Mc lc Mc lc 1 5 7 8

Ni dung ti tt nghip.

Nhn xt ca gio vin hng dn: Nhn xt ca gio vin duyt n: M u. 9

Chng I. Tng quan v vt liu cht do Polymer. I.1. Gii thiu v vt liu cht do Polymer. I.1.1. Phn loi cht do. 11 12 11

11

I.1.2. C s ho hc ca cht do.

I.2. iu kin k thut cn c i vi mt sn phm nha. I.3. c im cng ngh ca nha Polypropylen (PP). I.3.1. Tnh cht ca PP. 17 I.3.2. ng dng ca PP. 18 Chng II. Tng quan v cng ngh lm khun. 20 II.1. Nguyn l hot ng ca khun p nha. II.2. Gii thiu chung v khun. 21 II.2.1. Cc thut ng k thut c bn. II.2.2. Cc loi khun ph bin. 23 II.3. Trnh t thit k, c im cng ngh ch to khun. II.3.1. Trnh t thit k khun. 25 II.3.2. c im ca cng ngh sn xut khun. 26 II.4. Tnh ton v la chn loi my p nha. 26 22 20 17

14

25

II.5. Thit k s b kt cu ca khun p nha. 28 II.5.1. Chn mt phn khun. 29 29

II.5.2. Xc nh hnh dng ca lng khun.

II.5.3. Hnh dng v kt cu ca h thng dn nha. II.5.4. Thit k h thng lm mt lng khun: II.5.5. Thit k h thng y. II.5.6. Chn kt cu khun. 33 35 33

30

Chng III. Tng quan v gia cng tia la in. 43 III.1. Gii thiu chung v phng php gia cng tia la in. III.1.1. Bn cht ca phng php gia cng tia la in. 44 III.1.2. Qu trnh phng in trong khi gia cng tia la in: III.1.3. Cc phng php gia cng bng tia la in. III.2. Kh nng cng ngh ca gia cng tia la in. 47 49 45 43

III.3. Cc thng s iu chnh qu trnh xung nh hnh. 50 III.3.1. Dng phng tia la in Ie. III.3.2. ko di xung t1. III.3.3. Khong cch xung to. III.3.4. in p nh la UZ. III.3.5. Khe h phng in. 52 53 54 54 56 50

III.3.6. Cc hin tng xu khi gia cng tia la in. III.4. Cht lng b mt gia cng. 58

III.4.1. Cc yu t c trng cho cht lng b mt gia cng. III.4.2. Cc yu t nh hng ti cht lng gia cng. III.5. Vt liu s dng lm in cc. 61 61 59

58

III.5.1. Yu cu ca vt liu s dng lm in cc.

III.5.2. Cc loi vt liu thng c s dng lm in cc. III.5.3. Kch thc ca in cc. 65 III.6. Cht in mi trong gia cng tia la in. 65 III.6.1. Cc loi cht in mi. 67

61

III.6.2. Tiu chun nh gi cht lng ca cht in mi. III.6.3. Cc yu t an ton ca cht in mi. III.6.4. Cch thc vn chuyn cht in mi. III.6.5. Vi tr ca cht in mi. 70 68 69

67

III.7. Xu hng pht trin trong lnh vc gia cng tia la in tng lai.

71

Chng IV. Thit k v lp quy trnh cng ngh gia cng bin dng lng khun. 72 IV.1. iu kin k thut ca khun. 76

IV.2. La chn vt liu thch hp ch to cc chi tit. 77 IV.3. Lp phng n thit k v ch to lng khun. 78 81 81

IV.4. Lp Qui trnh cng ngh gia cng ch to lng khun.

IV.4.1. Thit k qui trnh cng ngh gia cng tm o khun trc. IV.4.1.1. Trnh t cng ngh gia cng tm o khun trn.81 IV.4.1.2. Thit k cc nguyn cng. 83

IV.4.1.2.1. Nguyn cng 1: Chun b phi cho qu trnh gia cng.

83 84 84 85

IV.4.1.2.2. Nguyn cng 2: Khoan 4 l f10,5 su 90 mm trn b mt bn B. IV.4.1.2.3. Nguyn cng 3: Khoan 4 l f10,5 su 90 mm trn b mt bn D. . IV.4.1.2.4. Nguyn cng 4: Gia cng bin dng trn mt phng A ca phi. IV.4.1.2.5. Nguyn cng 5: Gia cng cc bin dng c trn mt phng C. 86 IV.4.1.2.6. Nguyn cng 6: Gia cng mt phn ca h thng knh dn nha. IV.4.1.2.7. Nguyn cng 7: Mi mt phng y C ca tm o khun trn. 91 IV.4.1.2.8. Nguyn cng 8: Mi mt phng phn khun trn li khun. IV.4.1.2.9. Nguyn cng 9: Gia cng ngui ton b cm khun trn IV.4.2. Qui trnh cng ngh gia cng li khun trc. 93 91 92

88

IV.4.2.1. Lp tin trnh cng ngh gia cng tm li khun trc. 93 IV.4.2.2. Thit k cc nguyn cng. 94 94

IV.4.2.2.1. Nguyn cng 1: Chun b phi cho qu trnh gia cng c.

IV.4.2.2.2. Nguyn cng 2: Phay chiu rng phi t kch thc140h7. 95 IV.4.2.2.3. Nguyn cng 3: Phay chiu di phi t kch thc 240 h7 95 96 97

IV.4.2.2.4. Nguyn cng 4: Khoan 2 l f10,5 su 105 mm trn b mt bn B. IV.4.2.2.5. Nguyn cng 5: Khoan 2 l f10,5 su 120 mm trn b mt bn D. IV.4.2.2.6. Nguyn cng 6: Gia cng h thng cc l c trn b mt C. 98

IV.4.2.2.7. Nguyn cng 7: Gia cng ngui phi ghp vo o khun. 99 IV.4.2.2.8. Nguyn cng 8: Gia cng bin dng li khun. 99 103

IV.4.2.2.9. Nguyn cng 9: Gia cng xung cc rnh ca lng khun.

IV.4.2.2.10. Nguyn cng 10: Gia cng mt phn ca h thng dn nha. 106 IV.4.2.2.11. Nguyn cng 11: Gia cng xung thng l dn nha. 107 IV.4.2.2.12. Nguyn cng 12: Mi mt phng phn khun trn li khun. 110 IV.4.2.2.13. Nguyn cng 13: Gia cng ngui ton b cm khun trn IV.4.3. Thit k qui trnh cng ngh gia cng tm o khun sau. 110 IV.4.3.1. Lp tin trnh cng ngh gia cng tm khun sau. IV.4.3.2. Thit k cc nguyn cng. 113 113 113 114 114 110 110

IV.4.3.2.1. Nguyn cng 1: Chun b phi cho qu trnh gia cng c.

IV.4.3.2.2. Nguyn cng 2: Khoan 4 l f10,5 su 105 mm trn b mt bn B. IV.4.3.2.3. Nguyn cng 3: Khoan 4 l f10,5 su 105 mm trn b mt bn B. IV.4.3.2.4. Nguyn cng 4: Gia cng bin dng trn mt phng A ca phi. IV.4.3.2.5. Nguyn cng 5: Gia cng cc bin dng trn mt C. 115 IV.4.3.2.6. Nguyn cng 6: Gia cng h thng l lp cht y. 117 117 118

IV.4.3.2.7. Nguyn cng 7: Mi mt phng C ca tm khun trn. IV.4.3.2.8. Nguyn cng 8: Gia cng ngui ton b tm khun trn. IV.4.4. Qui trnh cng ngh gia cng lng khun sau. IV.4.4.1. Trnh t cng ngh gia cng lng khun sau. IV.4.4.2. Thit k cc nguyn cng. 120 119 119

IV.4.4.2.1. Nguyn cng 1: Chun b phi cho qu trnh gia cng.

120

IV.4.4.2.2. Nguyn cng 2: Phay chiu rng phi t kch thc 140h7. 121 IV.4.4.2.3. Nguyn cng 3: Gia cng chiu di phi t kch thc 240h7. IV.4.4.2.4. Nguyn cng 4: Khoan 4 l f10,5 su 80 mm trn b mt bn B. IV.4.4.2.5. Nguyn cng 5: Khoan 4 l f10,5 su 65 mm trn b mt bn D. IV.4.4.2.6. Nguyn cng 6: Gia cng h thng cc l trn b mt C. 124 124 121 122 123

IV.4.4.2.7. Nguyn cng 7: Gia cng ngui tm phi ghp vo v khun. IV.4.4.2.8. Nguyn cng 8: Gia cng bin dng lng khun sau. 125 IV.4.4.2.9. Nguyn cng 9: Gia cng h thng l lp cht y sn phm. 126 IV.4.4.2.10. Nguyn cng 10: Gia cng ngui ton b cm khun sau. IV.5. Tnh ton qu trnh ct gt khi gia cng vt liu. IV.5.1. Ch ct khi khoan l c ng knh d(mm). IV.5.2. Ch ct khi phay rnh. 130 126 127 126

IV.5.3. Ch ct khi phay mt phng. 132 IV.5.3.1. Ch ct khi phay mt phng s dng dao phay ngn. 132 IV.5.3.2. Ch ct khi phay mt phng bng dao phay mt u. 135 IV.5.4. Ch ct khi doa l sau khi khoan. 137 139

IV.6. Thit k g cho tng ng vi mi nguyn cng. IV.6.1. Chn c cu t c nh phi. 141 IV.6.1.1. Xc nh khong khng gian ti a ca g. 141 IV.6.1.2. Xc nh phng php nh v: 142

IV.6.1.3. Xc nh phng chiu v im t lc ca lc kp cht. IV.6.1.4. Tnh ton lc kp W cn thit. 143 IV.6.1.5. Tnh sai s ch to cho php ca g ?CT. IV.6.2. g l thanh k v Bulong-ai c. 146 145

142

IV.6.2.1. Xc nh khong khng gian ti a ca g. 146

IV.6.2.2. Xc nh phng php nh v: 147 IV.6.2.3. Xc nh phng chiu v im t ca lc kp cht. IV.6.2.4. Tnh ton lc kp W cn thit. 147 IV.6.2.5. Tnh sai s ch to cho php ca g ?CT. 150 151 147

IV.7. Cc lu trong qu trnh tnh ton ,thit k, ch to hai cm lng khun. IV.8. Chng trnh s dng iu khin my gia cng. 152 IV.8.1. Chng trnh cho nguyn cng 1. IV.8.2. Chng trnh cho nguyn cng 2. IV.8.3. Chng trnh cho nguyn cng 3. 153 154 154 154

IV.8.3.1. Chng trnh phay hc ch nht (240x140x40mm). IV.8.3.2. Chng trnh phay 4 hc lp nm cn. 156 IV.8.3.3. Chng trnh khoan 8 l ?20 su 43,5 mm. IV.8.3.4. Chng trnh khoan 8 l ?10,5 su 55 mm. IV.8.4. Chng trnh cho nguyn cng 4. 159 159 157 158

IV.8.4.1. Chng trnh khoan 4 l ?11,5 su 45mm

IV.8.4.2. Chng trnh gia cng h thng l x Bulong M8. IV.8.4.3. Chng trnh gia cng h thng l x Bulong M8. IV.8.5. Chng trnh cho nguyn cng 5. 163 163

160 161

IV.8.5.1. Chng trnh khoan 18 l ?7,8 su 45 mm IV.8.5.2. Chng trnh doa 18 l ?8 su 45 mm 165 Chng V. Lp t, Bo dng v bo qun khun Ti liu tham kho: 170

167

Ni dung ti tt nghip. : - Thit k khun p nha: Sn phm khay nha lm - Thit k v lp quy trnh cng ngh gia cng hai lng khun - Tm hiu cng ngh gia cng xung nh hnh.

Cc nhim v cn gii quyt. A. Thuyt minh v tnh ton.

M u. Chng 1. Tng quan v cht do POlymer. 1.1. 1.2. 1.3. Gii thiu chung v cht do Polymer. Phn tch cc iu kin k thut ca sn phm. c im ca cht do Polypropylen (PP).

Chng 2. Tng quan v cng ngh lm khun. 2.1. 2.2 2.2. 2.3. 2.4 Nguyn l hot ng ca khun p nha. Gii thiu chung v khun. Trnh t thit k, c im ca cng ngh ch to khun. Tnh ton v la chn loi my p nha ph hp vi sn phm. Thit k s b v kt cu ca khun p nha.

Chng 3. Tng quan v gia cng tia la in. 3.1. 3.2. 3.4. 3.5. 3.6. 3.7. 3.8. Gii thiu chung v phng php gia cng tia la in. Kh nng cng ngh ca phng php gia cng tia la in. Cc thng s iu khin qu trnh xung nh hnh. Cht lng b mt gia cng. Vt liu s dng lm in cc. Cht in mi trong gia cng tia la in. Xu hng pht trin trong tng lai ca gia cng bng tia la in.

Chng 4. thit k v lp qui trnh cng ngh gia cng bin dng lng khun. 4.1. Xc nh iu kin k thut chung cn thit cho khun.

4.2. 4.3. 4.4. 4.4.1 4.4.2 4.4.3 4.4.4 4.5. 4.6. 4.7.

La chn vt liu thch hp cho cc chi tit c trong khun. Lp phng n thit k v ch to lng khun. Lp qui trnh cng ngh gia cng ch to bin dng lng khun. Thit k qui trnh cng ngh gia cng tm o khun trc. Thit k qui trnh cng ngh gia cng tm li khun trc. Thit k qui trnh cng ngh gia cng tm o khun sau. Thit k qui trnh cng ngh gia cng tm lng khun trc. Tnh ton qu trnh ct ct lng kim loi d. Thit k g kp cht cho mi nguyn cng. Thit k lp chng trnh iu khin my thc hin gia cng.

Chng 5. lp t, bo dng v bo qun khun.

B. Cc bn v cn c. Bn v sn phm nha cn ch to vi y cc yu cu k thut. Bn v lp khun p nha c hai v tr ng v m. Bn v tch cc chi tit c trong khun vi y cc yu cu k thut (cc chi tit chnh). Bn v quy lng phi ca hai long khun cn ch to. Bn v quy trnh cng ngh gia cng hai lng khun. Bn v gii thiu v cng ngh gia cng xung nh hnh.

Ngy giao nhim v: Ngy hon thnh:

08/02/2004. 05/05/2004.

Sinh vin thc hin.

Gio vin hng dn.

Chu Quc Hiu.

Th.S_Nguyn Hip Cng.

Nhn xt ca gio vin hng dn: Gio vin hng dn

Th.S_Nguyn Hip Cng. Nhn xt ca gio vin duyt n:

 Gio vin duyt n.

PGS.TS_Trn Vn ch. M u. Trc y, cc sn phm c sn xut nh cng ngh c p lc, p phun, p n, t dp ni chung v cc sn phm nha ni ring t pht trin. Do kiu dng mu m n iu, t xut hin trn th trng. Bi v lc lnh vc gia cng ch to khun cha c iu kin pht trin do gp phi kh khn v trnh khoa hc cng ngh ca i ng k thut. Ngy nay, con ngi khng ngng nghin cu khoa hc nn t c cc thnh t nht nh trong cc lnh vc: Vt liu, iu khin in t, c kh t ng ho Cho nn ch to thnh cng c nhiu loi vt liu mi c kh nng to hnh nhanh nh phng php nh hnh (nh vt liu polymer, composit

) mang cc u im vt tri v mt vt l,ho hc v kinh t nn c s dng rt nhiu phc v nhu cu sinh hot ca con ngi. ng thi nn c kh ch to thnh cng c nhiu chng loi my kh nng gia cng ch to linh hot hn nh: My phay CNC, my tin CNC, my gia cng tia la in EDM Cc loi my ny c cc u im ni tri hn hn so vi cc loi my gia cng truyn thng nh: Phay, tin, bo cc im sau: - Chuyn ng to hnh ca dng cu ct phong ph hn. - chnh xc gia cng v nh v ca dng c tt hn (c phn nghn). - cng ca vt liu cn gia cng ch to hu nh khng hn ch. - Vic thit lp chng trnh my gia cng c cc b mt nh hnh mt cch t ng din ra nhanh trng v thun li hn nh s h tr ca my tnh in t. . Cho nn lnh vc khun mu c iu kin pht trin nhanh v mnh, p ng kp thi nhu cu s dng ca con ngi trn th trng. Do con ngi ngy nay cng ngy cng quan tm ti hnh thc v mu m ca sn phm h s dng. ng trc tnh hnh cc n v sn xut kinh doanh mun sn phm ca h lm ra c th cnh tranh tt trn trn th trng th ngoi vic nng cao cht lng v gim gi thnh cho sn phm th vic to mu hay thay i mu m cng l cng vic rt cn thit. Do vic nghin cu v tm hiu v cng ngh ch to khun mu mu l mt nhu cu cp bch i vi ngi k s cng ngh ch to my sp ra trng nh em, to iu kin thun li vic xin vic lm. Hn na y l cng vic sng to khng lp li, i hi ngi thit k phi c kin thc c bn v trc chn v cng ngh ch to gia cng ra sn phm c kh. Vy vn thit k v ch to khun mu l mt ti hay rt ph hp vi ni dng n ttt nghip cho mt sinh vin nm cui chuyn ngnh cng ngh ch to my nh em. Sau mt thi gian tm hiu v vi s ch bo, gip rt nhit tnh ca gio vin hng dn Th.S_Nguyn Hip Cng v thy duyt n PGS.TS_Trn Vn ch cng cc thy c gio trong b mn cng ngh ch to trng i hc Bch Khoa H Ni v cc k s trong trung tm khun mu v my CNC thuc vin My v Dng c Cng Nghip, n nay em hon thnh xong ton b ni dung ca n tt nghip c giao. Tuy nhin do kinh nghim thc t trong sn xut cn hn ch, nn trong qu trnh tnh ton v thit k vn cha lng ht c cc yu t s ny sinh trong sn xut thc t, cho nn s gp phi nhng sai st nht nh. Em rt mong c s ch bo ca cc thy c gio trong b mn cng ngh ch to my v s ng gp kin ca cc bn em c hiu r vn ny hn.

Sinh vin thc hin

Chu Quc Hiu.

Chng I. Tng quan v vt liu cht do Polymer. I.1. Gii thiu v vt liu cht do Polymer. Cht do c th c nh ngha nh sau: Vt liu do l loi vt liu c th nung nng cho mm ra nhiu ln sau khi ngui. N c th c phun vo khun, c nghin vn li v lp li qu trnh mt s ln. Tt nhin l vt liu do s b mt phm cht ( bn, c tnh) khi qu trnh lp i lp li nhiu ln. Vy cht do l loi vt liu bao gm: - Cht cao phn t: l cc hp cht hu c m tnh cht c l ca n ch thay i cht t trong khi i phn t ca n tip tc tng. - Cc cht n gia cng (Dng bt, dng si) nhm tng cng c tnh cho vt liu. - Cht ph gia tng cng ph hp cho mc ch s dng (Cht n nh, cht bi trn, cht ho do). - Cht to mu sc cho sn phm p ng nhu cu ngi s dng v mt cm quang. I.1.1. Phn loi cht do. Theo cu trc phn t.

- Vt liu v nh hnh: Vt liu do v nh hnh c th d dng nhn thy bi cc tnh cht cng trong sut ca n. Ngoi ra n c mu sc t nhin l mu trng nh nc hoc gn nh mu ct vng hoc mu m c. Loi vt liu ny c co rt rt nh ch bng 0,5 ? 0,8%. Mt vt liu thuc dng ny c tn thng mi l: Polycarbonate (PC), Styrene Acrylonitrile (SAN), Polystyrene (PS), Polymethylmethacrylate Chng c s dng rt thng dng cho cc mt cng nghip v gia dng i hi trong sut cao. - Vt liu tinh th: Loi vt liu nhit do ny thng cng v bn dai v c tnh nhng thng khng trong sut do cu trc tinh th gy cn tr cho s i qua ca nh sng. Cc vt liu ny thng c s dng trong cng nghip lm gia dng. Bao gm: Polypropylene (PP), Low density polyethylene (LDPE), High density polyethylene (HDPE) Cn i vi mt s lnh vc cng nghip th cc loi vt liu sau c s dng thng dng: Polyester (PBT ?PETP), Polyacetal (POM), Nylon Nhn thy rng s pht trin ca tinh th ca c hai loi vt liu nu trn u ng vai tr quan trng ti s thay i cc tnh cht ca chng. Polyme v nh hnh th tinh th ca chui thin v bt nh cn cc tinh th th li c cu trc trt t v i xng lm cho lc gia cc mt xch c kh nng pht trin lm cho tinh th ln ln chim ht khong trng. Mc hnh thnh tinh th ( trong sut) ca vt liu do ph thuc mt phn vo tc lm ngui trong qu trnh gia cng. Tc ngui thp s to ra trong sut cao hn. Do cc chui polymer chuyn ng c quy lut i hi qu trnh lm ngui din ra nhanh ngn cn chuyn ng ca chui v ngn cn s pht trin ca tinh th. Tnh cht ca cc vt liu c th b thay i bi s sa i trng lng phn t v s chia nhnh chui. S thay i nh th s

c hiu qu khng ch i vi cc tnh cht c hc m cn nh hng ti qu trnh in y khun ca vt liu. Theo cng ngh gia cng.

- Cht do nhit do: L loi vt liu di tc dng ca nhit hoc dung mi th n nng chy hoc ho tan. Khi lm ngui hoc lm bay hi dung mi th n tr li trng thi rn (Loi ny c kh nng ti sinh c). - Cht do nhit rn: L loi vt liu m nguyn liu ban u s nng chy v ho tan c khi c nhit hoc dung mi tc dng. Nhng khi gia cng thnh sn phm hoc bn sn phm th n chuyn sang trng thi rn, khng nng chy v ho tan na (Loi ny khng c kh nng ti sinh c). S d c hin tng v trong qu trnh gia cng di tc dng ca nhit v cc nhn t ho hc c trn trong nguyn liu ban u, chng gy ra phn ng ho hc vi nhau gi l phn ng khu mch. Nng lng cn ph v lin kt ho hc ny c khi ln hn nng lng cn thit ph hu vt liu. Theo cu trc phn t.

- Cu trc ca nhit do dng si: Si trn v si phn nhnh. - Cu trc ca nhit rn dng li: li phng v li khng gian. I.1.2. C s ho hc ca cht do. VD: Hnh thnh cht do Polypropylene (PP). Ban u cc n v c s hnh thnh nn ca cht do Polypropylene (PP) l propylen (CH2= CH - CH3) tn ti c lp. Di tc dng ca iu kin mi trng xung quanh (Nhit , p sut v cc cht ho hc khc) cc n tinh th lin kt li vi nhau to thnh mt a tinh th (Qu trnh ny gi l Polymer ho). Nu coi n tinh th l mt mt xch th a tinh th chnh l mt chui cc mt xch c ghp li vi nhau.

Hnh I 1: S hnh thnh mt mch polymer thng loi n gin. * Cc thng s cng ngh ca cht do. Phn t lng v trng hp:

y l hai i lng ph thuc v nh hng ti nhau. VD: PE c phn t lng trung bnh M = 56000 n v cn phn t kh Etylen = 28 n v. Nh vy mc trung hp s l nTH = 56000/28 = 2000. Nh vy cng mt loi Polyme (Cao phn t) th khi phn t lng tng th tt c cc tnh cht c l: bn ho hc, b kh hu, bn c hc u tng theo. Tuy nhin khi phn t lng tng ln th nht ca phn t khi nng chy cng tng theo s lm cho qu trnh gia cng kh khn hn.

T trng ? v h s ln cht ?.

- T trng ? (g/cm3) l i lng s dng xc ch xem vt liu do dng ht hay dng bt. i lng ny c s dng trong tnh ton cng ngh v thit k khc. - H s ln cht ? ca mt cht do c s dng tnh ton kch thc cn thit cho khoang np nhin liu. H s ln cht c xc nh bi t s gia th tch (hoc khi lng) ca vt liu trc gia cng vi th tch (hoc khi lng) ca vt liu sau khi thnh sn phm.

(I.1) Trong :

- V1 l th tch ca vt liu trc khi gia cng.

- V2 l th tch ca chnh vt liu sau khi gia cng. c trng chy ca cht do nhit do.

y l mt trong nhng c im cn phi bit ca vt liu do khi mun ch to sn phm t cht do. c trng ny ph thuc vo mc trng hp, hnh dng ca i phn t, tc v nhit ca dng vt liu khi nng chy. c biu th qu hai ch s: Ch s chy MFI (melt-flow-index), gi tr K. - Ch s chy MFI (melt-flow-index): Vi nhit to xc nh, p sut xc nh trong khong thi gian 10 pht. Ngi ta tin hnh p cht do nng chy qua mt khe hp hnh tr vi kch thc chun v tin hnh o khi lng vt liu chy qua . S ch MFI s dng so snh cc nhm vt liu c s cng loi v dng nh hng khi xc nh cc thng s cng ngh gia cng cht do. - Ch s K: Gi tr ny c trng cho phn t lng ca Polyvinyclorid (PVC). N thay i nh nht. Ngha l gi tr K cng ln th phn t lng ca PCV cng ln. c trng chy ca cht do nhit rn.

i vi cht do nhit rn th vi cng mt nhit m ta c th o c c trng chy th qu trnh to li do phn ng khu mch cng xy ra. Khi nhit tng th nht ca vt liu gim ng thi vt liu to li tng. Hai qu trnh ny lun i ng hnh vi nhau. - di ng chy: Vt liu t mt khoang tr trn c nung nng v b p vo mt knh b thu hp li trong cng mt iu kin nhit , p sut nh nhau. Ta tin hnh so snh chiu di cc thanh c p ra thanh no c di ln th c trng chy ca vt liu cng tt. - o thi gian chy: Cch ph bin nht ca phng php ny l to mu th c dng hnh ci chn. Bng phng php p ta ch to ra mt chic chn ri tin hnh o thi gian cn thit vt liu n y khun. Vi cc iu kin nh nhau thi gian in y khun ca mu th no nh hn th vt liu c c trng chy cao hn. I.2. iu kin k thut cn c i vi mt sn phm nha.

 sn phm nha, khay lm vin, c kh nng ch to c bng phng php c trong khun kim loi nh my p nha th kt cu ca sn phm phi tho mn mt s iu kin nht nh sau. - T l gia chiu cao v chiu dy ca thnh sn phm phi thch hp to iu kin dng nha nng chy bm vo lng y khun d dng. - Thnh sn phm phi c gc nghing nht nh to iu kin sn phm thot nhanh ra khi khun khi khun c m ra, hn ch bt hin tng sn phm b dnh vo lng khun. - Chiu dy thnh sn phm ti cc v tr chuyn tip khng c chnh lch nhau qu nhiu. Bng I 1: Chiu dy thnh sn phm nha nhit do. TT (mm) 1 2 3 4 5 6 7 Vt liu Chiu dy nh nht (mm) Chiu dy trung bnh (mm) Chiu dy ln nht

PA PC

0,38 1,00

1,6 2,4 1,6 1,6 2,0 1,6 2,4

3,2 9,5 6,4 6,4 7,6 6,4 9,5

LDPE 0,50 HDPE 0,90 PP PS PVC 0,63 0,76 1,00

Bng I 2: Quan h gia cao, chiu dy v nghing thnh sn phm. 1/40 1/20 10 20 30 40 50

Chiu cao thnh sn phm (mm)

0.11 0.22 0.33 0.44 0.55 0.66

0.22 0.44 0.65 0.87 1.09 1.31

0.44 0.88 1.31 1.75 2.19 2.63

0.87 1.75 2.62 3.49 4.36 5.24

1.31 2.62 3.93 5.24 6.55 7.86

1.74 3.50 5.24 7.00 8.74 10.49

2.19 4.37 6.56 8.75 1.94 13.12

0.77 0.88 0.99 1.10 1.21 1.32

1.52 1.74 1.96 2.18 2.39 2.61

3.06 3.50 3.94 4.38 4.81 5.25

6.11 6.98 7.85 8.73 9.60 10.47

9.17 10.48 11.97 13.10 14.41 15.72

12.23 13.98 15.73 17.48 19.21 20.97

15.31 17.50 19.68 21.87 24.06 45.84

Chiu dy thnh sn phm (mm) Cn c vo bn v chi tit sn phm nha, ta thy rng cc thng s kch thc trong kt cu hon ton ph hp ch to ra sn phm nh phng php c phun trong khun kim loi.

Hnh I 2: Hnh dng s b ca sn phm cn ch to. Cn c thc t sn xut, ta nhn thy rng cc cnh ca vin nu l gc nhn (90o) th vic gia cng gp rt nhiu kh khn. Cho nn vic qu trnh gia cng ch to sn phm c thun li th cc cnh vin ca khay nn c dng cung trn c bn knh thch hp vi kch thc ca dng c ct.

Hnh I 3: Hnh dng ca sn phm nha cn ch to. Cc thng s chnh xc v kch thc tham kho bn v chi tit sn phm trang sau (A3). * Yu cu k thut ca sn phm nha nh sau: - Sn phm sau khi bm t hnh dng tt nht m tn t cng sa li nht. - Sn phm sau khi bm khng tn ti khuyt tt nht nh: cong vnh, r kh, vt phun b ngn, c tn ti ng hn, hm co - C tnh n nh nhit thp 100C - Khng gy c hi cho ngi s dng.

- S dng loi vt liu thng dng nht. Cn c vo cc c tnh ta chn vt liu ch to khay l nha PP c co ngt l 1,6 %. Cn c vo thit k hnh dng khun sau khi p to ra sn phm t yu cu. I.3. c im cng ngh ca nha Polypropylen (PP). Polypropylen (PP) l loi polymer c dng tinh th. Trong qu trnh ch to cc nh sn xut to ra polypropylen c cu trc iu chnh lp th, cc mch i phn t ca n c cu trc cn i gn. - Phn t lng:80000 ? 200000 n v. - Mc tinh th: - T trng: - Cng thc ho hc: 80% ? 90%. 0,90 ? 0,91 (g/cm3).

I.3.1. Tnh cht ca PP. Tnh cht v nhit.

PP c nhit nng chy l 160 ? 175oC, bn vng vi s si c th tin hnh kh trng nhit 120oC m sn phm khng b bin dng. chu lnh c th xung ti 65oC. Tnh cht ho hc.

PP bn vng i vi cc axit long, mui, kim , kh tan trong cc dung mi nhit thng Nhng ti nhit 90oC th tnh bn vng km i. Tnh cht c hc:

Tnh cht c hc ca PP ph thuc vo phn t lng, ch lng cc pha c quy lut, phn tn cc pha c quy lut ca n. - Phn t lng ca PP c xc nh thng qua ch s chy 0,2 ? 5 (g/10). - Gii hn bn ko ca PP ph thuc vo tc cht ti. Tc ko thp th gii hn bn tng v ngc li - Tnh cht c hc ca PP cng s tng nu cc sn phm ca n c ko nh hng. u im: PP c cch in v bn nc (khng thm nc) kh hon ho v khng gy c hi cho ngi s dng. Nn rt thch hp lm cc sn phm gia dng. Bng I 3: Thng s k thut ca mt s cht do thng dng nh sau: Nha

Tn gi ABS

Nhit khun Nhit ti vi phun Styrene co-polyme 10 ? 80 (oC)

Nhit ph hu

co ngt % (0,4 ? 0,7)

170 ? 200 (oC) 310 (oC)

PA 6,6 Polyamide PS PP PVC Polystyrene

50 ? 80 (oC) 10 ? 75 (oC)

250 ? 280 (oC) 320 ? 330 (oC) 0,5 ? 2,5 200 ? 280 (oC) 250 (oC) 220 ? 235 (oC) 280 (oC) 0,3 ? 0,6 1,0 ? 2,0

Polypropylene 10 ? 80 (oC) Polyvinylclorid 20 ? 60 (oC)

190 ? 240 (oC) 180 ? 220 (oC) 0,5

I.3.2. ng dng ca PP. PP c th phi hp vi cc loi vt liu gia cng: Cao su t nhin hoc cao su nhn to v cc loi vt liu khc. Ngi ta dng my chn c b phn nung nng phi hp chng ri to ht. n nh PP ngi ta dng cc amin v mui cng nghip. to mu cho sn phm ngi ta dng ht mu v c hoc hu c nhum mu cho sn phm PP khi gia cng. - ng PP: Vt liu dng lm ng c ch s chy 0,5 ? 3 g/10 pht, ng c ng knh ? 25 ?150 mm. Chng c s dng vn chuyn nc nng, cht lng ho cht trong cng nghip ho hc. - Mng v tm: Mng PP c trong sut ngang giy bng knh li c bn c hc cao hn ng thi chu c nc. - Bc dy in: S dng cho k thut in, in t v nhng ni c bn nhit cao. - Sn phm dp nng hoc ht chn khng t cc tm PP c b dy 0,2 3 mm. Cc sn phm ny dng cho cng nghim ho hc, dt, sn, t - Sn phm c ch to cc chi tit my v dng phc v i sng hng ngy trong cc lnh vc t, xe my, my git, my lnh, in thoi, my thc phm, my tnh - To si do PP nh, bn thch hp s dng bn cp, li nh c, ti li, thm, dt vi bc trong cng ngh dt vi - To lp ph bo v cho cc chi tit chng n mn ca mi trng.

Chng II. Tng quan v cng ngh lm khun.

II.1. Nguyn l hot ng ca khun p nha. Ta bit rng khun l mt dng c dng nh hnh cho mt chng loi sn phm nht nh (hnh dng v vt liu...), y l sn phm nha. N c lp rp t nhiu chi tit c kh khc nhau. Khi khun c lp vi cc b phn cung cp chuyn ng thch hp (my p nha),n s c kh nng thc hin ng m khun theo mt chu k xc nh, to ra c nhng khong khng gian hp l c tc dng to hnh cho sn phm hoc to khong khng gian cn thit sn phm thot ra khi khun mt cch d dng (Khng phi ngng my, sn phm ra mt cch t ng) sau khi c hnh dng t yu cu. Nh m nng sut p ra sn phm nha rt cao. * Quy trnh p ra mt sn phm nha trn my p nha nh sau:

Hnh II 1: Trnh t p sn phm trn my p nha nm ngang. Ban u h thng thu lc ca my p nha thc hin chuyn ng ng khun to ra khong khng gian ng kn, lc ny dng nha c cm ho do (Xylanh hoc Piston) ho lng bm vo c nhit v p sut cao chy qua cung phun vo khun thc hin cng vic in y lng khun. Cm ng khun ca my p vn phi tc dng vo khun mt lc ln (lc kp khun) khng c mt cht cht do no c chy ra ti b mt phn khun (gy tn tht nha v to ph phm). Trn c s phn cch nhit gia lng khun v cm ho do, c hai u c mc nhit rt khc nhau. Lin kt ny ch c duy tr mt lc cho n khi cht do lng khng cn kh nng chy na. Bi v sau khi nha c bm vo lng khun th h thng lm mt ( khng kh, nc, dung dch lm mt) hot ng thc hin cng vic lm ngui nha, lm cho qu trnh nha t trng thi lng chuyn sang trng thi rn nhanh hn (nng cao nng sut lm vic). Do m sau khi in y khun nha bt u ng cng li, khi th tch ca sn phm s b co li (ph thuc vo h s co ngt ca vt liu). Do to ra sn phm c hnh dng ng theo yu cu th bng cch p tip v bm nha in y tip th th tch thiu ht do co ngt nha s c b xung thm. Cho nn phi duy tr p lc ln cht do cho n lc n ng cng li. V qu trnh ho do nha t trng thi rn sang lng cn mt thi gian nht nh, trc xon vt thc hin vic p cht do vo lng khun nh thc hin chuyn ng quay. Do to ra tng liu lng nhm lm chy n v xp t trc khi bm vo khun, trc xon to ra khong khng gian trng bng cch trt li li trong lng Xylanh phun bng chuyn ng tnh tin dc trc. Khi sn phm c lm ng li cm ho do s chuyn ng ri khi khun nh m cht do u vi phun khng b ng c li. Cm ng khun vn tip tc duy tr lc p khun cho n khi sn phm ng c ti mc c th tng ra ngoi c chuyn ng m khun kt hp vi h thng cht y. Qu trnh c tip tc ch to sn phm tip theo. *) Tm li chu k hot ng ca my p to ra mt sn phm nh sau: - Khung kp thc hin ng cht khun. - Vt liu do c ho do t trc c bm vo lng khun. - p lc tip tc duy tr (p lc gi).

- Ti thi im ny trc vt tip tc chuyn ng quay ho do vt liu chun b cho ln bm tip theo. - Khi cht do bt u ngui nh h thng lm mt ca khun. - M khun v y sn phm ra ngoi. II.2. Gii thiu chung v khun. Khun l mt dng c dng nh hnh cho mt sn phm nha. N c thit k sao cho c th c s dng cho mt s lng ln chu trnh gia cng ra sn phm tho mn yu cu cho trc. Kch thc v kt cu ca khun ph thuc vo kch thc v hnh dng ca sn phm. S lng sn phm cn c ch to ra t mt b khun (S ln p, s sn phm trong mt ln p) l mt yu t rt quan trng cn xt ti trong qu trnh thit k khun. Bi v i vi dng sn xut nh th khng cn n loi khun c nhiu lng khun hoc c kt cu c bit. Cc yu t c nh hng trc tip ti gi thnh ca khun cng nh l gi thnh ca sn phm cn ch to trn khun . II.2.1. Cc thut ng k thut c bn.

- Khun: l mt cm gm nhiu chi tit lp rp li vi nhau, nha c bm vo, c lm ngui, ri sn phm c y ra. Sn phm c to hnh gia hai phn ca khun. Khong trng gia hai phn c in y bi nha v n s mang hnh dng ca sn phm cn ch to. - Mt phn ca khun lm vo s xc nh hnh dng bn ngoi ca sn phm c gi l lng khun, cn phn li ra xc nh hnh dng bn trong ca sn phm gi l li khun. - ng phn khun (mt phn khun) l mt phng phn tip xc gia lng khun v li khun. *) Ngoi li khun v lng khun th cn c cc b phn c bn sau: - Tm kp pha trc: kp phn c nh ca khun vo my p phun. - Tm khun pha trc: l phn c nh ca khun to thnh phn trong v phn ngoi ca sn phm. - Tm khun pha sau: l phn chuyn ng ca khun, to nn phn trong v phn ngoi ca sn phm. - Tm kp pha sau: kp phn chuyn ng ca khun vo my p phun. - Tm : gi cho mnh ghp ca khun khng b ri ra ngoi. - Khi : Dng lm phn ngn gia tm v tm kp pha sau cho tm y hot ng c. - Tm gi: Gi cht y vi tm y. - Vng nh v: Bo m v tr thch hp ca vi phun vi khun. - Cht dn hng: Dn phn chuyn ng ti phn c nh ca khun. - Bc dn hng: trnh mi mn dn ti lm hng na khun sau.

- Bc m rng: Cng vi bc trnh mi mn lm hng tm kp pha sau khi ngn v tm . - B nh v: m bo cho s ph hp gia phn chuyn ng v phn c nh ca khun. - Cht hi v: lm cho cht y c th quay tr li khi khun ng li. - Cht y: Dng y sn phm ra khi khun m. - Bc dn hng cht: trnh mi mn v hng cht , tm y v tm gi do chuyn ng tng i gia chng. - Cht : Dn hng chuyn ng v cho tm trnh khi b cong vnh do p lc cao. - Bc cung phun: ni gia vi phun v knh nha vi nhau qua tm kp pha trc v tm khun trc. y ch l cc chi tit hay c s dng trong mt b khun, ngoi ra tu theo phc tp ca khun m s dng thm b phn khc nh: Van du, van kh hoc bt i mt s chi tit no khun hot ng hiu qu nht (Tham kho trong bn v lp khun). II.2.2. Cc loi khun ph bin. Kt cu ca khun thng gm hai phn, mt phn pha vi phun n c bt cht, c nh vi my p nha gi l tm khun trc, phn cn li c pha h thng y, khi hot ng n thc hin chuyn ng ng m khun gi l tm khun sau. Tu theo kt cu ca tm khun trc v sau cng nh l cch thc hin chuyn ng ng m khun khi lm vic m c cc loi khun ph bin sau: - Khun hai tm: L loi khun ch gm hai phn khun trc (phn khun c lp c nh trn my p nha) v khun sau (phn thc hin chuyn ng tnh tin thc hin cng vic ng m khun). y l loi khun c kt cu n gin (gi thnh thp) c s dng rng ri ch to cc sn phm c kch thc nh, s dng t ming phun, hnh dng n gin, sn lng ch to t

Hnh II 2: Kt cu ca khun p nha hai tm. - Khun ba tm: H thng ny gm c cc b phn sau: Khun trc, khun sau v h thng thanh . N c kh nng to ra hai vng khng gian khi ng m khun. Mt v tr m ly ra sn phm cn mt v tr m dng ly knh nha. Nhc im ca dng khun ny l khong cch gia vi phun ca my p nha vi lng khun cn bm nha vo kh di, lm gim p lc ca dng nha t vi phun vo lng khun v lng nha ph phm tiu tn h thng knh dn nha ln.

Hnh II 3: Kt cu ca khun p nha ba tm.

- Khun nhiu tng c ch to gi lc kp ca my thp (ngha l s dng cho cc loi my c kch thc nh gim tin vn u t vo my), nh s dng c h thng y c hai na khun. Do vn gi c gi thnh sn phm h trong khi c th sn xut c mt s lng sn phm ln.

Hnh II 4: Kt cu ca khun p nha nhiu tng. Ngoi cc vn trnh by trn th trong qu trnh thit k khun ta cng cn quan tm gii quyt ti mt s vn sau: - H thng knh dn nha phi gii quyt nh th no ? - H thng lm mt khun thit k nh th no ? - Cn phi thit k ch to b phn, chi tit no? cn chi tit no th mua theo tiu chun ? y l cc yu t nh hng trc tip ti gi thnh ch to khun, ng thi chng cng nh hng trc tip ti nng sut v cht lng ca sn phm c p ra trn khun ta thit k II.3. Trnh t thit k, c im cng ngh ch to khun. II.3.1. Trnh t thit k khun. hn ch bt s bt cp gia nhu cu t pha khc hng v iu kin sn xut thc t ti nh my, tng hiu qu ca cng vic thit k. Ta nn lp ra mt trnh t cc cng vic cn phi tin hnh sau khi nhn c cc s liu v n t hng, c th thit k v ch to ra mt sn phm khun t yu cu.

Hnh II 5: Trnh t cng vic khi thit k khun p nha. II.3.2. c im ca cng ngh sn xut khun. im ni bt nht ca cng ngh sn xut khun mu l thuc dng sn xut n chic, lot nh. Bi v khun dng nh hnh cho mt loi sn phm c hnh dng, vt liu c xc nh t trc. Cho nn khi m sn phm c s thay i mt trong hai yu t: hnh dng hoc vt liu th ngay lp tc khun c khng s dng c nu mun s dng tip th cn phi tin hnh gia cng sa cha li khun, chi ph cho cng vic nay khng nh. Hn th trong khun li c cc chi tit, b phn i hi c bin dng cn ch to rt phc tp (hnh dng ca sn phm phc tp: mt nh hnh, l, rnh hp li su), ng thi li i hi rt cao v cht lng sau gia cng gia cc cc chi tit vi nhau (do phi lp rp), gia cc v tr cn gia cng khc nhau trn cng mt sn phm Cho nn my mc s dng gia cng ch to trong lnh vc khun mu khng nhng c linh hot v vn nng m cao ng thi chnh xc t c sau khi gia cng cng phi tt. iu ny nu ch s dng cc bin php cng ngh truyn thng nh l: Phay, tin, bo, mi, c, hn, rn th gia cng ch to c sn phm khun t yu l rt kh khn, thm ch l khng th gia cng c, nu gia cng c th bi ton kinh t cng khng cho php.

Th nhng nh p dng c cc thnh tu mi t cc ngnh khoa hc nh: in t, vt l, ton hc, vt liu vo ngnh c kh. to ra c cc phng php gia cng mi nh l: Gia cng tia la in, gia cng tia nc, gia cng bng Lazehay l cc my cng c c kh nng linh hot hn nh: My NC (my iu khin s); My CNC (my iu khin s c s tr gip ca my tnh); My gia cng bng phng php phng tia la in (my ct dy, my gia cng xung ) Nh s dng cc loi my ta c th gia cng c b mt nh hnh phc tp, c chnh xc cao hay l cc loi vt liu c cng cao m cc bin php truyn thng kh hoc khng th gia cng c. II.4. Tnh ton v la chn loi my p nha. Ta bit rng sn phm nha ta cn ch to c dng tm b dy nh 1mm trong khi din tch b mt ca sn phm cn in dy nha kh ln. Cho nn nha do c th in y c ton b lng khun khi ngui to ra c sn phm t hnh dng v cht lng theo yu cu th dng nha bm cn c p lc (p) cao ln ti 400 ? 1200 atm (Kg/cm2) (Theo kinh nghim c nh vy th nha mi c bm y kn ton b lng khun). Do trong qu trnh bm nha vo khun th tm khun sau lun chu mt lc y bng tch s ca p lc bm (p) vi din tch b mt ca sn phm (S) cn p ra. Khin cho khun c xu hng chuyn ng li li s to khe h gia hai lng khun lm cho nha b phi ra lm cho sn phm sau khi ngui c ba via (gy tn nha v tn cng ct ba va sau ny). T l ba v ny tu thuc vo khe h to hay b. Cho nn to ra sn phm c hnh dng p ng thi tiu tn lng nha v cng lao ng t nht th ta phi chn my p nha to lc ho khun (F) v p lc bm ph hp. Tc l my tt nht l my c th to ra lc kho khun va sn phm khng c (hoc c rt t) ba v di p lc ca dng bm nha ho do c bm vo lng khun. Tuy nhin lc kho khun cng khng c tha qu nhiu s tiu tn kinh ph vic mua my v vn hnh my trong khi li khng s dng c trit kh nng cng ngh ca my. Vy ta phi la chn my to ra lc kho khun tho mn iu kin. F ? p.S (II.1) Trong :

- F l lc kho khun ca my p nha.

- p l p lc ca dng nha ho lng bm vo lng khun. - S l din tch ca sn phm chiu ln lng khun sau. Cn c vo kch thc ca sn phm cn ch to ta c th tnh ton c lc kho khun cn thit c nh v tr ca cc tm khun trong qu trnh bm nha nh sau:

Tnh din tch ca sn phm (S) c xc nh nh sau: S = 206.107 = 22042 (mm2) = 22,042 (cm2). Do lc kho khun ca my ti thiu l:

F = p.S = (400?1200).22,042 = 88168 ? 264504 (Kg)= 88 ? 265(Tn). Cn c vo lc kho khun cn phi c v tnh trng my mc hin c ti ni sn xut, ta s chn c my ph hp cho qu trnh gia cng. y em chn my p 160 tn (Ph hp vi ch tiu kinh t nht) p ra sn phm nha. Trong qu trnh p sn phm th khun, cn c vo tnh trng thc t ca sn phm ta c cc bin php x l thch hp sn phm t cht lng. Nu sn phm c tn ti ba via th s dng cc bin php cng ngh x l h thng knh dn nha lm gim p lc bm, cn nu p lc ca dng nha khng in dy khun th ta chn my c lc kho khun ln hn tin hnh gia cng nh l: 190 tn hay l 260 tn. Bng II 1: Thng s k thut ca my TW-160 S II (My p nha 160 tn). Model TW-160 S II A B C 42 45 50 2174 471.12 1761

Screw diameter Mm Injection pressure Capacity cm2

Kg/cm2 2496 332.4 381.6

Sot weight of injection gr oz Injection rate Nozzle stroke 10.5 12.1

299.16 343.44 424.0 14.9 114.26 131.17 161.94

cm3/sec mm 350

Screw rotation Screw speed rpm

Hydraulic motor 0 167 160

Mould clamping force ton Dayligt opening mm Clamping stroke Mould thickness 850 mm mm

400 200 450 mmx(HxV) 470x470

Distance between tie rods Mould plate mm

700x700

Ejector stroke mm/ton 100/4.3 Pump motor I-P (Kw) 25(18.65)

Heater capacity Kw Max. load capacity Machine weight Ton Machine dimersion

6.67 Kw 6 m(LxWxH) l 5.5x1.3x2.1 400 25.32

Hydraulic operation weight

Cooling water capacity m3/hr 1.4 II.5. Thit k s b kt cu ca khun p nha. ch to ra c sn phm khun c kh nng lm vic tt: Nng sut hot ng ca khun cao, t l ph phm t, vt liu s dng tit kim Th trong qu trnh thit k v ch to khun cn gii quyt tt cc vn sau: - Thit k mt phn khun. - Thit k lng khun c bin dng. - Thit k h thng knh dn nha. - Thit k h thng y sn phm. - Thit k h thng lm mt. - Chn loi khun ph hp. - S dng ti a cc chi tit trong khun c tiu chun ho nh: Vnh nh v, bc phun, cht y sn phm, cht hi, cht dn hng, kt cu khun c sn rt ngn thi gian v gim chi ph cho qu trnh ch to. II.5.1. Chn mt phn khun. Mt phn khun l b mt phn cch gia hai na khun vi nhau. N c la chn lm sao : - To iu kin cho vic thit k v ch to hai lng khun c thun li nht trong iu kin c th. - Hnh dng ca sn phm sau khi p ra c hnh dng p nht, tn t nguyn liu nht, tn t cng sa cha nht. - Sn phm sau khi lm ngui ly ra nhanh v d nht. II.5.2. Xc nh hnh dng ca lng khun. Hnh dng ca lng khun phi ph hp vi bin dng ca sn phm cn ch to v b mt phn khun la chn. Cho nn cn c vo hnh dng v c tnh vt l ca vt liu s dng lm ra sn phm ta s xc nh c hnh dng cn thit ca mi lng khun.

Hnh II 6: Hnh dng ca sn phm khay lm vin. Do sn phm c lm t vt liu PP c h s co ngt l 1,6%. Cho nn kch thc v hnh dng trn mi lng khun (Khun trc v khun sau) c xc nh bng cch em kch thc ca b mt chi tit cn ch to nhn vi h s t l k = 1,016 ta s xc nh c kch thc v hnh dng ca mi lng khun tng ng.

Hnh II 7: Hnh dng ca lng khun sau.

Hnh II 8: Hnh dng ca li khun trc. Sau khi xc nh kch thc ca bin dng m mi lng khun cn phi c. Ta s xc nh c kch thc ca phi thp dng tm c kch thc phi > 209,3x108,6x30,5 mm ch to ra lng khun. Bi v trn tm phi ngoi bin dng lng khun cn phi thit k 1 s loi c cu c bit. Do i vi tm li khun th l chn phi c kch thc 250x150x60 mm cn tm phi lng khun 250x150x50 mm. II.5.3. Hnh dng v kt cu ca h thng dn nha. y l h thng vn chuyn trc tip nha t vi phun ca trc vt (Piston bm nha) ti lng khun. Do cht lng sn phm ph thuc rt nhiu vo h thng cp nha ny.

Hnh II 9: S h thng dn nha t my p vo lng khun. H thng cp nha cho khun gm c cc b phn chnh nh sau: - Cung phun l ch ni gia vi phun ca my phun v knh nha. - Knh nha l on ni gia cung phun nha v ming phun. Knh nha phi c thit k sao cho bo m c cc yu t sau: + Chiu di ca knh dn nha ngn nht c th, dng nha do c th nhanh chng in y lng khun m khng b tn hao p lc. + Kch thc v tit din ca knh dn nha phi m bo ch to c d dng v nh lm gim lng ph liu v lng nha trong lng khun nhng cng phi ln lng vt liu in y lng khun mt cch nhanh trng. - Ming phun l on ni gia knh nha vi lng khun. Theo hnh dng v v tr t ming phu m ngi c cc loi ming phun nh sau: Ming phun cung phun, ming phun cnh, ming phun kiu bng, ming phun kiu ng ngm, ming phun kiu im cht, ming phun kiu cnh qut, ming phun kiu vng trn, ming phun kiu tin phng Tu theo c im kt cu ca sn phm m chn la kiu

ming phun ph hp m bo cht lng ca sn phm ng thi tn t cng lo ng dnh cho vic tch sn phm khi knh dn nha nht. Do khun ta thit k ra p ra sn phm dng tm mng dy 1mm trong khi dixrng l 209,3x108,71 (mm). Cho nn vic bm nha ra sao nha in y hon ton lng khun l mt vn cn phi gii quyt mt cch tht hp l, nu khng t l ph phm to ra l rt cao. nha c bm y lng khun ta c cc cch gii quyt sau: - S dng dng nha chy lng c p sut cao. - Thit k h thng knh dn nha c kt cu hp l. Trong hai phng php trn th vic s dng phng php th hai s em li hiu qu kinh t cao hn. Bi v nu s dng dng nha c p sut cao ng ngha vi vic cn phi c lc kho khun ln, cn phi s dng my p c ln (Chi ph u t ln). Trong kh phng php th hai ch n thun l x l cng ngh v kt cu. T cc phn tch v nh gi , ta chn kt cu knh dn nha c kt cu nh sau: - Knh dn nha c tit din dng hnh thang, loi tit din ny d gia cng ch to hn do nm hon ton mt mt phn khun. - Ming phun nha t knh dn nha vo lng khun c dng dng im cht (To iu kin cho vic git t sn phm ra khi knh dn nha mt cch t ng v d dng). Ngoi ra nh vic s dng ti nhiu im phun nha vo lng khun, ta s khng cn tng chiu dy ca thnh sn phm, trong khi vt liu vn c th in y v ng u c lng khun.

Hnh II 10: Kt cu ca knh dn nha s dng nhiu im phun. Ch : Vic t ming phun nha vo v tr thch hp s lm cho kt cu khun n gin hn lm gim chi ph ch to khun. II.5.4. Thit k h thng lm mt lng khun: Ta bit rng nng sut v cht lng ca sn phm nha c p ra chu nh hng rt nhiu vo tc ngui ca khun (chnh l thi gian cn thit nha chuyn t th lng sang th rn). Bi v i vi cht do nhit do tc ngui quyt nh ti t l hnh thnh cc pha tinh t trong cu trc ca nha lm thay i c tnh ca nha. Do iu khin nhit ca khun v thi gian lm ngui ngn th ta cn s dng h thng lm mt mt cch hp l. im ny rt quan trng v thc t l thi gian lm ngui chim 50-60% ton b thi gian ca chu k ch to sn phm nha. Vy qua trnh lm lnh hp l mang li hiu qu kinh t rt cao. iu khin c nhit trong khun cn lu ti cc vn sau: - Nhng knh lm ngui phi t cng gn b mt khun cng tt nhng phi ch ti bn c hc ca khun.

- ng knh ca cc knh lm ngui phi ln hn 8 mm v gi nguyn nh vy tc chy ca cht lng mt khng ng u. - Nn chia h thng lm ngui ra lm nhiu vng lm ngui trnh cc knh lm ngui qu di dn n s chnh lch nhit qu ln gia u ra v u vo lm qu tnh lm ngui khng hiu qu. - c bit ch ti cc bin php lm ngui y sn phm. - Ch ti tnh dn nhit ca vt liu lm khun. Vic lm ngui tng b phn ca khun nh: Tm khun, li khun, cht khun, lng khun nh th no phi ph thuc kt cu, kch thc c th ca khun cn ch to. II.5.5. Thit k h thng y. Cha nng chnh ca h thng ny l y sn phm ra khi lng khun mt cch t ng khi my p thc hin chuyn ng m khun. Ngoi ra nh s dng h thng y, ta s hn ch bt hin tng sn phm nha b kt, dnh trong lng khun. iu rt ngn thi gian ly sn phm ra khi lng khun lm nng sut p ra sn phm nha tng, ng thi nng cao tui th lm vic ca khun nu h thng ny c thit k hp l. h thng y lm vic t hiu qu cao, trong qu trnh thit k cn ch ti cc vn sau. - Khong y (K hiu A): Khong y c la chn n cui hnh trnh y th chiu cao ca nh cht cao hn b mt phn khun t = 5 ? 10 mm.

Hnh II 11: Qu trnh y sn phm ra khi lng khun. Ch : Khng nn chn khong y qu di, iu s lm yu cht y nh hng ti kh nng lm vic chung ca ton b h thng y. - Cht hi (K hiu B): l cht c tc dng a h thng cht y v v tr ban u trc khi dng nha lng c bm vo lng khun. Nu h thng cht y khng c a v v tr ban u th hnh dng ca sn phm s b nh hng bi cc cht y. H thng cht y v cht hi c lp t nh hnh v sau:

Hnh II 12: V tr ca cht y v cht hi. Tuy nhin trong qu trnh thit k h thng y cho khun cn chu gii quyt tt cc vn sau: - V l thuyt th phn nh ca cht y ch c nm ngang so vi b mt lng khun, nhng trong thc t nh cht c th l trn hoc di 0,05 ti 0,1 mm tu theo yu cu cht lng ca sn phm. - Kch thc ca cht y cng rt quan trng, Kch thc ca cht y ph thuc vo kch thc ca sn phm, nhng trong qu trnh ch to c gng trnh s dng cht c ng knh < 3mm.

- Thit k h thng y phi bo m l khng c lm yu khun sau. - Khi khun s dng sn xut t 50.000 sn phm tr ln hoc cc sn phm c hnh trnh y di hoc cn s dng cc cht y c kch thc nh th nn c thm cc cht dn hng cho h thng y. - cc cht y vo ng v tr cn phi c kin thc vng vng s l cc trc trc c th xy ra do qu trnh nha khi ngui bi c ngt gy ng sut ln cc cht y. - Chiu dy ca tm y phi khi chu p lc y khng b un cong lm cho lc y khng ng u trn ton b b mt ca sn phm. dy ca tm y xc nh da vo din tch b mt sn phm d tnh nh sau: B mt sn phm dy tm y B mt sn phm dy tm y

5 cm2 12 mm 50 cm2 30 mm 10 cm2 15 mm 100 cm2 25 cm2 20 mm Cn c vo kch thc v kt cu ca sn phm nha cn p cng cch b tr cc chi tit trong khun, ta chn c h thng y sn phm c cc thng s k thut nh sau: - Khong y l A = 45 mm, do sn phm c chiu cao ? 30 mm. - Cht y c dng trn c ng knh ? 8 mm. - Tm y dy 15 mm. II.5.6. Chn kt cu khun. Do trn th trng c rt nhiu n v tham gia cng vic thit k v ch to khun mu p ng nhu cu s dn t th trng. iu lm cho nhu cu s dng cc phi liu tiu chun phc v cho nghnh ch to khun mu cng tng theo. Cho nn trn th gii c cc nh my c kh chuyn ch to cc chi tit c tiu chun ho phc v cho ngnh c kh nh: Khi khun c s; vnh nh v; Bc cung phun; Cht y sn phm C nh vy th thi gian gia cng ch to khun mu mi c rt ngn xung trong khi vn bo m yu cu k thut chung ca ton b khun. Cho nn khun ta thit k ta cng la chn theo khi khun c s c tiu chun ho t trc. Cn c vo kch thc ca bin dng lng khun v li khun cn ch to cng cc kt cu khc cn thit cho khun nh: kt cu ca h thng h thng knh dn nha, h thng cht y sn phm, h thng dn dung dch lm mt ta chn khun c dng 3 tm (Three Plate Type) theo tiu chun ca hng LKM (Lung Kee Mould) c m s l FAI 2735 c kch thc v kt cu nh sau. 50 mm

Hnh II 13: Hnh dng v kt cu khun 3 tm FAI 2735 LKM.

Kch thc ca khi khun c s nh sau (n v mm): W 270 EJW 160 L 350 GPY 147 GP 25 PRX 57 RP 20 RPY 145 S1 14 S1X 107.5 S2 10 S1Y 115 S3 10 S2Y 55 PWI 320 S3X 68 SBW 53 S3Y 168

Chiu dy ca cc tm khun chnh A v B c th la chn nh sau: Tm phi A B 50 50 Kch thc chiu dy (mm). 60 60 70 70 80 80

Cn c vo kt cu ca khun ba tm ( c tiu chun ho) cng hnh dng s b ca cc kt cu khc trong khun nh l: - Kt cu ca tm o khun trc v sau. - Bin dng li v lng khun. - H thng dn dung dch lm mt lm ngui vng lm vic ca khun. - Kt cu ca knh dn nha vo lng khun. - H thng y sn phm ra khi khun. Cng mt s cc chi tit c kh khc ta c c hnh dng s b ca khun p khay khay nha nh sau:

Hnh II 14: Kt cu s b ca khun p nha. Chc nng v hnh dng ca mi loi chi tit in hnh c s dng trong khun nh sau: 1.Tm sau: c tc dng lp ghp vi h thng y (thu lc) ca my p nha nm ngang (Qua h thng ngm kp). Nh m cc tm khun sau, trung gia c th thc hin chuyn ng ng m khun to hnh cho sn phm, ng thi ly sn phm ra sau khi ngui cng. Hnh dng ca chi tit:

2. Tr : C tc dng tng cng vng cho khi khun sau ng thi to khong khng gian cn thit h thng cht y v cht hi lm vic. Hnh dng ca chi tit:

3. Cht y: c tc dng y sn phm nha sau khi c lm ngui c cng vng cn thit ra khi lng khun. Trnh tnh trng chi tit nha sau khi p b kt li trong lng khun. Hnh dng ca chi tit:

Ch : ng knh cht y khng nn lm nh hn 8 mm (Kh nng cng ngh mi p ng c). 4. Tm chn: C tc dng tng cng vng cho tm khun sau di p lc ca dng nha bm vo v lc kho khun. 5. Tm khun sau: L chi tit rt quan trng c vi tr c nh lng khun sau vi cc chi tit khc trong khun, cng vi lng khun trc khi ng li to ra khong khng hp l to hnh sn phm. Hnh dng ca chi tit:

6. Lng khun sau: L chi tit rt quan trong n mang hnh dng ca sn phm cn ch to, c vi tr cng vi lng khun sau to ra khong khng hp l to hnh sn phm. Hnh dng ca chi tit:

7. Nm cn: C tc dng dn hng cho hai lng khun trc v sau vo ng v tr cn thit to ra khong khng hp l to hnh sn phm. ng thi nm cn l chi tit c vai tr gia hai lng khun khng b x dch tng i vi nhau khi c p lc bm ca dng nha. Hnh dng ca chi tit:

8. Lng khun trc: L chi tit rt quan trng c vi tr cng vi lng khun sau to ra khong khng hp l to hnh sn phm. Hnh dng ca chi tit:

9. Tm khun trc: l chi tit c tc dng lp ghp vi lng khun trc to ra khong khng gian cn thit to hnh sn phm trong khi vn tit kim c vt liu lm lng khun trc.

Hnh dng ca chi tit:

10. Tm trung gian: l ni lp ghp cc chi tit ph tng hiu qu hot ng ca khun. C th l ni lp ghp cht git cung c tc dng gi li knh nha sau khi ng cng li. 11. Tm trc: dng kp phn c nh ca khun vo my p phun Hnh dng ca chi tit:

12. Vnh nh v: c tc dng nh v vi bm nha t pha sau trc vt vo bc cung phun. Hnh dng ca chi tit:

13. Bc phun: C tc dng ni vi phun nha v knh dn nha. Hnh dng ca chi tit:

14. Cht git cung: C tc dng lu gi li knh dn nha sau khi tch ra khi sn phm khong khng gian pha trc tm khun trc, Hnh dng ca chi tit:

15. Tm hi: C tc dng lp ghp vi tm y n khi cht hi chuyn ng s chuyn chuyn ng cn thit ti tm y v cht y. Hnh dng ca chi tit:

16. Tm y: C tc dng ko cht y v v tr cn thit trc khi qu trnh bm nha ln tip theo. Hnh dng ca chi tit:

17. Thanh k: C tc dng lm tng cng vng ca lng khun di p lc bm nha v lc kho khun. 18. Cht hi: C tc dng trong qu trnh ng khun li chun b bm sn phm mi th thc hin y tm y ko theo cht y v v tr cn thit trc khi nha c bm y lng khun.

Hnh dng ca chi tit:

19. Thanh ko: C tc dng gii hn cc hnh trnh chuyn ng ca cc tm khun khi thc hin m khun ly sn phm ra. Hnh dng ca chi tit:

Mun xem kch thc chnh xc ca mi chi tit s dung trong khun tham kho thm bn v tch cc chi tit (A0) Phn bn v.

Chng III. Tng quan v gia cng tia la in. Nguyn l tc ng n mn kim loi bi tia la in v cu trc c s ca qu trnh a c bit cch y gn 200 nm, khi nh nghin cu khoa hc t nhin ngi Anh, Joseph Priestley (1733-1809), trong th nghim ca mnh ng nhn thy hiu qu ca s n mn vt liu bi s phng tia la in. Ti nm 1940, v chng ngi Nga, Lazarenko, khi qut ho hin tng n mn vt liu bi s phng tia la in thnh cng ngh gia cng qua mt loi th nghim s dng cc mch in tr t in thu c tc ng tc dng ca s phng in ti qu trnh ht i mt lng vt liu kim loi mi khi cho dng c in cc tin gn n in cc phi. T n nay qu trnh ht kim loi trong gia cng tia la in vn c coi l vn phc tp ph thuc vo nhiu thng s cng ngh nh: Khong cch khe h phng tia la in trong mi trng cht in mi, n thng tin v knh Plasma, n s n mn vt liu trn c hai in cc v.v Li th gia cng v tnh phc tp v hin tng vt l ca qu trnh gia cng bng tia la in thu ht nhiu nh khoa hc quan tm nghin cu hiu r ht bn qu trnh, pht trin cc phng php gia cng lai ng thi ci tin pht trin thit b nhm mc ch nng cao cht lng v nng sut ca phng php ny. III.1. Gii thiu chung v phng php gia cng tia la in. Trong na th k qua ng trc nhu cu s dng cc loi vt liu lu mn v siu cng trong nhiu loi trang thit b in, ng c my bay, dng c, khun mu v.v tng ln khng ngng cc nc cng nghip pht trin. Th nhng vic gia cng v ch to cc loi vt liu c bn cao bng cng ngh ct gt thng thng (Tin, phay, bo, khoan ) l v cng kh khn, i khi khng th thc hin c d c th thc hin c th cng kh p dng cho thc t v bi ton kinh t.

Hnh III 1: S phng php gia cng kim loi bng tia la in. gii quyt vn kh khn ny ngi ta khng ngng nghin cu ng dng cc thnh tu mi trong nhiu lnh vc in t, vt l, ton hc, ho hc v.v xy dng nn cc phng php gia cng mi c c ch vn hnh thch hp v mang li hiu qu s dng cao. Mt trong cc phng php l:

Gia cng bng tia la in. Theo phng php ny th thng qua hin tng phng tia la in qua khong khng gian gia hai in cc m mt lng kim loi nht nh trn b mt in cc phi b bc hi rt nhanh, lm cho trn b in cc phi hnh thnh bin dng ca in cc dng c m khng h ph thuc vo cng ca vt liu cn gia cng. Khi cc tia la in c phng ra gia hai in cc, vt liu trn lp b mt phi s b bc i bi mt qu trnh nhit in thng qua s nng chy v bc hi kim loi. N thay th cho s tc ng c hc gia dng c ct gt vo phi (Cng ngh gia cng ct gt thng thng). Qu trnh bc i mt lng kim loi nh tc dng ca s phng in c gi l gia cng tia la in. Tn nguyn gc ting Anh l Electrical Discharge Machining gi tt l gia cng EDM. III.1.1. Bn cht ca phng php gia cng tia la in. Bn cht: Gia cng kim loi bng tia la in theo hip hi k s ngi c (IDL) nh ngha l l s tch vt liu nh tia la in l mt dng gia cng phng in n mn, thc cht ca qu trnh gia cng l qu trnh bin i nng lng t xung in thnh nhit nng, tp trung trn mt n v din tch ca b mt gia cng, lm mt phn kim loi ti lp b mt phi c nung nng cc b b nng chy v bc chy tch khi phi liu to nn hnh dng v kch thc cn thit. Vy iu kin thc hin qu trnh gia cng kim loi bng tia la in l s cung cp nng lng lin tc, bc ht lng d kim loi cn gia cng. Nng lng c cung cp y di dng in p mt chiu, khi hai in cc c cung cp in p cn thit ph hp vi khe h phng in th hai im nhp nh gn nhau nht trn b mt in cc bt u pht ra tia la in xuyn thng khong cch mi trng gia hai in cc, nhit mt vng nh nm trn in cc (Phn c khe h hp nht) c t nng ln ti hng ngn , nhit lng ny lm nng chy di p sut ca in mi s thi bay phn kim loi ra khi vng gia cng, kim loi cn bc b nh l b bc hi khi v tr cn gia cng. Trong qu trnh phng in c s ion ho rt mnh ti vng tc dng v to ln p lc va p ln a ra ht kim loi b ph hng khi vng gia cng, to vt lm trn b mt in cc. Qu trnh trn xy ra trong mt thi gian rt ngn v mch trng thi np in chun b cho ln phng in tip theo. Hin tng phng in xy ra n khi khong cch gia hai khe h ln khng cn kh nng phng in na th qu trnh gia cng dng li, mun qu trnh gia cng tip tc thc hin th phi cho hai in cc chuyn ng gn li vi nhau n khe h phng in. Bn cht tia la in l dng xung in, to c dng xung in th giai on u phi thc hin tch in v sau l qu trnh phng in.

Hnh III 2: Cu to ca my gia cng tia la in xung inh hnh. III.1.2. Qu trnh phng in trong khi gia cng tia la in: Qu trnh phng in khi gia cng tia la in bao gm 3 giai on. Giai on th 1: nh in.

My pht in tng in p mi in cc. Di nh hng ca in trng, t cc m (Catt) bt u pht ra cc in t v chng b ht v pha cc dng (Ant). S pht in t gy ra s tng cc b tnh

dn in ca cht in mi trong phm vi khe h gia hai in cc. Do b mt gia hai in cc khng bng phng m tn ti cc nhp nh li hoc lm ti cc v tr khc nhau. Cho nn in trng s mnh nht hai im gn nhau nht. Cht in mi b ion ho, tt c cc phn t dn in u hi t quanh im ny trong khong khng gian hp gia hai in cc v chng to nn mt chic cu (gm cc phn t dn in v in t) lin kt hai in cc li. Nh vy mt knh phng in c hnh thnh dc theo cu. S phng in c hnh thnh.

Hnh III 3: th in p v dng in trong mt xung phng in. Giai on th 2: S hnh thnh knh phng in.

Ti thi im phng in, in p bt u gim (Hnh III.3). S lng cc phn t dn in (in t v ion dng) tng ln mt cch t ngt v dng in bt u chy gia cc in cc. Dng in ny cung cp mt mt nng lng khng l lm dung dch in mi b bc hi cc b. p sut trong cc bong bng bc hi s y cht lng in mi sang hai bn. Nhng do c nht nn cht in mi to ra mt s cn tr, hn ch ti s ln ca knh phng in gia hai in cc.

Hnh III 4: Cc pha trc v sau khi phng tia la in. Giai on th 3: Nng chy v bc hi vt liu.

Li ca bt hi bao gm mt knh plasma. Plasma ny l mt cht kh c ln cc in t v cc ion dng p sut cao (khong 1 kbar) v nhit cc ln (6000 ? 100000C). Khi knh plasma ny c hnh thnh y th in p qua khe h t ti mc ca in p phng in Ue. Gi tr ca in p Ue l mt hng s vt l ph thuc vo s phi hp gia hai loi vt liu lm in cc Ant/Catt. VD: i vi cp vt liu ng-thp th Ue = 25V. Cht in mi gi cho knh plasma v gi cho nng lng c tp trung cc b. S va chm ca cc in t ln Ant v ca cc ion dng ln Catt lm nng chy v bc hi cc in cc. My pht in s ngt dng in sau khi din ra mt xung c hiu qu. in p b ngt t ngt lm cho knh phng in b bin mt p sut gim t ngt. iu ny khin cho kim loi b nng chy c y khi knh phng in v bc hi. Nh vy hin tng phng tia la in din ra u tin ti cc im cao nht ca cc in cc v kt thc khi m cc nh nhp nh b nng chy v bc hi khi b mt in cc. Qu trnh phng tia la in tip tc din ra ti cc v tr khc trong vng cn gia cng cho n khi bc ht lng kim loi b mt cn gia cng (Thng qua vic iu chnh chuyn ng ca in cc).

Hnh III 5: Qu trnh phng in bc kim loi. III.1.3. Cc phng php gia cng bng tia la in.

T hin tng vt l ni trn, cc nh nghin cu khi qut thnh phng php cng ngh gia cng bng tia la in m ngy nay ang c s dng rng ri trong cc ngnh cng nghip. Tp hp mt s phng php gia cng tia la in c pht trin, trong k n hai phng php c bn l: xung nh hnh v phng php ct bng in cc dy. Ngy nay c nhiu phng php gia cng lai c ng dng tia la in cng ang c nghin cu v pht trin thm trn th gii bao gm. Gia cng tia la in dng phay (Milling EDM): l phng php s dng in cc chun (hnh tr c hoc rng) quay thc hin n mn tia la in theo kiu phay. Hc khun c hnh thnh bi s i xung lin tc ca in cc ti su cn thit. T l ht vt liu tng ng vi gia cng xung nh hnh. c im ca phng php ny l khi hnh dng ca bin dng cn gia cng c hnh dng phc tp th thay v vic phi ch to in cc c bin dng phc tp tng ng ngi ta s dng in cc c hnh dng v kch thc chun ch to c tc dng gim gi thnh ch to. Tuy nhin gi thnh ca h thng iu khin li tng cao hn v in cc chuyn ng i hi s dng h thng iu khin theo qu o. Gia cng EDM c tr gip ca siu m: l phng php nhit bc tch vt liu nh tc ng kt hp ca n mn tia la in vi vic dng c c rung theo tn s siu m. S dng theo tn s siu m c tc dng tng cng n nh cho qu trnh gia cng v tng ng k tc gia cng khi khoan l nh hoc siu nh. Mi bng tia la in: l phng php gia cng lai, trong vt liu cn gia cng c tch ra bi tc dng ca s kt hp ca qu trnh n mn in v qu trnh mi c kh. Phng php ny s dng mi cc loi vt liu siu cng nh l vt liu kim cng a tinh th. S phng in c tc dng tng cng tc bc tch vt liu trong qu trnh mi c hc gip cho b mt sau gai cng c bng, mn cao hn. Gia cng bng xung nh hnh siu nh (MEDM): l dng gia cng bng xung nh hnh thu nh, trong in cc c quay vi tc ti 10000 (vg/ph). ng knh in cc c th nh ti 5?m, phng php ny c th ch to c cc l siu nh hoc cc bin dng phc tp trong cng ngh vt liu dn in siu mng. in cc s dng trong MEDM c ch to theo phng php gia cng tia la in chuyn dng nh mi kt hp vi ct dy WEDG. Kch thc l gia cng theo dng xung siu nh MEDM thng t 25?m n 250?m v chnh xc t c ?1 ? ?2 ?m. Gia cng MEDM thng c thc hin vi s tr gip ca knh hin vi in t. Ct dy tia la in siu nh (MWEDM) l phng php ct dy s dng dy in cc tungsten c ng knh nh hn 10?m. Phng php MWEDM ch yu c s dng gia cng cc chi tit c kch thc nh 0,1 ? 1 mm, vt liu kh gia cng , chiu dy nh hoc dng cho cng ngh gia cng ch to cc chi tit bn dn. Thit b s dng cho mt h thng gim st MWEDM c kh nng phn tch v iu khin cc chc nng bn ngoi. Gia cng tia la in theo kiu chn (Mole EDM): l mt qu trnh gia cng c bit, c kh nng gia cng c cc ng cong kn hoc mt hnh xuyn kn qua phi. Hnh dng ca cc my Mole EDM tng t nh mt thanh c th un cong v mt h thng nhn dng, vic ghi nh hnh dng c s dng nh l b kch thch. Vic nhn dng ng hm cn gia cng c thc hin bng sng siu m.

Phng php ny do trng i hc tng hp TOKYO v hng Mitsubishi Electrics Corporation-Nht bn nghin cu. III.2. Kh nng cng ngh ca gia cng tia la in. Phng php gia cng tia la in l mt dng phng php phng in n mn nn c y cc c im ca phng php n mn kim loi nh s phng in. ? u im ca phng php gia cng bng tia la in.

- Cht lng gia cng, tnh cht gia cng khng ph thuc vo c tnh ca vt liu gia cng m ch ph thuc vo tnh cht dn in, nhit ca n. - Dng c lm in cc khng cn c cng cao nn d ch to. - Phm vi lm vic trong khong rng nn c kh nng ch to c nhiu b mt c hnh dng phc tp v t chnh xc cao m cc phng php khc khng th t c. - Tit kim c vt liu, nng cao h s s dng vt liu. - Cng ngh n gin c kh nng gia cng c mt b phn nh trn mt chi tit ln. - D dng c kh ho v t ng ho ci thin iu kin lm vic. - Hn ch c ph phm do phi ch to in cc trc kh gia cng bin dng trn sn phm. - C kh nng gia cng c cc l, rnh nh m cc phng php khc khng th gia cng c(Cng ngh micro EDM). - C kh nng gia cng c cc hng, hc c hnh dng phc tp. - Chi tit c kt cu phc tp c th c gia cng bi cc in cc c hnh dng n gin. ? Nhc im ca phng php gia cng bng tia la in.

- Ch c th p dng c vi cc loi vt liu c kh nng dn in. - Nng sut gia cng khng cao nh cc bin php gia cng khc. - chnh xc v n nh trong khi gia cng kh khng ch, v dng c lm in cc cng b mn trong qu trnh gia cng. - Kh iu chnh v quan st do qu trnh gia cng din ra trong mi trng cht lng. - i hi phi u t vo trang thit b cng ngh tng i tn km, ch t hiu qu s dng trong mt phm vi gii hn. V vy vic p dng vo sn sut cha c rng ri. Cn c vo cc u im v nhc im ca phng php gia cng bng tia la in, ta thy rng phng php gia cng bng tia la in ch c p dng ch yu trong lnh vc gia cng ch to khun mu. Bi v ngnh sn xut ny thuc dng sn xut n chic, sn phm li i hi phi ch to c cc mt nh

hnh dng ng thng v khng gian, cc rnh nh hnh, ct cc congtua, cc l nh v ttt chnh xc t cp 8 ti cp 9 v nhm b mt Ra = 5 ?1,25 ?m i khi trong mt s trng hp c it c th t ti 0,32 ?m. III.3. Cc thng s iu chnh qu trnh xung nh hnh. Mc tiu ca mi phng php gia cng kim loi u l: Thi gian gia cng ngn (nng sut bc tch vt liu cao), cht lng b mt gia cng cao v chnh xc kch thc t c sau gia cng cao. Tuy nhin, gia cng xung nh hnh t c cc mc tiu hay khng cn ph thuc rt nhiu vo vic la chn mt lot cc thng s iu chnh my v cc thng s gia cng tia la in. III.3.1. Dng phng tia la in Ie. Dng phng tia la in Ie l gi tr trung bnh ca dng in t khi bt u phng tia la in n khi ngt in. y l yu t c nh hng ln nht n lng ht vt liu, mn ca in cc v cht lng b mt gia cng. Nhn chung khi Ie cng ln th lng ht vt liu cng ln, nhm b mt gia cng cng cao cn mn in cc li cng nh. c trng cho dng phng tia la in, mt s h thng iu khin cn s dng khi nim bc dng in. Bc dng in cng ln th dng phng tia la in cng cao. Tu thuc vo kiu my, c t 18 ? 21 bc phng in, s cho dng phng in t 0,5A ? 80A. Bc dng in v mn in cc.

Ta bit rng mn ca in cc (?) cng c nh hng khng nh ti chnh xc v cht lng b mt gia cng. mn ca in cc khng ch ph thuc vo s phi hp vt liu gia in cc v phi, s u cc, ko di xung m cn ph thuc vo bc ca dng phng in. VD: i vi hai cp vt liu ph bin nht ng/thp v grafit/thp th nh hng ca bc dng in n s mn in cc din ra nh sau: - Khi gia cng th: mn tng i ca in cc (?) s gim nu bc ca dng in tng. iu c ngha l khi bc ca dng in cao hn th lng ht vt liu tng trong khi mn tng i (?) ca in cc gim. iu ny rt c li cho vic tng nng sut gia cng nguyn cng ph th. - Khi gia cng tinh: mn tng i ca in cc (?) tng khi m bc ca dng in gim. iu c ngha l khi bc ca dng in thp hn th lng ht vt liu gim trong khi mn tng i (?) ca in cc tng. Kh nng cao nng sut cho nguyn cng gia cng tinh. Bc dng in v din tch b mt b n mn.

Khi gia cng cung nh hnh bng in cc nh th cng dng in s tp trung trn mt vng rt nh. Nu s dng in cc c din tch b mt ln th cng dng in phi phn b trn mt din tch ln. Do xut hin khi nim tp trung b mt ca dng in hay cn gi l mt dng in (A/mm2).

Khi mt dng in cao s sinh ra mt lng nhit rt ln lm cho qu trnh nng chy bc hi lp vt liu b mt nhanh v nhiu hn. V vy phi cn c vo vng in tch cn gia cng la chn bc dng in ph hp. VD: Khi cn gia cng mt vng b mt nh th cn bc dng in nh v ngc li khi cn gia cng mt b mt ln th cn s dng bc dng in ln. Cch la chn ng bc dng in.

Ta bit rng vic lc chn bc dng in gia cng ra sao c nh hng rt ln ti nng sut, cht lng t c sau gia cng. Mun la chn bc dng in hp l ta phi xc nh ng mc ch ca vic gia cng l th hay l tinh, hnh thc s dng in cc khi gia cng mt loi hay nhiu loi. - Khi gia cng xung nh hnh mt giai on n l (ch s dng duy nht mt in cc) th la chn bc dng in sao cho n cho php t c lng ht vt liu ln nht c th c trong khi vn duy tr c th v mn ca in cc trong cc gii hn cho php. - Khi gia cng xung nh hnh nhiu giai on (tc l t c hnh dng cn gia cng th s dng nhiu loi in cc khc nhau) th nn bt u t vic s dng bc dng in cao ri sau ln lt s dng bc dng in thp hn sau mi ln thay i in cc. mn tng i ? ca in cc rt cao trong giai on gia cng tinh cui cng. Tuy iu c tc ng mnh n chnh xc kch thc nhng chng ch dng li sai s mt vi ?m ht i giai on cui cng. V vy mn tuyt i ca in cc thay i khng ng k. Bng III 1: iu ghi nh khi la chn bc dng in. Bc dng in ln. Bc dng in nh.

- Lng ht vt liu: ln. - B mt gia cng: th. - mn tng i ? thp. - B mt gia cng: nhn bng. - mn tng i ?: cao. III.3.2. ko di xung t1. ko di xung (t1) l khong thi gian gia hai ln ng - ngt ca my pht trong mt chu k phng in. ko di xung nh hng ti: - Lng ht vt liu. - mn in cc. - nhm b mt gia cng. - Lng ht vt liu: nh.

Hnh III 6: Mi quan h gia ti vi cc i lng Vw,? v Rmax. nh hng ca ko di xung ti lng ht vt liu Vw(Hnh III 6.a).

Khi ko di xung gi nguyn bng hng s th tc ng ca dng phng in s lu hn. Ban u lng ht vt liu tng nhng ch ti mt gi tr cc i ti mt gi tr ko di xung nht nh no , sau s gim. Gi tr xung cho lng ht kim loi cc i s l gi tr ti u ca ko di xung. Nu tip tc tng di xung qu gi tr ti u th nng lng phng in s khng cn s dng ht vt liu gy tn tht nng lng mt cch v ch. nh hng ca ko di xung ti mn in cc ? (Hnh III 6.b).

mn tng i ? ca in cc s gim khi tng ko di xung ti thm ch ngay c sau khi t lng ht vt liu ln nht. nh hng ca ko di xung ti nhm b mt Rmax (Hnh III 6.c)

Khi tng ko di xung ti th nh hng ca dng din ti b mt gia cng s tng ln lm cho chiu cao nhp nh Rmax tng ln, ngay c sau im di xung ti u. Vy vic la chn gi tr ko di xung ti u ph thuc vo bc ca dng in. ko di xung cn c tng tng i vi bc ca dng in. tng bc dng in s khng c hiu qu nu ko di xung qu ngn. III.3.3. Khong cch xung to. Khong cch xung to l thi gian gia hai ln ngt v ng mch ca my thuc hai chu k phng in k tip nhau. Khong cch xung to thng c theo mt t l cho i vi ko di xung. nh hng ca khong cch xung ti lng ht vt liu.

Khong cch xung to c hiu qu thc s i vi lng ht vt liu. Khong cch xung cng ln th lng ht vt liu cng nh, v ngc li. Tuy nhin nu khong cch xung qu ngn th cht in mt khng thi gian thi ion ho. Cc phn t b n mn v nhit ca cht in mi khng th c a ra khi khe h phng in trong khong thi gian ngn ny. Kt qu l xy ra hin tng h quang v ngn mch. Cht lng b mt gia cng gim v lng ht kim loi b mt b gim nhanh.

Hnh III 7: Mi quan h gia khong cch xung v lng ht vt liu. Mi quan h gia khong cch xung vi ko di xung.

Trong thc t, ko di xung ti v khong cch gia hai xung to c xc nh bi t l ti/to, t l ny ph thuc vo kiu my. T l ny cng ln khi gia cng th v cng nh khi gia cng tinh v rt tinh.

- Khi gia cng rt th: Chn ti/to > 10. - Khi gia cng th: Chn ti/to ? 10. Tuy nhin gi tr to khng qu nh trnh cc khuyt tt ca qu trnh. - Khi gia cng rt th: Chn ti/to = 5 ? 10. Bi v khi gia cng tinh, khe h phng in gim, nguy c to cc li qu trnh s gim nhiu hn. Do c th tng to ln lm gim ti/to. - Khi gia cng rt tinh khe h phng in cn gim na, do cn tng to lm cho ti/to gim rt nhiu thm ch ti/to < 1(thng chn ti/to = 0,4). Do vic la chn to theo nguyn tc sau:

- Theo t l ti/to thch hp. - Chn to ph hp vi lng vt liu cn ht b. III.3.4. in p nh la UZ. in p nh la UZ dng khi u cho qu trnh phng tia la in sau . cng vi bc ca dng in, UZ chi phi khe b rng ca h phng in cn thit. Tuy nhin nh hng ca UZ ti kt qu ca qu trnh gia cng tia la in thc t nh hn s tc ng ca bc dng in, ko di xung v khong cch xung to. Cn phi phn bit in p nh in UZ (l gi tr c kh nng iu chnh c) vi in p phng tia la in Ue(l hng s vt l, gi tr ny khng thay i c chng ph thuc vo cp vt liu s dng lm in cc) III.3.5. Khe h phng in. Cho n nay, ta c rt nhiu cc thng s iu chnh c: I, ti, to, Uz tc ng ti qu trnh phng tia la in quyt nh ti lng ht vt liu v cht lng b mt sau gia cng. Nhng d kin c lng ht vt liu t u n cui sau mt s ln phng tia la in nht nh s to ra bin dng t kch thc cn thit, th phi la chn v iu chnh khe h phng in mt cch ti u. l cch bo m chc chn rng in cc tip tc n xung xm nhp vo phi cho n khi bc ht c lng kim loi d cn gia cng.

Hnh III 8: Vai tr iu chnh khe h phng in ti qu trnh gia cng o chiu rng khe h phng in.

Khe h phng in s c o gin tip thng qua vic o in p phng tia la in Ue. in p Ue l i din chnh xc khi in cc tin ti phi cha, hnh thnh nn s phng in. Nu coi in p Ue tng th khe h phng in cng tng theo. Cho nn Ue c th coi l in p khe h.

 duy tr mt chiu rng khe h phng in khng i th in p khe h v tnh trng phi phi c o v iu chnh mt cch lin tc. Vic iu chnh khe h c thc hin bi mt h thng in t. iu khin khe h.

H iu khin in t bit chnh xc in p khe h no tng ng vi mt khe h rng bao nhiu. V vy n cho nhng in p khe h thay i v iu chnh c. N so snh vi mt gi tr danh ngha v iu chnh chiu rng khe h phng tia la in cho ph hp. Nu in p khe h c o gim xung (lc ny in cc c h xung qu nhiu) th h thng iu khin bit rng khe h tr nn qu hp v n s ra lnh ng c servo nng in cc ln mt lng ph hp. Tuy nhin vic iu iu khin khe h phng in theo cc nhn t: I, to, ti, Ue l khng phi lc no cng ph hp. Bi v trong mt s trng hp gia cng c bit nh l gia cng rnh su th i hi khe h phng in phi ln hn mt cht so vi bnh thng, to iu kin cc phn t b n mn c thot khi vng gia cng c d dng. V vy chiu rng khe h c th c iu chnh t trc bi h iu khin ph hp vi iu kin gia cng. Cc loi khe h phng in.

Trong gia cng xung nh hnh to ra cc bin dng: rnh hoc hc t yu cu th cn phn bit cc loi khe h phng in sau c cch s dng chng mt cch hp l. - Khe h phng in mt trc gf. - Khe h phng in mt bn gls. - Khe h phng in mt bn i xung gfu.

Cn c vo cch thc chuyn ng ca in cc trong qu trnh gia cng. Ta xc nh c loi khe h phng in nh hng ti kch thc b mt gia cng, c trong qu trnh xy dng qu o in cc xt thm nh hng ca loi khe h thch hp. III.3.6. Cc hin tng xu khi gia cng tia la in. H quang (S phng in khng c thi gian tr t chy)

H quang l hin tng phng in lp li cng mt ch m khng c thi gian tr t chy td. N c th c pht hin khi o v kim tra my pht nh h thng in t da vo cc ng c tnh thi gian ca ng in p. Nguyn nhn ca hin tng h quang: - Do trong qu trnh phng in c mt s lng ln cc phn t vt liu l lng trong cht in mi pha trn cc ming ni la. Hn na c mt s ion vn cn bn trn cc ming ni la. lm hin

tng h quang trc khi chng b mt i in p v b y ra khi khe h phng in bi dng in ca cht in mi. Hin tng h quang xt ra khong gia cc xung. - Nu khong cch xung to qu ngn th mt cn tia la in c tp hp bi cc ion v cc phn t b an mn in vn tip tc duy tr, xung tip theo s xy ra lp tc v t chy cng mt im vi xung trc. Qu trnh c lp i lp li trn mt im ca phi gy sra l su trn b mt phi ch khng phi loi b mt lp kim loi b mt nh d kin. iu ny lm cho c in cc ln b mt phoi u b h hng c th khng s dng c na.

Hnh III 9: Hin tng h quang in. Tm li hin tng h quang xy ra khi: - Dng chy ca cht in mi qu yu. - Khon cch xung to qu ngn. Ngn mch v st p.

Ngn mch l hin tng khi dng in chy t in cc qua phi m khng c hin tng phng tia la in c gi l dng ngn mch. Qu trnh ngn mch xy ra khi in p tt xung gi tr rt thp xp x zr cn cng dng in t ti gi tr max. Hin tng ngn mch khng ch nh hng ti nng sut ht vt liu m cn nh hng ti cu trc ca phi. Do dng in khi xy ra hin tng ngn mch s to ra nhit lng nh hng su vo kim loi phi. Tm li dng ngn mch s xy ra khi: - S tip xc trc tip ca in cc vo phi. - Cc phn t b kt trong khe h phng in. - Chiu rng khe h phng in qu nh v dng chy qu yu. Xung mch h khng c dng in.

iu kin m trong cc xung gy ra s phng tia la in th c gi l xung mch h. Cc xung mch h khng gy ra s ht vt liu v cng khng lm h hi b mt gia cng. Chng ch lm gim nng sut gia cng. Tm li dng ngn mch s xy ra khi: - Chiu rng khe h phng in qu ln. - Dng chy qu mnh, thi ht ion ra khi vng gia cng. S qu nhit ca cht in mi.

Khi vng gia cng qu rng nhng ke h phng in li qu nh (trong gia cng tinh), cht in mi b t nng n mc b phn hu rt mnh thnh cacbon s nh hng ti qu tnh gia cng: Cc phn t cacbon ny khi hnh thnh s lm tng tnh dn in ca cht in mi khin cho qu trnh gia cng b nhiu loi, hin tng h quang thng xuyn. Nu Cacbon b lng ng trn b mt in cc, n s gy ra s khng n nh do qu trnh ngn mch. Khi cht in mi b qu nhit, phi tm cch ti u ho li iu kin dng chy v cho gia cng theo phng php nhp. III.4. Cht lng b mt gia cng. III.4.1. Cc yu t c trng cho cht lng b mt gia cng. Cht lng b mt sau gia cng c th hin qua cc thng s k thut sau: - Hnh hc: - C hc: - Ho l: nhp nh b mt, hnh dng b mt cng, h s ma st, s bin cng Thnh phn ho hc, phn t hp th, phn gii

Do tnh cht phc tp ca b mt nn i hi cc phng php phn tch v nh gi b mt cng rt phc tp. Do mc ch ca vic phn tch tnh cht b mt l xc nh cu trc vt liu ti b mt sn phm nh th no ? Nng bao nhiu? Vic xc nh cu trc vt liu ti lp ngoi cng cho ti nay vn l mt cng vic kh khn. Bi v cc phng php quang ph lun vp phi kh khn v cc mu chun. Mt khc vic xc nh s thay i cu trc hay nng theo chiu su nu ch da vo cc phng php phn tch c s cho kt qu khng c chnh xc. Ngy nay vi s tr gip ca my tnh v cc phn mm ng dng cc kt qu phn tch ngy cng tr nn r rng v chnh xc hn. Khi phn tch hay nh gi cht lng b mt ngoi cng ca sn phm, ngi ta thng gp phi mt s yu t gy nhiu ti kt qu o. Cc yu t ny tn ti di dng oxit v hnh thnh trn b mt chi tit mt lp rt mng, lp ny ph trn b mt chi tit.

Hnh III 10: nh hng nhit ti cht lng b mt phi sau gia cng. Ta bit rng cu trc t v ca lp b mt ng mt vai tr quan trng trong vic nh gi cht lng b mt sn phm hoc bn sn phm sau gia cng. Trong qu trnh gia cng th vic chuyn trng thi nng (Khong 100000C ) sang trng thi lnh mt cch t ngt v s lng ng mt phn kim loi nng chy trn b mt gia cng to ra mt phn b mt b nh hng ca hiu ng nhit (K hiu l HAZ Hnh III 10). Ta thy lp vt liu mng trn cng mu trng 1 l lp kt tinh li, trn c th tn ti cc vt nt t vi do hin tng nng lnh t ngt lp i lp li trong sut qu trnh gia cng gy ra. Lp tip theo l lp b ti cng 2 c cu trc rn, cng th tng vt so vi cng ca kim loi nn (trn 1000 HV). Lp cui 3 cng ca HAZ l lp chu nh hng ca nhit (do nhit ti vng ny vt qu nhit hnh thnh pha austenit Fe-Fe3C) trong mt thi gian ngn. cng ca lp ny t khong 800 HV.

Chiu su ca vng nh hng nhit HAZ ph thuc vo cc tham s in t l thun vi dng phng tia la in Ie, thi gian ct. Vt nt t vi thng c i vi kim loi cng hoc cc hp kim bn nhit. so snh cht lng ca b mt ny so vi b mt khc, ngi ta s dng cc i lng c tiu chun ho. Cc ch tiu nh gi c la chn sao cho cc mc tiu c th hin r rng nht. VD: Khi nh gi cht lng b mt sau gia cng bng phng php tia la in ta c th thng qua cc yu t sau: Ch s hnh hc ( nhm, thnh phn vt liu, thnh phn kt cu); Ch s ho tnh (Cc phn t ti lp bin, cc phn ng din ra trn lp bin). Cht lng b mt gia cng bng phng php tia la in c gi tr nhm b mt trung bnh nm trong gii hn 0,4 ? 20 ?m. Trn c s tiu chun VDI 3400 ngi ta chia gii hn nhm b mt ca sn phm sau gia cng ny thnh 35 bc vi phm vi t K12 n K46 nh sau: Bng III 2: Phn loi nhm b mt gia cng theo tiu chun VDI 3400. Phn loi K 12 15 18 21 0,40 0,56 0,80 1,12 Ra (?m)Phn loi K 24 27 30 33 1,60 2,24 5,15 4,50 36 39 42 45 46 Ra (?m)Phn loi K 6,30 9,00 12,5 18 20 Ra (?m)

III.4.2. Cc yu t nh hng ti cht lng gia cng. Trong qu trnh gia cng tia la in (EDM) th cht lng b mt sau gia cng ph thuc rt nhiu vo cc yu t: Ch cng ngh (Gm: Cng dng phng in, b rng khe h phng in), thnh phn v chng loi cht in mi, vt liu lm in cc, chnh xc ca my gia cng Tuy nhin yu t c nh hng nhiu nht v c th iu khin c l ch cng ngh v cht in mi. ? Ch cng ngh c tc ng rt ln ti cht lng gia cng bng tia la in, c bit l qu trnh ct bng in cc dy, cht lng b mt c quyt nh khu cui tc l khu ct tinh, cho nn cc ch cng ngh c p dng qu trnh cui ny u l nhng thng s cng ngh c ti u ho. Mi vn nghin cu ng dng cho mt cng ngh gia cng u tp chung gii quyt mi quan h gia cht lng gia cng v nng sut gia cng. Theo nguyn l ca cng ngh gia cng bng tia la in th trong mt iu kin gia cng ging nhau nu s dng mt dng in c cng ln s c kh nng ht i mt lng kim loi nhiu hn so vi dng in nh hn (Do lng nhit pht sinh ln hn s lm nng chy vng kim loi ln hn), ng thi b mt sau gia cng cng th v cng tng ng. iu ny cng ng vi cc phng php gia cng truyn thng, lp ct cng dy th bng ca b mt t c cng thp. Ngc li c mt b mt gia cng mn v nhn cn s dng dng in c cng thp to ra mch ct mng, tc ht kim loi thp. Nh vy nng sut ct gt v cht lng b mt sau gia cng l hai yu t t l nghch vi nhau. Do

vi ngi vn hnh cn phi la chn hai yu t tht ph hp vi yu cu ca sn phm t c hiu qu cao nht. Cc yu cu v cht lng sau gia cng km theo i vi sn phm, phi c cc nh da trn c s: Xem sn phm c lm t vt liu g ? Chc nng ca b mt trong h thng cng ngh, n l b mt bin dng cho sn phm hay l b mt tip xc, lp ghp vi cc b mt khc. ? Cht in mi c nh hng trc tip ti cht lng b mt sau gia cng.

- dn in ca cht in mi nh hng trc tip ti b rng ca khe phng tia la in, do c tc ng trc tip ti cht lng sau gia cng. - Thnh phn ho hc ca cht in mi c tc dng trc tip ti thnh phn ho hc ca lp kim loi b mt sn phm. VD: Khi s dng cht in mi l du th ngi ta thy rng t l Cacbon lp kim loi b mt tng ng k, ngc li khi s dng nc lm cht in mi th hm lng Cacbon lp kim loi b mt gim ng k. Cho nn ngi ta c xu hng tin hnh nghin cu ra cc bt kim loi pha vo dung dch in mi gim b rng ca khe h phng in c tc dng nng cao cht lng b mt bc gia cng tinh, ng thi ci thin c cht lng b mt sau gia cng nh lp kim loi b mt thm thu c mt s nguyn t ho hc c li (Ging hin tng thm Cacbon,Nit). III.5. Vt liu s dng lm in cc. III.5.1. Yu cu ca vt liu s dng lm in cc. Mi vt liu c kh nng dn in v dn nhit u c th s dng lm in cc. Tuy nhin s dng c chng mt cch kinh t v hiu qu nht th cc loi vt liu c chn lm in cc phi tho mn cc yu cu sau: - C tnh dn in tt dng in c th truyn qua in cc to ra dng phng in tia la in. - C tnh cht nhit vt l tt: C dn nhit, kh nng nhn nhit, im nng chy v im si cao. - C bn mn cao tc l bn vng trong gia cng tia la in. y l tiu chun quan trng nht. N nh gi thng s bn mn (E) c xc nh bi cng thc. E = ?.?.C.T2m Trong : (III.1)

- ? l h s dn nhit.

- ? l khi lng ring. - C l nhit dung ring. - Tm l nhit nng chy.

- C bn c hc tt, tc l phi c bn vng v hnh dng hnh hc khi gia cng tia la in. C ng sut ring nh. - C tnh gia cng tt, ngha l phi d gia cng. - L loi vt liu thng dng, d tm v c gi thnh thp. - C khi lng ring nh, c th ch to c in cc c kch thc ln m vn khng lm nh hng n kh nng dch chuyn ca my. III.5.2. Cc loi vt liu thng c s dng lm in cc. Nhm vt liu thng c s dng lm in cc l: ng, ng thau, hp kim nhm, hp kim Cu-W, Ag-W, Grafit, ng in phn Trong ng in phn c s dng ph bin nht lm dng c in cc. Hp kim Cu-W, Ag-W c gi thnh cao ch c s dng lm cc in cc nh c chnh xc cao, cn tnh cht mi mn thp. in cc Grafit cng c tnh cht mi mn thp v hiu qu lm vic cao nhng li c cng thp nn d dng b nh v ti cc gc cnh. Ngi ta phn bit 3 nhm vt liu lm in cc nh sau: - Nhm vt liu kim loi: ng in phn, ng thau, thp, Cu-W, Ag-W. - Nhm vt liu phi kim loi: Grafit. - Nhm vt liu pha trn phi kim-kim loi: ng Grafit. Phm vi s dng ca cc loi s dng ca cc kim loi lm in cc ph bin nh sau: Nhm vt liu kim loi: Thng dng l ng in phn v Cu-W. - Phn trm ca Cu ? 99,92% v ti a 0,005%O2. ? = 8,9 (g/cm3) tnc = 1083oC. 0,0187 ?mm2/m.

+ ng in phn:

- Khi lng ring: - im nng chy: - in tr ring:

ng in phn c s dng nhiu trong gia cng vt liu l thp. N c th c dng li nhiu ln gia cng th v tinh. Vic gia cng to hnh cho cc in cc ng l rt d dng, tuy nhin ng vn kh gia cng hn Grafit. Trc khi s dng ng in phn lm in cc ta phi tin hnh kh ng sut d trnh pht bin dng nhit khng u (xy ra do nhit hnh thnh trong gia cng) lm sai lch kch thc v hnh dng chi tit cn gia cng. in cc lm bng ng in phn c lng ht vt liu cao v mn nh (tng thi gian s dng cho in cc v chnh xc ca sn phm sau gia cng). Nhc im ln nht ca in cc lm bng ng in phn l nng v c gin n nhit ln nn khng thch hp cho vic ch to in cc c kch thc ln. Ngoi ra ng in phn mn nn d b bin dng cho nn khi s dng lm in cc mnh d th c hnh dng khng n nh. Khi tng cng phng in th in cc s b mi mn nhiu hn.

+ Vt liu Cu-W:

- Gm (65 ? 80)% W cn li l Cu. ? = 15 ? 18 (g/cm3) tnc = 2500oC. (0,045 ? 0,055) ?mm2/m.

- Khi lng ring: - im nng chy: - in tr ring:

Hp kim Cu-W l mt hn hp vt liu c pht trin thng qua cng ngh luyn kim bt, trn c s ca Wolfram v ng c trn theo mt t l nht nh. in cc lm bng hp kim Cu-W c bn n mn cao nh W , c tnh dn in cao nh Cu. in cc lm bng Cu-W cng cho cht lng b mt sau gia cng tng ng vi in cc lm bng ng in phn, nhng chng li c tnh gia cng ch to kh hn. Nhc im ln nht ca hp kim Cu-W l chng c khi lng ring ln v gi thnh cao nn kch thc ca in cc b gii hn. Nhm vt liu phi kim.

Trong nhm vt liu phi kim ny th ch c Grafit c s dng ph bin lm in cc. Grafit: - L Cacbon tinh khit vi t l 0,1% tro. - Khi lng ring: - bn gy: - in tr ring: ? = 1,6 ? 1,85 (g/cm3) 200 ? 700 kg/cm3. 8 ? 15 ?mm2/m.

Grafit c cu trc gm ln c bn nhit rt cao. Grafit thch hp gia cng thp. Khi gia cng thp nu Grafit c ni vi in cc dng s c mn t hn so vi ng. Grafit c in tr ring ln hn nhiu ln so vi ng in phn nn khi tng cng cho dng phng in th khc vi ng Grafit c mn in cc l khng i, ch khi dng phng tia la in tng rt cao (200A) mi c s thay i v mn ca in cc lm bng Grafit.

Hnh III 11: Trnh t ch to in cc bng Grafit. Kh nng ch to in cc bng Grafit rt d dng, n c ch to nhanh hn in cc ng 10 ln. Vi khi lng ring thp lm cho Grafit rt thch hp lm cc in cc c kch thc ln. Ngoi ra n c bn nhit cao khng b nng chy ngay c nhit 3600oC, grafit cn c bn xung nhit cao, mi trng khng kh c nhit 480oC th Grafit vn gi c bn khng i. Grafit c tnh dn in tt, dn in l 10 ??m. dn nhit Grafit cao hn hn mt s kim loi v n gim khi m nhit tng. dn n nhit ca Grafit rt thp, bng 6.10-6/K ch bng 1/6 gin n nhit ca ng in phn, nn n gi c kch thc chnh xc ca in cc trong sut qu trnh gia cng c v gia cng xung .

Nhc im ca Grafit l c dn nn i khi b mi mn hoc b v ti gc in cc. Ngoi ra trong qu trnh ch to in cc to ra nhiu bi than lm nhim nh xng. Do trn th trng c hn 100 loi Grafit khc nhau, cho nn vic la chn loi vt liu lm in cc nh hng rt nhiu n nng sut gia cng tia la in v mn in cc ca chng. Bng III 3: Cc loi Grafit ca cc nh my ch to khc nhau (tham kho). Ch s ht Un gy Mc Grafit ??m) Mt cng rng t c

(N/mm2)

(g/cm3) (Shore) %

VDI 21 Grafit nhm C < 5 1 PocoEDM 3 91 1,83 70 90 95 1,90 3 65 6 1,90 1,88 80 95 1,85 80 85 8 1,90 85 90 10 10 11 7 75 90 1,8 1,9 70 - 80 5 - 10

Alectro G1700 2,5 2 3 4 5 6

Ringsdorf V940-V1364 3 Carbone Ellor +35 Alectro G1818 3 3 95

Novotec Technograph 45 Ringsdorf V1345 7

Grafit nhm B < 20

50 70 1,85

60 - 75 10 15

VDI 25 1 2 3 Ringsdorf EK 88 10 50 10 1,85 50 75 1,85 10 58 10

Novotec Technograph 20/25 Erograph 70 50 1,85

Alectro G1700 15

60

12

4 5

Carbone Ellor 10/12 Ringsdorf V1345 < 50

20 15

-45

1,85 1,73 10 20

65 85

7/10 15

Grafit nhm A > 10

< 1,85 < 65

VDI 30 1 2 3 Carbone Ellor +25 20 -10 1,82 42 65 1,78 10 54 15

Novotec Technograph 15 Erograph 50 10 42 1,78 10

Alectro G500 4

54 33

20 1,75 55 12,5

Ringsdorf EK 86/85

Nhm vt liu pha trn phi kim - kim loi.

Vi cp vt liu Grafit - Cu l in hnh: - Khi lng ring: - bn gy: - in tr ring: ? = 2,4 ? 3,2 (g/cm3) 700 ? 900 kg/cm3. 3 ? 5 ?mm2/m.

Nh c Cu nn vt liu grafit-Cu c bn gy cao hn hn so vi grafit, c in tr ring gim nn tng c tnh dn in. Vt liu grafit-Cu c gi thnh cao nhng li c cng vng tt hn grafit nn thng c s dng lm cc in cc nh khi gia cng cc chi tit c chnh xc cao. Nhm vt liu khc: Bao gm Volfram, nhm, Molipden v mt s hp kim cng c th s dng lm in cc trong mt s trng hp c bit khi cn gia cng l su, gia cng vi in cc rng v.v Bng tng hp v mt s vt liu thng s dng lm in cc Bng III 4: Thng s cng ngh ca mt s vt liu lm in cc. Vt liu in tr ring ?mm2/m. OK OK im nng chy

im si Kh nng truyn nhit

Cal/(s*cm*grad) Wolfram 0,05 3643 6273 (200C),(5000C)

ng in phn (99,8% Cu, 0,2%O) 0,85 (5000C) ng- Wolfram (72%Cu-28%W) Grafit >11 0,04 3773

0,017

1356

2613

0.93 (200C)

5100

(200C),(5000C)

Khng chy

90W/mK

III.5.3. Kch thc ca in cc. Chng ta bit rng chnh xc ca lng khun ph thuc rt nhiu vo chnh xc ca kch thc in cc c s dng gia cng. Do kch thc ca in cc c xc nh theo yu ci ca bin dn cn gia cng. Ta s dng mt v d xc nh kch thc ca mt in cc dng gia cng xung to l c kch thc (D) b mt c chiu cao nhp nh cc i (Rmax) minh ho qu trnh xc nh kch thc ca in cc: Kch thc ca in cc c xc nh bi cng thc sau: d = D 2.FS 2.Rmax. (Gia cng th) (III.2) d = D 2.FS Trong :

(Gia cng tinh) (III.3)

- D l kch thc ca l cn gia cng.

- FS l khe h phng in gia lng khun v in cc. - Rmax l cao nhp nh cc i ca b mt sau gia cng. III.6. Cht in mi trong gia cng tia la in. Cht in mi (Dielectric) c 4 nhim v chnh nh sau: - Cch in. - Ion ho - Lm ngui. - Vn chuyn phoi. Cch in:

Nhim v quan trng nht ca cht in mi l cch in gia in cc v phi. N bo m rng s cch ly gia in cc v phi khi khe h gia chng hp. Ch khi no khe h gia chng t mt gi tr nht

nh th mi cho php phng tia la in i qua. Nu khe h cng nh th lng ht vt liu v chnh xc in hnh trong gia cng cng tng. Cht in mi c s dng trong thc t t khi l nguyn cht. V vy trc khi i vo vng gia cng, n phi i qua mt h thng lc. Mc d vy, vn lun lun cn st li cc phn t t vi ca vt liu c hnh thnh trong qu trnh gia cng. iu ny phi c tnh ti trong qu trnh la chn cht in mi. Ion ho:

Cht in mi phi to iu kin ti u cho qu trnh phng in, ngha l n phi c kh nng ion ho vo ng thi im chun b phng in. iu ny gip cho s tp trung nng lng knh plasma to iu kin cho qu trnh ht vt liu khi phng tia la in. n khi xung b ngt th cht in mi phi dng qu trnh ion ho, to u kin s phng tia la in tip theo s xy ra ti v tr khc tc ng n phi (trnh hin tng phng tia la in sm khng ng vo v tr cn thit). Cht in mi cng bao trm knh phng in, nh to c tp trung mt nng lng cao ti mt s v ch lm tng hiu qu cho qu trnh phngs tia la in. Lm ngui:

knh phng in, trong mt khng thi gian cc ngn (c phn triu giy), nhit c th ln ti 100000C. Nhit xut hin y cn phi c chuyn i, nu khng th mn in cc s tng nn. B mt phi cng s b h hi do qu nhit. Bn thn cht in mi cng khng c php qu nhit. Bi v s qu nhit s lm cho cht in mi d b phn hu thnh kh v cacbon t do. Khi ny c tc dng m rng knh phng in khng mong mun, dn n lm gim lng ht vt liu. Cn cc cn cacbon s lng xung b mt ca in cc s gy ra hin tng ngn mch. V vy cn phi to ra mt dng chy lin tc i qua khe h phng in lm ngui c in cc v phi. Vn chuyn phi liu:

Nu cht in mi b bn s gy ra s in hnh khng chnh xc v cc khuyt tt qu trnh s tng nn. S bn ca cht in mi ch yu l do cc phn t b n mn cn l lng hoc lng ng trong khe h phng in. Mt t l qu ln ca cc phn t ny dn n s phng in tht hng v gy ra sai s in hnh, nguy c to h quang v ngn mch tng ln. V vy, phi c mt h thng dng chy ca cht in mi lin tc qua khe h phng in vn chuyn ht cc phn t c n mn ra khi vng gia cng v bo m cht in mi trong khe h phng in l sch. Dng chy mang theo cc phn t c n mn s c a vo h thng lc to ra cht in mi sch, a vo vng gia cng. III.6.1. Cc loi cht in mi. Cho n nay, c hai loi cht in mi c s dng ch yu cho hai phng php gia cng tia la in khc nhau l:

- Hydrocacbo: Ch yu s dng cho gia cng xung nh hnh. - Nc kh khong: Ch yu s dng cho gia cng ct dy.

Ngoi ra trn th trng th gii mi xut hin mt loi cht in mi mi da trn thnh phn chnh l nc. N c nht cao hn nc v hiu qu lm mt tt hn du. N c s dng ch yu cho gia cng xung nh hnh vi in cc grafit ln v bc dng in gia cng ln. Do n c lng ht vt liu cao. V cht in mi ny c thnh phn chnh l nc nn dng in d l rt ln khi gia cng tinh. N lm cho kh nhn ra b mt tinh v nhm Ramax ? 10?m. Cc tiu chun nh thnh phn ho hc, nht s quyt nh cht lng v kh nng p dng ca cht in mi. III.6.2. Tiu chun nh gi cht lng ca cht in mi. - bn lu, t hao ph. - V sinh: Khng hi da, khng c, d ngi. - C im chy tng i cao (Kh chy). - C mt v m c nht nh. - C trong sut tin quan st vng gia cng. - C nht nht nh. - C kh nng dn in di mt iu kin nht nh. - Cch in iu kin bnh thng. - C kh nng chu in p. - C kh nng b ion ho. - C kh nng mang huyn ph. - C kh nng lc sch. - Gi c phi chng. Trong cc tiu chun nh gi k trn th tiu chun nht ca cht in mi c t ln hng u. Bi v n nh hng trc tip n knh phng in. nht c trng cho ma st trong l tr lc ca cht lng i vi s chy. nht o bng (mm2/s). - nht quyt nh n s m rng ca knh phng in. - nht ca cht in mi cng cao th knh phng in cng c tp trung hn, hiu qu phng in cng cao hn.

Khi gia cng th, ta nn s dng cht in mi c nht cao, thng th gi tr nht t n 4 mm2/s. Cn ti khi gia cng tinh th ta s dng cht in mi c nht thp hn, thng thng l 2 mm2/s. Trong thc t s dng, trnh phi thay i cht in mi nhiu ln trong qu trnh gia cng ngi ta thng s dng cht in mi c nht trung bnh cho c hai ln gia cng th v tinh. Tuy nhin cn lu rng, khi gia cng tinh v rt tinh th cht in mi phi c chy qua cc khe h phng in rt nh. Khi t hiu qu gia cng tt nht ta phi s dng cht in mi c nht thp. III.6.3. Cc yu t an ton ca cht in mi. Do nhit trong khe h phng in gia hai in cc rt cao lm cho bn thn cht in mi tr nn rt nng. V th cn phi trnh s dng cc loi cht in mi c im chy thp (d chy). Mt khc phi chc chn rng khi cht kh bc hi ra khi cht in mi v cc sn phm lng cn ca cht in mi khng gy hi n sc kho ca ngi ng vn hnh my. Vi cc cht in mi m c s l nc th dng in d g l rt ln khi s gy bt li cho vic gia cng tinh.

Hnh III 12: Biu s dng cht in mi. Trong qu trnh gia cng khng c s dng nc kh khong lm cht in mi, v b mt in cc s cho dng in d qu ln. III.6.4. Cch thc vn chuyn cht in mi. Vic vn chuyn vt phm sau gia cng ra khi vng gia cng c h tr bi cc phng php sc ra (to dng chy thng xuyn) ca cht in mi qua vng ang gia cng.

Hnh III 13: S cc loi dng chy cht in mi. Cc phng php to dng chy thng c s dng cho my EDM thng mi l: Dng chy bn ngoi (Hnh IV.12.a) , dng chy p lc (t in cc hoc phi) (Hnh IV.12.b), dng chy ht (qua in cc hoc phi) (Hnh IV.12.c,e), dng chy phi hp (Hnh IV.12.f), dng chy nhp trong dng chy ngoi c s dng ph bin v thng dng hn c. im li th ca dng chy bn ngoi hon ton c lp vi cp in cc, cht in mi c a vo trc tip khe h phng in nh iu khin c hng ca dng chy. Cc li ca dng chy. - Li do p lc cao v s dung ng: Do p lc cao ca dng chy, in cc c th chu mt i khng rt mnh. Tc ng ng ca dng chy i vi in cc ging nh mt kch thu lc, c bit khi lng khun su v hp. Cc im trn in cc khi chu p lc cao c th b rung ng lm cho v tr gia in cc v phi c th b sai khc nh hng ti bin dng cn gia cng.

-Li do s gim p lc dng chy: Khi khe h phng in hp v di th p lc dng dung mi s gim mnh cui hnh trnh, iu lm cc phn t b n mn khng thot khi vng gia cng, gy ra hin tng tc nghn khe h phng in, lm sai khc hnh dng lng khun. III.6.5. Vi tr ca cht in mi. T cc phn tch trn ta nhn thy rng cht in mi c nh hng rt ln ti qu trnh gia cng tia la in. N khng ch nh hng trc tip ti nng sut gia cng m cn nh hng trc tip ti cht lng ca b mt gia cng. Qua th nghim ngi ta thy rng cht lng ca b mt ph thuc rt nhiu vo chng loi v thnh phn trong dung dch cht in mi s dng trong qu trnh gia cng. VD: Nu s dng cht in mi l nc th sau khi gia cng bng phng php tia la in ngi ta thy lp b mt hm lng Cacbon gim i ng k. Cn khi s dng du lm dung dch in mi th lp b mt ca sn phm sau khi gia cng hm lng Cacbon tng ln ng k. Nh vy nu tin hnh pha hp l cc bt kim loi c bit vo trong dung dch in mi th cht lng b mt sau gia cng s c ci tin ng k. V mt hm lng nht nh kim loi ny s thm thu vo b mt sn phm ci thin c tnh cho sn phm (Ging nh qu trnh thm C, N cho chi tit trong qu trnh nhit luyn). III.7. Xu hng pht trin trong lnh vc gia cng tia la in tng lai. m rng kh nng gia cng cho phng php tia la in. Cc nh khoa hc ang nghin cu v ci tin kh nng gia cng tia la in theo cc xu hng sau: - Khng cn s dng dung dch in mi. Theo h th mt mi trng sch c tnh cht cch in l tng nh l cht in mi, vic vn chuyn vt phm sau gia cng s nh tc ca dng kh thi ra khi vng gia cng. y l phng php ang trong giai on u c nghin cu v pht trin, nhng kt qu ban u t cc th nghim n gin khng nh tnh thc t ca vn . - Trong dung dch in mi c pha thm bt kim loi tng kh nng dn in cho cht in mi, nh trong qu trnh gia cng tinh th chiu rng khe h phng in cn thit s c thu hp li nh m cht lng b mt gia cng s tng ln, ng thi cht lng b mt cng c ci tin nh k. - Ci tin ng c iu khin dng c in cc c kh nng thc hin c nhiu chuyn ng hn (gia cng c nhiu loi bin dng hn) hay l c gia tc ln hn in cc c th tin st b mt cn gia cng hn. - Nghin cu v ci tin tm ra cc loi vt liu mi lm dng c in cc cho mn l t nht nng cao tui th lm vic ca dng c. - Nghin cu pht trin mch iu khin in t c th pht ra c cc loi xung mi tc ng ti qu trnh phng in trong qu trnh gia cng, nh m cht ca b mt sau gia cng c cht lng cao hn (Trng i hc Luven chng minh khi s dng xung mi ??? th lp HAZ gn nh l khng c).

- Tip tc nghin cu cc bin php gia cng mi thc hin nh qu trnh phng tia la in. VD: Phay tia la in... - Nghin cu v pht trin cng ngh gia cng Micro EDM, gia cng cc loi vt liu mi nh l: Vt liu gm, vt liu Silicon m rng th trng cho gia cng tia la in. - Lu ti vic k tha v pht huy cc kin thc, kinh nghim ca ngi vn hnh my khi gia cng.

Chng IV. Thit k v lp quy trnh cng ngh gia cng bin dng lng khun. Khun l mt sn phm ca c kh, c s dng nh hnh cho mt chng loi sn phm c hnh dng v vt liu nht nh. N c cu to t nhiu chi tit c kh khc nhau, cc chi tit c kh ny lp rp li vi nhau theo mt trnh t nht nh to ra mt sn phm hon chnh, ti y vt liu sau khi c gia nhit s nng chy c bm vo, c lm ngui to ra sn phm c hnh dng t yu cu. Bi vy khun ch to ra c cc sn phm nha t yu cu th cc chi tit lp rp nn n phi c ch to t chnh xc v kch thc v cht lng b mt nht nh. Xc nh ng li cng ngh.

qu trnh thit k v ch to khun t hiu qu cao nht, c v kinh t (chi ph cho thit k, gia cng thp nht) v k thut (cht lng ca sn phm sau gia cng cao nht), th vic lp ra quy trnh cng ngh ch to sn phm phi ph hp vi iu kin sn xut hin ti ca ni sn xut v hnh thc sn xut (qui m ca sn xut). Do khun c thit k v ch to theo nhu cu ca khch, p ng cng vic sn xut ra mt loi mt hng nha no (kiu dng v loi vt liu nht nh) mt cch nhanh nht, kp thi p ng nhu cu tiu dng ca th trng. Cho nn vic qui m ca sn xut v ch to khun l dng sn xut n chic, lot nh: S lng sn phm mi loi cn ch to t, sn phm khng c tnh lp li, chu k lp li hu nh l khng c Nh vy ph hp vi qui m ch to sn phm th vic lp quy trnh cng ngh gia cng ch to sn phm, c thit k da theo nguyn tc tp chung nguyn cng. Theo nguyn tc ny th cc qui trnh cng ngh gia cng cc bin dng cn thit trn chi tit theo thit k c gp li mt cch ti a, thc hin gia cng ch to mt cch lin tc trn mt my cng c nht nh. Nh m chnh xc chung ca khun c nng cao, do hn ch c sai s g t gy ra. Chn phng php gia cng.

Cn c vo hnh thc ch to sn phm khun, nhn thy phng php ch to ph hp nht cho dng sn xut khun chnh l: - S dng cc loi my hin i c chnh xc gia cng v qu o chuyn ng to hnh phng ph. C nh vy mi c kh nng ch to c cc bin dng phc tp t chnh xc cao, trong khi s lng sn phm ch to t. VD: Cc loi my CNC, my gia cng bng phng php tia la in

- S dng cc loi g vn nng nh: t, mm cp, bn t ch khng s dng cc loi g chuyn dng (tn thi gian thit k v lp t g). - Qu trnh ct gt kim loi tin hnh theo phng php gi g v ct th. Loi my, dng c ct, thng s gia cng s c trnh by c th mi bc gia cng. Di y l hai my s dng ch yu cho cng vic gia cng bin dng ln khun. l my phay P1050-CNC hoc my phay Manho DMU 60T v my gia cng tia la in Hurco Spark 900. Bng IV 1: Thng s k thut ca my phay P1050-CNC nh sau: Tn gi n v Gi tr Kch thc ca bn my X,Y. Rnh T. mm 16x4x80 mm -mm mm 1000x500x500 DC Servo mm 0,005/300 ? 0,003 5000 1-3000 mm 425x1524

Hnh trnh: X,Y,Z. ng c: X,Y,Z. chnh xc nh v. chnh xc lp li. Tc chy nhanh.

mm/pht

Tc chy khi ct gt. mm/pht L cn trc chnh. Cng sut trc chnh. Tc trc chnh. Ti trng. Kg -kW BT 40

5,5 7,5 60 6000

Vng/pht 600 hidenhain

B iu khin. --

Hnh IV 1: My phay iu khin s P1050-CNC. Bng IV 2: Thng s k thut ca my gia cng xung Hurco Spark 900: CHARACTERISTICS SPECIFICATIONS Performance

Accuracy (Positionning). Repeatability. Rosolution. Rapid traverse poiition rate for X,Y and Z axes. ? 10 ?m. ? 5 ?m. ? 1 ?m. 600 mm/min. Stock Removal (Graphite Electrode) Wear 1% polarity +ve. Max. stock polarity ve. Min. wear available. Finest surface finish. 650 cu mm. < 0,5%. 21 VDI Stock removal (Copper Electrode) Wear 1% polarity +ve. Min. wear available. Finest surface finish. < 0,5%. 16 VDI Maximum generator output. 45/100/200/300 Volts. Physical and Drive Limits. Table size. Area covered by quill. 60 amps. 390 cu mm. Max. stock removal/min. 570 cu mm. Max. stock removal/min.

Work tank size. Vertical travel of quill. Distancefrom tooling face to surface of table.

Max. depth of dielectric over table. Type of electrode mouning. Max. weight on quill. Max. weight of workpiece on table 270 mm x 190 mm. 874 mm x 480 mm. 265 mm. Max. 440 mm. Min. 175 mm. 220 mm. Optional. 100 kg. 300 kg. Machine Dimernstions Height max. Height min. Width. Depth. Net Weight. 1822 mm. 1100 mm. 1450 mm. 2084 mm. 550 mm x 350 mm.

1750 kg. Filter Unit Dimensions Height Width Depth 890 mm. 840 mm. 700 mm. Volume of dielectric required

Power Service 220/600 Volts. 3 phase 50 Cycle supply 7 kVA

Hnh IV 2: My gia cng xung tia la in Hurco Spark 900.

Hnh IV 3: Hnh dng ca my ct dy HITACHI 3D. My ct dy Hitachi 3D c th gia cng c cc l c kch thc nh, bin dng phc to, ng thi cht lng b mt bin dng sau gia cng t c l rt cao. Rt thch hp cho vic cht to in cc c bin dng l mt phng. IV.1. iu kin k thut ca khun. * Cc yu cu k thut cho khun gm c: Do khun ta thit k c kt cu l khun ba tm cho nn trong qu trnh thit k v gia cng phi ch ti cc vn sau. - Cht dn hng ca khun phi c di lm vic v cng vng cn thit khun lm vic c n nh trong thi gian di. V trong qu trnh lm vic, cc tm khun trc v sau lun phi thc hin cc chuyn ng tnh tin vo ra, to cc khong khng gian lm vic cn thit nh l: To khng

gian mang hnh dng sn phm (khi ng khun) v to khong khng gian cn thit ly sn phm ra (khi m khun) sau khi qu trnh lm ngui sn phm kt thc. - Cc tm khun sau, tm gia v khun trc phi c c nh trong sut qu trnh bm nha vo lng khun. - bng ca bin dng li v lng khun phi t ?8 tr nn (Ra ? 0,63). - nhn bng v song song ca cc b mt phn khun phi m bo qu trnh ng khun c hon ton kn kht hn ch hin tng ba via. - Khong khng gian lm vic ca khun phi ph hp vi khong khng gian ca my p nha. - Cc knh dn nha phi c kch thc thch hp to iu kin nha in y lng khun nhanh nht m lng nha tiu tn t nht. - Cc chi tit phi ch to theo ng yu cu ca bn v khi lp gip li chng vi nhau th khun c kh nng lm vic tt.

Hnh IV 4: Kt cu chung ca khun p nha ba tm. IV.2. La chn vt liu thch hp ch to cc chi tit. Khun c cu to t rt nhiu chi tit khc nhau, c iu kin lm vic khc nhau. Cho nn tu theo in kin lm vic c th ca chi tit m la loi vt liu thch hp va bo m thi gian s dng ln yu cu v gi thnh. - i tm o khun (o khun) ch mang nhim v che chn v bo v lng khun nn vt liu ch to ra n khng yu cu cao lm ta ch cn s dng thp C45 l . - i vi lng khun vt liu c la chn va c tnh gia cng tt li pi c l tnh thch hp, v khun lm vic trong mi trng c nhit cao (nhit gia cng PP) li chu p lc ln nn rt d b bin dng. Trc nhu cu ca th trng, cc hng sn xut ln xy dng cc mc thp tiu chun s dng trong lnh vc gia cng ch to khun mu. Do em chn thp Stavax (20X13) c thnh phn ho hc nh sau: Thnh phn ho hc 0,35 Tiu chun Tnh trng 0,9 C 0.45 Mn 13.0 Mn 0,005 Cr 0,50 Smax Si

AISI 420, SF-420, HPM-38, STAVAX. ti v ram, cng t 28 ? 34 HRC

Kch thc ca phi dng ch to tm lng khun nh sau:

Hnh IV 5: Kch thc phi thp dng ch to lng khun trc.

Hnh IV 6: Kch thc phi thp dng ch to lng khun sau. *) c im ca chng loi thp ny nh sau: Stavax l thp hp kim Crm khng g c ti v ram sn, c cc c tnh k thut sau: - Kh nng chng g cao. - Kh nng nh bng tt. - Kh nng chng mi mn cao. - Kh nng gia cng d dng. - cng ng nht mi kch thc. - Chi ph bo dng khun thp. *) L tnh: Truyn nhit (W/m.k) 20.0 Gin n nhit (10-6m/m.k) 10.5 20-100 20-200 20-300 20-400 20-500 20-600 20-700 11.0 11.0 11.5 20 23.0 350 26.2 700

*) Cc ch nhit luyn: Cch nhit luyn mm 760 ? 800 Ti 1020 ? 1050 Nhit (oC) Cch lm ngui cng t c Trong l Trong du 230 HB. 56 HRC.

Ram 200

100

300 400 500 600 ----------56 HRC. ---

55 HRC. 52 HRC. 51 HRC. 52 HRC. 40 HRC. Cn cc tm khc hoc cc chi tit khc trong khun c s dng theo tiu chun ho. Cho nn t mua v ri ch to thm cho ph hp vi bn thit k. Lu : Ta ch cn la chn vt liu cho cc chi tit cn ch to m thi, cn cc chi tit theo tiu chun th vn vt liu cng c chun ha sn ri. IV.3. Lp phng n thit k v ch to lng khun. Sn phm nha c to ra trn nguyn tc bm nha nng chy vo khong khng gian kn c hnh dng ca sn phm cn ch to nha c nh hnh nh lm ngui to ra sn phm s c ly ra. Do vic u tin rt quan trng l la chn b mt phn khun thch hp vi kt cu ca sn phm : - To iu kin thun li cho vic thit k v ch to c hai lng khun. - Hnh dng ca sn phm sau khi p ra c hnh dng p nht, tn t nguyn liu nht, tn t cng sa cha nht. - Sn phm sau khi lm ngui ly ra nhanh v d nht. Sau ta tin hnh thit k hnh dng ca hai tm khun: Mt tm mang hnh dng trong ca chi tit gi l li khun v mt tm trn mang hnh dng bn ngoi ca sn phm gi l lng khun. khun lm vic hiu qu trn hai tm khun ny ta phi thit k mt s b phn c tc dng: nh v tr gia hai

khun vi nhau; lm ngui khun nhanhNhng vn khng nh hng ti khi khun c s. Vy trn khun cn c cc b phn sau: - Bin dng cn thit to hnh cho sn phm. - Bin dng lp thm chi tit c nh v tr gia hai khun. - H thng knh dn nha vo lng khun. - H thng lm mt khun. - Kt cu s dng lp ghp vi cc b phn khc trong khun. Vy kt cu chung ca hai tm khun c dng nh sau.

Hnh IV 7: Kt cu ca tm li khun trc.

Hnh IV 8: Kt cu ca tm lng khun sau. Nh vy s c hai phng n thit k ch to ra hai tm khun trc v sau: - Khun lin khi l khun c ch to mt tm c vt liu ng nht nh hnh v trn. - Khun lp ghp l khun c ch to t 2 tm c vt liu khc nhau c kt cu nh hnh v trang sau.

Hnh IV 9: Tm li khun v tm lng khun ghp li vi nhau. Tin hnh phn tch iu kin lm vic v kh nng ch to cng nh sa cha gia hai loi khun lp ghp v lin tm th khun lp ghp c cc u v nhc im sau: ? u im:

- Rt ngn thi gian cng hn, do c th gia cng ng thi 2 tm ca 1 khun ti hai v tr khc nhau. - Nng cao tui th lm vic ca khun, do la chn c vt liu hp l lm bin dng khun m vn tit kim c vt liu t tin. - Rt ngn thi gian ch to chung ca khun nh s dng cc tm khun c kch thc tiu chun ho sn. - Hn ch t l ph phm trong qu trnh gia cng ch to bin dng khun. - Vic tin hnh s cha v bo dng khun c thun li v d dng. ? Nhc im:

- Khi lng cng vic cn phi gia cng nhiu hn. - i hi my gia cng phi c chnh xc v tr tt hn (yu cu lp ghp v lm vic). Bi v i vi mi lng khun th tm o khun v tm lng khun c gia cng ti hai my khc nhau. Nhc im ca khun lp ghp hon ton c th khc phc c do cc my gia cng hin i ngay nay (nh l my CNC) c chnh xc gia cng lp li t c c mt vi ?m trn mt hnh trnh chy dao. Do em la phng n thit k v gia cng hai lng khun dng khun lp ghp. IV.4. Lp Qui trnh cng ngh gia cng ch to lng khun. Vic gia cng ct gt ht lng kim loi d to ra sn phm c hnh dng t yu cu, u c thc hin trn my iu khin s P1050-CNC. Do vy vic thit lp chng trnh iu khin cho my trong mi bc gia cng cng l vn cn phi gii quyt. tng nng sut cho qu trnh ch to v m bo cht lng sn phm ch to ra sau mi nguyn cng th: - i vi cc bc gia cng n gin nh: Khoan l, phay mt phng, phay hc c dng khi phng th vic la chn dng c ct v chng trnh iu khin c ngi cng nhn vn hnh my, lp trnh trc tip bng tay trn bng iu khin ca my. - i vi cc b mt gia cng c bin dng phc tp (dng 3 D) nh l bin dng mi lng khun. Cng vic la chn dao c v chng trnh iu khin my s c ngi thit k to ra nh s dng phn mm CAM (DEL-CAM). IV.4.1. Thit k qui trnh cng ngh gia cng tm o khun trc. IV.4.1.1. Trnh t cng ngh gia cng tm o khun trn.

Hnh IV 10: Hnh dng tm khun trc dng phi trc gia cng.

Hnh IV 11: Kt cu ca tm o khun trc cn gia cng. Cn c vo hnh dng ca phi sau khi mua v theo tiu chun trc khi gia cng (Hnh IV 10) v hnh dng v kt cu ca tm khun trc ta thit k (Hnh IV 11). *) Nhn thy rng t phi ch to ra c tm o khun t yu cu k thut phc v tt cho cng vic, ta cn phi tin hnh cc cng vic sau: - Gia cng phn hc hnh ch nht c kch thc 240x140mm su 30 mm to v tr t li khun vo. - H thng l x Bulong chm M8 qua. - Gia cng 4 hc ch nht lp nn cn. - Gia cng h thng dn dung dch lm mt khun.

- Gia cng h thng knh dn nha. *) Trnh t cc nguyn cng ch to tm khun trc nh sau: Th t Ni dung cng vic. 1 2 3 4 Chun b phi cho qu trnh gia cng ch to. Khoan 2 l f10,5 su 90 mm trn b mt bn B. Khoan 2 l f10,5 su 90 mm trn b mt bn D. Trn b mt A tin hnh gia cng ch to cc bin dng sau:

- Phay hc ch nht c kch thc 240H7x140H7 mm su 30 mm. + Khoan l f20 su 32,5 mm tm phi. + Gia cng th to hc ch nht 239,8x139,8 su 30 mm. + Gia cng tinh to hc ch nht 240H7x140H7 su 30 mm. - Gia cng h thng lm mt lng khun trc: + Phay 4 l f20 su 33,5 mm. + Khoan 4 l f10,5 su 56 mm. - Gia cng hc lp nm cn: + Hai hc cn 7o c kch thc 110x20x17 mm bn knh ln R6. + Hai hc cn 7o c kch thc 80x20x17 mm bn knh ln R6. 5 Trn b mt C tin hnh gia cng ch to cc bin dng sau:

- Gia cng h thng l x Bulong M8 qua. + Phay 6 l f14 su 10 mm. + Khoan 6 l f9 su 30 mm. - Gia cng h thng knh dn nha vo lng khun. + Rnh c tit din trn R3 rng 6mm su 4 mm. + Hc hnh cu c bn knh R = 5mm su 6 mm. + Gia cng l f12 su 5 mm. + Gia cng h thng l f4 su 30 mm chun b xung l dn nha.

6 7 8 9

Gia cng xung mt phn l ca h thng knh dn nha. Mi phng y C ca tm khun trn. Tin hnh mi phng b mt phn khun. Tin hnh gia cng ngui ton b cm khun trn:

- nh bng ton b bin dng li khun t bng cn thit. - Tin hnh mi 4 hc n khp vi nn cn. - Tin hnh nh bng lng knh dn nha t bng yu cu. - Tin hnh taro ren M12 cho cc ng dn dung dch lm mt.

IV.4.1.2. Thit k cc nguyn cng. IV.4.1.2.1. Nguyn cng 1: Chun b phi cho qu trnh gia cng. Tin hnh kim tra phi xem c t yu cu k thut hay khng: - Kch thc ca phi c t x x hay khng. - B mt phi l b mt tinh t bng cp 5. - Khng tn ti cc khuyt tt: nt, rn, r . IV.4.1.2.2. Nguyn cng 2: Khoan 4 l f10,5 su 90 mm trn b mt bn B. S nh v (Trang sau):

nh v:

Hai mt phng D v A ca phi ln lt tip xc vi thanh k v m tnh ca t. Nn phi c khng ch c 6 bc t do, v s dng hai mt phng nh v. Cho nn ta ch cn tin hnh kp cht phi chun b cho qu trnh gia cng ch to ti cc v tr thch hp. Kp cht:

phi khng b dch chuyn khi chu cc lc ct gt tc dng nn. Ta ch cn quay trc vt ca t lm m ng chuyn ng li gn phi to ra lc kp cht W cn thit c nh phi. Chn my gia cng:

Chi tit c gia cng trn my phay P1050-CNC iu khin theo chng trnh. Cng sut ca ng c l 7,5 kW (cc thng s k thut tham kho thm Bng IV 1). Chn dng c ct:

Qu trnh gia cng c tin hnh nh s dng mi khoan lm bng thp gi c f10,5 mm chiu di ct > 120 mm. IV.4.1.2.3. Nguyn cng 3: Khoan 4 l f10,5 su 90 mm trn b mt bn D. . S nh v (Trang sau):

nh v:

Do hai mt phng B v A ca phi ln lt tip xc vi thanh k v m tnh ca t. Nn phi c khng ch c 6 bc t do, ta ch cn tin hnh kp cht phi chun b cho qu trnh gia cng ti cc v tr thch hp. Cc qu trnh tip theo tin hnh hon ton ging nh nguyn cng 2.

IV.4.1.2.4. Nguyn cng 4: Gia cng bin dng trn mt phng A ca phi. S nh v.

nh v:

Nh s dng mt phng y C lm mt phng nh v, ta khng ch c 3 bc t do ca phi trc khi kp cht phi gia cng. Kp cht:

Lc kp cht cn thit W c phng vung gc vi mt nh v c tc dng c nh chi tit trong qu trnh gia cng c hc, c to bi mi ghp bulong-ai c v tay n. Qu trnh kp cht chi tit din ra nh sau: - Tin hnh kp cht s b c nh phi mt cch tng i. - Lp ng h o ln trc my tin hnh r v tin hnh iu chnh li v tr ca phi mt hai mt phng B v E song vi ng chy dao ca trc my. - Tin vn cht 4 Bulong kp cht chi tit. Chn my gia cng:

Chi tit c gia cng trn my phay P1050-CNC iu khin theo chng trnh. Cng sut ca ng c l 7,5 kW (Cc thng s k thut ca my tham kho thm Bng IV 1). Dng c ct: Tu theo bin dng cn gia cng v cht lng ca b mt sau gia cng m chn dng c ct cho ph hp. C th. - gia cng c hc ch nht c kch thc 240x140 mm su 30 mm t cp chnh xc 7 bng b mt cp 4 5 l 10 5?m. Ta tin hnh gia cng theo trnh t sau. + Khoan l c ng knh f20 mm su 32,5 mm tm ca phi bng mi khoan chun b tin hnh phay hc ch nht t kch thc yu cu. + Gia cng th, hc ch nht kch thc 239,8x139,8 mm su 30 mm bng dao phay ngn c f20 mm, Z = 5. + Gia cng tinh hc ch nht t kch thc x mm su 30 mm bng dao phay ngn f20 mm, Z = 5. - Gia cng h thng lm mt. + Gia cng 4 l f20 su 33,5 mm bng dao ngn f20 mm, Z = 2. + Gia cng 4 l f10,5 su 56 mm bng mi khoan thp gi f10,5 mm. - Gia cng hc lp nm cn: + Gia cng hai hc cn 7o c kch thc 80x20x17 mm bn knh ln R6 mm bng dao phay f12 mm c hai rnh ct mi cn 7o di 17 mm. + Gia cng hai hc cn 7o c kch thc 110x20x17 mm bn knh ln R6 mm bng dao phay f12 mm c hai rnh ct mi cn 7o di 17 mm.

IV.4.1.2.5. Nguyn cng 5: Gia cng cc bin dng c trn mt phng C. S nh v.

nh v:

Nh s dng mt phng y A lm mt phng nh v, ta khng ch c 3 bc t do ca phi trc khi kp cht phi gia cng. Kp cht:

Lc kp cht cn thit W, c to bi mi ghp bulong-ai c c phng vung gc vi mt phng nh v, c tc dng c nh chi tit trong qu trnh gia cng c hc. Qu trnh kp cht chi tit din ra nh sau:

- Tin hnh kp cht phi mt cch tng i. - Lp ng h o ln trc my tin hnh r v iu chnh li v tr ca phi mt hai mt phng B v E song vi ng chy dao ca trc my. - Tin vn cht 4 Bulong to lc kp cht W cn thit. Chn my gia cng:

Chi tit c gia cng trn my phay P1050-CNC iu khin theo chng trnh. Cng sut ca ng c l 7,5 kW (Cc thng s k thut ca my tham kho thm Bng IV 1). Dng c ct: Tu theo bin dng v cht lng b mt sau gia cng m la chn dng c ct cho ph hp.C th: - Gia cng lng knh dn nha t bc phun vo lng khun.

Hnh IV 12: Kt cu ca knh dn nha ti lng khun. Cn c vo kt cu ca knh dn nha, ta s dng cc loi dng c ct sau ch to cc bin dng ph hp vi thit k. + Gia cng lng knh rng 6mm su 4 mm bng dao phay cu vn nng c ng knh trc dao f6 mm v bn knh nh cu R = 3. + Gia cng hc hnh cu c bn knh R = 5mm su 6 mm bng dao phay cu vn nng c ng knh trc dao f10 mm cn bn knh nh cu R = 5. + Gia cng l f12 su 5 mm bng dao ngn c f12 mm, Z = 2. + Gia cng l f4 su 25 mm bng mi khoan rut g . - Gia cng h thng l dng lp lng khun bng Bulong chm M8. + Gia cng 6 l f14 su 10 mm bng dao ngn f14 mm, Z = 2. + Gia cng 6 l f9 su 30 mm bng mi khoan rut g f9 mm.

IV.4.1.2.6. Nguyn cng 6: Gia cng mt phn ca h thng knh dn nha. u im ca khun ba tm l c kh nng tch di c knh dn nha v sn phm ra khi khun mt cch rt nhanh chng v hon ton t ng. Do knh dn nha c th thot ra khi khun mt cch nhanh trng v thun li nht th kt cu ca dn nha m bo bng v hnh dng tt. Cho nn khi gia cng h thng dn nha qua tm khun trc, ta phi lp cht lng khun trn vo tm o khun trn gia cng ng thi hai chi tit cng mt lc. Nh vy mi p ng c chnh xc v tr v hnh dng cn u cho h thng l dn nha.

S nh v.

nh v:

Chn mt phng phn khun 1 ca tm o khun lm mt phng nh v, mt phng y ny s khng ch 3 bc t do cho phi, trc khi kp cht phi gia cng. Kp cht:

Lc kp cht cn thit W, c to bi mi ghp bulong-ai c c phng vung gc vi mt phng nh v, c tc dng c nh chi tit trong qu trnh gia cng c hc. Qu trnh kp cht chi tit din ra nh sau: - Tin hnh kp cht s b c nh phi mt cch tng i. - Lp ng h o ln trc my tin hnh r v iu chnh li v tr ca phi mt hai mt phng B v E song vi ng chy dao ca trc my. - Tin vn cht 4 Bulong kp cht chi tit. Chn my gia cng:

Chi tit c gia cng trn my phay xung Hurco Spack 900 iu khin theo chng trnh (Cc thng s k thut ca my tham kho thm Bng V.2) Dng c ct:

Dng c ct trong qu trnh gia cng bng xung in chnh l in cc. Do hnh dng ca in cc phi c ch to tng ng vi bin dng cn gia cng. ? Qu trnh lp chng trnh gia cng xung nh hnh tin hnh nh sau: Bc 1: Chn vt liu v hnh dng ca in cc.

in cc bng ng c hnh dng v kch thc nh sau:

Hnh IV 13: Hnh dng in cc ng dng gia cng xung l cn. in cc ng dng gia cng xung c ch to bng phng php tin thng thng, sau c nh bng bng giy gip t bng yu cu. Hnh dng ca in cc c xc nh theo hnh dng v kch thc ca bin dng cn gia cng sau khi loi tr bt phn khe h phng in l 0,055 mm i vi nguyn cng gia cng tinh ln cui cng. ? Bc 2: Chn cc tham s gia cng tia la in xung nh hnh i vi s u cc, s phng in v iu khin khe h.

- S u cc: in cc l cc dng. - Cc tham iu khin ti qu trnh gia cng nh: Thng s phng tia la in, thng s iu khin khe h, thng s kt thc qu trnh gia cng, thng s ngn nga li c la chn ph hp vi ch gia cng th, bn tinh hay l gia cng tinh s c biu din trong bng iu khin chng trnh gia cng. ? Bc 3: Chn im Zero chng trnh t im Zero ca phi (W).

im gc phi W l im chnh gia ca phi. ? Bc 4: Xc nh cc to gia cng.

- Hai to OX v OY dng xc nh v tr cn gia cng. - To OZ dng xc nh chiu su cn gia cng. (S trang sau)

Hnh IV 14: S to nh v in cc khi gia cng xung l cn. ? Bc 5: Xc nh k hoch gia cng.

K hoch gia cng (trnh t gia cng) c din ra theo th t sau. - Thc hin chuyn ng in cc theo trc OZ n khong cch an ton cch mt trn ca phi 2mm. - a in cc n v tr xut pht (v tr cn gia cng) X?, Y?. - Gia cng xung nh hnh n chiu su Z yu cu. + Gia cng th (gia cng ph) t chiu su: - 15,000 mm.

+ Gia cng bn tinh ln 1 t chiu su: - 30,000 mm. + Gia cng bn tinh ln 2 t chiu su: - 58,885 mm. + Gia cng tinh ln cui t chiu su: - 58,890 mm

- Sau khi gia cng t chiu su cn thit thc hin rt dng c ln theo trc Z n mt cao thch hp, chun b cho qu trnh gia cng ti v tr tip theo. ? Bc 6: Vit chng trnh gia cng.

Chng trnh gia cng c vit theo cc tham s cng ngh a c xc nh sn theo s tay cng ngh hoc theo kinh nghim ca ngi th ng my. i vi my gia cng xung nh hnh Hurco Spark 900 chng trnh gia cng nh sau: STP End Depth Servo Gain Strike Volts ARC SUPP POL AMPS ON Time Time Dwell Time Lift OFF Time GAP Volts

1 2 3 4 -30.000 -58.885 -58.890 45 100 200 300 POS -15.000

POS POS POS 6 8 7 3 128 72 40 12 7 5 48 48 52 25 25 25 30 25 48 11 115

30 30 30 1.2 0.8 0.8 8.0 10.0 10.0 6.0 1.4

IV.4.1.2.7. Nguyn cng 7: Mi mt phng y C ca tm o khun trn. S nh v.

nh v:

S dng mt phng y C ca phi nh v, mt phng y ny s khng ch 3 bc t do ca phi trc khi kp cht c nh phi gia cng. Kp cht:

Lc kp cht cn thit W c phng vung gc vi mt nh v c tc dng c nh chi tit trong qu trnh gia cng c hc, c to bi lc ht nam chm in do bn t sinh ra. Chn my gia cng:

Chi tit c gia cng trn my mi phng bn hnh ch nht 3B724. Cng sut ca ng c l 30kW. Dng c ct:

mi c ng knh D = 200 mm, chiu rng B = 40 mm.

IV.4.1.2.8. Nguyn cng 8: Mi mt phng phn khun trn li khun. S nh v (Trang sau).

nh v:

S dng mt phng y C ca phi nh v, mt phng y ny s khng ch 3 bc t do ca phi trc khi kp cht phi c nh gia cng. Kp cht:

Lc kp cht cn thit W c phng vung gc vi mt nh v c tc dng c nh chi tit trong qu trnh gia cng c hc, c to bi lc ht nam chm in do bn t sinh ra. Chn my gia cng:

Chi tit c gia cng trn my mi phng bn hnh ch nht 3B724. Cng sut ca ng c l 30kW. Dng c ct:

mi c ng knh D = 200 mm, chiu rng B = 40 mm.

IV.4.1.2.9. Nguyn cng 9: Gia cng ngui ton b cm khun trn Cc cng vic trong nguyn cng nay gm c: - Mi bng ton b bin dng li khun. - Mi mt b mt ca hc cn n khp vi nn cn lp trn cm khun sau. - Mi bng ton b bin dng lng knh dn nha . - Tin hnh taro ren M12 cho cc u ng dn dung dich lm mt. Tu theo tnh cht ca cng vic gia cng m c th tin hnh gia cng trn mt bn mp hoc kp chi tit trn t. Ch : Nguyn cng mi mt phng l nguyn cng bo m loi ht cc ba va, vt sc pht sinh khi vn chuyn phi qua cc bc gia cng trc nhm bo m phng cn thit cho chi tit khi lp rp. Do ta chi cn lng d 0,25 mm cho nguyn cng mi l bo m c cc yu cu ra. IV.4.2. Qui trnh cng ngh gia cng li khun trc. IV.4.2.1. Lp tin trnh cng ngh gia cng tm li khun trc. Cn c vo hnh dng ca phi trc gia cng (Hnh IV 5) v sau gia cng.

Hnh IV 15: Hnh dng v kt cu ca tm lng khun sau gia cng. *) Nhn thy rng t phi ch to ra c tm o khun t yu cu k thut th ta cn phi tin hnh cc cng vic sau:

- Gia cng phi tinh mua v t kch thc 240x140x60 mm. - Gia cng h thng lm mt lng khun. - Gia cng h thng l ren bt Bulong chm M8. - Gia cng bin dng lng khun. - Gia cng h thng dn nha vo lng khun. - Tin hnh sa cha cc sai xt nh (nu c) trc khi lp ghp vi cc chi tit khc ca khun.

*) Trnh t cc nguyn cng gia cng lng khun trc nh sau: Th t Ni dung cng vic. 1 2 3 4 5 6 Chun b phi cho qu trnh gia cng. Gia cng chiu rng phi t kch thc 140h7 mm. Gia cng chiu di phi t kch thc 240h7 mm. Khoan 2 l f10,5 su 125 mm trn b mt bn B. Khoan 2 l f10,5 su 120 mm trn b mt bn D. Gia cng h thng cc l trn b mt C ca phi,

- Gia cng 4 l ?10,5 su 20 mm dn dung dch lm mt. - Gia cng 6 l ?6 su 20 mm taro ren M8. - Gia cng 6 l ?2,5 su 25 mm chun b xung l dn nha. - Gia cng vt mp phi mt lng 10mmx45o. 7 8 9 10 11 12 13 Tin hnh sa ngui phi lp c vo hc o khun trn. Trn b mt A tin hnh gia cng bin dng li khun. Gia cng xung to rnh t kch thc cn thit trn li khun. Gia cng xung s b h thng l dn nha vo lng khun. Gia cng xung thng l dn nha vo lng khun. Tin hnh mi phng b mt phn khun. Tin hnh gia cng ngui ton b cm khun trn:

- nh bng ton b bin li khun t bng cn thit. - Tin hnh mi 4 hc n khp vi nn cn. - nh bng lng knh dn nha. - Taro ren M12 cho ng ng dn dung dch lm mt.

IV.4.2.2. Thit k cc nguyn cng. IV.4.2.2.1. Nguyn cng 1: Chun b phi cho qu trnh gia cng c. Tin hnh kim tra phi sau khi mua v trc khi dng ch to tm o khun xem c t yu cusau hay khng: - Kch thc ca phi x x hay khng. - nhn bng b mt t cp 5. - Khng tn ti cc khuyt tt: nt, rn, r - Phi c t cng 28 ? 34 HRC. IV.4.2.2.2. Nguyn cng 2: Phay chiu rng phi t kch thc140h7. S nh v:

nh v:

Do hai mt phng D v A ca phi ln lt tip xc vi thanh k v m tnh ca t. Nn phi c khng ch c 6 bc t do, ta ch cn tin hnh kp cht phi chun b cho qu trnh gia cng ch to ti cc v tr cn thit. Kp cht:

phi khng b dch chuyn khi chu cc lc ct gt tc dng nn. Ta ch cn quay trc vt ca t lm m ng chuyn ng li gn phi to ra lc kp cht W cn thit c nh phi. Chn my gia cng:

Chi tit c gia cng trn my phay P1050-CNC iu khin theo chng trnh. Cng sut ca ng c l 7,5 kW (Cc thng s k thut ca my tham kho thm Bng IV 1).

 Chn dng c ct: gia cng chiu rng ca phi t kch thc 140 mm t bng 5 ?m. Ta s dng dao phay mt u c ng knh D = 100 mm chiu cao ca dao H = 39 mm c Z = 10 rng tin hnh gia cng th v tinh. Lng d gia cng.

- Gia cng th: B rng ct B = 60 mm cn chiu su ct t = 2 mm. - Gia cng tinh: B rng ct B = 60 mm cn chiu su ct t = 0,2 mm.

IV.4.2.2.3. Nguyn cng 3: Phay chiu di phi t kch thc 240 h7 S nh v (Trang sau):

nh v:

Do hai mt phng C v E ca phi ln lt tip xc vi thanh k v m tnh ca t. Nn phi c khng ch c 6 bc t do, ta ch cn tin hnh kp cht phi chun b cho qu trnh gia cng ch to ti cc v tr cn thit. Kp cht:

phi khng b dch chuyn khi chu cc lc ct gt tc dng nn. Ta ch cn quay trc vt ca t lm m ng chuyn ng li gn phi to ra lc kp cht W cn thit c nh v tr ca phi. Chn my gia cng:

Chi tit c gia cng trn my phay P1050-CNC iu khin theo chng trnh. Cng sut ca ng c l 7,5 kW (Cc thng s k thut ca my tham kho thm Bng IV 1). Chn dng c ct: gia cng chiu rng ca phi t kch thc 140 mm t bng 5 ?m. Ta s dng dao phay mt u c ng knh D = 100 mm chiu cao ca dao H = 39 mm c Z = 10 rng. Thc hin ct th v ct tinh va t c nng sut gia cng ln cht lng b mt sau gia cng. Lng d gia cng.

- Gia cng th: B rng ct B = 60 mm cn chiu su ct t = 2 mm. - Gia cng tinh:B rng ct B = 60 mm cn chiu su ct t = 0,2 mm.

IV.4.2.2.4. Nguyn cng 4: Khoan 2 l f10,5 su 105 mm trn b mt bn B. S nh v (Trang sau):

nh v:

Do hai mt phng D v A ca phi ln lt tip xc vi thanh k v m tnh ca t. Nn phi c khng ch c 6 bc t do, ta ch cn tin hnh kp cht phi chun b cho qu trnh ti cc v tr cn thit trn phi. Kp cht:

phi khng b dch chuyn khi chu cc lc ct gt tc dng nn. Ta ch cn quay trc vt ca t lm m ng chuyn ng li gn phi to ra lc kp cht W cn thit c inh phi. Chn my gia cng:

Chi tit c gia cng trn my phay P1050-CNC iu khin theo chng trnh. Cng sut ca ng c l 7,5 kW (Cc thng s k thut v my tham kho thm Bng IV 1). Chn dng c ct:

S dng mi khoan lm bng thp gi c f10,5 mm gia cng h thng l theo yu cu thit k.

IV.4.2.2.5. Nguyn cng 5: Khoan 2 l f10,5 su 120 mm trn b mt bn D. Nhn thy rng nguyn cng 5 ny hon ton ging nh nguyn cng 4 ch khc mi s nh v m thi. nguyn cng 4 ta s dng mt phn y D v 1 mt bn nh v phi cn nguyn cng ny ta s dng b mt B v mt mt bn lm mt phng nh v, do vy ta ch cn tin hnh o li v tr ca phi so vi t, tc l tin hnh quay phi i mt gc 180o th qu trnh gia cng c thc hin hon ton tng t nh nguyn cng 4.

IV.4.2.2.6. Nguyn cng 6: Gia cng h thng cc l c trn b mt C. S nh v.

nh v:

Chn mt phng y C ca phi lm mt phng nh v, nh s dng mt phng ny m ta hn c ch 3 bc t do ca phi trc khi kp cht phi gia cng. Kp cht:

Lc kp cht cn thit W c phng vung gc vi mt nh v c tc dng c nh chi tit trong qu trnh gia cng c hc, c to bi mi ghp bulong-ai c v tay n. Qu trnh kp cht chi tit din ra nh sau: - Tin hnh kp cht s b c nh phi mt cch tng i. - Lp ng h o ln trc my tin hnh r v iu chnh li v tr ca phi mt hai mt phng B v E song vi ng chy dao ca trc my. - Tin vn cht 4 Bulong kp cht chi tit. Chn my gia cng:

Chi tit c gia cng trn my phay P1050-CNC iu khin theo chng trnh. Cng sut ca ng c l 7,5 kW (Cc thng s k thut v my tham kho thm Bng IV 1). Dng c ct: c la chn tu thuc vo yu cu cn gia cng.

- S dng mi khoan thp gi ?2,5 mm gia cng 6 l ?2,5 su 25 mm chun b cho nguyn cng xung l dn nha. - S dng mi khoan thp gi c ng knh 6 mm gia cng 6 l ?6 taro l ren M8. - S dng mi khoan thp gi c ng knh 10,5 mm gia cng 4 l ?10,5 dn dung dch lm mt. - S dng dao phay ngn thp gi c ng knh 20 mm gia cng vt mp tm phi 10mmx45o. IV.4.2.2.7. Nguyn cng 7: Gia cng ngui phi ghp vo o khun. hn ch nh hng sai s ca mi lp gia lng khun vi v khun ti chnh xc khi lp rp lng khun v li khun li vi nhau. Ta cn s dng chun thng nht khi gia cng hai bin dng ca lng khun khi khng th gia cng chng trong 1 ln gia cng c. Do vy ta cn tin hnh lp rp tm phi lng khun vo tm o khun sau mi tin hnh gia cng bin dng li khun. Do sai s ca dao c v ch ct nh hng ti hnh dng ca hc ch nht 240x140mm su 30 mm trn tm o khun. Cho nn ta cn tin hnh s ngui tm lng khun bo m v tr lp ca tm lng khun. - Mi li bn mt xung quanh ca phi bng tay. - Taro ren M8 ti cc v tr dng bt bulong M8. - Taro ren M12 cho cc u ca ng dn dung dch lm mt li khun . Tu theo tnh cht ca cng vic m tin hnh gia cng trn bn mp hoc kp cht phi bng t. IV.4.2.2.8. Nguyn cng 8: Gia cng bin dng li khun. S nh v.

nh v:

Chn mt phng y C ca phi lm mt phng nh v, nh s dng mt phng ny m ta hn c ch 3 bc t do ca phi trc khi kp cht phi gia cng. Kp cht:

Lc kp cht cn thit W c phng vung gc vi mt nh v c tc dng c nh chi tit trong qu trnh gia cng c hc, c to bi mi ghp bulong-ai c v tay n. Qu trnh kp cht chi tit din ra nh sau: - Tin hnh kp cht s b c nh phi mt cch tng i. - Lp ng h o ln trc my tin hnh r v iu chnh li v tr ca phi mt hai mt phng B v E song vi ng chy dao ca trc my. - Tin vn cht 4 Bulong kp cht chi tit. Chn my gia cng:

Chi tit c gia cng trn my phay P1050-CNC iu khin theo chng trnh. Cng sut ca ng c l 7,5 kW (Cc thng s k thut v my tham kho thm Bng IV 1). Dng c ct: c la chn theo b mt bin dng cn gia cng v ch gia cng (S,V,t).

Do b mt cn gia cng c bin dng phc tp ng thi cht lng sau gia cng yu cu rt cao. Cho nn yu cu qu o chuyn ng ca dng c ct phi trong qu trnh gia cng, phi thc hin c cc chuyn ng to hnh phc tp li c chnh xc cao. phc v cho qu trnh lp chng trnh my gia cng c bin dng lng khun ta s dng phm mm DEL-CAM. * Trnh t to dng chng trnh gia cng bng phn mm DEL-CAM. Bc 1: Dng m hnh b mt chi tit cn gia cng. Ta s dng m hnh khung dy sau dng m hnh b mt (y l cch lm n gin v hiu qu nht i vi nhng b mt khng qu c bit). y l bc kh thc hin nht trong ton b qu trnh to dng chng trnh gia cng, n i hi ngi thit k phi nm vng cc dng b mt c bn, s dng thnh tho cc cng c thit k ca DEL-CAM dng c m hnh nhanh chng v chnh xc b mt cn gia cng. Bc 2: Thit lp k hoch gia cng. Sau khi c c m hnh ca b mt cn gia cng. Ta tin hnh hoch nh cc nguyn cng thit v trnh t thc hin cc nguyn cng ny gia cng c cc b mt chi tit t yu cu. Bc 3: Xc nh bin gii gia cng. Chnh l vic ch ra mt hay nhiu congtua kn hoc h bao quanh vng cn gia cng tng ng vi mi nguyn cng.

Bc 4: Chn dng c ct. Chn dng c ct y l chn la mt trong nhng dng c ct khai bo trong th vin dng c tng ng vi nguyn cng hin hnh, cc thng s ca dng c ct nh: Hnh dng, chiu di, ng knh khai bo khi nh ngha dng c. Bc 5: Chn cc thng s cng ngh cho qu trnh gia cng. Cc thng s cng ngh cho qu trnh gia cng bao gm: Bc tin ct F (mm/ph), bc tin nhanh, bc tin thng ca dng c, chiu v tc ca trc chnh S (vg/ph), khi gia cng c ti dung dch trn ngui hay khng Bc 6: Xc nh phng n chy dao. bc ny chng ta phi tin hnh m mt ng chy dao (Tool path). Mt ng chy dao bao gm mt chui cc th tc m n c gi khi nh ngha cho mt qu trnh gia cng. Mi th tc VD: POCKET, PROFILE, SURMILL c to ra bng cch gi mt hm gia cng cha cc d liu m t cc thuc tnh hnh hc tng ng, cc thng s gia cng v cc khi dch chuyn ca dao. Bc 7: Thit lp thng s hnh hc cho ng chy dao. Cc thng s hnh hc ca ng chy dao bao gm: Cch thc chy dao (hnh chiu bng ca ng chy dao); hng tin dao: ct thun, ct nghch hay l hn hp; khong cch gia hai ln dch dao ngang. Bc 8: Tnh ton ng chy dao. Phn mm CAM s s dng cc d liu ca cc qu trnh trn tnh ton ra cc ng chy dao c hin th trn mn hnh cng vi chi tit cn gia cng, d liu ca ng chy dao s c ghi li trong tp d liu CL-data file. Phn mm cho php ngi hiu chnh cc im khng ph hp ca ng chy dao ny trc tip trn mn hnh ho. Bc 9: M phng qu trnh gia cng. M phng qu trnh gia cng l s dng cc m hnh ho: Phi, dao din t trc qu trnh gia cng s din ra thc t trn mn hnh. M hnh ca dng c ct c dn theo ng chy dao tnh ton c. Da vo din bin trong qu trnh m phng v kt qu sau khi gia cng nh m phng, ta c th nh gi c cc vn : Dao, ng chy dao, cht lng b mt sau gia cng, nng sut gia cng, kh nng an ton cho my, dao, phi se din ra trong trnh gia cng c tt hay khng. Nh ta c th pht hin c cc yu t cha hp l c nhng sa cha kp thi trc khi tin hnh gia cng ch to thc trn phi. Bc 10: To ra chng trnh NC cho h thng iu khin my CNC. Chng trnh iu khin s c trnh x l Post-Proccessor ghi ra a ph hp vi ngn ng dng iu khin my CNC khai bo, d liu xut ra chng trnh NC chnh l CL-data file vi nhiu ngn ng lp trnh tng thch vi cc b iu khin s hin c nh l: Fanuc, Denford, Heindehain, Maho Bc 11: Truyn d liu sang my CNC.

Chng trnh iu khin s c truyn vo b nh ca my CNC v tin hnh iu khin qu trnh gia cng thc. i vi cc chng trnh di c th ct nh chng trnh v chuyn tng on mt vo my gia cng phi.

Hnh IV 16: Quy trnh to chng trnh iu khin s nh phn mm CAM. Cc thng s v phi cn qua tm khi thit lp chng trnh gia cng:

- Kch thc ca phi: 240x140x60 mm. - cng ca vt liu: 28 ? 34 HRC. - Gc to dng lp chng trnh gia cng. - Cc thng s cng ngh gia cng (S,v,t) tng ng vi loi do c. Cc loi dao phay hay c s dng gm c.

(a) (a) (b) (c) (d)

(b)

(c)

(d)

Dao phay tr c nhieu li ct (dao phay ngn). Dao phay cu c 2 li ct. Dao phay tr c 2 li ct. Dao phay tr c 2 li ct nh dao mi cu bn knh R.

IV.4.2.2.9. Nguyn cng 9: Gia cng xung cc rnh ca lng khun. S nh v.

nh v:

Chn mt phng C ca phi lm mt phng nh v, mt phng y ny s khng ch 3 bc t do cho phi trc khi kp cht phi gia cng. Kp cht:

Lc kp cht cn thit W c phng vung gc vi mt nh v c tc dng c nh chi tit trong qu trnh gia cng c hc, c to bi mi ghp bulong-ai c v tay n. Qu trnh kp cht chi tit din ra nh sau:

- Tin hnh kp cht s b c nh phi mt cch tng i. - Lp ng h o ln trc my tin hnh r mt hai mt phng B v E song vi ng chy dao ca trc my. - Tin vn cht 4 Bulong kp cht chi tit. Chn my gia cng:

Chi tit c gia cng trn my phay xung Hurco Spack 900 iu khin theo chng trnh (Cc thng s k thut v my tham kho thm Bng V.2 ) Dng c ct:

Dng c ct trong qu trnh gia cng bng xung in chnh l in cc. Do hnh dng ca in cc phi c ch to tng ng vi hnh dng ca bin dng cn gia cng. ? Qu trnh lp chng trnh gia cng xung nh hnh tin hnh nh sau: Bc 1: Chn vt liu v hnh dng ca in cc.

in cc bng ng c hnh dng v kch thc nh Hnh IV 17. Khe h phng in FS = 0,05 mm cho ln gia cng tinh ln cui cng.

Hnh IV 17: Cc in cc ng dng gia cng xung rnh. in cc ng dng gia cng xung su rnh t chiu su v bin dng yu cu c ch to bng phng php ct dy t kch thc yu cu. Hnh dng ca in cc c xc nh theo hnh dng v kch thc ca bin dng cn gia cng sau khi loi tr bt khe h phng in l 0,05 mm i vi nguyn cng gia cng tinh ln cui cng. ? Bc 2: Chn cc tham s gia cng tia la in xung nh hnh i vi s u cc, s phng in v iu khin khe h. - S u cc: in cc l cc dng. - Cc tham iu khin ti qu trnh gia cng nh: Thng s phng tia la in, thng s iu khin khe h, thng s kt thc qu trnh gia cng, thng s ngn nga li c la chn ph hp vi ch gia cng th, bn tinh hay l gia cng tinh s c biu din trong bng iu khin chng trnh gia cng. ? Bc 3: Chn im Zero chng trnh t im Zero ca phi (W).

im gc phi W l im chnh gia ca phi. ? Bc 4: Xc nh cc to gia cng.

Chc nng ca cc trc to trong vic xc nh v tr ca in cc trong qu trnh gia cng nh sau.

- Hai to OX v OY dng xc nh v tr cn gia cng. - To OZ dng xc nh chiu su cn gia cng.

Hnh IV 18: S to nh v in cc khi gia cng xung rnh. ? Bc 5: Xc nh k hoch gia cng.

K hoch gia cng (trnh t gia cng) c din ra theo th t sau. S dng in cc 1 v 2 tin hnh gia cng rnh trn phi c dng nm cn su 23,37 mm. Sau s dng in cc 3 xung tip rnh t chiu su 26,42 mm. * i vi in cc 1 v 2 qu trnh gia cng nh sau: - Thc hin chuyn ng in cc theo trc OZ n khong cch an ton cch mt trn ca phi 2mm. - a in cc n v tr xut pht (v tr cn gia cng) X?, Y?. - Gia cng xung nh hnh n chiu su Z yu cu. + Gia cng th (gia cng ph) t chiu su: + Gia cng bn tinh ln 1 t chiu su: + Gia cng bn tinh ln 2 t chiu su: + Gia cng tinh ln cui t chiu su: - 22,000 mm. - 23,350 mm. - 23,365 mm. - 23,370 mm

- Sau khi gia cng t chiu su cn thit thc hin rt dng c ln theo trc Z n mt cao thch hp, chun b cho qu trnh gia cng ti v tr tip theo. * i vi in cc 3 qu trnh gia cng nh sau: - Thc hin chuyn ng in cc theo trc OZ n khong cch an ton cch mt trn ca phi 2mm. - a in cc n v tr xut pht (v tr cn gia cng) X?, Y?. - Gia cng xung nh hnh n chiu su Z yu cu. + Gia cng th (gia cng ph) t chiu su: + Gia cng bn tinh ln 1 t chiu su: + Gia cng bn tinh ln 2 t chiu su: + Gia cng tinh ln cui t chiu su: - 24,000 mm. - 26,400 mm. - 26,415 mm. - 26,424 mm

- Sau khi gia cng t chiu su cn thit thc hin rt dng c ln theo trc Z n mt cao thch hp, chun b cho qu trnh gia cng ti v tr tip theo. ? Bc 6: Vit chng trnh gia cng.

Chng trnh gia cng c vit theo cc tham s cng ngh a c xc nh sn theo s tay cng ngh hoc theo kinh nghim ca ngi th ng my. i vi my gia cng xung nh hnh Hurco Spark 900 chng trnh gia cng nh sau: * Khi gia cng bng in cc 1 hoc 2 th chng trnh gia cng nh sau: STP End Depth Servo Gain Strike Volts ARC SUPP POL AMPS ON Time Time Dwell Time Lift OFF Time GAP Volts

1 2 3 4 -23.350 -23.365 -23,370 100 100 200 300 POS -22.000

POS POS POS 6 8 7 3 128 72 40 12 7 11 115

5 48 48 52 25 25 25 30 30 30 1.2 1.0 0.8 8.0 9.0 10.0

48

25

30

1.4

7.0

* Khi gia cng bng in cc 3 th chng trnh gia cng nh sau: STP End Depth Servo Gain Strike Volts ARC SUPP POL AMPS ON Time Time Dwell Time Lift OFF Time GAP Volts

1 2 3 4 -26.400 -26.415 -26.424 100 100 -24.000

200 300 POS

POS POS POS 4 6 5 2 115 54 37 11 5 5 48 48 52 25 25 25 30 30 30 1.1 0.8 0.6 7.0 8.0 6.0 1.2 30 25 52 8 85

10.0

IV.4.2.2.10. Nguyn cng 10: Gia cng mt phn ca h thng dn nha. S gia cng.

Cc qu trnh gia cng tip theo c thc hin hn ton ging nh nguyn cng 6 (IV.4.1.2.6) trong quy trnh cng ngh gia cng tm o ca khun trn. IV.4.2.2.11. Nguyn cng 11: Gia cng xung thng l dn nha. S nh v.

nh v:

Chn mt phng phn khun 1 ca tm lng khun lm mt phng nh v, nh s dng mt phng nh v ta khng ch 3 bc t do trc khi tin hnh kp cht gia cng. Kp cht:

Lc kp cht cn thit W c phng vung gc vi mt nh v c tc dng c nh chi tit trong qu trnh gia cng c hc, c to bi mi ghp bulong-ai c v tay n. Qu trnh kp cht chi tit din ra nh sau: - Tin hnh kp cht s b c nh phi mt cch tng i. - Lp ng h o ln trc my, tin hnh r v iu chnh li v tr ca phi mt hai mt phng B v E song vi ng chuyn ng ca in cc. - Tin vn cht 4 Bulong kp cht chi tit. Chn my gia cng:

Chi tit c gia cng trn my phay xung Hurco Spack 900 iu khin theo chng trnh (Cc thng s k thut v my tham kho thm Bng V.2). Dng c ct:

Dng c ct trong qu trnh gia cng bng xung in chnh l in cc. Do hnh dng ca in cc phi c ch to theo bin dng cn gia cng. Qu trnh lp chng trnh gia cng xung nh hnh tin hnh nh sau:

Bc 1: Chn vt liu v hnh dng ca in cc.

in cc bng ng c hnh dng v kch thc nh Hnh IV 19.

Hnh IV 19: Hnh dng ca in cc ng xung l ming phun. ? Bc 2: Chn cc tham s gia cng tia la in xung nh hnh i vi s u cc, s phng in v iu khin khe h. - S u cc: in cc l cc dng. - Cc tham iu khin ti qu trnh gia cng nh: Thng s phng tia la in, thng s iu khin khe h, thng s kt thc qu trnh gia cng, thng s ngn nga li c la chn ph hp vi ch gia cng th, bn tinh hay l gia cng tinh s c biu din trong bng iu khin chng trnh gia cng. ? Bc 3: Chn im Zero chng trnh t im Zero ca phi (W).

im gc phi W l im chnh gia ca phi. ? Bc 4: Xc nh cc to gia cng.

Hnh IV 20: S xc nh v tr in cc khi gia cng xung. ? Bc 5: Xc nh k hoch gia cng.

K hoch gia cng (trnh t gia cng) c din ra theo th t sau. - Thc hin chuyn ng in cc theo trc OZ n khong cch an ton cch mt trn ca phi 2mm. - a in cc n v tr xut pht (v tr cn gia cng) X?, Y?. - Gia cng xung nh hnh n chiu su Z yu cu. + Gia cng th (gia cng ph) t chiu su: - 30,000 mm.

+ Gia cng bn tinh ln 1 t chiu su: - 31,975 mm. + Gia cng bn tinh ln 2 t chiu su: - 31,990 mm. + Gia cng tinh ln cui t chiu su: - 32,030 mm

- Sau khi gia cng t chiu su cn thit thc hin rt dng c ln theo trc Z n mt cao thch hp, chun b cho qu trnh gia cng ti v tr tip theo. ? Bc 6: Vit chng trnh gia cng.

Chng trnh gia cng c vit theo cc tham s cng ngh c xc nh theo s tay cng ngh hoc theo kinh nghim ca ngi th ng my. i vi my gia cng xung nh hnh Hurco Spark 900 chng trnh gia cng nh sau: STP End Depth Servo Gain Strike Volts ARC SUPP POL AMPS ON Time Time Dwell Time Lift OFF Time GAP Volts

1 2 3 4 -31.975 -31.990 -32.030 45 45 100 200 POS -30.000

POS POS POS 4 5 4 3 93 82 37 9 8 5 48 52 52 25 52 8 82

25 25 25 30 30 30 1.2 0.8 0.6 8.0 10.0 12.0 6.0 1.4 30

IV.4.2.2.12. Nguyn cng 12: Mi mt phng phn khun trn li khun. Thc hin hon ton nh Nguyn cng 9 (IV.4.1.2.9) ca qui trnh gia cng tm o khun trn. IV.4.2.2.13. Nguyn cng 13: Gia cng ngui ton b cm khun trn Cc cng vic trong nguyn cng nay gm c: - Mi bng ton b bin dng li khun. - Mi mt b mt ca hc cn an khp vi nn cn lp trn cm khun sau. - nh bng lng knh dn nha. - Taro ren M12 cho ng ng dn dung dch lm mt. Tu theo tnh cht ca cng vic gia cng m c th tin hnh gia cng trn mt bn mp hoc kp chi tit trn t. IV.4.3. Thit k qui trnh cng ngh gia cng tm o khun sau. IV.4.3.1. Lp tin trnh cng ngh gia cng tm khun sau.

Hnh IV 21: Hnh dng tm khun sau, trc khi tin hnh gia cng.

Hnh IV 22: Hnh dng ca tm khun sau cn gia cng ch to. Cn c vo hnh dng ca phi trc khi gia cng (Hnh IV 21) v hnh dng v kt cu ca tm khun sau thit k (Hnh IV 22). *) Nhn thy rng t phi ch to ra c tm o khun t yu cu k thut th ta cn phi tin hnh cc cng vic sau: - Gia cng phn hc hnh ch nht c kch thc 240x140mm su 40 mm - H thng l bt Bulong chm M8 ( bt lng khun vi v khun). - Gia cng h thng hc v l lp nn cn. - Gia cng h thng lm mt lng khun trc. - Gia cng h thng l lp tm o khun sau vi tm sau 001 bng M14.

*) Trnh t cc nguyn cng ch to tm khun sau nh sau: Th t Ni dung cng vic. 1 2 3 4 Chun b phi cho qu trnh gia cng ch to chi tit. Khoan 4 l f10,5 su 105 mm trn b mt bn B. Khoan 4 l f10,5 su 105 mm trn b mt bn D. Trn b mt A ca phi tin hnh gia cng:

- Phay hc ch nht c kch thc 240H7x140H7 mm su 40 mm. + Gia cng to hc ch nht kch thc 239x139 mm su 40 mm. + Gia cng to hc ch nht kch thc 240H7x140H7 su 40 mm. - Trn mt y ca hc 240x140x40, gia cng h thng lm mt: + Phay 4 l f20 su 43,5 mm. + Khoan 4 l f10,5 su 55 mm. - Gia cng hc lp nm cn: + Hai hc c kch thc 110x20x17 mm bn knh ln R6.

+ Hai hc c kch thc 80x20x17 mm bn knh ln R6. 5 Trn b mt C tin hnh gia cng:

- Gia cng h thng l bt Bulong M8 vi lng khun trc. + Phay 6 l f14 su 10 mm. + Khoan 6 l f9 su 30 mm. - Gia cng 4 l f11,5 su 35 mm taro ren M14. - Gia cng h thng lp nm cn M8. + Phay 8 l f114 su 10 mm. + Khoan 8 l f9 su 55 mm. 6 Gia cng h thng l ?8mm lp cht y sn phm.

- Tin hnh khoan 18 l ?7,8mm. - Tin hnh doa th 18 l ?7,8mm t kch thc ?8mm. 7 8 Mi phng b mt y C ca tm khun trn. Gia cng ngui ton b cm khun trn theo yu cu ca thit k.

- Mi bin ton b bin dng lng khun. - Mi b mt hc ch nht lp nm cn. - Tin hnh taro ren M14 u ng dn dung dch lm mt. - Tin hnh nghin th l lp cht t sn phm. IV.4.3.2. Thit k cc nguyn cng. IV.4.3.2.1. Nguyn cng 1: Chun b phi cho qu trnh gia cng c. Tin hnh kim tra phi s dng ch to tm o khun xem c t yu cu k thut hay khng: - Kch thc ca phi x x hay khng. - nhn bng ca cc b mt xung quanh t bng cp 5. - Khng tn ti cc khuyt tt: nt, rn, r IV.4.3.2.2. Nguyn cng 2: Khoan 4 l f10,5 su 105 mm trn b mt bn B.

S nh v:

nh v:

Do hai mt phng D v A ca phi ln lt tip xc vi thanh k v m tnh ca t. Nn phi c khng ch c 6 bc t do, ta ch cn tin hnh kp cht phi chun b cho qu trnh giacng ch to cc bin dng thch hp Kp cht:

phi khng b dch chuyn khi chu cc lc ct gt tc dng nn. Ta ch cn quay trc vt ca t lm m ng chuyn ng li gn phi to ra lc kp cht W cn thit. Chn my gia cng:

Chi tit c gia cng trn my phay P1050-CNC iu khin theo chng trnh. Cng sut ca ng c l 7,5 kW (Tham kho thm Bng V.1). Chn dng c ct:

Qu trnh gia cng c tin hnh nh s dng mi khoan lm bng thp gi c f10,5 mm.

IV.4.3.2.3. Nguyn cng 3: Khoan 4 l f10,5 su 105 mm trn b mt bn B. S nh v:

nh v:

Do hai mt phng D v A ca phi ln lt tip xc vi thanh k v m tnh ca t. Nn phi c khng ch c 6 bc t do, ta ch cn tin hnh kp cht phi chun b cho qu trnh gia cng ch to cc bin dng thch hp Kp cht:

phi khng b dch chuyn khi chu cc lc ct gt tc dng nn. Ta ch cn quay trc vt ca t lm m ng chuyn ng li gn phi to ra lc kp cht W cn thit. Chn my gia cng:

Chi tit c gia cng trn my phay P1050-CNC iu khin theo chng trnh. Cng sut ca ng c l 7,5 kW (Tham kho thm Bng IV 1). Chn dng c ct:

Qu trnh gia cng c tin hnh nh s dng mi khoan lm bng thp gi c f10,5 mm.

IV.4.3.2.4. Nguyn cng 4: Gia cng bin dng trn mt phng A ca phi. S nh v.

nh v:

Chn mt phng y C ca tm phi khun sau lm mt phng nh v, nh s dng mt phng nh v ta khng ch 3 bc t do trc khi tin hnh kp cht gia cng. Kp cht:

Lc kp cht cn thit W c phng vung gc vi mt nh v c tc dng c nh chi tit trong qu trnh gia cng c hc, c to bi mi ghp bulong-ai c v tay n. Qu trnh kp cht chi tit din ra nh sau: - Tin hnh kp cht s b c nh phi mt cch tng i. - Lp ng h o ln trc my tin hnh r mt hai mt phng B v E song vi ng chy dao ca trc my. - Tin vn cht 4 Bulong kp cht chi tit. Chn my gia cng:

Chi tit c gia cng trn my phay P1050-CNC iu khin theo chng trnh. Cng sut ca ng c l 7,5 kW (Tham kho thm Bng IV 1). Dng c ct: Tu theo bin dng cn gia cng v cht lng ca b mt sau gia cng m chn dng c ct cho ph hp. C th. - gia cng c hc ch nht c kch thc 240x140 mm su 40 mm t cp chnh xc 7 bng b mt cp 45 l 10 5 ?m. Ta tin hnh gia cng theo trnh t sau. + Gia cng l f20 su 42,5 mm bng mi khoan thp gi chnh gia phi. + Gia cng th hc ch nht t kch thc 239,8x139,8 mm su 40 mm bng dao phay hai li ct f20 mm, Z = 5. + Gia cng tinh hc ch nht t kch thc 240x140 mm su 40 mm bng dao phay hai li ct f20 mm, Z = 5. - Gia cng hc lp nm cn:

+ S dng dao phay ngn c hai li ct c f12 gia cng hai hc t kch thc 110x20x17 mm bn knh ln R6. + S dng dao phay ngn c hai li ct c f12 gia cng hai hc t kch thc 80x20x17 mm bn knh ln R6.

IV.4.3.2.5. Nguyn cng 5: Gia cng cc bin dng trn mt C. S nh v.

nh v:

Chn mt phng y A ca tm phi khun sau lm mt phng nh v, nh s dng mt phng nh v ta khng ch 3 bc t do trc khi tin hnh kp cht gia cng. Kp cht:

Lc kp cht cn thit W c phng vung gc vi mt nh v c tc dng c nh chi tit trong qu trnh gia cng c hc, c to bi mi ghp bulong-ai c v tay n. Qu trnh kp cht chi tit din ra nh sau: - Tin hnh kp cht phi mt cch tng i. - Lp ng h o ln trc my tin hnh r mt hai mt phng B v E song vi ng chy dao ca trc my. - Tin vn cht 4 Bulong kp cht chi tit. Chn my gia cng:

Chi tit c gia cng trn my phay P1050-CNC iu khin theo chng trnh. Cng sut ca ng c l 7,5 kW (Tham kho thm Bng IV 1). Dng c ct: Tu theo bin dng v cht lng b mt sau gia cng m la chn dng c ct cho ph hp. C th. - Gia cng h thng l bt Bulong M8 vi lng khun trc. + Gia cng 6 l f14 su 10 mm bng dao phay hai li ct f14 c Z = 2. + Gia cng 6 l f9 su 30 mm bng mi khoan rut g f9mm. - Gia cng h thng l f11,5 taro ren M14 bng mi khoan rut g f11,5 - Gia cng h thng l bulong chm M8 s qua lp vi nm cn.

+ Gia cng 8 l f14 su 10 mm bng dao phay hai li ct f14 c Z = 2. + Khoan 8 l f9 su 55 mm bng mi khoan rut g f9 mm. IV.4.3.2.6. Nguyn cng 6: Gia cng h thng l lp cht y. S nh v.

nh v:

Chn mt phng y ca cm phi lm mt phng nh v, nh s dng mt phng nh v ta khng ch 3 bc t do trc khi tin hnh kp cht gia cng. Kp cht:

Lc kp cht cn thit W c phng vung gc vi mt nh v c tc dng c nh chi tit trong qu trnh gia cng c hc, c to bi mi ghp bulong-ai c v tay n. Qu trnh kp cht chi tit din ra nh sau: - Tin hnh kp cht phi mt cch tng i. - Lp ng h o ln trc my tin hnh r mt hai mt phng B v E song vi ng chy dao ca trc my. - Tin vn cht 4 Bulong kp cht chi tit. Chn my gia cng:

Chi tit c gia cng trn my phay P1050-CNC iu khin theo chng trnh. Cng sut ca ng c l 7,5 kW (Tham kho thm Bng IV 1). Dng c ct: Tu theo bin dng v cht lng b mt sau gia cng m la chn dng c ct cho ph hp. C th. - Dng mi khoan rut g f7,8 gia cng h thng l f7,8. - Dng dao doa f8mm gia cng bng h thng l f7,8 t kch thc f8 c bng t cp 5 7 Ra t t 5 ti 1,25 ?m.

IV.4.3.2.7. Nguyn cng 7: Mi mt phng C ca tm khun trn. S nh v (Trang sau).

nh v:

S dng mt phng y C ca phi nh v, mt phng y ny s khng ch 3 bc t do cho phi trc khi kp cht phi gia cng. Kp cht:

Lc kp cht cn thit W c phng vung gc vi mt nh v c tc dng c nh chi tit trong qu trnh gia cng c hc, c to bi lc ht nam chm in do bn t sinh ra. Chn my gia cng:

Chi tit c gia cng trn my mi phng, bn hnh ch nht 3B724. Cng sut ca ng c l 30kW. Dng c ct:

mi c ng knh D = 200 mm, chiu rng B = 40 mm.

IV.4.3.2.8. Nguyn cng 8: Gia cng ngui ton b tm khun trn. Cng vic gm c: - Mi bin ton b b mt bin dng lng khun t bng yu cu ?1,25. - Mi b mt hc ch nht lp nm cn. - Tin hnh taro ren M14 u ng dn dung dch lm mt. - Tin hnh nghin th l lp cht t sn phm. - Tin hnh mi b mt phn khun bng phng php r bng sn. Cc cng vic tin hnh hon ton trn bn mp, chi tit c khng ch ba bc t do nh s dng mt phng nh v khng cn s dng c cu to lc kp cht W c nh phi. Ch : Nguyn cng mi mt phng l nguyn cng bo m loi ht cc ba va, vt sc pht sinh khi vn chuyn phi qua cc bc gia cng trc nhm bo m phng cn thit cho chi tit khi lp rp. Do ta chi cn lng d 0,25 mm cho nguyn cng mi l bo m c cc yu cu ra. IV.4.4. Qui trnh cng ngh gia cng lng khun sau. IV.4.4.1. Trnh t cng ngh gia cng lng khun sau. Cn c vo hnh dng ca phi trc khi gia cng (Hnh IV 6-Trang 75). Vi hnh dng v kt cu ca tm lng khun sau thit k nh sau:

Hnh IV 23: Kt ca tm lng khun sau cn gia cng. *) Nhn thy rng t phi ch to ra c tm o khun t yu cu k thut th ta cn phi tin hnh cc cng vic sau: - Gia cng phi t kch thc 240x140x50 mm . - Gia cng h thng lm mt lng khun. - Gia cng h thng l ren bt Bulong chm M8. - Gia cng bin dng lng khun sau. Tin hnh sa cha cc sai xt nh cc chi tit (nu c) trc khi lp ghp. *) Trnh t cc nguyn cng gia cng lng khun sau nh sau: Th t Ni dung cng vic. 1 2 3 4 5 6 Chun b phi cho qu trnh gia cng ch to. Gia cng chiu rng phi t kch thc 140h7 mm. Gia cng chiu di phi t kch thc 240h7 mm. Khoan 4 l f10,5 su 80 mm trn b mt bn B. Khoan 4 l f10,5 su 60 mm trn b mt bn D. Gia cng h thng l trn b mt C ca phi,

- Gia cng 6 l ?6 su 20 mm taro ren M8. - Gia cng 8 l ?10,5 su 10 mm dn dung dch lm mt. 7 Tin hnh sa ngui lng khun, lp c vo v khun trn.

- Mi bn mt bn ca phi. - Taro 6 l ren M8 su 15 mm bt Bulong M8 qua. 8 9 Trn b mt A tin hnh gia cng bin dng li khun. Gia cng h thng l lp cht y sn phm.

- Khoan 18 l ? 7,8 su 45 mm - Doa th l ?7,8 ln thnh ?8 su 45 mm 10 Gia cng ngui ton b cm khun sau theo yu cu ca thit k.

- Mi bin ton b bin dng lng khun.

- Mi b mt hc ch nht lp nm cn. - Tin hnh taro ren M14 u ng dn dung dch lm mt. - Tin hnh nghin th l lp cht t sn phm.

IV.4.4.2. Thit k cc nguyn cng. IV.4.4.2.1. Nguyn cng 1: Chun b phi cho qu trnh gia cng. Tin hnh kim tra phi s dng ch to tm o khun xem c t yu cu k thut hay khng: - Kch thc ca phi x x hay khng. - nhn bng b mt ca cc b mt . - Khng tn ti cc khuyt tt: nt, rn, r IV.4.4.2.2. Nguyn cng 2: Phay chiu rng phi t kch thc 140h7. S nh v:

nh v:

Do hai mt phng D v A ca phi ln lt tip xc vi thanh k v m tnh ca t. Nn phi c khng ch c 6 bc t do, ta ch cn tin hnh kp cht phi chun b cho qu trnh gia cng ch to cc bin dng thch hp Kp cht:

phi khng b dch chuyn khi chu cc lc ct gt tc dng nn. Ta ch cn quay trc vt ca t lm m ng chuyn ng li gn phi to ra lc kp cht W cn thit. Chn my gia cng:

Chi tit c gia cng trn my phay P1050-CNC iu khin theo chng trnh. Cng sut ca ng c l 7,5 kW (Tham kho thm Bng IV 1). Chn dng c ct: gia cng chiu rng ca phi t kch thc 140 mm t bng 2,5 ?m. Ta s dng dao phay mt u c ng knh D = 100 mm chiu cao ca dao H = 39 mm c Z = 10 rng. Thc hin ct th v ct tinh bo m c nng sut gia cng ln cht lng b mt sau gia cng. Lng d gia cng.

- Gia cng th: B rng ct B = 60 mm cn chiu su ct t = 2 mm.

- Gia cng tinh:B rng ct B = 60 mm cn chiu su ct t = 0,2 mm.

IV.4.4.2.3. Nguyn cng 3: Gia cng chiu di phi t kch thc 240h7. S nh v (Trang sau):

nh v:

Do hai mt phng D v A ca phi ln lt tip xc vi thanh k v m tnh ca t. Nn phi c khng ch c 6 bc t do, ta ch cn tin hnh kp cht phi chun b cho qu trnh giacng ch to cc bin dng thch hp Kp cht:

phi khng b dch chuyn khi chu cc lc ct gt tc dng nn. Ta ch cn quay trc vt ca t lm m ng chuyn ng li gn phi to ra lc kp cht W cn thit. Chn my gia cng:

Chi tit c gia cng trn my phay P1050-CNC iu khin theo chng trnh. Cng sut ca ng c l 7,5 kW (Tham kho thm Bng IV 1). Chn dng c ct: Tu theo tnh cht gia cng v bin dng cng gia cng m la chn dng c ct cho ph hp. Chn dng c ct: gia cng chiu rng ca phi t kch thc 140 mm t bng 2,5 ?m. Ta s dng dao phay mt u c ng knh D = 100 mm chiu cao ca dao H = 39 mm c Z = 10 rng. Thc hin ct th v ct tinh cht lng b mt t yu cu.

Lng d gia cng.

- Gia cng th: B rng ct B = 60 mm cn chiu su ct t = 2 mm. - Gia cng tinh:B rng ct B = 60 mm cn chiu su ct t = 0,2 mm.

IV.4.4.2.4. Nguyn cng 4: Khoan 4 l f10,5 su 80 mm trn b mt bn B. S nh v (Trang sau):

nh v:

Do hai mt phng D v A ca phi ln lt tip xc vi thanh k v m tnh ca t. Nn phi c khng ch c 6 bc t do, ta ch cn tin hnh kp cht phi chun b cho qu trnh giacng ch to cc bin dng thch hp Kp cht:

phi khng b dch chuyn khi chu cc lc ct gt tc dng nn. Ta ch cn quay trc vt ca t lm m ng chuyn ng li gn phi to ra lc kp cht W cn thit. Chn my gia cng:

Chi tit c gia cng trn my phay P1050-CNC iu khin theo chng trnh. Cng sut ca ng c l 7,5 kW (Tham kho thm Bng IV 1). Chn dng c ct:

Qu trnh gia cng c tin hnh nh s dng mi khoan lm bng thp gi c f10,5 mm.

IV.4.4.2.5. Nguyn cng 5: Khoan 4 l f10,5 su 65 mm trn b mt bn D. S nh v :

Cc qu trnh tip theo tin hnh hon ton tng t nh nguyn cng 4. IV.4.4.2.6. Nguyn cng 6: Gia cng h thng cc l trn b mt C. S nh v.

nh v:

Chn mt phng y A ca phi lm mt phng nh v, mt phng y ny s khng ch 3 bc t do cho phi trc khi kp cht phi gia cng. Kp cht:

Lc kp cht cn thit W c phng vung gc vi mt nh v c tc dng c nh chi tit trong qu trnh gia cng c hc, c to bi mi ghp bulong-ai c v tay n. Qu trnh kp cht chi tit din ra nh sau: - Tin hnh kp cht s b c nh phi mt cch tng i. - Lp ng h o ln trc my tin hnh r mt hai mt phng B v E song vi ng chy dao ca trc my.

- Tin vn cht 4 Bulong kp cht chi tit. Chn my gia cng:

Chi tit c gia cng trn my phay P1050-CNC iu khin theo chng trnh . Cng sut ca ng c l 7,5 kW (Tham kho thm Bng IV 1). Dng c ct: c la chn tu thuc vo bin dng cn gia cng.

- S dng mi khoan thp gi ?6 mm gia cng 6 l ?6. - S dng mi khoan thp gi ?10.5 mm gia cng 8 l ?6. - S dng dao phay ngn ?20 mm gia cng vt mp 10x45o cnh phi.

IV.4.4.2.7. Nguyn cng 7: Gia cng ngui tm phi ghp vo v khun. hn ch nh hng sai s ca mi lp gia lng khun vi v khun ti chnh xc khi lp rp lng khun v li khun li vi nhau. Ta cn s dng chun thng nht khi gia cng hai bin dng ca lng khun khi khng th gia cng chng trong 1 lm gia cng c. Do vy ta cn tin hnh lp rp tm phi lng khun vo tm o khun sau mi tin hnh gia cng bin dng li khun. Do sai s ca dao c v ch ct nh hng ti hnh dng ca hc ch nht 240x140mm su 30 mm trn tm o khun. Cho nn ta cn tin hnh gia cng ngui phi lp kn kht vi tm o khun sau. Cng vic gm c. - Mi bn mt bn ca phi. - Taro 6 l ren M8 su 15 mm bt Bulong M8 qua. Tu theo tnh cht ca cng vic m qu trnh gia cng c th tin hnh trn bn mp hoc trn t.

IV.4.4.2.8. Nguyn cng 8: Gia cng bin dng lng khun sau. S nh v.

nh v:

Chn mt phng y C ca phi lm mt phng nh v, nh s dng mt phng ny m ta hn c ch 3 bc t do ca phi trc khi kp cht phi gia cng. Kp cht:

Lc kp cht cn thit W c phng vung gc vi mt nh v c tc dng c nh chi tit trong qu trnh gia cng c hc, c to bi mi ghp bulong-ai c v tay n. Qu trnh kp cht chi tit din ra nh sau:

- Tin hnh kp cht s b c nh phi mt cch tng i. - Lp ng h o ln trc my tin hnh r v iu chnh li v tr ca phi mt hai mt phng B v E song vi ng chy dao ca trc my. - Tin vn cht 4 Bulong kp cht chi tit. Chn my gia cng:

Chi tit c gia cng trn my phay P1050-CNC iu khin theo chng trnh. Cng sut ca ng c l 7,5 kW (Tham kho thm Bng IV 1). Cc qu trnh cn li tham kho thm phn to chng trnh gia cng bin dng li ca tm lng khun trn. IV.4.4.2.9. Nguyn cng 9: Gia cng h thng l lp cht y sn phm. S nh v.

Cc qu trnh tip theo c thc hin hon ton tng t nh nguyn cng 6 (4.3.2.6) trong qui trnh cng ngh ch to tm o khun sau. IV.4.4.2.10. Nguyn cng 10: Gia cng ngui ton b cm khun sau. Cng vic gm c: - Mi bin ton b bin dng lng khun. - Mi b mt hc ch nht lp nm cn. - Tin hnh taro ren M14 u ng dn dung dch lm mt. - Tin hnh nghin th l lp cht t sn phm. - Tin hnh mi b mt phn khun bng phng php r bng sn. Cc cng vic tin hnh hon ton trn bn mp, chi tit c khng ch ba bc t do nh s dng mt phng nh v khng cn s dng c cu to lc kp cht W c nh phi. IV.5. Tnh ton qu trnh ct gt khi gia cng vt liu. Cn c vo trnh t cc bc cng ngh trong mi nguyn cng ch to ch to c cc tm khun t yu cu (tm o khun trc, tm o khun sau, tm li khun trc v tm lng khun sau). Nhn thy rng mi chi tit cn gia cng ch to c mt s v tr gia cng ging nhau. Do hn ch bt s trng lp trong qu trnh tnh ton gim bt khi lng tnh ton khn cn thit, ta ch cn xc nh chnh xc ch ct (S,v,t) cho mi ln gia cng khc nhau cn cc ln gia cng tng t ta tnh ton bng phn mm Excel c c kt qu cui cng. Vy ch to ra c cc chi tit ng theo thit k, ta cn tit hnh gia cng ch to cc bin dng sau:

Bng IV 3: Cc b mt, bin dng cn gia cng trn hai lng khun. TT 1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 Cng vic. Dng c ct. Mi khoan c ng knh ?2,5 mm.

Khoan l ?2,5 su 25 mm

Khoan l ?4 su 30 mm Mi khoan c ng knh ?4 mm. Khoan l ?6 su 20 mm Mi khoan c ng knh ?6 mm. Khoan l ?7,8 su 45 mm Khoan l ?9 su 30,55 mm Mi khoan c ng knh ?7,8 mm. Mi khoan c ng knh ?9 mm.

Khoan l ?10 su 6 mm Dao phay cu c ng knh ?10 mm. Khoan l ?10,5 su 10, 20,55,56,60,80,90,105,120,125. Mi khoan c ng knh ?10,5 mm. Khoan l ?11,5 su 35 mm Mi khoan c ng knh ?11,5 mm.

Khoan l ?12 su 5 mm Dao phay hai rnh ct ?12 mm. Khoan l ?14 su 10 mm Khoan l ?18 su 12 mm Dao phay hai rnh ct ?14 mm. Dao phay hai rnh ct ?18 mm.

Khoan l ?20 su 2;32,5;42,5;43,5 mm Dao phay hai rnh ct ?20 mm. Doa l t ?8 su 45 mm Dao doa c ng knh ?8 mm. Dao phay cu ng knh ?6 mm.

Phay rnh rng 6 mm su 0,2mm (0,1mm) Phay rnh rng 12 mm su 1,0 mm

Dao phay ngn ?12 mm, Z = 2.

Phay mt phng rng 20 mm su 2mm (0,2mm) Dao phay ngn ?20 mm, Z = 5. Phay mt phng su 2mm (0,2mm) Dao phay mt u c gn thp gi.

IV.5.1. Ch ct khi khoan l c ng knh d(mm). * Ch ct khi khoan l c ng knh d = 20 mm su 43,5 mm. S ct gt (Hnh bn): Lng d gia cng:

Khi khoan l c ng knh ?20 mm lng d gia cng t = 0,5.d = 10 mm. Ch ct:

? ?

Chiu su ct gt: t = 10 (mm). Lng chy dao: S = Sb.kls = 0,23.1,0 = 0,23 (mm/vg).

Tra bng 5.25 - Trang 21 (Quyn 2) vi d = 20 mm ta c: Sb = 0,23(mm/vg) Tra bng 5.25 - Trang 21 (Quyn 2) vi t l l/d < 3 ta c kls = 1. ? Tc ct (V) c xc nh bi cng thc sau:

(m/ph) (IV 1)

kv = kMV.kUV.klV.

(IV 2)

- Cc h s Cv, m, y, q c xc nh theo Bng 5-28 - Trang 23 (Quyn 2). Vi mi khoan c li ct lm bng thp gi P6M5 thc hin chy dao S ? 0,2 (mm/vg) ta c: Cv = 7, m = 0,2; q = 0,40 ; y = 0,7. - Vi d = 20 ta tra bng 5-30 (Trang 24- (Quyn 2)) c gi tr trung bnh tui bn ca dao T = 45 (pht). - kv l h s hiu chnh chung cho tc : kv = kMV.knv.kuv. Trong : - knv l h s ph thuc vo trng thi b mt ca phi: kUV = 1. - kuv h s ph thuc vo vt liu ca dng c ct: klV = 1. - kMV l h s ph thuc vo tnh cht c l ca vt liu gia cng cho trong Bng 5-1 ?5-4 (Quyn 2) i vi thp ta c. kMV = = = 1 y: - ?b : Gii hn bn ca vt liu, ?b = 750 Mpa. - kn l h s iu chnh ? vo nhm thp theo tnh gia cng, kn = 1. - nv l s m cho trong Bng 5-2 (Quyn 2): nv = 1. ? kv = kMV.kUV.klV = 1.1.1 = 1. Tin hnh cc gi tr va xc nh c trn vo cng thc (IV 1) ta c: = 30,315 (m/ph). Khi tc quay ca mi khoan l:

Chn tc quay ca trc chnh khi gia cng l: ngc = 450 (vg/ph). Khi vn tc ct thc t s l: Vgc = ngc.?.D/1000 = 28,27 (m/ph). Cn lng chy dao (mm/ph) : Sgc = Sgc.ngc = 0,23.450 = 103,5 (m/ph). Vy lng chay dao khi gia cng s l Sgc = 100 (m/ph). ? Mmen xon (Mx) v lc chiu trc (Po):

Mmen xon (MX) v thnh phn lc chiu trc (Po) pht sinh trong qu trnh khoan c xc nh bi cng thc: Mx = 10.CM.Dq.tx.Sy.kp. (N.m) (IV 3)

Po = 10.Cp.Dq.Sy.kp.

(N)

(IV 4)

- Tra bng bng 5-32 - Trang 25 (Quyn 2) ta c: CM = 0,0345; q = 2; y = 0,8 v Cp = 68; q = 1; y = 0,7. - H s tnh n cc yu t gia cng thc t kp ch ph thuc vo tnh cht c l ca vy liu gia cng c xc nh nh sau: kp = kMP i vi thp v gang theo bng 5-9 - Trang 25 (Quyn 2). kMP = = = 1 Thay cc gi tr vo cng thc (IV 3) v (IV 4) ta c: Mx = 10.CM.Dq.Sy.kp = 10.0,0345.202.0,230,8.1 = 42,58 (N.m). Po = 10.Cp.Dq.Sy.kp = 10.68.201.0,230,7.1 = 48,61 (N). Lc ny cng sut ct c tnh nh sau: = 1,965 (kW). * Nhn thy rng ng vi mi v tr l cn gia cng c ng knh d v chiu su l, ta cn s dng mi khoan c ng knh tng ng gia cng. Tin hnh tra bng 5.25 v 5.28 (Quyn 2) ta xc nh c gi tr chy dao S (mm/vg) cng gi tr tui bn trung bnh T (pht) tng ng. Tin hnh thay cc gi tr (Cv, m, q, y, D = d, S) ; (CM, q; y) ; (Cp, q, y) . vo cc cng thc cng thc (IV 1); (IV 3) v (IV 4) ta s xc nh c cc gi tr V, Mx, Po v N tng ng : Khi c vn t ct V th tc quay ca mi khoan l: ntt = 1000.V/(D.?) Chn li gi tr tc quay ca trc chnh cho ph hp vi qu trnh gia cng l: ngc (vg/ph). Khi vn tc ct thc t s l: V = ngc.?.D/1000 (m/ph). Tin hnh tnh ton ln lt i vi mi mi khoan c ng knh khc nhau ri ta lp thnh bng ch ct nh sau.

Bng IV 4: Bng biu din thng s ch ct gt khi khoan. Kch thc l gc d(mm) L(mm) T ?2,5 ?4 ?6 ?7,8 ?9 ?9 ?10 25 25 20 45 30 55 6 10 10,5 20 55 56 60 ?10,5 80 90 105 120 125 ?11 ?11,5 ?12 ?14 ?18 55 35 5 10 12 30 45 1,0 25 25 15 15 Thng s cng ngh kls 0,75 0,8 0,9 0,8 0,9 0,8 1,0 1,0 1,0 0,9 0,9 0,8 0,8 0,75 0,75 0,5 0,5 0,9 0,9 0,20 0,20 0,25 0,18 Sb 0,07 0,10 0,12 0,12 0,15 0,15 0,18 Stt 0,053 0,080 0,108 0,096 0,135 0,120 0,180 0,180 0,180 0,168 0,168 0,144 0,144 0,135 0,135 0,090 0,090 0,162 0,162 0,200 0,200 0,250 Gi tr tnh ton Gi tr gia cng Thng s lc ct Vtt 46,23 41,55 39,60 43,13 35,97 39,06 30,68 30,68 30,68 30,68 30,68 35,86 35,86 37,52 37,52 49,84 49,84 30,50 30,50 27,25 28,99 27,42 ntt ngc Vgc 31,4 37,7 28,3 36,8 33,9 33,9 25,1 25,1 25,1 25,1 25,1 31,4 31,4 31,4 31,4 37,7 37,7 27,6 27,6 26,4 26,4 25,4 Po 216,1 464,2 859,1 1029 1507 1507 2047 2047 2047 2047 2047 1751 1751 1674 1674 1260 1260 2092 2092 2645 3086 4638 Mx 0,20 0,73 2,09 3,22 5,63 5,63 8,75 8,75 8,75 8,75 8,75 7,32 7,32 6,95 6,95 5,03 5,03 9,73 9,73 13,71 18,66 36,87 N 0,08 0,23 0,32 0,50 0,69 0,69 0,72 0,72 0,72 0,72 0,72 0,75 0,75 0,71 0,71 0,62 0,62 0,80 0,80 0,98 1,15 1,70

5886,5 4000 3306,2 3000 2101,1 1500 1760,0 1500 1272,3 1200 1381,6 1200 976,5 976,5 976,5 884,9 884,9 800 800 800 800 800

1141,6 1000 1141,6 1000 1194,3 1000 1194,3 1000 1586,3 1200 1586,3 1200 882,7 882,7 722,9 659,0 484,8 800 800 700 600 450

?20

40 43,5

0,27

0,270

27,10

431,3

400

25,1

5439

48,41

1,99

Trong khi cng sut ca my l: Nmy = 7,5.0,8 = 6,0 (kW). Nh vy my phay P1050-CNC c cng sut gia cng cc l c ng knh khc nhau theo thit k. Ch : Cn thm mt bc quy i lng chay dao t (mm/vg) sang (mm/ph), do ta thc hin cng vic khoan l trn my phay ng. IV.5.2. Ch ct khi phay rnh. Dng c ct: gia cng rnh c b rng 6 mm su 0,5mm ta s dng dao phay cu ?6 mm c s rng ct Z = 2. S ct gt (hnh v bn): Lng d gia cng: - Chiu su ct t = d = 6 mm.

- Chiu rng ct B = 0,5 mm. ? Ch ct khi gia cng tnh nh sau: Tc ct (V) c xc nh bi cng thc sau:

(m/ph) (IV 5)

kv = kMV.kUV.klV.

(IV 6)

- Tra bng 5-36 Trang 29 (Quyn 2) i vi chiu su ct t = 6 mm dng dao phay hai rnh c li ct bng thp gi. Ta c SZ = 0,05 mm (Phay rnh). - Tra bng 5-33 Trang 29 (Quyn 2) khi gia cng c dung dch trn ngui, dao dng ngn lin khi. Ta c h s m nh sau: CV = 46,7 ; q = 0,45; x = 0,5; y = 0,5; u = p = 0,1 v m = 0,33. - Tra bng 5-40 Trang 34 (Quyn 2) Vi dao phay hai li ct c ng knh ?20mm ? Tui bn ca dao T = 80 pht. - Tra bng 5-1 ?5-6 (Quyn 2). Ta xc nh c kMV; klV; kUV. Trong : - kUV l h s ph thuc vo trng thi b mt phi: kUV = 1.

- kLV l h s ph thuc vo vt liu ca dng c ct: klV = 1. - kMV l h s ph thuc vo tnh cht c l ca vt liu gia cng cho trong i vi thp ta c.

kMV = = = 1 y: - ?b : Gii hn bn ca vt liu, ?b = 750 Mpa. - kn l h s iu chnh ? vo nhm thp, kn = 1. - nv l s m cho trong bng 5-2 (Quyn 2): nv = 0,9. ? kv = kMV.kUV.klV = 1 *) Thay cc gi tr va xc nh c vo cng thc (IV 5)ta c : = 66,01 (m/ph) Khi tc quay ca tr my n (vg/ph) c xc nh nh sau: = 3501,4 (vg/ph) Chn ngc = 3000 (vg/ph). Khi vn tc ct thc t s l: Vgc = ngc.?.D/1000 = 56,55 (m/ph). ? ? Lng chy dao: Sph = SZ.Z.n = 0,05.2.3000 = 300 (mm/ph). Mmen xon (Mx) v lc ct (PZ):

Mmen xon MX v lc ct PZ c xc nh bi cng thc nh sau: PZ = (N) (IV 7)

Mx = PZ.D/(2.100)

(N.m)

(IV 8)

- Tra bng 5-41 Trang 34 (Quyn 2) khi gia cng bng dao ngn c li ct thp gi. Ta c c cc h s m: CP = 69,2 ; q = 0,86; x = 0,86; y = 0,72 cn u = 1,0 v w = 0. - trn ta xc nh c n = 3000 (vg/ph) v kMV = 1. *) Thay cc gi tr vo cng thc (IV 7) v (IV 8) ta c. PZ = = 80,05 (N) Mx = PZ.D/(2.1000) = 80,05.6/(2.1000) = 0,24 (N.m) Khi cng sut ct c xc nh nh sau: = 0,07 (kW) Trong khi cng sut my l: Nmy = 7,5.0,8 = 6(kW) > Ntt. Vy my c ct lng kim loi cn thit.

* Nhn thy rng ng vi mi ch gia cng rnh c b rng d th c cc thng s v lng d ct gt khc nhau (t,B). Ta cn cn xc nh ch gia cng tng ng, tin hnh tra bng 5-33; 5-39 v 5-40 (Quyn 2) ta xc nh c gi tr chy dao S (mm/vg) cng gi tr tui bn trung bnh T (pht) cng cc h s m tng ng. Tin hnh thay cc gi tr vo cc cng thc cng thc (IV 5); (IV 7) v (IV 8) ta s xc nh c cc gi tr V, Mx, Po v N tng ng : Khi c vn t ct V th tc quay ca trc dao phay l: ntt = 1000.V/(D.?). Chn li gi tr tc quay ca trc chnh cho ph hp vi qu trnh gia cng l: ngc (vg/ph) v vn tc ct thc t khc nhau. Tin hnh tnh ton ln lt i vi mi ng knh dao khc nhau vi lng d gia cng khc nhau c kt qu ta lp thnh bng ch ct nh sau. Bng IV 5: Bng ch ct gt khi phay rnh bng dao hai li ct. Dao D ?6 Thng s cng ngh T 6,0 6,0 ?12 12,0 B 0,5 0,1 1,0 Sb 0,05 0,05 0,10 Gi tr tnh ton Gi tr gia cng Thng s lc ct T 25 25 45 Vtt 66,01 77,54 34,65 ntt ngc Vgc 56,5 47,1 30,2 Sgc 300 250 160 PZ 80,1 16,0 263,7 Mx 0,24 0,05 1,58 N 0,07 0,01 0,13

3501,893000 4113,392500 919,10 800

IV.5.3. Ch ct khi phay mt phng. IV.5.3.1. Ch ct khi phay mt phng s dng dao phay ngn. bc ht lp kim loi b mt dy a mm, ta s dng dao phay hai li ct c ?20 mm c Z = 5 chiu di phn ct > 45 mm mi ln chy dao bc c mt lp kim loi dy 1 mm. S ct gt (hnh v bn): Lng d gia cng: - Chiu su ct t = d = 20 mm.

- Chiu rng ct B = 1 mm. ? Ch ct khi gia cng tnh nh sau: Tc ct (V) c xc nh bi cng thc sau:

(m/ph) (IV 5)

kv = kMV.kUV.klV.

(IV 6)

- Tra bng 5-35 Trang 29 (Quyn 2) i vi chiu su ct t = 20 mm dng dao phay ngn c li ct bng thp gi. Ta c SZ = 0,1 mm. - Tra bng 5-39 Trang 29 (Quyn 2) khi gia cng c dung dch trn ngui, dao dng ngn lin khi. Ta c h s m nh sau: CV = 46,7 ; q = 0,45; x = 0,5; y = 0,5; u = p = 0,1 v m = 0,33. - Tra bng 5-40 Trang 34 (Quyn 2) Vi dao phay ngn c ng knh ?20mm ? Tui bn ca dao T = 80 pht. - Tra bng 5-1 ?5-6 (Quyn 2). Ta xc nh c kMV; klV; kUV. Trong : - kUV l h s ph thuc vo trng thi b mt phi: kUV = 1.

- kLV l h s ph thuc vo vt liu ca dng c ct: klV = 1. - kMV l h s ph thuc vo tnh cht c l ca vt liu gia cng cho trong i vi thp ta c. kMV = = = 1 y: - ?b : Gii hn bn ca vt liu, ?b = 750 Mpa. - kn l h s iu chnh ? vo nhm thp, kn = 1. - nv l s m cho trong bng 5-2 (Quyn 2): nv = 0,9. Thay cc gi tr kMV, kUV, klV vo (IV 5) ta c: kv = kMV.kUV.klV = 1 *) Thay cc gi tr va xc nh c vo cng thc (IV 5)ta c : = 25,49 (m/ph) Khi tc quay ca tr my n (vg/ph) c xc nh nh sau: = 405,67 (vg/ph) Chn ngc = 350 (vg/ph). Khi vn tc ct thc t s l: Vgc = ngc.?.D/1000 = 21,99 (m/ph). ? ? Lng chy dao: Sph = SZ.Z.n = 0,1.5.350 = 175 (mm/ph). Mmen xon (Mx) v lc ct (PZ):

Mmen xon MX v lc ct PZ c xc nh bi cng thc nh sau:

PZ = (N) (IV 7)

Mx = PZ.D/(2.100)

(N.m)

(IV 8)

- Tra bng 5-41 Trang 34 (Quyn 2) khi gia cng bng dao ngn c li ct thp gi. Ta c c cc h s m: CP = 69,2 ; q = 0,86; x = 0,86; y = 0,72 cn u = 1,0 v w = 0. - trn ta xc nh c n = 350 (vg/ph) v kMV = 1. *) Thay cc gi tr vo cng thc (IV 7) v (IV 8) ta c. PZ = = 659,3 (N) Mx = PZ.D/(2.1000) = 659,3.20/(2.1000) = 6,59 (N.m) Khi cng sut ct c xc nh nh sau: = 0,3 (kW) Trong khi cng sut my l: Nmy = 7,5.0,8 = 6 (kW) > Ntt. Vy my c ct lng kim loi cn thit. *) Do mi b mt cn cng c nhng yu cu v cht lng b mt khc nhau. Cho nn t c nng sut gia cng cao nht, trong khi vn bo m c cht lng b mt sau gia cng, ta phi tin hnh phn b lng d trong mi ln gia cng gia cng th hoc tinh hp l. Do vi tng ng vi mi lng d gia cng khc nhau (thay i t hoc B) ta s xc nh c mt ch ct khc nhau. Bng cch tra bng 5-35; 5-39 v 5-40 (Quyn 2) ta xc nh c gi tr chy dao S (mm/vg) cng gi tr tui bn trung bnh T (pht) cng cc h s m tng ng. Ri tin hnh thay cc gi tr vo cc cng thc cng thc (IV 5); (IV 7) v (IV 8) ta s xc nh c cc gi tr V, Mx, Po v N tng ng : Khi c vn t ct V th tc quay ca dao phay l: ntt = 1000.V/(D.?) Chn li gi tr tc quay ca trc chnh cho ph hp vi qu trnh gia cng l: ngc (vg/ph) Khi vn tc ct thc t s l: V = ngc.?.D/1000 (m/ph). Tin hnh tnh ton ln lt cho mi ch ct (D,t,B) khc nhau ri ta lp thnh bng ch ct nh sau: Bng IV 6: Thng s ch ct khi phay mt phng bng dao phay ngn. Dao D Thng s cng ngh t B Sb Gi tr tnh ton Gi tr gia cng Thng s lc ct T Vtt ntt ngc Vgc Sgc PZ Mx N

20 ?20 0,1 0,1

1,0 30,0 40,0

0,1 0,1 0,1

80 80 80

25,49

405,67 350

22,0 157,1 157,1

175 1250 1250

659,3 207,6 276,9

6,59 2,08 2,77

0,24 0,53 0,71

256,54 4082,932500 249,26 3967,142500

IV.5.3.2. Ch ct khi phay mt phng bng dao phay mt u. bo m phng v nhn bng cn thit khi tin hnh gia cng mt phng c din tch rng (gia cng chiu di v chiu rng ca tm phi c kch thc 250x150 t kch thc 240x140). Ta s dng dao phay mt u rng chp mnh thp gi: D = 100 mm, H = 39 mm; Z = 10 rng (Bng 4-94 - Trang 340 (Quyn 1)). S ct gt (Trang sau): Lng d gia cng: - Chiu su ct t = 2 mm.

Gia cng th:

- Chiu rng ct B = 50 mm. Gia cng tinh: - Chiu su ct t = 0,2 mm. - Chiu rng ct B = 50 mm. ? Ch ct cho ln gia cng th nh sau: Tc ct (V) c xc nh bi cng thc sau:

(m/ph) (IV 5)

kv = kMV.kUV.klV.

(IV 6)

- Tra bng 5-34 Trang 29 (Quyn 2) i vi chiu su ct t = 2 mm dng dao phay mt u c li ct bng thp gi. Ta c SZ = 0,1 mm. - Tra bng 5-39 Trang 29 (Quyn 2) khi gia cng c dung dch trn ngui, dao phay mt u gn li ct thp gi, trong qu trnh gia cng c s dng dung dch trn ngui. Ta xc nh c h s m nh sau: CV = 64,7 ; q = 0,25; x = 0,1; y = 0,2; u = 0,15; p = 0,0 v m = 0,2. - Tra bng 5-40 Trang 34 (Quyn 2) Vi dao phay mt u c ng knh ?100mm ? Tui bn ca dao T = 180 pht. - Tra bng 5-1 ?5-6 (Quyn 2). Ta xc nh c kMV; klV; kUV.

Trong :

- kUV l h s ph thuc vo trng thi b mt phi: kUV = 1.

- kLV l h s ph thuc vo vt liu ca dng c ct: klV = 1. - kMV l h s ph thuc vo tnh cht c l ca vt liu gia cng cho trong i vi thp ta c. kMV = = = 1 y: - ?b : Gii hn bn ca vt liu, ?b = 750 Mpa. - kn l h s iu chnh ? vo nhm thp, kn = 1. - nv l s m cho trong bng 5-2 (Quyn 2): nv = 0,9. ? kv = kMV.kUV.klV = 1 *) Thay cc gi tr va xc nh c vo cng thc (IV 5)ta c : = 59,55 (m/ph) Khi tc quay ca tr my n (vg/ph) c xc nh nh sau: = 189,56 (vg/ph) Chn ngc = 180 (vg/ph). Khi vn tc ct thc t s l: Vgc = ngc.?.D/1000 = 62,83 (m/ph). ? ? Lng chy dao: Sph = SZ.Z.n = 0,1.10.200 = 200 (mm/ph). Mmen xon (Mx) v lc ct (PZ):

Mmen xon MX v lc ct PZ c xc nh bi cng thc nh sau: PZ = (N) (IV 7)

Mx = PZ.D/(2.100)

(N.m)

(IV 8)

- Tra bng 5-41 Trang 34 (Quyn 2) khi gia cng bng dao ngn c li ct thp gi. Ta c c cc h s m: CP = 82,5 ; x = 0,95; y = 0,8; u = 1,1 cn q = 1,3 v w = 0. - trn ta xc nh c n = 180 (vg/ph) v kMV = 1. *) Thay cc gi tr vo cng thc (IV 7) v (IV 8) ta c. PZ = = 469,1 (N) Mx = PZ.D/(2.1000) = 469,1.100/(2.1000) = 23,46 (N.m)

Khi cng sut ct c xc nh nh sau: = 1,53 (kW) Trong khi cng sut my l: Nmy = 7,5.0,8 = 6 (kW) > Ntt. Vy my c cng sut ct ht lng kim loi cn thit. Khi dng c ct khng i nhng vi cc ch ct khc: * Gia cng th: - Chiu su ct t = 2 mm, t = 1,8 mm. - Chiu rng ct B = 50, 60 mm. * Gia cng tinh: - Chiu su ct t = 0,2.

- Chiu rng ct B = 50, 60 mm. Th cng vic tnh ton xc nh thng s cng ngh khi ct tng ng vi mi ch gia cng, cng c thc hin hon ton tng t nh trn, ta c bng ch ct nh sau: Bng IV 7: Thng s ch ct khi phay mt phng bng dao mt u. Dao D Thng s cng ngh Z N t B Gi tr tnh ton Gi tr gia cng Thng s lc ct Sb T Vtt ntt ngc Vgc Sgc PZ Mx

2,0 1,38 1,8 0,84 ?100 10 0,17 0,2 50 0,1 180

59,55

189,56 180

56,55

180

469,1

23,46

60,18

191,57 210

65,97

105

243,8

12,19

74,97

238,64 200

62,83

200

52,6

2,63

2,0 1,69 1,8 1,53 0,2 0,21 60 0,1 180

57,95

184,45 180

56,55

180

573,3

28,67

58,56

186,40 180

56,55

180

518,7

25,94

72,95

232,21 200

62,83

200

64,3

3,22

IV.5.4. Ch ct khi doa l sau khi khoan. * Ch ct khi doa l ng knh d = 8 mm t l c d = 7,8 mm.

S ct gt (Hnh bn): Lng d gia cng:

Lng d gia cng t = 0,5.(D-d) = 0,5.(8 - 7.8) = 0,1(mm). ? ? ? Ch ct: Chiu su ct gt: t = 0,1 (mm). Lng chy dao: S = 0,25 (mm/vg) do l cn doa thuc dng l su l/d >5. Tc ct (V) c xc nh bi cng thc sau:

(m/ph) (IV 9)

kv = kMV.kUV.klV.

(IV 10)

- Cc h s Cv, m, y, q c xc nh theo Bng 5-28 - Trang 23 (Quyn 2). Vi mi khoan c li ct lm bng thp gi P6M5 thc hin chy dao S ? 0,2 (mm/vg) ta c: Cv = 10,5, m = 0,4; q = 0,3 ; y = 0,65; x = 0,2. - Vi d = 8 ta tra bng 5-30 (Trang 24- (Quyn 2)) c gi tr trung bnh tui bn ca dao T = 25 (pht). - kv l h s hiu chnh chung cho tc : kv = kMV.knv.klv. Trong : - klv l h s ph thuc chiu su l cn gia cng: Chn klv = 1. - kuv h s ph thuc vo vt liu ca dng c ct: kuV = 1. - kMV l h s ph thuc vo tnh cht c l ca vt liu gia cng cho trong Bng 5-1 ?5-4 (Quyn 2) i vi thp ta c. kMV = = = 1 y: - ?b : Gii hn bn ca vt liu, ?b = 750 Mpa. - kn l h s iu chnh ? vo nhm thp theo tnh gia cng, kn = 1. - nv l s m cho trong Bng 5-2 (Quyn 2): nv = 1. ? kv = kMV.kUV.klV = 1.1.1 = 1. Tin hnh cc gi tr va xc nh c trn vo cng thc (IV 1) ta c: = 4,22 (m/ph).

Khi tc quay ca mi khoan l:

Chn tc quay ca trc chnh khi gia cng l: ngc = 150 (vg/ph). Khi vn tc ct thc t s l: V = ngc.?.D/1000 = 3,77 (m/ph). ? Mmen xon (Mx) v lc chiu trc (Po):

Mmen xon (MX) v thnh phn lc chiu trc (Po) pht sinh trong qu trnh khoan c xc nh bi cng thc: Mx = 10.CM.Dq.tx.Sy.kp (N.m) (IV 11)

Po = 10.Cp.Dq.Sy.kp.

(N)

(IV 12)

- Tra bng bng 5-32 - Trang 25 (Quyn 2) ta c: CM = 0,0345; q = 2; y = 0,8 v Cp = 68; q = 1; y = 0,7. - H s tnh n cc yu t gia cng thc t kp ch ph thuc vo tnh cht c l ca vy liu gia cng c xc nh nh sau: kp = kMP i vi thp v gang theo bng 5-9 - Trang 25 (Quyn 2). kMP = = = 1 Thay cc gi tr vo cng thc (IV 3) v (IV 4) ta c: Mx = 10.CM.Dq.tx.Sy.kp = 10.0,09.81.0,10,9.0,50,8.1 = 0,30 (N.m). Po = 10.Cp.Dq.tx.Sy.kp = 10.67.81. 0,11,2.0,50,7.1 = 17,17 (N). Lc ny cng sut ct c tnh nh sau: =0,005 (kW). Vy my phay P1050-CNC hon ton d kh nng gia cng doa th l. IV.6. Thit k g cho tng ng vi mi nguyn cng. Do hnh thc ch to khun l dng sn xut n chic, lot nh vi sn lng ch to t. Cho nn g s dng trong lnh vc khun mu hu ht u l cc loi g vn nng c sn xut sn v bn theo tiu chun ho. Bi v nu s dng g chuyn dng th rt tn thi gian cho vic thit k v ch to, trong khi hiu sut s dng n li khng cao, cho nn hiu qu kinh t t c rt thp. Do ta khng cn thit k g m ch cn la chn loi g c kh nng to ra lc kp cht cn thit c nh c phi khi gia cng m thi. Do vi cc chi tit cn ch to: Tm v khun trc, tm o khun sau, tm lng khun trc v tm lng khun sau. Ta ch s dng hai loi g sau c nh phi: - t kt hp vi thanh k (*).

- Thanh k kt hp vi c cu bulong-ai c

(**).

Cc cch thc s dng g mi nguyn cng c th nh bng sau. Bng IV 8: Cch thc s dng g mi nguyn cng. Tn chi tit Nguyn cng Loi g.

Ao khun trc.

1. Chun b phi cho qu trnh gia cng. Bn mp (*)

2. Khoan 2 l f10,5 su 90 mm trn b mt bn B. 3. Khoan 2 l f10,5 su 90 mm trn b mt bn D. 4. Gia cng cc bin dng c trn mt phng A - Hc ch nht c kch thc 240x140 mm su 30 mm. - Gia cng h thng lm mt lng khun trc. - Gia cng hc lp nm cn.

(**)

5. Gia cng cc bin dng c trn mt phng C. - Gia cng h thng l t Bulong M8 qua. - Gia cng h thng knh dn nha vo lng khun. 6. Gia cng xung mt phn ca h thng knh dn nha 7. Gia cng ngui ti cc v tr cn thit ca khun. Bn mp

8. Mi phng b mt A ca tm khun trn.

Bn t

9. Mi phng b mt phn khun ca tm li khun trn. 10. Gia cng ngui ton b cm khun trc. Bn mp

Li khun.

1. Chun b phi cho qu trnh gia cng. Bn mp

2. Gia cng chiu rng phi t kch thc 140 mm. (*) 3. Gia cng chiu di phi t kch thc 240 mm. 4. Khoan 2 l f10,5 su 125 mm trn b mt bn B. 5. Khoan 2 l f10,5 su 120 mm trn b mt bn D. 6. Gia cng h thng cc l trn b mt C ca phi, - Gia cng l ?10,5 dn dung dch lm mt. - Gia cng 6 l ?6 su 20 mm taro ren M8. - Gia cng 6 l ?2,5 su 25 mm. (**) 7. Gia cng ngui tm lng khun. 8. Gia cng bin dng li khun trn mt phng A. 9. Gia cng xung lng khun t kch thc cn thit. 10. Gia cng xung s b h thng knh dn nha. 11. Gia cng xung hon thin h thng knh dn nha. 12. Mi b mt phn khun trn tm li khun. 13. Tin hnh gia cng ngui ton b cm khun trn Bn t Bn mp (*) (**)

Ao khun sau. 1. Chun b phi cho qu trnh gia cng ch to (*) 2. Khoan 4 l f10,5 su 105 mm trn b mt bn B. 3. Khoan 4 l f10,5 su 105 mm trn b mt bn D.

(**) 4. Gia cng cc bin dng trn mt phng A. - Hc ch nht c kch thc 240x140 mm su 40 mm. - H thng lm mt. - Gia cng hc lp nm cn. 5. Gia cng cc bin dng trn mt phng C. - Gia cng h thng l bt Bulong M8. - Gia cng h thng l f11,5 taro ren M14. - Gia cng h thng lp nm cn M10. Bn mp Bn t

6. Gia cng ngui nh bng lng knh dn nha. 7. Mi phng b mt C ca tm khun trn. 8. Gia cng ngui ton b cm bin dng khun sau.

Lng khun

1. Chun b phi cho qu trnh gia cng ch to. Bn mp

2. Gia cng chiu rng phi t kch thc 140 mm.

(*) 3. Gia cng chiu di phi t kch thc 240 mm. 4. Khoan 4 l f10,5 su 80 mm trn b mt bn B. 5. Khoan 4 l f10,5 su 60 mm trn b mt bn D. 6. Gia cng h thng l trn b mt C ca phi, - Gia cng 6 l ?6 taro ren M8. - Gia cng 8 l ?10,5 dn dung dch lm mt. 7. Gia cng nguui tm lng khun. 8. Gia cng bin dng lng khun. Bn mp (**) (**) Bn mp

9. Gia cng h thng l ?8 lp cht y sn phm. 10. Tin hnh gia cng ngui ton b cum khun sau.

Do khi lng gia cng rt nhiu i hi qu trnh tnh ton la chn g cng rt nhiu. Cho nn rt gn qu trnh la chn kt g ta xem xt ti trng hp gia cng pht sinh la ct ln nht, gy nh hng xu nht ti vic nh v chi tit m thi. Cn cc nguyn cng khc th cn c vo cch thc nh v v kp cht s c cch s dng li loi g thch hp. Ring i vi nguyn cng gia cng bng tia la in (xung nh hnh), do lc pht sinh trong qu trnh gia cng b cho nn ta chn Bulong M10 to lc kp cht l c nh phi. Trong qu trnh gia cng, dao cn tc dng ln phi mt ngoi lc ln bc ht lng kim loi d cn thit, chnh thnh phn lc(Mx;Px,y,z) ny c xu hng lm phi chuyn ng tnh tin hoc quay quanh v tr nh v. Tu theo cch thc chy dao v nh v khi gia cng m phi c xu hng quay hoc chuyn ng tnh tin ra khi v tr nh v. S dng kt qu tnh ton ch ct cho mi ln gia cng c (Bng IV 4); (Bng IV 5); (Bng IV 6) v (Bng IV 7) ta thy rng. - Khi s dng Et v thanh k th ln bc phay th mt phng nguyn cng 3 v 4 khi ch to tm lng khun trc, phi c kh nng chuyn ng ln nht. - Khi s dng thanh k v bulng-ai c th ln gia cng th bc gia cng phay hc cha nht 240x140x30 nguyn cng 3 khi ch to tm o lng khun trc, phi c kh nng chuyn ng ln nht. IV.6.1. Chn c cu t c nh phi. Qu trnh gia cng tin hnh trn my P1050-CNC. Cho nn g (t) c la chn ph hp vi my gia cng v dung sai ca bin dng cn gia cng. IV.6.1.1. Xc nh khong khng gian ti a ca g. Ta bit rng g l ni chi tit c g t v kp cht chi tit trong sut qu trnh gia cng c. N c tc dng m rng kh nng cng ngh cho my ct gt, ng thi rt ngn thi gian gia cng chi tit

to iu kin tng nng sut trong khi cht lng ca sn phm li ng u bo m theo yu cu k thut ra. Do khi gia cng c g cng chi tit u nm trong khong khng gian gia cng ca my. Vy kch thc ca g khng vt qu khong khng gian lm vic ca my. i vi my phay P1050-CNC c cng sut ca ng c 7,5 kw cn hiu sut ? = 0,8. Cn khong khng gian gia cng ca my l: - Kch thc bn my: 425x1524 mm (Bng IV 1). 1000x500x500 mm (Bng IV 1).

- Khon dch chuyn ca trc my: IV.6.1.2. Xc nh phng php nh v:

Yu cu ca chi tit sau qu trnh gia cng, m bo tho mn iu kin vung gc ca l cn khoan vi b mt B ca phi gip vic ch to h thng lm mt lng khun n gin hn. Do phi chun b gia cng c dng tm hnh hp c kch thc 250x150x60 mm c cc b mt xung quanh u t chun tinh. Cho nn b mt s dng nh v tt nht l dng mt phng. Do ta chn m tnh ca t v thanh k l cc chi tit dng nh vi phi. - B mt bn ca phi l mt phng nn nh vi c 3 bc t do. - B mt y ca phi l mt phng nn nh vi c 3 bc t do. IV.6.1.3. Xc nh phng chiu v im t lc ca lc kp cht. m bo chnh xc ca chi tit sau khi gia cng th lc kp cht phi m bo cc yu cu sau: - Khng ph hng v tr nh v ca phi. - Lc kp cht phi chi tit khng b x dch di tc dng ca lc ct nhng khng c qu ln so vi gi tr cn thit trn bin dng ca phi. - Khng lm hng b mt do lc kp tc dng vo. - C gng lm cho phng chiu khng i ngc chiu vi lc ct m cn vung gc v hng vo b mt nh v. - Kt cu nh, n gin, gn nht c th nhng bo m an ton, tho tc nhanh, t tn sc, d bo qun v sa cha. p ng ti a cc iu kin ta chn phng n kp cht nh trn.

IV.6.1.4. Tnh ton lc kp W cn thit. S gia cng.

Trong qu trnh phay mt phng, tu theo v tr cn gia cng v cch thc nh v v kp cht m lc ct gt c th lm phi c xu hng chuyn dng theo mt qu o no . Nhn thy rng khi dao mi n vo phi l lc d gy chuyn ng nht cho phi. - Vi nguyn cng 2: Gia cng chiu rng ca phi t kch thc 140 mm th phi c hai xu hng chuyn ng chnh l chuyn ng tnh tin trt theo hai m ca t v chuyn ng quay xung quanh trc dao ac. - Vi nguyn cng 3: Gia cng chiu di ca phi t kch thc 240 mm th phi c hai xu hng chuyn ng chnh l chuyn ng tnh tin trt theo hai m ca t v chuyn ng quay xung quanh cnh ab ca phi. Do c nh c phi trong sut qu trnh gia cng t phi sinh ra lc kp cht tho mn iu kin sau:

(IV 13)

K = Ko.K1. K2. K3. K4. K5. K6 Trong :

(IV 14)

- M: mmen ca qu trnh ct. Mx= 16,46 (N.m )(Bng IV 7).

- PYZ v Ph c xc nh theo PZ. PZ = 330 (N) (Bng IV 7). - L1: Khong cch t tm m t ti trc dao khi mi gia cng. - L2: Khong cch t tm m t ti y phi. - L3: Khong cch t li ct ti y phi. - W: Lc do c cu kp cht sinh ra. - K: H s an ton chung, c xc nh nh sau. - Ko:l h s an ton trong mi trng hp. Chn Ko = 1,5 - K1:l h s k n lng d khng u. Chn K1 = 1 - K2:l h s k n dao cn lm tng lc ct. Chn K2 =1 - K3:l h s k n lc ct khng lin tc. Chn K3 = 1 - K4:l h s k n ngun sinh lc, kp cht bng tay. Chn K4 = 1,3 - K5:l h s k n v tr tay quay. Chn K5 = 1.

- K6:l h s k n tnh cht tip xc. Chn K6 = 1,5. Vy: K = 1,5.1.1.1.1,3.1.1,5 = 2,95. Chn K = 3.

Cc thnh phn lc pht sinh trong qu trinh ct c xc nh theo thnh phn PZ theo bng 5-43 Trang 35 (Quyn 2) ta c: Dao phay mt u H s t l so vi PZ Gia tr (N) ? (N). Thay s vo cng thc (IV 13) ta xc nh c gi tr lc W nh sau: Ph (N) Pv(N) Py (N) 0,3 ? 0,4 0,85 ? 0,95 0,3 ? 0,4

172 ? 229

487 ? 545

172 ? 229

Vy lc kp cn thit l W = 9888 N. Xc nh c cu to lc W.

i vi c cu to lc kp cht bng mi ghp ren th lc W c xc nh bi cng thc sau: P.L = 0,5.W.[tg(? + ??).dtb + tg?2.?tb]. (IV 15)

dtb = 2. P.L/[ W.[tg(? + ??) + 0,8.tg?2] (mm). Trong :

(IV 16)

- ?tb = 0,8.dtb vi dtb l ng knh trung bnh ca ren.

- ? l gc nng ca ren. Ta c tg ? = S/(?. dtb). - ?? v ???l gc ma st. - tg(? + ??) v tg?2 l h s ma st ti cc tr tip xc tng ng. Do: - tg(? + ??) = tg?2 = 0,2 nn ta c: - P l lc dng xit ren to lc kp cht: Chn P = 100 N. - L l chiu di ca c l dng xit ren. Chn L = 200 mm. Khi ta xc nh c ng knh trung bnh ca ren cc i nh sau: dtbmax = 2.100.400/[9888.[0,2 + 0,8.0,2] = 8.104/(5304.0,36) = 22,47 mm.

 bo m qu trnh gia cng chi tit lun lun c nh di tc dng ca lc ct th Q > 9888 (N) ? dtb < dtbmax. Vy c nh chi tit khi gia cng ta chn loi trc vt c ng knh ngoi 20 mm. IV.6.1.5. Tnh sai s ch to cho php ca g ?CT. Nhn thy rng g l dng c c nhim v nh v v c nh phi trong sut qu trnh gia cng, tc l n bo m v tr tng quan gia dao v chi tit. Cho nn sai s ca g khi ch to v lp gip s nh hng trc tip n sai s ca kch thc khi gia cng, c th n nh hng n sai s v tr tng quan gia b mt gia cng v b mt chun chn lm nh v. Do kch thc sau gia cng yu cu t chnh xc h7 theo bng 2 trang 140 - (Quyn 9) ta c . - Vi kch thc danh ngha 240 th dung sai l ? = 0 - (-460) = 460 ?m. - Vi kch thc danh ngha 240 th dung sai l ? = 0 - (-400) = 400 ?m. Sai s g t c tnh theo cng thc nh sau: = Trong : - ?c: Sai s chun do chun nh v khng trng vi gc kch thc gy ra. y do chi tit c nh v trc tip vi g, nh s dng hai mt phng c v tr vung gc so vi vi nhau. Do ?c = 0. - ?k: Sai s kp cht do lc kp gy ra. Sai s kp cht c xc nh theo cc cng thc trong bng 24 trang 48 - (Quyn 5). Cn nh rng khi phng ca lc kp vung gc vi phng ca kch thc thc hin th sai s kp cht bng khng ? ?k = 0. - ?m: Sai s mn. Sai s mn c xc nh theo cng thc sau y: (?m) = 0,3. = 22,61 ?m. - ?c: Sai s iu chnh c sinh ra trong qu trnh lp rp v iu chnh g. Sai s iu chnh ph thuc vo kh nng iu chnh v dng c iu chnh khi lp rp. Trong thc t khi tnh ton g ta c th ly ?c = 5 ? 10 ?m. - ?g: Sai s g t, khi tnh ton g ta ly gi tr sai s g t cho php: [?g] = (1/3?1/5).? (vi ? dung sai ca nguyn cng) ? [?g] = 400/3 = 133 ?m. - ?ct: Sai s ch to cho php g. Sai s ny cn c xc nh khi thit k g. Do a s cc sai s phn b theo qui lut chun v phng ca chng kh xc nh nn ta s dng cng thc sau tnh sai s g t cho php: ?ct= = =130 ?m. Cn c vo sai s g t cho php ?ct ca g ch to v lp rp cc chi tit to nn g p ng c yu cu ch to ca chi tit nguyn cng . Yu cu k thut ca g nh sau: - khng // gia mt phng thanh k vi xng t = 0,130 mm/100mm.

- khng vung gc gia thanh k vi m tnh t = 0,130 mm/100mm. - khng vung gc ca bc dn so vi y g = 0,130 mm/100 mm. - i vi cc chi tit dng nh v cho chi tit hoc dn hng cho dng c ct phi c nhit luyn t cng 50?? 55 HRC. IV.6.2. g l thanh k v Bulong-ai c. Qu trnh gia cng tin hnh trn my P1050-CNC. Cho nn g (t) s dng c nh chi tit trn bn my c la chn ph hp vi my cng c s dng gia cng v dung sai ca bin dng cn gia cng. IV.6.2.1. Xc nh khong khng gian ti a ca g. Ta bit rng g l ni chi tit c g t v kp cht chi tit trong sut qu trnh gia cng c. N c tc dng m rng kh nng cng ngh cho my ct gt, ng thi rt ngn thi gian gia cng chi tit to iu kin tng nng sut trong khi cht lng ca sn phm li ng u bo m theo yu cu k thut ra. Do khi gia cng c g cng chi tit u nm trong khong khng gian gia cng ca my. Vy kch thc ca g khng vt qu khong khng gian lm vic ca my. i vi my phay P1050-CNC c cng sut ca ng c 7,5 kw cn hiu sut ? = 0,8. Cn khong khng gian gia cng ca my l: - Kch thc bn my: 425x1524 mm (Bng IV 1). 1000x500x500 mm (Bng IV 1).

- Khon dch chuyn ca trc my: IV.6.2.2. Xc nh phng php nh v:

Yu cu ca chi tit sau qu trnh gia cng, m bo tho mn iu kin vung gc ca l cn khoan vi b mt B ca phi gip vic ch to h thng lm mt lng khun n gin hn. Do phi chun b gia cng c dng tm hnh hp c kch thc 250x150x60 mm c cc b mt xung quanh u t chun tinh. Cho nn b mt s dng nh v tt nht l dng mt phng. Do ta chn m tnh ca t v thanh k l cc chi tit dng nh vi phi. - B mt y ca phi l mt phng nn nh vi c 3 bc t do. IV.6.2.3. Xc nh phng chiu v im t ca lc kp cht. m bo chnh xc ca chi tit sau khi gia cng th lc kp cht phi m bo cc yu cu sau: - Khng ph hng v tr nh v ca phi. -Lc kp cht phi chi tit khng b x dch di tc dng ca lc ct nhng khng c qu ln so vi gi tr cn thit trn bin dng ca phi. - Khng lm hng b mt do lc kp tc dng vo.

- C gng lm cho phng chiu khng i ngc chiu vi lc ct m cn vung gc v hng vo b mt nh v. - Kt cu nh, n gin, gn nht c th nhng bo m an ton, tho tc nhanh, t tn sc, d bo qun v sa cha. p ng ti a cc iu kin ta chn phng n kp cht nh sau. S kp cht:

IV.6.2.4. Tnh ton lc kp W cn thit. - S lc ct:

Nhn thy rng khi tin hnh gia cng to hc ch nht 239,8x139,8x40 mm th trong qu trnh phay rnh c b rng 20 mm su 1 mm th cc thnh phn lc ct tc ng ln phi gm c: Pz, Py, Pv, Ph c tc dng lm phi chuyn ng tnh tin theo phng ca lc cn thnh phn mmen ct Mx s lm cho phi quay xung quanh trc ca dao phay. Do mun phi ng yn trong sut qu trnh ct gt th lc W do bn bulong sinh ra phi ln. Mun vy th W phi tho mn biu thc ton hc sau:

(IV 17)

K = Ko.K1. K2. K3. K4. K5. K6 Trong : Bng IV 6). - Pyz: Lc ct khi phay:

(IV 14)

- M: mmen ca qu trnh ct. Mx= 6,59 (N.m) (

- L: Khong cch m kp ti tm trc dao. - W: Lc do c cu kp cht sinh ra. - f l h s ma st gia tm kp vi phi: f = 0,1. - K: H s an ton chung, c xc nh bi cc thnh phn sau. - Ko:l h s an ton trong mi trng hp. Chn Ko = 1,5 - K1:l h s k n lng d khng u. Chn K1 = 1

- K2:l h s k n dao cn lm tng lc ct. Chn K2 =1 - K3:l h s k n lc ct khng lin tc. Chn K3 = 1 - K4:l h s k n ngun sinh lc, kp cht bng tay. Chn K4 = 1,3 - K5:l h s k n v tr tay quay. Chn K5 = 1. - K6:l h s k n tnh cht tip xc. Chn K6 = 1,5. ? K = 1,5.1.1.1.1,3.1.1,5 = 2,95. Chn K = 3. Cc thnh phn lc pht sinh trong qu trinh ct c xc nh theo thnh phn PZ theo bng 5-43 Trang 35 (Quyn 2) ta c: Dao ngn Ph Pv Py 0,0 ? 0,25 0,4 ? 0,6

H s t l so vi PZ Gia tr (N) Vy: (N).

1,1 ? 1,2

725 ? 790

0 ? 165 264 ? 395

Thay s vo cng thc (IV 17) ta xc nh c gi tr lc W nh sau: ?

Vy lc kp cn thit l W = 23040 N. Xc nh c cu to lc W.

C cu to lc kp phi l 4 cm bulong v thanh truyn nh hnh v: Chn a = 0,5.b Nh vy mi c cu bulong ai c phi to ra mt lc Wi = 11520 (N) kp cht phi. Mun vy kch thc ca bulong c xc nh bng biu thc sau: P.L = 0,5.W.[tg(? + ??).dtb + tg?2.?tb]. (IV 15)

dtb = 2. P.L/[ W.[tg(? + ??) + 0,8.tg?2] (mm). Trong :

(IV 16)

- ?tb = 0,8.dtb vi dtb l ng knh trung bnh ca ren.

- ? l gc nng ca ren. Ta c tg ? = S/(?. dtb). - ?? v ???l gc ma st. - tg(? + ??) v tg?2 l h s ma st ti cc tr tip xc tng ng.

Do:

- tg(? + ??) = tg?2 = 0,2 nn ta c: - P l lc dng xit ren to lc kp cht: Chn P = 100 N. - L l chiu di ca c l dng xit ren. Chn L = 200 mm.

Khi ta xc nh c ng knh trung bnh ca ren cc i nh sau: dtbmax = 2.100.200/[11520.[0,2 + 0,8.0,2] = 4.104/(11520.0,36) = 19,29 mm. bo m qu trnh gia cng chi tit lun lun c nh di tc dng ca lc ct th Q > 11520 (N) ? dtb < dtbmax. Vy c nh c chi tit khi gia cng ta chn loi bulong c ng knh M18. IV.6.2.5. Tnh sai s ch to cho php ca g ?CT. Nhn thy rng g l dng c c nhim v nh v v c nh phi trong sut qu trnh gia cng, tc l n bo m v tr tng quan gia dao v chi tit. Cho nn sai s ca g khi ch to v lp gip s nh hng trc tip n sai s ca kch thc khi gia cng, c th n nh hng n sai s v tr tng quan gia b mt gia cng v b mt chun chn lm nh v. Do kch thc sau gia cng yu cu t chnh xc h7 theo bng 2 trang 140 - (Quyn 9) ta c . - Vi kch thc danh ngha 240 th dung sai l ? = 0 - (-460) = 460 ?m. - Vi kch thc danh ngha 240 th dung sai l ? = 0 - (-400) = 400 ?m. Sai s g t c tnh theo cng thc nh sau: = Trong : - ?c: Sai s chun do chun nh v khng trng vi gc kch thc gy ra. y do gc ta c xc nh thng qua ba cht dn hng lp trn 3 bc dn hng theo ch lp trung gian H7/h8. Do sai s chun ?c = Smax (Khe h ln nht gia cht dn hng v bc dn hng). Ta c: L ?25H7 ;Trc ?25h8 ? Vy ta c: ?c = Smax = 54 ?m. - ?k: Sai s kp cht do lc kp gy ra. Sai s kp cht c xc nh theo cc cng thc trong bng 24 trang 48 - (Quyn 5). Cn nh rng khi phng ca lc kp vung gc vi phng ca kch thc thc hin th sai s kp cht bng khng ? ?k = 0. - ?m: Sai s mn. Sai s mn c xc nh theo cng thc sau y: (?m) = 0,3. = 32,12 ?m. - ?c: Sai s iu chnh c sinh ra trong qu trnh lp rp v iu chnh g. Sai s iu chnh ph thuc vo kh nng iu chnh v dng c iu chnh khi lp rp. Trong thc t khi tnh ton g ta c th ly ?c = 5 ? 10 ?m.

- ?g: Sai s g t, khi tnh ton g ta ly gi tr sai s g t cho php: [?g] = (1/3?1/5).? (vi ? dung sai ca nguyn cng) ? [?g] = 400/3 = 133 ?m. - ?ct: Sai s ch to cho php g. Sai s ny cn c xc nh khi thit k g. Do a s cc sai s phn b theo qui lut chun v phng ca chng kh xc nh nn ta s dng cng thc sau tnh sai s g t cho php: ?ct= = =116 ?m. Cn c vo sai s g t cho php ?ct ca g ch to v lp rp cc chi tit to nn g p ng c yu cu ch to ca chi tit nguyn cng . Yu cu k thut ca g nh sau: - khng // gia mt phng thanh k vi xng t = 0,116 mm/100mm. - khng vung gc gia thanh k vi m tnh t = 0,116 mm/100mm. - khng vung gc ca bc dn so vi y g = 0,116 mm/100 mm. - i vi cc chi tit dng nh v cho chi tit hoc dn hng cho dng c ct phi c nhit luyn t cng 50?? 55 HRC. IV.7. Cc lu trong qu trnh tnh ton ,thit k, ch to hai cm lng khun. Trong qu trnh tnh ton nhn thy rng i vi dng sn sut n chic v lot nh nh ch to khun mu th: - Phng n la chn kch thc phi dng gia cng theo phng php gn ng ri cn c vo kch thc phi c sn theo tiu s em li li ch nhiu hn so vi phng n xc nh kch thc khi theo phng php tnh chnh xc ri t ch to hoc t hng do phi c kch thc khng theo tiu chun. - Xc nh thi gian gia cng c bn l khng cn thit. Bi v mc ch chnh ca cng vic xc nh thi gian gia cng c bn l cn c cch thc phn b thi gian thc hin cc cng vic gia cng c bn trn cc chng loi my khc nhau. Ta s c cch thc sp xp v b tr my hp l vi dng chi tit cn gia cng nng sut gia cng l cao nht. iu khng cn ph hp vi nghnh gia cng ch to khun mu, ni m cc chi tit cn gia cng ch to lun lun thay i. Trong qu trnh gia cng cc chi tit hai cm lng khun trc v sau hn ch sai s v tr ca cc bin dng gia cc ln gia cng khc nhau ta cn quan tm ti cc vn sau * S dng ba cht dn hng lp trn cc bc dn hng ca khi khun c s lm chun thng nht xc nh cc gc ta lp trnh gia cng. * Do c im hnh thc sn xut l n chic v loi nh, nn qu trnh kim tra hu nh l khng s dng g kim tra chuyn dung m ch s dng cc dng c o c tnh vn nng v thng dng nh: ng h o, thc cp, panmer... Cho ln cng vic kim tra cht lng v chnh xc ca chi tit ch to thc hin nh sau:

- Thc hin vic m phng trc qu trnh gia cng, hn ch bt s sai st trc khi tin hnh gia cng thc s. - Cng vic kim tra ny c thc hin ngay ti v tr gia cng sau mi bc gia cng. - Ln tng kim tra cui cng cht lng ca sn phm sau khi ch to c thc hin trc khi tin hnh lp gip cc chi tit to ra sn phm khun hon chnh. Sau khi tin hnh gia cng ch to v t mua c cc chi tit c trong khun theo nh thit k. Ta cn tin hnh cc cng vic tip theo nh sau: - Lp rp cc chi tit li to ra mt sn phm c kh hon thin. - Tin hnh p th sn phm trn khun c lp gip hon chnh. Trong qu trnh lp gip khun ta cng thc hin thm cc sa cha ngui nh khc cho cc chi tit c trong khun (r, mi, nh bng) cc mi lp ghp t yu cu ca thit k sn phm khun lm vic tt. c bit khi tin hnh p th sn phm trn khun mi ch to, tu theo tnh trng sn phm to thnh m c cc bin php iu chnh my p (ch vn hnh my) hay iu chnh li sa i li cc chi tit trong khun. Tuy cng vic ny khng c lp nn trong trnh t cng ngh gia cng hai lng khun, nhng li l mt cng vic ht sc quan trng khng th thiu c trong qu trnh ch to ra mt sn phm khun mu theo n t hng. l cng vic quyt nh ti cht lng ln cui cho sn phm khun. Bi vy i hi ngi thit k khun phi c vn kinh nghim lm khun phng ph phn on c cc li ca khun t c cc bin php cng ngh linh hot sa cha khc phc cc li pht sinh khi tin hnh th khun. IV.8. Chng trnh s dng iu khin my gia cng. Ty theo cu trc ca b iu khin my s c cc moduyl chng trnh vit sn trong phn cng ca b iu khin, c kh nng n gin ha mt cc chng trnh gia cng nht nh (Khoan l, phay hc ch nht, hc trn...). Nu ta s dng trit v hiu qu cc moduyl sn c ny, s n gin ha c vic vit chng trnh gia cng, ng thi nng cao cht lng v nng sut gia cng. Do rt ngn c thi gian vit chng trnh ng thi hn ch cc c cc nhm ln ng tic cho ngi vn hnh my trong khi vit chng trnh . phn ny em ch vit chng trnh s dng iu khin my thc hin cng vic gia cng gia cng tm o khun sau theo trnh t cc nguyn cng thit k c tin hnh trn my gia cng iu khin theo chng trnh. Cc chi tit khc cn gia cng cng c lp trnh hon ton tng t. IV.8.1. Chng trnh cho nguyn cng 1. S gia cng.

Ch thch: - Kch thc ca phi: X = 350 mm; Y = 70 mm; Z = 270 mm.

- To gia cng biu din nh hnh v. 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Chng trnh khoan l ?10,5 su 105 mm. BEGIN PGM 01 MM BLK FORM 0.1 Z-270 X-175 Y-35 BLK FORM 0.2 Z0 X+175 Y+35 TOOL DEF 0.1 L0.000 R5.250 TOOL CALL 0.2 Z0.000 S1000 L Z+20.000 R0 F2500 M13 L X+60.960 Y-20.000 CALL LBL1 L X+30.480 Y-20.000 CALL LBL1 L X-30.480 Y-20.000 CALL LBL1 L X+60.960 Y-20.000 CALL LBL1 STOP M02 LBL1 CYLDEF 1.1 (SETUP) 2 -105 1.0 (PECKING)

1.2 (DEPTH)

1.3 (PEKING) 2 1.4 (DELL) F140 DR16 L Z2 R0 F2500 M99 17 L Z20 R0 S1000

18 LBL0 19 END PGM 01 MM IV.8.2. Chng trnh cho nguyn cng 2. Thc hin hon ton tng t nh nguyn cng 1 sau khi g t phi vo v tr hp l. IV.8.3. Chng trnh cho nguyn cng 3. S gia cng.

* Trnh t cc bc gia cng nh sau: - Gia cng hc ch nht c kch thc 240x140 mm su 40 mm. + Chng trnh khoan l ?20 su 42 mm tm phi. + Chng trnh phay th hc t kch thc 239,8x139,8 mm su 40 mm. + Chng trnh phay tinh hc t kch thc 240x140 mm su 40 mm. - Gia cng 4 hc tin hnh lp t nm cn. - Gia cng h thng dn dung dch lm mt lng khun. + Chng trnh khoan l 8 l ?20 su 43,5 mm. + Chng trnh khoan l 8 l ?10,5 su 55 mm. IV.8.3.1. Chng trnh phay hc ch nht (240x140x40mm). 0 1 2 3 4 5 6 7 Chng trnh khoan l ?20 su 40 mm. BEGIN PGM 02 MM BLK FORM 0.1 Z-60 X-175 Y-120 BLK FORM 0.2 Z0 X+175 Y+120 TOOL DEF 0.1 L0.000 R10.000 TOOL CALL 0.2 Z0.000 S400 L Z+20.000 R0 F2500 M13 L X0.000 Y0.000 CALL LBL1

8 9

STOP M02 LBL1 CYLDEF 1.0 (PECKING)

1.1

(SETUP) -2 -40

1.2 (DEPTH)

1.3 (PEKING) -2 1.4 (DELL) F100 DR10 L Z2 R0 F2500 M99 11 L Z20 R0 S2500 12 LBL0 13 END PGM 02 MM 0 1 2 3 4 5 6 7 10 Chng trnh phay th hc ch nht (239,8x139,8x40 mm). BEGIN PGM 03 MM BLK FORM 0.1 Z-60 X-175 Y-120 BLK FORM 0.2 Z0 X+175 Y+120 TOOL DEF 0.1 L0.000 R10.100 TOOL CALL 0.2 Z0.000 S450 L Z+20.000 R0 F2500 M13 CALL LBL1 STOP M02 LBL1 CYLDEF 4.1 4.2 (SETUP) -2 (DEPTH) -40 4.0 (POCKET MILLING)

4.3 (PECKING) -2

4.4 X240 4.5 Y140 F225 DR11 L Z2 R0 F2500 M99 12 L Z20 R0 S2000 13 LBL0 14 END PGM 03 MM 0 1 2 3 4 5 6 7 8 9 10 11 12 13 Chng trnh phay tinh hc ch nht (240x140x40). BEGIN PGM 04 MM BLK FORM 0.1 Z-60 X-175 Y-120 BLK FORM 0.2 Z0 X+175 Y+120 TOOL DEF 0.1 L0.000 R10.000 TOOL CALL 0.2 Z0.000 S1200 L Z-38.000 R0 F2500 M13 L X+0.000 Y+50.000 RR CR X+30.000 Y+70.000 R20 R+ RR F100 L X120.000 RR F1000 L Y-70.000 RR F1000 L X-120.000 RR F1000 L Y+70.000 RR F1000 L X+35.000 RR F1000 L Y+50.000 Z-20.000 F2500

14 L Z20 R0 S2000 14 END PGM 04 MM

IV.8.3.2. Chng trnh phay 4 hc lp nm cn. 0 BEGIN PGM 05 MM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

BLK FORM 0.1 Z-60 X-175 Y-120 BLK FORM 0.2 Z0 X+175 Y+120 TOOL DEF 0.1 L0.000 R6.000 TOOL CALL 0.2 Z0.000 S800 L Z+20.000 F2500 M15. CALL LBL1 RFD STOP M02 LBL11 FN1: Q1=-1 FN2: Q2=-1 LBL1 L Z+1.000 X+0.000 Y+105.000 F2000 L Z+Q1 F60 L X+0.000 Y+115.000 RL F60 L X-55.000 RL F160 L Y+95.000 RL F160 L X+55.000 RL F160 L Y+115.000 RL F160 L X-5.000 RL F160 L Z+10.000 F2000 L X-145.000 Y+0.000 F2000 L Z+1.000 F2000 L Z+Q1 F160 L X-155.000 RL F160 L Y-40.000 RL F160 L X-135.000 RL F160

27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51

L Y+40.000 RL F160 L X-155.000 RL F160 L Y-5.000 RL F160 L Z+20.000 F2000 L X+0.000 Y-105.000 F2000 L Z+1.000 F2000 L Z+Q1 F160 L X+0.000 Y-115.000 RL F160 L X-55.000 RL F160 L Y-95.000 RL F160 L X+55.000 RL F160 L Y-115.000 RL F160 L X-5.000 RL F160 L Z+10.000 F2000 L X+145.000 Y+0.000 F2000 L Z+1.000 F2000 L Z+Q1 F160 L X+155.000 RL F160 L Y-40.000 RL F160 L X+135.000 RL F160 L Y+40.000 RL F160 L X+155.000 RL F160 L Y-5.000 RL F160 L Z+20.000 F2000 FN1: Q1=+Q1+Q2

IF=-15 LBL1

52 53

L Z+10 F2000 END PGM 05 MM

IV.8.3.3. Chng trnh khoan 8 l ?20 su 43,5 mm. 0 1 2 3 4 5 6 7 8 9 10 BEGIN PGM 06 MM BLK FORM 0.1 Z-60 X-175 Y-120 BLK FORM 0.2 Z0 X+175 Y+120 TOOL DEF 0.1 L0.000 R10.000 TOOL CALL 0.2 Z0.000 S400 L Z-20.000 R0 F2500 M13 L X+61.000 Y+45.000 CALL LBL1 L X+30.500 Y+45.000 CALL LBL1 L X-30.500 Y+45.000

11 CALL LBL1 12 L X-61.000 Y+45.000 13 CALL LBL1 14 15 16 17 18 L X-61.000 Y-45.000 CALL LBL1 L X-30.500 Y-45.000 CALL LBL1 L X+30.500 Y-45.000

19 CALL LBL1 20 L X+61.000 Y-45.000 21 CALL LBL1 22 STOP M02

23 LBL1 CYLDEF 1.1 (SETUP) -2 -43.5 1.0 (PECKING)

1.2 (DEPTH)

1.3 (PEKING) -1.75 1.4 (DELL) F100 DR24 L Z2 R0 F2500 M99 25 L Z20 R0 S2000 26 LBL0 27 END PGM 06 MM IV.8.3.4. Chng trnh khoan 8 l ?10,5 su 55 mm. 0 1 2 3 4 5 6 7 8 9 10 BEGIN PGM 07 MM BLK FORM 0.1 Z-60 X-175 Y-120 BLK FORM 0.2 Z0 X+175 Y+120 TOOL DEF 0.1 L0.000 R5.250 TOOL CALL 0.2 Z0.000 S355 L Z-20.000 R0 F2500 M13 L X+61.000 Y+45.000 CALL LBL1 L X+30.500 Y+45.000 CALL LBL1 L X-30.500 Y+45.000

11 CALL LBL1 12 L X-61.000 Y+45.000 13 CALL LBL1

14 15 16 17 18

L X-61.000 Y-45.000 CALL LBL1 L X-30.500 Y-45.000 CALL LBL1 L X+30.500 Y-45.000

19 CALL LBL1 20 L X+61.000 Y-45.000 21 CALL LBL1 22 STOP M02 23 LBL1 CYLDEF 1.1 (SETUP) -2 -55 1.0 (PECKING)

1.2 (DEPTH)

1.3 (PEKING) -2 1.4 (DELL) F120 DR24 L Z2 R0 F2500 M99 25 L Z20 R0 S2000 26 LBL0 27 END PGM 07 MM IV.8.4. Chng trnh cho nguyn cng 4. S gia cng.

* Trnh t cc bc gia cng nh sau: - Gia cng h thng l x Bulong M8 qua. + Chng trnh khoan l 6 l ?14 su 10 mm.

+ Chng trnh khoan l 6 l ?9 su 30 mm. - Gia cng h thng l x Bulong M10 qua. + Chng trnh khoan l 8 l ?18 su 14 mm. + Chng trnh khoan l 8 l ?11 su 55 mm. IV.8.4.1. Chng trnh gia cng h thng l x Bulong M8. 0 1 2 3 4 5 6 7 8 9 8 9 10 Chng trnh khoan 6 l ?14 su 10 mm BEGIN PGM 08 MM BLK FORM 0.1 Z-60 X-175 Y-120 BLK FORM 0.2 Z0 X+175 Y+120 TOOL DEF 0.1 L0.000 R5.750 TOOL CALL 0.2 Z0.000 S355 L Z+20.000 R0 F2500 M13 L X+110.000 Y+50.000 CALL LBL1 L X+0.000 Y+50.000 CALL LBL1 L X-110.000 Y+50.000 CALL LBL1 L X-110.000 Y-50.000

11 CALL LBL1 12 13 L X+0.000 Y-50.000 CALL LBL1

14 L X+110.000 Y-50.000 15 CALL LBL1 16 STOP M02 17 LBL1

CYLDEF 1.1 (SETUP) -2 -10

1.0 (PECKING)

1.2 (DEPTH)

1.3 (PEKING) -2 1.4 (DELL) F120 DR18 L Z2 R0 F2500 M99 19 L Z20 R0 S2000 20 LBL0 21 END PGM 08 MM 0 1 2 3 4 5 6 8 8 9 8 9 10 Chng trnh khoan 6 l ?9 su 30mm BEGIN PGM 09 MM BLK FORM 0.1 Z-60 X-175 Y-120 BLK FORM 0.2 Z0 X+175 Y+120 TOOL DEF 0.1 L0.000 R4.500 TOOL CALL 0.2 Z0.000 S355 L Z+0.000 R0 F2500 M13 L X+110.000 Y+50.000 CALL LBL1 L X+0.000 Y+50.000 CALL LBL1 L X-110.000 Y+50.000 CALL LBL1 L X-110.000 Y-50.000

11 CALL LBL1 12 L X+0.000 Y-50.000

13

CALL LBL1

14 L X+110.000 Y-50.000 15 CALL LBL1 16 STOP M02 17 LBL1 CYLDEF 1.1 (SETUP) -2 -30 1.0 (PECKING)

1.2 (DEPTH)

1.3 (PEKING) -2 1.4 (DELL) F150 DR18 L Z2 R0 F2500 M99 19 L Z20 R0 S2000 20 LBL0 21 END PGM 09 MM IV.8.4.2. Chng trnh gia cng h thng l x Bulong M8. 0 1 2 3 4 5 6 7 8 Chng trnh khoan 8 l ?14 su 10 mm. BEGIN PGM 10 MM BLK FORM 0.1 Z-60 X-175 Y-120 BLK FORM 0.2 Z0 X+175 Y+120 TOOL DEF 0.1 L0.000 R7.000 TOOL CALL 0.2 Z0.000 S355 L Z+20.000 R0 F2500 M13 L X+145.000 Y+30.000 CALL LBL1 L X+45.000 Y+105.000

9 10

CALL LBL1 L X-45.000 Y+105.000

11 CALL LBL1 12 L X-145.000 Y+30.000 13 CALL LBL1 14 15 16 17 18 L X-145.000 Y-30.000 CALL LBL1 L X-45.000 Y-105.000 CALL LBL1 L X+45.000 Y-105.000

19 CALL LBL1 20 L X+145.000 Y-30.000 21 CALL LBL1 22 STOP M02 23 LBL1 CYLDEF 1.1 (SETUP) -2 -10 1.0 (PECKING)

1.2 (DEPTH)

1.3 (PEKING) -2 1.4 (DELL) F120 DR24 L Z2 R0 F2500 M99 25 L Z20 R0 S2000 26 LBL0 27 END PGM 10 MM Chng trnh khoan 8 l ?9 su 55 mm.

0 1 2 3 4 5 6 7 8 9 10

BEGIN PGM 11 MM BLK FORM 0.1 Z-60 X-175 Y-120 BLK FORM 0.2 Z0 X+175 Y+120 TOOL DEF 0.1 L0.000 R4.500 TOOL CALL 0.2 Z0.000 S355 L Z+20.000 R0 F2500 M13 L X+145.000 Y+30.000 CALL LBL1 L X+45.000 Y+105.000 CALL LBL1 L X-45.000 Y+105.000

11 CALL LBL1 12 L X-145.000 Y+30.000 13 CALL LBL1 14 15 16 17 18 L X-145.000 Y-30.000 CALL LBL1 L X-45.000 Y-105.000 CALL LBL1 L X+45.000 Y-105.000

19 CALL LBL1 20 L X+145.000 Y-30.000 21 CALL LBL1 22 STOP M02 23 LBL1 CYLDEF 1.1 (SETUP) -2 1.0 (PECKING)

1.2 (DEPTH)

-55

1.3 (PEKING) -2 1.4 (DELL) F140 DR24 L Z2 R0 F2500 M99 25 L Z20 R0 S2000 26 LBL0 27 END PGM 11 MM IV.8.5. Chng trnh cho nguyn cng 5. * Trnh t cc bc gia cng nh sau: - Khoan 18 l ?7,8 su 45 mm. - Doa 18 l ?8 su 45 mm. S gia cng.

IV.8.5.1. Chng trnh khoan 18 l ?7,8 su 45 mm 0 1 2 3 4 5 6 7 8 9 10 BEGIN PGM 12 MM BLK FORM 0.1 Z-60 X-175 Y-120 BLK FORM 0.2 Z0 X+175 Y+120 TOOL DEF 0.1 L0.000 R3.9000 TOOL CALL 0.2 Z0.000 S1500 L Z+20.000 R0 F2500 M13 L X+76.200 Y+30.480 CALL LBL1 L X+45.720 Y+30.480 CALL LBL1 L X+15.240 Y+30.480

11 CALL LBL1 12 L X-15.240 Y+30.480 13 CALL LBL1 14 15 16 17 18 19 20 21 22 L X-45.720 Y+30.480 CALL LBL1 L X-76.200 Y+30.480 CALL LBL1 L X-76.200 Y+0.000 CALL LBL1 L X-45.720 Y+0.000 CALL LBL1 L X-15.240 Y+0.000

23 CALL LBL1 24 L X+15.240 Y+0.000 25 CALL LBL1 26 27 28 29 30 31 32 33 34 L X+45.720 Y+0.000 CALL LBL1 L X+76.200 Y+0.000 CALL LBL1 L X+76.200 Y-30.480 CALL LBL1 L X+45.720 Y-30.480 CALL LBL1 L X+15.240 Y-30.480

35 CALL LBL1 36 L X-15.240 Y-30.480

37 CALL LBL1 38 39 40 41 L X-45.720 Y-30.480 CALL LBL1 L X-76.200 Y-30.480 CALL LBL1

42 STOP M02 43 LBL1 CYLDEF 1.2 (SETUP) -2 -45 1.0 (PECKING)

1.2 (DEPTH)

1.3 (PEKING) -2 1.3 (DELL)

F140 DR44 L Z2 R0 F2500 M99 45 L Z20 R0 S2000 46 LBL0 47 END PGM 12 MM IV.8.5.2. Chng trnh doa 18 l ?8 su 45 mm 0 1 2 3 4 5 6 7 BEGIN PGM 13 MM BLK FORM 0.1 Z-60 X-175 Y-120 BLK FORM 0.2 Z0 X+175 Y+120 TOOL DEF 0.1 L0.000 R4.000 TOOL CALL 0.2 Z0.000 S150 L Z+20.000 R0 F2500 M13 L X+76.200 Y+30.480 CALL LBL1

8 9 10

L X+45.720 Y+30.480 CALL LBL1 L X+15.240 Y+30.480

11 CALL LBL1 12 L X-15.240 Y+30.480 13 CALL LBL1 14 15 16 17 18 19 20 21 22 L X-45.720 Y+30.480 CALL LBL1 L X-76.200 Y+30.480 CALL LBL1 L X-76.200 Y+0.000 CALL LBL1 L X-45.720 Y+0.000 CALL LBL1 L X-15.240 Y+0.000

23 CALL LBL1 24 L X+15.240 Y+0.000 25 CALL LBL1 26 27 28 29 30 31 32 33 L X+45.720 Y+0.000 CALL LBL1 L X+76.200 Y+0.000 CALL LBL1 L X+76.200 Y-30.480 CALL LBL1 L X+45.720 Y-30.480 CALL LBL1

34

L X+15.240 Y-30.480

35 CALL LBL1 36 L X-15.240 Y-30.480 37 CALL LBL1 38 39 40 41 L X-45.720 Y-30.480 CALL LBL1 L X-76.200 Y-30.480 CALL LBL1

42 STOP M02 43 LBL1 CYLDEF 1.4 (SETUP) -2 -46 1.0 (PECKING)

1.2 (DEPTH)

1.3 (PEKING) -2 1.5 (DELL)

F35 DR44 L Z2 R0 F2500 M99 45 L Z20 R0 S2000 46 LBL0 47 END PGM 13 MM.

Chng V. Lp t, Bo dng v bo qun khun A- Lp t khun: 1- Theo qui tc chung cn phi kim tra cc im sau y trc khi lp t cc chi tit li vi nhau to ra sn phm khun hon chnh. 1.1. i vi khun c s dng t trc cn xem th n c sa cha h hng no cha ?

1.2. Kim tra u vo v u ra ca knh nc bng cch thi kh nn chc chn rng knh nc thng thong v sch s 1.3. Kim tra v chc chn rng vng nh v n khp chnh xc vi l tm ca tm khun c nh. iu s bo m thng hng gia cung phun ca khun v vi phun ca my. 1.4. Kim tra xem chiu cao tng ca khun c vt qu khong sng ca my khng. 1.5. Kim tra khong cch max gia cc tm khun c tho sn phm ra khng. 1.6. Kim tra gi tr lc kp khi gia cng. 1.7. Theo quy tc thc t, chc chn rng trng lng max ca 1 pht n khi lng cho sn phm. 2- Tin hnh kim tra song song ca hai tm khun trc khi lp rp khun. Kim tra xem cc bulong kp an ton c chc chn khng, cc tr c bm bi bn hoc phoi kim loi khng. 3- t khun trng thi hai na ng li vi nhau. iu ny ngn nga hai khun dc bit l li khun khi b cc h hng c th xy ra trong qu trnh lp rp khun. 4- Khng nn c gng tin hnh lp rp khun nng bng tay. Cn s dng my nng, cn cu thch hp hoc cc c cu xch rng rc. Xch rng rc c th iu chnh chm nhng li rt thch hp cho cng vic lp rp khun. 5- Gi cho xch cng vi khun cho n khi c hai na khun gn cht vo cc tm khun. i vi khun nng, l mt thc t tt trnh hin tng kt bulong lp tm di ng trnh bt k mt chuyn ng i xung no ca khun trn qu trnh di chuyn. 6- Trong lc tho khun, khng bao gi c g ba vo khun trong khi cc bulong an ton vn cn ng cht, nu khng s lm hng khun v b phn my ni vi khun. Trong khi khun cn c gi bi xch, ch ni lng mt na s bulong an ton v lm cc iu chnh cn thit thng qua cc bulng kch. B- Hot ng ca khun: 1- bo m cht lng sn phm tt nht, khun phi c duy tr nhit lm vic ca n. 2- Khi tho khun bng tay khng nn s dng cc dng c kim loi cng hoc c cnh sc trnh cc xy xc b mt khun hoc cc cnh sc ny s c th lm hng b mt phn khun, to ra khe h dc theo ng phn khun. 3- Khng bao gi s dng ba g tho khun. 4- Khng c s tay trc tip vo b mt nhn bng ca khun khun, khng li du vn tay khi gy hin tng b mt khun b n mn. 5- Ngi th ng vn hnh my phi xem xt xem khun c sn sng lm vic khng.

6- Nu my khng c s dng qua m th cn bi nn phn b mt nhn bng ca khun mt lp mng kerosin hoc turpenline. 7- Khi khng lm vic, tt c khun c cc phn t l xo cn c trng thi th lng. 8- Khun khng hot ng cn trng thi m nhng c che ph bng vi kh. 9- Trc khi ngh cn cho h thng nc lm ngui khun tip tc vn hnh cho n khi khun c lm ngui hon ton. C- Lu gi khun: 1- Cn phi gi sn phm cui cng c tho ra khi khun tham kho cho bt k s sa cha no cn thit. Cn lm nhn cho sn phm vi tn gi, kch thc, vt liu, s khun v s sn xut chnh ca sn phm . 2- Tt c cc b phn ca khun cn c kim tra v sa cha trc khi ct vo kho n thng xuyn sn sng cho n khi c yu cu cho ln sn xut tip theo. 3- Cc khun c xc nh s khng a vo sn xut cn phi c tho ra, loi ra, phng cha khun khng c ln cc khun khng cn s dng c 4- Cn di chuyn tt c cc n lp knh nc v chng d b h hng khi lu gi. Tin hnh thi kh nn vo knh nc n khi nc ra ngoi ht v gi cho n kh. y kn mt u v rt vo knh lm mt 1 loi du khong ph hp. 5- Bi m cho tt c cc chi tit ca khun v gi gn chng trong thi gian lu gi. 6- i vi khun c l xo th khng nn ng cht, hy t cc nm cao su ph hp vi trng thi m khun gi cho l xo v tr tho lng v lun bt kn ming l trnh bi bn hoc hi m. i vi khun nh ch cn cho chng vo ti nilong l c.

im hn ch, thiu xt ca n tt nghip. Do thi gian hon thnh n c hn ch v khi lng cng vic em thc hin c cng kh nhiu. Cho nn trong khun kh n ca em cha th cp ti vic to dng chng trnh gia cng t ng nh s dng phn mm CAD-CAM. Bi v y l cng vic i hi ngi thit k c kin thc cng ngh thc t phong ph v kh nng s dng phn mm thit k chuyn dng, tch hp gia my tnh vi my cng c, mt cch thnh tho mi c th s tt v hp l cc b mt cn gia cng phc tp. lm bt c iu l rt kh khn i vi sinh vin sp ra trng cha c iu kin thc t sn xut nhiu. Do trong khun kh n ca em cha th cp c th v trit ti vn ng dng CADCAM trong vic thit k khun mu. Vy em knh mong cc thy, c gio thuc b mn cng ngh ch to v b mn c kh my lng th cho thiu xt ny.

H Ni, ngy 05/05/2204 Sinh vin thc hin.

Chu Quc Hiu.

Ti liu tham kho: - PGS-PTS.Nguyn c Lc, PGS-PTS.L Vn Tin, PGS-PTS.Ninh c Tn, PTS.Trn Xun Vit, S tay cng ngh ch to my -Tp 1 (H Ni 1999). (Quyn 1) - PGS-PTS.Nguyn c Lc, PGS-PTS.L Vn Tin, PGS-PTS.Ninh c Tn, PTS.Trn Xun Vit, S tay cng ngh ch to my -Tp 2 (H Ni 2000). (Quyn 2)

- Gio trnh cng ngh ch to my - Tp 1 (NXBKH?KT-H Ni 2000) (Quyn 3)

- Gio trnh cng ngh ch to my - Tp 2 (NXBKH?KT-H Ni 2000) (Quyn 4) - PGS-TS.Trn Vn ch, Hng dn thit k n CNCTM (NXBKHKT- H Ni 2000). 5) - PGS-TS.Trn Vn ch, Cng ngh trn my CNC (H ni 2000).

(Quyn

(Quyn 6)

- PGS-TS.V Hoi n, Gia cng tia la in CNC (NXBKH?KT H Ni 2003). (Quyn 7) - TS.V hoi n, Thit k khun cho sn phm p nha (H ni 1997). - PGS-TS_Ninh c Tn, Dung sai lp ghp (NXBGD). (Quyn 9) - PGS-TS.V Hoi n, Nn sn xut CNC (NXBKH?KT H Ni 2003). (Quyn 10)

(Quyn 8)

- PGS-TS_Phm minh Hi, Vt liu cht do (2003).

(Quyn 11)