi khoet tho:

1
=0,05
0
= 0,05.384= 19 m
Sai lech khong gian sau khi khoet tinh khong con

2
=
3
=0
Lung d gia cong:
2Z
mini
=
( )
i i i
T Rz + + +
1 - i 1 1
2
Lng d cho bc khoet tho
2Z
min1
=
( )
2
1
2
0 0 0
2 + + +T Rz
= ( )
2 2
90 384 700 2 + + = 2189 m
Lng d cho bc khoet tinh:
2Z
min2
=
( )
2
2
2
1 1 1
2 + + +T Rz
= ( )
2 2
90 19 0 50 2 + + + = 284 m
Lng d cho bc doa tinh:
2Z
min3
=
( )
2
3
2
2 2 2
2 + + +T Rz
= ( )
2 2
90 0 0 5 , 12 2 + + + = 205 m
-Kch thc trung gian:
Kch thc ln nhat cua chi tiet:
D
max3
=51+0,046=51,046 mm
Kch thc trung gian ln nhat cua phoi trc khi doa
tinh:
D
max2
=D
max3
-2Z
min3
=51,046-0,205=50,841 mm
Kch thc trung gian ln nhat cua phoi trc khi
khoet tinh:
D
max1
=D
max2
-2Z
min2
=50,841-0,284=50,557 mm
Kch thc trung gian ln nhat cua phoi trc khi
khoet tho :
D
max0
= D
max1
-2Z
min1
= 50,557 2,189 = 48,368 mm
_ Dung sai kch thc trung gian :
+ Dung sai phoi :
0
= 1,9 mm ( IT 16) ( Bang 3.11
[3,182] )
+ Dung sai kch thc sau bc khoet tho :
1
=
0,3 mm ( H12)
+ Dung sai kch thc sau bc khoet tinh :
2
=
0,12 mm ( H10)
+ Dung sai kch thc sau bc doa tinh :
3
=
0,046 mm ( H8)
_ Quy tron cac kch thc tnh toan tren va tnh kch
thc nho nhat:
D
max0
= 48,4 mm D
min0
= D
max0

0
= 48,4 1,9 =
46,5 mm
D
max1
= 50,6 mm D
min1
= D
max1

1
= 50,6 0,3 =
50,3 mm
D
max2
= 50,8 mm D
min2
= D
max2

2
= 50,8 0,12 =
50,68 mm
D
max3
= 51,046 mm D
min3
= D
max3

3
= 51,046
0,046 = 51 mm
_ Lng d trung gian be nhat va ln nhat cua cac
bc :
+ Bc khoet tho :
2Z
min1
= D
max1
D
max0
= 50,6 48,4 = 2,2 mm
2Z
max1
= D
min1
D
min0
= 50,3 46,5 = 3,8 mm
+ Bc khoet tinh :
2Z
min2
= D
max2
D
max1
= 50,8 50,6 = 0,2 mm
2Z
max2
= D
min2
D
min1
= 50,68 50,3 = 0,38 mm
+ Bc doa tinh :
2Z
min3
= D
max3
D
max2
= 51,046 50,8 = 0,246
mm
2Z
max3
= D
min3
D
min2
= 51 50,68 = 0,32
mm
_ Lng d tong cong be va ln nhat :
2Z
0min
=

3
1
min
2
i
i
Z
=2,2 + 0,2 + 0,246 = 2,646
mm
2Z
0max
=

3
1
max
2
i
i
Z
= 3,8 + 0,38 + 0,32 = 4,5
mm
_ Th ket qua :
2Z
0max
-2Z
0min
= 4,5 2,646 = 1,854 mm

ph

ct
= 1,9 0,046 = 1,854 mm
_ Lng d tong cong danh ngha :
2Z
0
=2Z
0min
+ ES
ph
ES
ct
= 2,646 + 0,95 0,046 = 3,55 mm 3,6
Kch thc danh ngha cua phoi :
D
0
= D
ct
2Z
0
= 51 3,6 = 47,4 mm
Kch thc ghi tren ban ve phoi :
D
ph
= 47,4
* Bang tong ket:
Trnh t
gia cong
lo
51
+0,046
Cac yeu to
tao thanh
lng d
Ln
g d
tnh
toa
n
2Z
mini
(m)
Kch
tc
tnh
toa
n
(mm)
Dun
g
sai
i
(m
m)
Kch thc
gii han
(mm)
Lng d
gii han
(mm)
Rz
i
T
i

i

i
D
mini
D
maxi
2Z
mi
ni
2Z
ma
xi
0. Phoi
uc
700 38
4
48,3
68
1,9 46,5 48,4
1. Khoet
tho
50 0 19 9
0
2189 50,5
57
0,3 50,3 50,6 2,2 3,8
2. Khoet
tinh
12,
5
0 0 9
0
284 50,8
41
0,12 50,6
8
50,8 0,2 0,3
3. Doa
tinh
10 0 0 9
0
205 51,0
46
0,04 51 51,0
46
0,24
6
0,32
Tong
cong
2,64
6
4,5
6.2Xac nh lng d gia cong va kch thc
trung gian bang phng phap tra bang.
_ Chon 2 mat 6&8 e xac nh lng d va kch
thc trung gian bang phng phap tra bang
_ Phoi uc cap chnh xac
2
16 IT
t

lng d tong cong 2 pha la 2 3,5 = 7 mm
_ Kch thc phoi :
D
0
= 44 + 7 = 51 mm
_ Kch thc ln nhat cua phoi :
D
max0
= 51 + 0,95 = 51,95 mm
- Qua trnh cong nghe gom cac bc :
Phay tho: at IT12

,dung sai cho kch thc 51 la

1
=0,25 mm
Phay ban tinh: at IT10 ,dung sai bang
2
=0,1 mm
Phay tinh: at IT9 , dung sai cho kch thc 44 la

3
=0,062 mm
Tra bang 3.42 [4,tr282], ta co lng d trung gian cho
bc phay tinh la
2Z
3
=2x1=2 mm
Lng d tong cong danh ngha:
2Z
max0
=7+ES
0
=7+0,95=7,95 mm
Lng d con lai cho bc phay tho va phay ban
tinh:
2Z
max0
-2Z
3
=7,95-2=5,95 mm
Ta chia lng d nay thanh 2 phan:
Phay ban tinh: 2Z
2
=2,4 mm
Phay tho: 2Z
1
=3,55 mm
ng knh phoi sau bc phay tho:
D
max1
=D
max0
-2Z
1
=51,95-3,55=48,4
Tren bang ve ghi la 84,4
-0,25
ng knh phoi sau bc phay ban tinh:
D
max2
=D
max1
-2Z
2
=48,4-2,4=46
Tren bang ve ghi la 46
-0,1
ng knh chi tiet sau bc phay tinh:
D
max3
=D
max2
-2Z
3
=46-2=44
Tren bang ve ghi la :44
t
0,031
* Bang ket qua tnh lng d va kch thc trung gian
bang phng phap tra bang:
Xac nh lng d va kch thc trung gian cho cac be
mat con lai,tng t nh tren ta co bang ket qua sau:
a. Mat 6&8 : hai mat au cua lo 15
+0,027
,cap
chnh xac t
2
16 IT
chi tiet a=44
t
0,031

Cac
bc
gia
cong
Cap
chnh
xac
Dung sai

I
(mm)
Long d
tra bang
2Z
i
(mm)
Kch thc
trung gian
tren bang
ve
0. Phoi
t
IT16/2
t 0,95 2 3,5 51t 0,95
1. Phay
tho
IT12 -0,25 3,55 48,4
-0,25
2. Phay
ban
tinh
IT10 -0,1 2,4 46
-0,1
3. Phay
tinh
IT9
t 0,031
2
44t 0,031
b. Mat 5 (lo 15
+0,027
): phoi cap chnh xac t
2
16 IT
Cac bc
gia cong
Cap
chnh
xac
Dung sai

I
(mm)
Lng d
tra bang
2Z
i
,mm
Kch
thc
trung gian
tren
bang ve
0. phoi
t IT16/2
1. Khoan IT 14 0,43 13,6
13t 0,43
2. Khoet
tho
IT 12 0,18 0,6
14,45t 0,
18
3. Khoet
tinh
IT 10 0,07 0,2
14,76t 0,
07
4. Doa
tinh
IT 8 0,027 0,197
15t 0,027
Khi gia cong mat lo 11 ( 15
+0,43
) , ranh 14 ta khong
can xac nh lng d
7. XAC NH CHE O CAT & THI GIAN GIA
CONG C BAN
7.1 Phng phap phan tch:
Phng phap nay ap dung cho mat tru trong 51
+0,046
+ Kch thc ghi tren bang ve phoi: 47,4
t
0,95
+ May khoan can 2A55
+ Vat lieu gia cong: GX32-52 vi HB=190
+ Vat lieu cua dung cu cat ( mui khoet tho,
mui khoet tinh, mui doa tinh) : thep gio P6M5
7.1.1 Che o cat khi khoet tho
1. Chieu sau cat: t=0,5(D-d) [4,tr20]
D ng knh mui khoet tho, D=50,3 mm
d ng knh lo trc khi khoet tho, d=47,4
mm
t=0,5(50,3-47,4)=1,45 mm
2. Lng chay dao
S=C
s
.D
0,6
Vi C
s
: he so phu thuoc vao tnh cha vat
lieu va yeu to cong nghe khi tnh lng chay dao
Bang 1-3 [12,tr83]: C
s
=0,15
=>S=0,15 x 50,3
0,6
=1,57 mm/vg
Theo ly lch may , chon S=1,54 mm/vg
3. Toc o cat:
V=
v
y x m
q
v
k
S t T
D C
.
. .
.
Vi + C
v
: he so anh hng cua ieu kien
cat oi vi toc o cat