Cơ Khí Đ I Cương

gio trnh: c kh i cng
Chng 1
Cc khi nim c bn v sn xut c kh

1.1. Cc khi nim v qu trnh sn xut
1.1.1. S qu trnh sn xut c kh
K thut c kh l mn hc gii thiu mt cch khi qut qu trnh sn xut c kh v phng php cng ngh gia cng kim loi v hp kim ch to cc chi tit my hoc kt cu my. Qu trnh sn xut v ch to bao gm nhiu giai on khc nhau c tm tt nh sau:
Ti nguyn thin nhin Qung, nhin liu, tr dung...
Phi kim
Ch to vt liu
Luyn kim
Thp, gang, ng, nhm v hp kim
Ch to phi Ph phm v ph liu Gia cng ct gt Ph phm v ph liu X l v bo v
c, cn, rn dp, hn...
Tin, phay, bo, khoan, mi...
Nhit luyn, ho nhit luyn, m, sn...
Chi tit my
H.1.1.S qu trnh sn xut c kh
nng - 2002
1.1.2. Qu trnh thit k

L qu trnh khi tho, tnh ton, thit k ra mt dng sn phm th hin trn bn v k thut, thuyt minh, tnh ton, cng trnh v.v... l qu trnh tch lu kinh nghim, s dng nhng thnh tu khoa hc k thut sng to ra nhng sn phm mi ngy cng hon thin. Bn thit k l c s thc hin qu trnh sn xut, l c s php l kim tra, o lng, thc hin cc hp ng. v.v...
1.1.3. Qu trnh sn xut

Qu trnh sn xut l qu trnh tc ng trc tip ca con ngi thng qua cng c sn xut nhm bin i ti nguyn thin nhin hoc bn thnh phm thnh sn phm c th p ng yu cu ca x hi. Qu trnh sn xut thng bao gm nhiu giai on. Mi giai on tng ng vi mt cng on, mt phn xng hay mt b phn....lm nhng nhim v chuyn mn khc nhau. Qu trnh sn xut c chia ra cc cng on nh, theo mt qu trnh cng ngh.
1.1.4. Qui trnh cng ngh

QTCN l mt phn ca qu trnh sn xut nhm trc tip lm thay i trng thi ca i tng sn xut theo mt th t cht ch, bng mt cng ngh nht nh. V d: QTCN nhit luyn nhm lm thay i tnh cht vt l ca vt liu chi tit nh cng, bn.v.v...Cc thnh phn ca quy trnh cng ngh bao gm: a/ Nguyn cng: l mt phn ca qu trnh cng ngh do mt hoc mt nhm cng nhn thc hin lin tc ti mt ch lm vic gia cng chi tit (hay mt nhm chi tit cng gia cng mt ln). b/ Bc: l mt phn ca nguyn cng trc tip lm thay i trng thi hnh dng k thut ca sn phm bng mt hay mt tp hp dng c vi ch lm vic khng i. Khi thay i dng c, thay i b mt, thay i ch ...ta chuyn sang mt bc mi. c/ ng tc: l tp hp cc hot ng, thao tc ca cng nhn thc hin nhim v ca bc hoc nguyn cng.
1.1.5. Dng sn xut

Tu theo quy m sn xut, c trng v t chc, trang b k thut v quy trnh cng ngh m c cc dng sn xut sau: a/ Sn xut n chic: l dng sn xut m sn phm c sn xut ra vi s lng t v thng t lp li v khng theo mt quy lut no. Chng loi
nng - 2002
mt hng rt a dng, s lng mi loi rt t v th phn xng, nh my thng s dng cc dng c, thit b vn nng. y l dng sn xut thng dng trong sa cha, thay th... b/ Sn xut hng lot: l dng sn xut m sn phm c ch to theo l (lot) c lp i lp li thng xuyn sau mt khong thi gian nht nh vi s lng trong lot tng i nhiu (vi trm n hng nghn) nh sn phm ca my bm, ng c in.v.v...Tu theo khi lng, kch thc, mc phc tp v s lng m phn ra dng sn xut hng lot nh, va v ln. Trong sn xut hng lot cc dng c, thit b s dng l cc loi chuyn mn ho c km c loi vn nng hp. c/ Sn xut hng khi: hay sn xut ng lot l dng sn xut trong sn phm c sn xut lin tc trong mt thi gian di vi s lng rt ln. Dng sn xut ny rt d c kh ho v t ng ho nh x nghip sn xut ng h, xe my, t, xe p.v.v...
1.1.6. Khi nim v sn phm v phi

a/ Sn phm: l mt danh t quy c ch mt vt phm c to ra giai on cui cng ca mt qu trnh sn xut, ti mt c s sn xut. Sn phm c th l my mc hon chnh hay mt b phn, cm my, chi tit...dng lp rp hay thay th. b/ Chi tit my: l n v nh nht v hon chnh v mt k thut ca my nh bnh rng, trc c, bi v.v... c/ Phi: cn gi l bn thnh phm l danh t k thut c quy c ch vt phm c to ra t mt qu trnh sn xut ny chuyn sang mt qu trnh sn xut khc. V d: sn phm c c th l chi tit c (nu em dng ngay) c th l phi c nu n cn gia cng thm (ct gt, nhit luyn, rn dp...) trc khi dng. Cc phn xng ch to phi l c, rn, dp, hn, g, ct kim loi v.v..
1.1.7. Khi nim v c cu my v b phn my

a/ B phn my: y l mt phn ca my, bao gm 2 hay nhiu chi tit my c lin kt vi nhau theo nhng nguyn l my nht nh (lin kt ng hay lin kt c nh) nh hp tc , may xe p v.v... b/ C cu my: y l mt phn ca my hoc b phn my c nhin v nht nh trong my. V d: a, xch, lp ca xe p to thnh c cu chuyn ng xch trong xe p.
nng - 2002
1.2. Khi nim v cht lng b mt ca sn phm

Cht lng b mt ca cc chi tit my ng mt vi tr rt quan trng cho cc my mc thit b c kh nng lm vic chnh xc chu ti trng, tc cao, p lc ln, nhit .v.v... N c nh gi bi nhn b mt v tnh cht c l ca lp kim loi b mt.
1.2.1. nhn b mt (nhm)

B mt chi tit sau khi gia cng khng bng phng mt cch l tng nh trn bn v m c nhp nh. Nhng nhp nh ny l do vt dao li, ca L rung ng trong qu trnh ct.v.v... y Rmax ng nh bng b mt l nhp nh t y1 h3 h5 h1 vi ca lp b mt (H.1.2) gm li lm, h9 x h10 0 sng, bng (nhm). nh gi h6 h4 yn h2 nhp nh b mt sau khi gia cng ngi ng y ta dng hai ch tiu l Ra v Rz (m).
H.1.2. nhm b mt chi tit
TCVN 2511- 95 cng nh ISO quy nh 14 cp nhm c k hiu km theo cc tr s. Ra l sai lch trung bnh s hc cc khong cch t nhng im ca profil o c n ng trung bnh ox o theo phng vung gc vi ng trung bnh ca nhp nh t vi trn chiu di chun L. Ta c th tnh:
Ra = 1 y dx L 0
L
Ra =
n 1 ( y1 + y 2 + y3 + ... + y n ) = 1 yi . n n i =1
Rz l chiu cao nhp nh t vi trn chiu di chun L vi gi tr trung bnh ca tng cc gi tr tuyt i ca chiu cao 5 nh cao nht h1, h3, h5, h7, h9 v chiu su ca 5 y thp nht h2, h4, h6, h8, h10 ca profin trong khong chiu di chun.
Rz =
(h
+ h2 + + h9 ) ( h2 + h4 + + h10 5
2,5
a/
.
Rz20
T cp 6 12, ch yu dng Ra, cn i vi cc cp 1 5 v 13 14 dng Rz. khi ghi trn bn v bng c th hin nh H.1.3
b/
H.1.3. K hiu bng a/ K hiu bng theo Ra b/ K hiu bng theo RZ
Trong thc t sn xut, tu theo cc phng php gia cng khc nhau ta c cc cp bng khc nhau. V d: B mt rt th, th t cp 1 3 (Rz = 320 40): c, rn
nng - 2002
Gia cng na tinh v tinh t cp 46 (Rz = 4010, Ra = 2,5): tin, phay, khoan. Gia cng tinh t cp 6 8 (Ra = 2,5 0,32): khot, doa, mi. Cc gi tr thng s nhm b mt (TCVN 2511 - 78)
Cp nhm 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Tr s nhm (m) Ra Rz 2,5-1,25 1,25-0,63 0,63-0,32 0,32-0,16 0,16-0,08 0,08-0,04 0,04-0,02 320 - 160 160 - 80 80 - 40 40 - 20 20 - 10 0,1 - 0,05 0,05 - 0,025 Chiu di chun L(mm) 8 8 8 2,5 2,5 2,5 0,8 0,8 0,8 0,25 0,25 0,25 0,08 0,08 Phng php gia cng Tin th, ca, da, khoan ... Tin tinh, da tinh, phay... Doa, mi, nh bng v.v... Mi tinh mng, nghin, r, gia cng c bit, ph. php khc ng dng
Cc b mt khng tip xc, khng quan trng: gi , chn my v.v... B mt tip xc tnh, ng, trc vt, b. rng ... B mt tip xc ng: mt rng, mt pittng, xi lanh, cht v.v... B mt mt, van, bi, con ln, dng c o, cn mu v.v... B mt lm vic chi tit chnh xc, dng c o
1.2.2. Tnh cht c l ca lp b mt sn phm

Tnh cht c l ca lp b mt gm cu trc t vi b mt, cng t vi, tr s v du ca ng sut d b mt. Chng nh hng nhiu n tui th ca chi tit my. Cu trc t vi v tnh cht c l ca lp b mt chi tit sau gia cng c gii thiu trn H.1.4: Mt ngoi b ph hu (1) do chu lc p v ma st khi ct gt, nhit tng cao. Ngoi cng l mng kh hp th dy khong 23 ngstron (1 = 108 cm), n hnh thnh khi tip xc vi khng kh v mt i khi b nung nng. Sau l lp b xy ho dy khong (40 80). Lp cng ngui (2) l lp kim loi b bin dng do c chiu dy khong 50.000, vi cng cao thay i gim dn t ngoi vo, lm tnh cht c l thay i. Kim loi c bn t vng (3) tr vo.
1 2 3 h H.1.4. Tnh cht c l lp b mt HB 1- Mt ngoi b ph hu 2- Lp cng ngui 3- Kim loi c bn h- Chiu su kim loi HB- cng
nng - 2002
1.3. Khi nim v chnh xc gia cng c kh

1.3.1. Khi nim v chnh xc gia cng
chnh xc gia cng ca chi tit my l c tnh quan trng ca ngnh c kh nhm p ng yu cu ca my mc thit b cn c kh nng lm vic chnh xc chu ti trng, tc cao, p lc ln, nhit v.v... chnh xc gia cng l mc chnh xc t c khi gia cng so vi yu cu thit k. Trong thc t chnh xc gia cng c biu th bng cc sai s v kch thc, sai lch v hnh dng hnh hc, sai lch v v tr tng i gia cc yu t hnh hc ca chi tit c biu th bng dung sai. chnh xc gia cng cn phn no c th hin hnh dng hnh hc lp t vi b mt. l bng hay nhn b mt, cn gi l nhm.
1.3.2. Dung sai

a/ Khi nim Khi ch to mt sn phm, khng th thc hin kch thc, hnh dng, v tr chnh xc mt cch tuyt i c sn phm ging ht nh mong mun v ging nhau hng lot, v vic gia cng ph thuc vo nhiu yu t khch quan nh chnh xc ca dng c, thit b gia cng, dng c o, trnh tay ngh ca cng nhn v.v...Do mi sn phm khi thit k cn tnh n mt sai s cho php sao cho m bo tt cc yu cu k thut, chc nng lm vic v gi thnh hp l. Dung sai c trng cho chnh xc yu cu ca kch thc hay cn gi l chnh xc thit k v c ghi km vi kch thc danh ngha trn bn v k thut. Tr s dung sai kch thc (IT- m)
D (d) Cp chnh xc 5 6 7 8 9 10 11 12 3 >3 6 6 8 12 18 30 48 75 120 >6 10 8 9 15 22 36 58 90 150 > 10 18 8 11 18 27 43 70 110 180 > 18 30 9 13 21 33 52 84 130 210 > 30 50 11 16 25 39 62 100 160 250 > 50 80 13 19 30 46 74 120 190 300 > 80 120 15 22 35 54 87 140 220 350 > 120 180 18 25 40 63 100 160 250 400 >180 250 20 29 46 72 115 185 290 460
4 6 10 14 25 40 60 100
D (d) - Kch thc danh ngha ca chi tit.
nng - 2002
b/ Dung sai kch thc Dung sai kch thc l sai s cho php gia kch thc t c sau khi gia cng v kch thc danh ngha. l hiu gia kch thc gii hn ln nht v nh nht hoc hiu i s gia sai lch trn v sai lch di. Trn H.1.5. biu din dung sai kch thc l v trc:
ES EI Dmin Dmax D es ei dmin dmax d ITl ITt
a/ Dung sai kch thc l
b/ Dung sai kch thc trc
H.1.5. Dung sai kch thc trc v l
Theo TCVN 2244 - 99 cng nh ISO k hiu ch in hoa dng cho l, k hiu ch thng dng cho trc. Trong : D (d): Kch thc danh ngha, s dng theo kch thc trong dy u tin ca TCVN 192 - 66. - Dmax, dmax: kch thc gii hn ln nht. - Dmin, dmin: kch thc gii hn nh nht. - ES = Dmax - D, es = dmax - d : sai lch trn. - EI = Dmin - D, ei = dmin - d : sai lch di. - ITl = Dmax - Dmin = D = ES - EI : khong dung sai ca l. - ITt = dmax - dmin = d = es - ei : khong dung sai ca trc. Dung sai lp ghp l tng dung sai ca l v trc. c/ Min dung sai L l tn gi c dng k hiu cc b mt tr trong cc chi tit. Theo ISO v TCVN min dung sai ca l c k hiu bng mt ch in hoa A, B, C..., ZA, ZB, ZC (k hiu sai lch c bn) v mt s (k hiu cp chnh xc), trong c l c s c sai lch c bn H vi EI = 0 (Dmin= D), cp chnh xc JS c cc sai lch i xng (| ES = EI ). Trc l tn gi c dng k hiu cc b mt tr ngoi b bao ca chi tit. Min dung sai ca trc c k hiu bng ch thng a, b, c..., za, zb, zc; trong trc c bn c cp chnh xc h vi ei = 0 (dmax= d), cp chnh xc js c cc sai lch i xng ( es = ei ). Tri s dung sai v sai lch c bn xc nh min dung sai. Min dung sai ca trc v l c trnh by trn H.1.6:
nng - 2002
H.1.6. V tr cc min dung sai ca Trc v L
Mi kch thc c ghi gm 2 phn: kch thc danh ngha v min dung sai. Trn bn v ch to ghi kch thc danh ngha v gi tr cc sai lch. V d: trn bn thit k ghi 20H7, 40g6 cn trn bn v ch to ghi kch thc tng ng (tra bng): 20+0,021, 40 0,,009 ... 0 025 d/ Sai s hnh dng v v tr Sai s hnh dng hnh hc l nhng sai lch v hnh dng hnh hc ca sn phm thc so vi hnh dng hnh hc khi thit k nh thng, phng, cn...
Sai s hnh dng hnh hc
TT Tn gi 1 Dung sai thng 2 Dung sai phng 3 Dung sai trn 4 Dung sai tr K hiu
Sai s v tr tng i cc b mt
TT 1 2 3 4 5 6 7 Tn gi Dung sai song song Dung sai vung gc Dung sai ng tm Dung sai i xng Dung sai giao nhau D. sai o mt u D. sai o hng knh K hiu
nng - 2002
Sai lch v tr tng i l s sai lch v tr thc ca phn t c kho st so vi v tr danh ngha nh khng song song, khng vung gc, khng ng tm, o v.v...Cc k hiu v v d cch ghi cc sai lch ny trn bng trn. / Cp chnh xc Cp chnh xc c qui nh theo tr s t nh n ln theo mc chnh xc kch thc. TCVN v ISO chia ra 20 cp chnh xc nh s theo th t chnh xc gim dn l 01, 0, 1, 2, ...15, 16, 17, 18. Trong : Cp 01 cp 1 l cc cp siu chnh xc. Cp 1 cp 5 l cc cp chnh xc cao, cho cc chi tit chnh xc, dng c o. Cp 6 cp 11 l cc cp chnh xc thng, p dng cho cc mi lp ghp. Cp 12 cp 18 l cc cp chnh xc thp, dng cho cc kch thc t do (khng lp ghp).
1.3.3. Lp ghp v phng php lp ghp

a/ H thng lp ghp H thng l: l h thng lp ghp ly l lm chun, ta chn trc c cc kiu lp khc nhau; min dung sai k hiu bng ch in hoa; ti min dung sai l c bn H c ES > 0, cn EI = 0. H thng l thng c s dng nhiu hn h thng trc. H thng trc: l h thng lp ghp ly trc lm chun, ta chn l c cc kiu lp khc nhau; min dung sai k hiu bng ch thng; min dung sai trc c bn h c es = 0, cn ei < 0. b/ Phng php lp ghp Lp lng: l phng php lp ghp m kch thc trc lun lun nh hn kch thc ca l, gia 2 chi tit lp ghp c h, chng c th chuyn ng tng i vi nhau nn dng cc mi lp ghp c truyn chuyn ng quay hay trt. Dng lp ghp ny, theo TCVN l c min dung sai A, B, ...G, H hoc cc trc c min dung sai a, b, ...g, h. Lp cht: l phng php lp ghp m kch thc trc lun lun ln hn kch thc l. Khi lp ghp gia 2 chi tit c di nn cn c lc p cht hoc gia cng nhit cho l (hoc trc), thng dng cho cc mi lp ghp c truyn lc. Dng lp ghp ny, theo TCVN l c min dung sai P, R, ..., ZC hoc cc trc c min dung sai p, r, ..., zc.
nng - 2002
10
Lp trung gian: l loi lp ghp m tu theo kch thc ca l v kch thc trc mi lp c th c h hoc di. Gia 2 chi tit lp ghp c th c h rt nh hoc di rt nh. Khi lp c th p nh c mi lp. Dng lp ghp ny, theo TCVN l c min dung sai JS, K, M, N hoc cc trc c min dung sai js, k, m, n.
25
25
H7 e8
b/
+ 0,021 + 0,028 + 0,015
a/
H.1.7. S v cch ghi k hiu lp ghp a/ Cch ghi k hiu trn bn v thit k b/ Cch ghi k hiu trn bn v lp
1.3.4. Phng php o v dng c o

a/ Phng php o Tu theo nguyn l lm vic ca dng c o, cch xc nh gi tr o, ta c cc phng php o sau: o trc tip: l phng php o m gi tr ca i lng o c xc nh trc tip theo ch s hoc s o trn dng c o: o trc tip tuyt i dng o trc tip kch thc cn o v gi tr o c nhn trc tip trn vch ch th ca dng c. o trc tip so snh dng xc nh tr s sai lch ca kch thc so vi mu chun. Gi tr sai s c xc nh bng php cng i s kch thc mu chun vi tr s sai lch . o gin tip: dng xc nh kch thc gin tip qua cc kt qu o cc i lng c lin quan n i lng o. o phn tch (tng phn): dng xc nh cc thng s ca chi tit mt cch ring bit, khng ph thuc vo nhau. b/ Dng c o Cc loi dng c o thng gp l cc loi thc: thc thng, thc cun, thc dy, thc l, thc cp, thc o gc, compa, panme, ng h so, calp, cn mu...Cc loi thit b o tin tin thng dng nh: u o kh nn, u o bng siu m hoc laze, thit b quang hc, thit b o bng in hoc in t v.v... Thc l: c vch chia n 0,5 hoc 1mm c chnh xc thp khong 0,5mm. Thc cp: l dng c o vn nng o cc kch thc c gii hn v ngn nh chiu di, chiu su, khong cch, ng knh l v.v... vi chnh xc khong (0,020,05)mm.
nng - 2002
11
Panme: dng o ng knh ngoi, l, rnh...vi chnh xc cao, c th t (0,0050,01)mm. Panme ch o c kch thc gii hn. V d panme ghi 0 - 25 ch o c kch thc 25mm. Calp - cn mu: l loi dng c kim tra dng trong sn xut hng lot, hng khi kim tra kch thc gii hn cc sn phm t yu cu hay khng. ng h so: c chnh xc n 0,01mm, dng kim tra sai s o so vi kch thc chun bng bn r, bn g chun nn c th kim tra c nhiu dng b mt. Dng ng h so c th xc nh c khng song song, khng vung gc, ng tm, trn, phng, thng, o v.v... Dng: ch dng kim tra mt kch thc hoc hnh dng.
nng - 2002
12
Chng 2
Vt liu dng trong c kh

2.1. Tnh cht chung ca kim loi v hp kim
Kim loi v hp kim c s dng rng ri trong cng nghip ch to cc chi tit my. Mi loi chi tit my phi c nhng tnh nng k thut khc nhau ph hp vi iu kin lm vic. Mun vy phi nm c cc tnh cht c bn ca chng sau y:
2.1.1. C tnh
C tnh l c trng c hc biu th kh nng ca kim loi hay hp kim khi chu tc dng ca cc ti trng. Chng c trng bi: a/ bn: l kh nng ca vt liu chu tc dng ca ngoi lc m khng b ph hu. bn c k hiu . Tu theo cc dng khc nhau ca ngoi lc ta c cc loi bn: bn ko (k); bn un (u); bn nn (n). Gi tr bn ko tnh theo cng thc :
k =
P (N/mm2). F0
P(N) F0 P(N)
H.2.1.S mu o bn ko
Ti thi im khi P t n gi tr no lm cho thanh kim loi c F0 b t s ng vi gii hn bn ko ca vt liu . Tng t ta s c gii hn bn un v bn nn. b/ cng: l kh nng chng ln ca vt liu khi chu tc dng ca ngoi lc. Nu cng mt gi tr lc nn, lm bin dng trn mu o cng ln, cng su th cng ca mu o cng km. cng c o bng cch dng ti trng n vin bi bng thp cng hoc mi cn kim cng hoc mi chp kim cng ln b mt ca vt liu mun th, ng thi xc nh kch thc vt lm in trn b mt vt liu o. C cc loi cng Brinen; cng Rcoen; cng Vicke. cng Brinen: dng ti trng P (i vi thp v gang P = 30D2) n vin bi bng thp nhit luyn, c ng knh D (D = 10; 5; 0,25 mm) ln b mt vt liu mun th (H.2.2.a). cng Brinen c tnh theo cng thc:
HB = P F
(kG/mm2).
y, F - din tch mt cu ca vt lm (mm2).
nng - 2002
13
cng Brinen dng o vt liu c cng thp (< 4500 N/mm2)

D P P P
h a/
d d b/ c/
H.2.2. S th nghim o cng
cng Rcoen: (H.2.2.b) c xc nh bng cch dng ti trng P n vin bi bng thp nhit luyn, c ng knh D = 1,587 mm tc l 1/16 (thang B) hoc mi cn bng kim cng c gc nh 1200 (thang C hoc A) ln b mt vt liu th. Trong khi th, s cng c ch trc tip ngay bng kim ng h. cng Rcoen c k hiu HRB khi dng bi thp th vt liu t cng; HRC v HRA khi dng mi cn kim cng th vt liu c cng cao (>4500 N/mm2). Chn thang o cng Brinen - Rcoen
cng Brinen HB 60230 230700 > 700 Thang o Rcoen (mu) B () C (en) A (en) Mi th Ti trng chnh P (N) 1000 1500 600 K hiu cng Rcoen HRB HRC HRA Gii hn cho php thang Rcoen 25100 2067 > 70
Vin bi thp Vin bi thp Mi kim cng
cng Vicke (HV) dng mi o 1 (hnh chp gc vt = 1360) bng kim cng (H.2.2.c) dng o cho vt liu mm, vt liu cng v vt liu c cng nh lp mng ca b mt c thm than, thm nit.v.v...
HV = 1,8544 P . d2
Trong d - ng cho ca vt lm (mm); P- ti trng (kg). c/ Tnh do: l kh nng bin dng vnh cu ca kim loi v hp kim khi chu tc dng ca ngoi lc. Khi th mu n c th hin qua dn di tng i (%) l t l tnh theo phn trm gia lng dn di sau khi ko v chiu di ban u:
=
l1 l0 * 100% . l0
y l1 v l2 - di mu trc v sau khi ko (mm). Vt liu c (%) cng ln th cng do v ngc li.
nng - 2002
14
d/ dai va chm (ak): C nhng chi tit my lm vic thng chu cc ti trng tc dng t ngt (ti trng va p). Kh nng chu ng cc ti trng m khng b ph hu ca vt liu gi l dai va chm.
ak = A F
(J/mm2).
Trong : A - cng sinh ra khi va p lm gy mu (J); F - din tch tit din mu (mm2).
2.1.2. L tnh
L tnh l nhng tnh cht ca kim loi th hin qua cc hin tng vt l khi thnh phn ho hc ca kim loi khng b thay i. N c c trng bi: khi lng ring, nhit nng chy, tnh dn n, tnh dn nhit, tnh dn in v t tnh...
2.1.3. Ho tnh
Ho tnh l bn ca kim loi i vi nhng tc dng ho hc ca cc cht khc nh xy, nc, axt v.v... m khng b ph hu. a/ Tnh chu n mn: l bn ca kim loi i vi s n mn cc mi trng xung quanh. b/ Tnh chu nhit: l bn ca kim loi i vi s n mn ca xy trong khng kh nhit cao. c/ Tnh chu axt: l bn ca kim loi i vi s n mn ca axt.
2.1.4. Tnh cng ngh

Tnh cng ngh l kh nng ca kim loi v hp kim cho php gia cng theo phng php no l hp l. Chng c c trng bi: a/ Tnh c: c c trng bi chy long, co, ho tan kh v tnh thin tch. chy long cng cao th cng d c; co, ho tan kh v tnh thin tch cng ln th cng kh c. b/ Tnh rn: l kh nng bin dng vnh cu ca kim loi khi chu tc dng ca ngoi lc to thnh hnh dng ca chi tit m khng b ph hu. Thp d rn v c tnh do cao, gang khng rn c v dn; ng, ch rt d rn. c/ Tnh hn: l kh nng to s lin kt gia cc chi tit hn. Thp d hn, gang, nhm, ng kh hn.
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2.2. Thp
2.2.1. Thp ccbon
a/ Khi nim chung v thp ccbon
Thp ccbon l hp cht ca Fe-C vi hm lng ccbon nh hn 2,14%. Ngoi ra trong thp ccbon cn cha mt lng tp cht nh Si, Mn, S, P ... Cng vi s tng hm lng ccbon, cng v bn tng ln cn do v dai li gim xung. Si, Mn l nhng tp cht c li cn S v P th c hi v gy nn dn nng v dn ngui nn cn hn ch < 0,03%. Thp ccbon c c tnh tng hp khng cao, ch dng trong xy dng, ch to cc chi tit chu ti trng nh v va trong iu kin p sut v nhit thp. b/ Phn loi thp ccbon C nhiu cch phn loi thp ccbon nhng c bn c mt s cch nh sau: a/ Phn loi theo hm lng ccbon Thp ccbon thp C < 0,25%. Thp ccbon trung bnh C = 0,250,5%. Thp ccbon cao C > 0,50%. b/ Phn loi theo cng dng Thp ccbon cht lng thng: loi ny c tnh khng cao, ch dng ch to cc chi tit my, cc kt cu chu ti trng nh. Thng dng trong ngnh xy dng, giao thng. Nhm thp thng dng ny hin chim ti 80% khi lng thp dng trong thc t, thng c cung cp dng qua cn nng (tm, thanh, dy, ng, thp hnh: ch U, I, thp gc, ...). Nhm thp ny c cc mc thp sau: Mc thp LX CT0 CT1 CT2 CT3 CT4 CT5 CT6 Mc thp VN CT31 CT33 CT34 CT38 CT42 CT51 CT61 k (kG/mm2) 31 3242 3444 3849 4254 5064 60 0,2 (kG/mm2) 20 21 24 26 30 (%) 20 31 29 23 21 17 12
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Theo TCVN 1765-75 nhm thp ny c k hiu bng ch CT vi con s tip theo ch gii hn bn ko ti thiu. Thp ccbon kt cu: l loi thp c hm lng tp cht S, P rt nh, c th: S 0,04%, P 0,035%, tnh nng l ho tt thun tin, hm lng ccbon chnh xc v ch tiu c tnh r rng. Theo TCVN 1766-75, nhm thp ny c k hiu bng ch C vi con s ch lng ccbon trung bnh theo phn vn. V d: thp C40 l thp ccbon kt cu vi lng ccbon trung bnh l 0,40%. Thp ccbon kt cu dng ch to cc chi tit my chu lc cao nh cc loi trc, bnh rng, l xo v.v... Loi ny thng c cung cp di dng bn thnh phm vi cc mc thp sau: C08, C10, C15, C20, C30, C35, C40, C45, C50, C55, C60 C65, C70, C80, C85. Thp ccbon dng c: l loi thp c hm lng ccbon cao (0,701,3%), c hm lng tp cht P v S thp (< 0,025%). Thp ccbon dng c tuy c cng cao sau khi nhit luyn nhng chu nhit thp nn ch dng lamf cc dng c nh c, da hay cc loi khun dp, cc chi tit cn cng cao. Theo TCVN 1822-76, nhm thp ny c k hiu bng ch CD vi con s ch lng ccbon trung bnh theo phn vn. V d: CD70 l thp ccbon dng c vi 0,70% C. Loi thp ny gm cc mc thp: CD70, CD80, CD90, ...CD130 tng ng vi thp Lin x l: Y7, Y8, Y9, ...Y13. Thp ccbon c cng dng ring: Thp ng ray cn c bn v kh nng chu mi mn cao l loi thp ccbon cht lng cao c hm lng C v Mn cao (0,500,8% C, 0,61,0% Mn). Ray hng c th dng ch to cc chi tit v dng c nh c, dao, nhp, dng c gia cng g,...Dy thp cc loi: dy thp ccbon cao v c bin dng ln khi ko ngui (d = 0,1 mm), gii hn bn ko c th t n 400450 kG/mm2. Dy thp ccbon thp thng c m km hoc thic dng lm dy in thoi v trong sinh hot. Dy thp c thnh phn 0,50,7% C dng cun thnh cc l xo trn. Trong k thut cn dng cc loi dy cp c bn cao c bn t cc si dy thp nh. Thp l dp ngui: c hm lng ccbon v Si nh (0,050,2% C v 0,070,17% Si). tng kh nng chng n mn trong kh quyn, cc tm thp l mng c th ng trng Sn (gi l st ty) hoc trng Zn (gi l tn trng km).
2.2.2.Thp hp kim
a/ Khi nim v thp hp kim Thp hp kim l loi thp m ngoi st, ccbon v cc tp cht ra, ngi ta cn c a vo cc nguyn t c bit vi mt lng nht nh lm thay i t chc v tnh cht ca thp hp vi yu cu s dng. Cc nguyn t a
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vo gi l nguyn t hp kim thng gp l: Cr, Ni, Mn, Si, W, V, Mo, Ti, Nb, Cu,...vi hm lng nh sau: Mn: 0,8 - 1,0%; Si: 0,5 - 0,8%; Cr: 0,2 - 0,8%; Ni: 0,2 - 0,6%; W: 0,1 - 0,6%; Mo: 0,05 - 0,2; Ti, V, Nb, Cu > 0,1%; B > 0,002%. Trong thp hp kim, lng cha cc tp cht c hi nh S, P v cc kh xy, hyr, nit l rt thp so vi thp ccbon. V c tnh thp hp kim c bn cao hn hn so vi thp ccbon dc bit l sau khi nhit luyn. V tnh chu nhit: Thp hp kim gi c cng cao v tnh chng do ti 6000C (trong khi thp ccbon ch n 2000C), tnh chng xy ho ti 800-10000C. V cc tnh cht vt l v ho hc c bit: thp ccbon b g trong khng kh, b n mn mnh trong cc mi trng axit, baz v mui,...Nh hp kim ho m c th to ra thp khng g, thp c tnh gin n v n hi c bit, thp c t tnh cao v thp khng c t tnh, ... b/ Phn loi thp hp kim C nhiu cch phn loi thp hp kim nhng n gin v thng dng nht l phn loi theo cng dng: a/ Thp hp kim kt cu Trn c s l thp ccbon kt cu cho thm cc nguyn t hp kim. Thp hp kim kt cu c hm lng ccbon khong 0,10,85% v lng phn trm nguyn t hp kim thp. Thp ny phi qua thm than ri nhit luyn c tnh mi cao. Loi thp ny c dng ch to cc chi tit chu ti trng cao, cn cng, chu mi mn, hoc cn tnh n hi cao v.v... Cc mc thp hp kim kt cu thng gp: 15Cr, 20Cr, 40Cr, 20CrNi, 12Cr2Ni4, 35CrMnSi; cc loi c hm lng ccbon cao dng lm thp l xo nh 50Si2, 60Si2CrA v.v... K hiu mc thp biu th ch s u l hm lng ccbon tnh theo phn vn, cc ch s t sau nguyn t hp kim l hm lng ca nguyn t , ch A l loi tt. V d: thp 12Cr2Ni4A trong c 0,12% C, 2% Cr, 4% Ni v l thp tt. b/ Thp hp kim dng c L loi thp dng ch to cc loi dng c gia cng kim loi v cc loi vt liu khc nh g, cht do v.v... Thp hp kim dng c cn cng cao sau khi nhit luyn, chu nhit v chu mi mn cao. Hm lng ccbon trong thp hp kim dng c cao t 0,71,4%; cc nguyn t hp kim cho vo l Cr, W, Si v Mn. Thp hp kim dng c sau khi nhit luyn c cng t 6062 HRC. C mt s mc thp chuyn dng nh sau:
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Thp dao ct dng ch to cc loi dao ct nh dao tin, dao bo, dao phay, mi khoan v.v...nh 90CrSi, 140CrW5, 100CrWMn, hoc mt s thp gi nh 80W18Cr4VMo, 90W9V2, 75W18V cc loi thp gi c cng cao, bn, chu mi mn v chu nhit n 6500C. Thp lm khun dp: i vi khun dp ngui thng dng 100CrWMn, 160Cr12Mo, 40CrSi. i vi khun dp nng hay dng cc mc thp: 50CrNiMo, 30Cr2W8V, 40Cr5W2VSi. Thp ln: l loi thp dng ch to cc loi bi hay a l loi thp chuyn dng nh OL100Cr2, OL100Cr2SiMn. Cc ln lm vic trong mi trng nc bin phi dng thp khng g nh 90Cr18 v lm vic trong iu kin nhit cao phi dng thp gi loi 90W9Cr4V2Mo. Cc k hiu ca thp hp kim dng c cng c biu th nh cc loi thp hp kim khc tr thp ln l c thm ch OL ban u. c/ Thp hp kim c bit Trong cng nghip c nhiu chi tit my phi lm vic trong nhng iu kin c bit v vy chng cn phi c nhng tnh cht c bit p ng yu cu ca cng vic. Thp khng g: l loi thp c kh nng chng li mi trng n mn. Thng dng cc mc thp: 12Cr13, 20Cr13, 30Cr13, 12Cr18Ni9, 12Cr18Ni9Ti,... Thp bn nng: l loi thp lm vic nhit cao m bn khng gim, khng b xy ho b mt. V d 12CrMo, 04Cr9Si2 chu c nhit 3005000C; loi bn nng 10Cr18Ni12, 04Cr14Ni14W2Mo chu c nhit 5007000C; hoc l thp NiCrm chuyn ch to dy in tr 10Cr150Ni60. Thp t tnh: l loi thp c nhim t cao. Thp hp kim t cng thng dng cc thp Cr, Cr-W, Cr-Co hoc dng hp kim h Fe-Ni-Al, Fe-Ni-AlCo ch to cc loi nam chm vnh cu bng phng php c v qua mt qu trnh nhit luyn c bit trong t trng. Thp v hp kim t mm c lc kh t nh t thm ln dng lm li my bin p, stato my in, nam chm in cc loi,...Thng dng: st ty nguyn cht k thut (<0,04% C), thp k thut in (thp Si) c 0,010,1% C v 24,4% Si; c th dng hp kim permaloi c thnh phn 79% Ni, 4% Mo cn li l Fe. Thp khng t tnh: l loi vt liu khng nhim t nh 55Mn9Ni9Cr3.
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2.3. Gang
2.3.1. Khi nim chung
Gang l hp kim Fe-C, hm lng ccbon ln hn 2,14% C v cao nht cng < 6,67% C. Cng nh thp trong gang c cha cc tp cht Si, Mn, S, P v cc nguyn t khc. c tnh chung ca gang l cng v dn, c nhit nng chy thp, d c.
2.3.2. Phn loi gang

a/ Gang trng: rt cng v dn, kh ct gt. N ch dng ch to gang do hoc dng ch to cc chi tit my cn tnh chng mi mn cao nh bi nghin, trc cn...Gang trng khng c k hiu ring. b/ Gang xm: l loi gang m hu ht ccbon trng thi graphit. Gang xm c bn nn cao, chu mi mn, c bit l c tnh c tt. K hiu gang xm gm 2 phn cc ch ci ch loi gang v nhm s ch th t bn ko v bn un. V d: GX 21-40 c k = 21 kG/mm2; u = 40 kG/mm2. Hin nay thng dng cc mc gang xm GX 12-28, GX 15-32 ch to v hp s, np che, GX 28-48 c bnh , thn my hoc GX 36-56, GX 40-60 ch to v xi lanh. c/ Gang cu: c t chc nh gang xm nhng graphit c dng thu nh thnh hnh cu. Gang cu c bn rt cao v c do bo m dng ch to cc loi trc khuu, trc cn. Gang cu c k hiu theo TCVN nh sau: v d GC 42-12 l loi gang cu c k = 42 kG/mm2, dn di tng i = 12%. Thng c cc loi: GC 45-15, GC 60-2, GC 50-2. d/ Gang do: l loi gang c ch to t gang trng, chng c bn cao, do ln. Chng c k hiu nh gang cu v c cc mc sau: GZ 33-8, GZ 45-6, GZ 60-3 dng ch to cc chi tit phc tp v thnh mng.
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2.4. Kim loi v hp kim mu

St v hp kim ca n (thp v gang) gi l kim loi en. Kim loi v hp kim mu l kim loi m trong thnh phn ca chng khng cha Fe, hoc cha mt liu lng rt nh. Kim loi mu c nhiu u im nh tnh cng ngh tt, tnh do cao, c tnh kh cao, c kh nng chng n mn v chng mi mn tt, c dn nhit, dn in tt, ...Cc kim loi thng gp l ng, nhm, manh v titan.
2.4.1.ng v hp kim ng
a/ ng ng l mt kim loi c nhiu tnh cht qu nh: do cao, kh nng chng n mn tt trong nhiu mi trng, c bit l dn nhit v dn n rt cao. ng c khi lng ring: 8,94 G/cm3; nhit nng chy: 10830C; bn: b= 16 kG/mm2. Theo TCVN 1659-75 ng c 5 loi sau y: Cu99,99, Cu99,97, Cu99,95 dng lm dy dn in; Cu99,90, Cu99,0 dng ch to brng khng Sn. b/ Hp kim ng Latng La tng l hp kim ng, trong km l nguyn t hp kim chnh. La tng c mu sc p, do, d bin dng, m tt, gi thnh thp hn ng , ph bin nht trong thc t. nng cao mt s tnh cht c bit ca latng ngi ta a vo hp kim mt s nguyn t nh thic tng kh nng chng n mn trong nc bin. Latng vi thnh phn 29%Zn-1%Sn-70%Cu rt thng dng trong ngnh ng tu; hoc thm nhm, Mn v st tng c tnh v kh nng chng n mn ca latng. Hp kim ng c 17-27%Zn, 8-18%Ni gi l mayxo dng lm dy in tr. C cc mc Latng thng dng: LCuZn30, LCuZn40, LCuZn29Sn1, LCuZn27Ni18,...Latng c k hiu bng ch L ri ln lt cc ch Cu, Zn, sau l cc nguyn t hp kim khc nu c. Cc con s ng pha sau mi nguyn t ch hm lng trung bnh ca nguyn t theo phn trm.
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c/ Hp kim ng Brng Brng l hp kim ca ng vi cc nguyn t hp kim khc nh Sn, Al, Pb,...ng thanh c mt s loi sau: Brng thic: Cu-Sn (8-10%Sn) c c tnh cao v kh nng chng n mn trong nc bin tt. Chng c s dng lm cng tc in, a ly hp, l xo, bnh rng v i khi lm bc lt. C cc mc sau: BCuSn5P0,15; BCuSn5Zn5Pb5, ... Brng nhm: Cu-Al c cha khong <13% Al c tng hp c tnh cao, kh nng chng mi mn v gii hn mi tng i ln thng dng ch to h thng trao i nhit, cc chi tit my bm. Cc mc Brng nhm nh: BCuAl5, BCuAl9Fe4, ... Brng ch: Cu-Pb c s dng nhiu ch to trt, thng dng nht l hp kim BCuPb30. Brng berili: l mt th h hp kim mi c bn, kh nng chng mn, chng mi, bn nng cao. c bit l gii hn n hi rt cao. Brng berili thng cha khong 2% Be. N c s dng lm l xo, mng n hi v cc chi tit i hi chu nhit, n hi v dn in cao. V d: BCuBe2.
2.4.2. Nhm v hp kim nhm

a/ Nhm nguyn cht Nhm nguyn cht c mu trng bc, c khi lng ring nh khong 2,7 3 G/cm , c tnh dn in, dn nhit cao, chng n mn tt do c lp xt nhm Al203 bn ngoi. Nhit nng chy 6600, bn thp nhng do. Nhm nguyn cht c chia thnh 3 nhm: Al99,999 - l loi nhm tinh khit. Al99,995; Al99,97; Al99,95 - l loi c sch cao. Al99,85; Al99,80; Al99,70,...Al99,00 - l loi nhm k thut. Nhm sch k thut c dng ch to cp ti in trong kh quyn, cc ng bc x nhit, cc ng ng dn v bn cha xng, du,... b/ Hp kim nhm bin dng Hp kim nhm bin dng c sn xut ra di dng tm mng, bng di, cc thi nh hnh v cc loi ng. Hp kim nhm ny c th rn, dp, cn, p hoc cc phng php gia cng p lc khc. Hp kim nhm bin dng c cc h sau:
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H Al-Mn: chu gia cng bin dng nng v ngui tt, c tnh hn v chng n mn trong kh quyn cao. Chng c s dng thay cho nhm nguyn cht k thut khi c yu cu cao hn v c tnh. H Al-Mg: c tnh hn tt, kh nng chng n mn trong kh quyn cao, gii hn bn mi cao, b mt sau khi gia cng p nn c dng nhiu trong cng nghip ch to t v xy dng cng trnh. H Al-Cu v Al-Cu-Mg: chng c hiu ng ho bn cao c gi l uyra. V d: AlCu4,5Mg0,5MnSi - dng trong t v hng khng. H Al-Mg-Si: c dng ch to cc chi tit chu hn, cc cu kin tu thu. V d: AlMgSi1,5Mn. Hp kim h Al-Zn-Mg v Al-Zn-Mg-Cu: c s dng trong hng khng, ch to v kh, dng c th thao, v.v... V d: AlZn5,5Mg2,5Cu1,5Cr. c/ Hp kim nhm c Hp kim nhm c cn tnh c tt d dng to hnh cc chi tit, chng cha lng nguyn t hp kim ln hn. C cc dng hp kim nhm c in hnh v thng dng: Hp kim Al-Si: cho thm mt s nguyn t khc na ta s c mt loi hp kim c tnh c tt, h s dn n nhit nh, chng mn tng i dng ch to pittng ng c t trong nh: AlSi12CuMg1Mn0,6Ni. Hp kim Al-Cu v mt s nguyn t khc c kh nng bn nng cao v gii hn mi kh ln rt thch hp ch to cc chi tit nh, hnh dng phc tp lm vic nhit cao nh: AlCu5Mg1Ni3Mn0,2. Mt s h hp kim nhm c khc nh Al-Mg; Al-Zn-Mg c s dng nhiu trong nc bin v mt s mi trng in ly khc. Ch : Cc k hiu ca hp kim nhm c pha sau cng c ch phn bit vi hp kim nhm bin dng.
2.5. Hp kim cng

Bng phng php c bit: nn thnh tng bnh hp kim cng dng bt di p sut hng nghn at ri thiu kt 15000C ngi ta to ra hp kim cng t cc ccbt (cacbit vonfram, cacbit titan, cacbit tantan) cng vi mt lng cban lm cht dnh kt. Hp kim cng l mt loi vt liu in hnh vi cng nng rt cao (80010000C). V vy hp kim ny c dng ph bin lm cc dng c ct gt kim loi v phi kim loi c cng cao. c bit l khng cn nhit luyn vt liu ny vn t cng 8592 HRC. C cc loi hp kim cng thng dng:
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a/ Nhm mt cacbit: WC + Co gm cc k hiu: WCCo2; WCCo4; WCCo6; WCCo8; WCCo10; WCCo20; WCCo25. V d: WCCo8 c 8% Co v 92% WC. Nhm ny c do thch hp vi gia cng vt liu dn, cc loi khun ko, p. b/ Nhm 2 cacbit: WC + TiC + Co gm cc k hiu: WCTiC30Co4; WCTiC14Co8; WCTiC5Co10, ... dng ch to dao tin v cc loi dng c ct gt khc. c/ Nhm 3 cacbit: WC + TiC + TaC +Co gm WCTTC7Co12; WCTTC10Co8 dng ch to dng c ct gt cc loi vt liu kh gia cng nh cc hp kim bn nhit.
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chng 3
k thut c
3.1. khi nim chung
3.1.1. Thc cht ca sn xut c
c l phng php ch to chi tit bng cch nu chy v rt kim loi lng vo khun c hnh dng nht nh, sau khi kim loi ho rn trong khun ta thu c vt c c hnh dng ging nh khun c. Nu vt phm c a ra dng ngay gi l chi tit c, cn nu vt phm c phi qua gia cng ct gt nng cao chnh xc kch thc v bng b mt gi l phi c. c c nhng phng php sau: c trong khun ct, c trong khun kim loi, c di p lc, c li tm, c trong khun mu chy, c trong khun v mng, c lin tc v.v... nhng ph bin nht l c trong khun ct.
3.1.2. c im
c c th gia cng nhiu loi vt liu khc nhau: Thp, gang, hp kim mu v.v... c khi lng t mt vi gam n hng trm tn. Ch to c vt c c hnh dng, kt cu phc tp nh thn my cng c, v ng c v.v...m cc phng php khc ch to kh khn hoc khng ch to c. chnh xc v hnh dng, kch thc v bng khng cao (c th t cao nu c c bit nh c p lc). C th c c nhiu lp kim loi khc nhau trong mt vt c. Gi thnh ch to vt c r v vn u t t, tnh cht sn xut linh hot, nng sut tng i cao. C kh nng c kh ho v t ng ho. Hao tn kim loi cho h thng rt, u ngt, u hi. D gy ra nhng khuyt tt nh: thiu ht, r kh, chy ct v.v... Kim tra khuyt tt bn trong vt c kh khn, i hi thit b hin i.
3.1.3. phm vi s dng

Sn xut c c pht trin rt mnh v c s dng rt rng ri trong cc ngnh cng nghip. khi lng vt c trung bnh chim khong 4080% tng khi lng ca my mc.
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Trong ngnh c kh khi lng vt c chim n 90% m gi thnh ch chim 2025%.
3.1.4. Phn loi

K thut c c phn loi theo s sau:
K thut c c c bit
c trong khun ct
c trong hm khun
c trn nn xng
c bng dng gt
khun kim loi
c p lc
c ly tm
c lin tc
c trong khun v mng
c trong khun mu chy
H.3.1. S phn loi phng php c
3.2. c trong khun ct

3.2.1. Cc b phn chnh ca phn xng c
B phn k thut Ch to hn hp lm khun Lm khun Sy khun B phn mc mu Nu kim loi Ch to hn hp lm li Lm li Sy li
Lp rp khun v rt kim loi
Ph khun ly vt c
Ph li khi vt c
Lm sch vt c
Kim tra cht lng sn phm
H.3.2. Cc b phn chnh ca xng c
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3.2.2. cc b phn c bn ca mt khun c

Mun c mt chi tit, trc ht phi v bn v vt c da trn bn v chi tit c tnh n ngt ca vt liu v lng d gia cng c kh. Cn c theo bn v vt c, b phn xng mc mu ch to ra mu v hp li. Mu to ra lng khun 6 - c hnh dng bn ngoi ca vt c. Li 7 c ch to t hp li c hnh dng ging hnh dng bn trong ca vt c. Lp li vo khun v lp rp khun ta c mt khun c. dn kim loi lng vo khun ta phi to h thng rt 10. Rt kim loi lng qua h thng rt ny. Sau khi kim loi ho rn, ngui em ph khun ta c vt c. Lng khun 6 ph hp vi hnh dng vt c, kim loi lng c rt vo khun qua h thng rt. B phn 11 dn hi t lng khun ra ngoi gi l u hi ng thi cn lm nhim v b sung kim loi cho vt c khi ho rn cn gi l u ngt. Hm khun trn 1, hm khun di 9 lm na khun trn v di. lp 2 na khun chnh xc ta dng cht nh v 2. Vt liu trong khun 4 gi l hn hp lm khun (ct khun). nng cao bn ca hn hp lm khun trong khun ta dng nhng xng 5. tng tnh thot kh cho khun ta tin hnh xin cc l thot kh 8.
11 10 1234567891011Hm khun trn Cht nh v Mt phn khun Ct khun Xng khun Lng khun Li Rnh thot kh Hm khun di H thng rt u hi (hoc u ngt)
1 2
4 5 6 7 8 9
H.3.3. Cc b phn chnh ca mt khun c ct
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3.2.3. cc loi vt liu lm khun v lm li

Vt liu lm khun, li ch yu l ct, t st, cht dnh kt, cht ph v.v... a/ Ct: Thnh phn ch yu l SiO2, cn c tp cht Al2O3, CaCO3, Fe2O3...Ct c chn theo hnh dng ht nh ct ni, ct sng... Ct sng ht trn u, ct ni ht sc cnh. Ngi ta xc nh ht ca ct theo kch thc l ry. b/ t st: Thnh phn ch yu: cao lanh mAl2O3, nSiO2, qH2O, ngoi ra cn c tp cht: CaCO3, Fe2O3, Na2CO3. c im: Do, dnh khi c lng nc thch hp, khi sy th bn tng nhng dn, d v, khng b chy khi rt kim loi vo. t st thng hay cao lanh c sn trong t nhin. Thnh phn ch yu l Al2O3.2SiO2.2H2O, loi ny lm khun c thng, c mu trng, kh nng ht nc km, tnh do v dnh km, b co t khi sy. Nhit nng chy cao (175017850C). t st bentnit (I ) thnh phn ch yu l: Al2O3.4SiO2.H2O. N l t st trng c tnh do dnh ln, kh nng ht nc v trng n ln, b co nhiu khi sy, ht rt mn, nhit chy thp (125013000C). Do ni la sinh ra lu ngy bin thnh. Loi ny lm khun quan trng cn do, bn cao. c/ Cht kt dnh Cht dnh kt l nhng cht a vo hn hp lm khun, li tng tnh do ca hn hp. N c mt s yu cu: Khi trn vo hn hp, cht dnh kt phi phn b u. Khng lm dnh hn hp vo mu v hp li v d ph khun, li. Kh nhanh khi sy v khng sinh nhiu kh khi rt kim loi . Tng do, bn v tnh bn nhit cho khun v li. Phi r, d kim, khng nh hng n sc kho cng nhn. Nhng cht dnh kt thng dng: Du: du lanh, du bng, du tru... em trn vi ct v sy t0 = 200 2500C , du s b xy ho v to thnh mng xt hu c bao quanh cc ht ct lm chng dnh kt chc vi nhau. Nc ng (mt): dng lm khun, li khi c thp. Loi ny b sy b mt khun s bn nhng bn trong rt do nn vn m bo thot kh v
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tnh ln tt. Khi rt kim loi n b chy, do tng tnh xp, tnh ln, thot kh v d ph khun nhng ht m nn sy xong phi dng ngay. Bt h: (nng 2,53%) ht nc nhiu, tnh cht nh nc ng, dng lm khun ti rt tt. Cc cht dnh kt ho cng: Nha thng, ximng, hc n, nha ng. Khi sy chng chy lng ra v bao quanh cc ht ct. Khi kh chng t ho cng lm tng bn, tnh dnh kt cho khun. Thng dng loi ximng pha vo hn hp khong 12%, m ca hn hp 68%, trong khng kh 2427 gi c kh nng t kh, loi ny rt bn. Nc thu tinh: chnh l cc loi dung dch silicat Na2O.nSiO2.mH2O hoc K2O.nSiO2.mH2O sy 2002500C, n t phn hu thnh nSiO2.(m-p)H2O l loi keo rt dnh. Khi thi CO2 vo khun lm xong, nc thu tinh t phn hu thnh cht keo trn, hn hp s cng li sau 1530 pht. d/ Cc cht ph: L cc cht a vo hn hp khun v li c mt s tnh cht c bit nh nng cao tnh ln, tnh thng kh, lm nhn mt khun, li v tng kh nng chu nhit cho b mt khun li, gm 2 loi: Trong hn hp thng cho thm mn ca, rm vn, phn tru b kh, bt than... Khi rt kim loi lng vo khun, nhng cht ny chy li trong khun nhng l rng lm tng tnh xp, thng kh, tnh ln cho khun li. T l khong 3% cho vt c thnh mng v 8% cho vt c thnh dy. Cht sn khun: mt khun nhn bng v chu nng tt, ngi ta thng qut ln b mt lng khun, li mt lp sn, c th l bt than, bt grafit, bt thch anh hoc dung dch ca chng vi t st. Bt than v grafit qut vo thnh khun, khi rt kim loi vo n s chy to thnh CO, CO2 lm thnh mi trng hon nguyn rt tt, ng thi to ra mt lp kh ngn cch gia kim loi lng vi mt lng khun lm cho mt lng khun khng b chy ct v to cho vic ph khun d dng.
3.2.4. hn hp lm khun
Hn hp lm khun c hai loi: a/ Ct o: Dng ph st mu khi ch to khun nn cn c bn, do cao, ng thi n trc tip tip xc vi kim loi lng nn cn phi c chu nhit cao, ht cn nh hn b mt c nhn bng, thng thng ct o lm bng vt liu mi, n chim khong 1015% tng lng ct khun.
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b/ Ct m: Dng m cho phn khun cn li, khng trc tip tip xc vi kim loi lng nn tnh chu nhit, bn khng cn cao lm, nhng phi c tnh thng kh tt chim 8590% lng ct. Vt c cng ln yu cu ht ca hn hp lm khun cng ln tng tnh thng kh.
3.2.5. Ch to b mu v hp li
B mu l cng c chnh dng to hnh khun c. B mu bao gm : Mu, tm mu, mu ca h thng rt, u hi, u ngt.Tm mu kp mu khi lm khun, dng kim tra.
a/ Vt liu lm b mu v hp li
Yu cu: Bo m bng, chnh xc khi gia cng ct gt. Cn bn, cng, nh, khng b co, trng, nt, cng vnh trong khi lm vic. Chu c tc dng c, ho ca hn hp lm khun, t b mn, khng b r v n mn ho hc. R tin v d kim.
b/ Cc loi vt liu lm mu v hp li
Vt liu thng dng: G, kim loi, thch cao, ximng, cht do. Ch yu l g, kim loi. G: u im l r, nh, d gia cng, nhng c nhc im l bn, cng km; d trng, nt, cong vnh nn g ch dng trong sn xut n chic, lot nh, trung bnh v lm mu ln. Thng dng cc loi sau: g lim, g, sn, m, d, thng, b , v.v... Kim loi: c bn, cng, nhn bng, chnh xc b mt cao, khng b thm nc, t b cong vnh, thi gian s dng lu hn, nhng kim loi t kh gia cng nn ch s dng trong sn xut hng khi v hng lot. Thng dng: hp kim nhm, gang xm, hp kim ng. Thch cao: Bn hn g (lm c 1000 ln) nh, d ch to, d ct gt. Nhng gin, d v, d thm nc. Nn lm nhng mu nh khi lm bng tay, tin li khi lm mu ghp v dng trong c m ngh (v d sa). Ximng: Bn, cng hn thch cao, chu va chm tt, r, d ch to, nhng nng tuy khng ht nc, kh gt, sa nn ch dng lm nhng mu, li phc tp, mu ln, mu lm khun bng my.
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3.2.6. Cc phng php lm khun bng ct

Trong sn xut c, khun c ng mt vai tr quan trng, l mt trong nhng yu t quyt nh cht lng vt c. Thng c ti 50 n 60% ph phm l do khun c gy ra. V vy phi tun th quy trnh cng nhg lm khun cht ch. Khun c c 3 loi: khun dng mt ln, khun bn vnh cu lm bng vt liu chu nng a sy 6007000C, sau khi ly vt c em sa cha ri dng li c mt s ln (50200 ln). Khun vnh cu lm bng kim loi dng trong sn xut hng lot v hng khi.
a. Cc phng php lm khun bng tay

a/ Lm khun trong 2 hm khun vi mu nguyn
Trnh t nhng thao tc lm khun vi hai hm v mu nguyn nh sau:
a/
b/
c/
H.3.4. Lm khun trong 2 hm khun
d/
Lm na khun di: u tin t mu ln tm mu, t hm khun ln tm mu, ct o xung quanh mu, ct m, dm cht ln th nht, tip ct m ri dm cht, l phng, xm kh (a). Lm na khun trn: Quay na khun di 1800, ly tm mu, t hm khun trn ln, bt cht nh v, t mu u hi, mu ng rt, mu rnh lc x, ct o xung quanh mu v tin hnh lm khun nh hm khun di (b, c).
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Tho lp khun: Tho cht nh v, tho na khun trn ra, rt b mu, khot rnh dn v cc rt, sa cha cc nI b h hng, qut sn ln mt phn khun, lp rp khun lI, bt cht c cu kp cht (d).
b/ Lm khun trn nn xng:

Lm khun trn nn xng l dng ngay nn xng to khun di. Phng php ny thch ng trong sn xut n chic v hng lot nh, vt c trung bnh v ln khng yu cu b mt nhn p, kch thc khng cn chnh xc. Lm khun trn m cng (H.3.5): trn nn xng o l c chiu su ln hn chiu cao ca mu 300400 mm, dm cht y l ri 1 lp x hoc si dy 150200 mm. tng thot kh, t hai ng nghim 2 dn kh ra ngoi, lp ct m sau ct o 3 v dm cht mt t, n mu xung mt phn khun ca mu trng mt bng ca nn, rc lp bt cch v t hm khun 4 ln, c nh v tr ca hm bng cht 9 st vo thnh hm v tin hnh lm khun trn. Nhc hm khun trn v ct mng dn 8, rt b mu ra v lp khun trn vo, to cc rt 7, t ti trng 6 v rt kim loi.
5 6
8 9 123456789si (hoc x) ng nghim Ct o Hm khun trn u hi Ti trng Cc rt Rnh dn Cht nh v
H.3.5.Lm khun trn nn xng vi nn m cng
c/ Lm khun trong 3 hoc nhiu hm khun

Phng php ny thch ng khi lm khun vi mu phc tp m khng th lm trong 2 hm khun c.
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H.3.6. Lm khun trong 3 hm khun
B/ Cc phng php lm khun bng my

Lm khun bng my tc l c kh ho hon ton qu trnh lm khun hoc mt s nguyn cng c bn nh dm cht v rt mu. Lm khun, rut bng my nhn c cht lng tt, nng sut cao song vn u t cao nn ch dng trong sn xut hng lot hay hng khi.
a/ Dm cht khun c
Dm cht khun c bng cch p: C nhiu kiu dm cht hn hp lm khun c bng cch p: p trn xung, p di ln v p c 2 pha. My p lm khun c nng sut cao, khng n nhng dm cht thay i mnh theo chiu cao. Khi p trn dm cht mt di khun thp nn chu p lc kim loi lng km. My p ch thch hp vi hm khun thp.
6 5 4 3 2 1 8 7 a/ 9 b/ H.3.7. Dm cht khun c bng cch p a/ p trn xung; b/ p di ln h, mm h, mm
g/cm3
1233 4g/cm 56789-
bn my mu hm khun chnh hm khun ph chy p x ngang van kh phttng y xilanh
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Nguyn l lm vic: khun chnh v ph c t trn bn my 1, kh nn qua van 7 i vo xi lanh 9 nng piston y 8 i ln, chy p 5 s p ln hn hp khun ph v nn chng vo khun chnh tng dm cht cho n. My p di ln th quay x ngang v v tr p nh hnh v, mu nm trn piston y v c piston y v pha khun chnh cng vi hn hp lm tng dm cht cho khun chnh. Dm cht khun c trn my dn (H3.8.a): Mu 2 v hm khun chnh 3 lp trn bn my 1, hm khun ph 4 bt cht vi hm khun 3. Sau khi hn hp lm khun, ta m cho kh p theo rnh 5 vo xi lanh 6 y pittng 7 cng bn my i ln. n cao khong 3080 mm th l kh vo 5 b ng li v h l kh 8, nn kh p trong xi lanh thot ra ngoi, p sut trong xi lanh gim t ngt, bn my b ri xung v p vo thnh xi lanh. Khi pittng ri xung th l kh vo 5 li h ra v qu trnh dn lp li.
5 4 3 2 1 8 5 7 6 g/cm3 7 8 10 a b 6 9 11 h, mm 4 3 2 1 g/cm3 h, mm
H.3.8. Dm cht trn my dn, va dn va p a/ Dm cht trn my dn; b/ Dm cht trn my va dn va p
Dm cht khun c trn my va dn va p (H.3.b): Mu 2, hm khun 3,4 lp cht trn bn my 1. y hn hp lm khun. Kh p theo rnh 8 vo xi lanh 9 v y pittng 7 cng bn my i ln, khi l kh 6 h ra kh p thot ra ngoi, bn my li ri xung thc hin qu trnh dn. Sau khi dn xong quay chy p 5 v v tr trn hm khun, ng ca vo rnh 8, m rnh 10, kh p s nng pittng 11 cng ton b pittng 7 v bn my i ln thc hin qu trnh p. dm cht hn hp lm khun phng php ny tng i u. Trong thc t khi lm khun thp dng my p, lm khun cao dng my dn hoc va dn va p.
b/ Cc phng php ly mu bng my

Vic ly mu ra khi khun c tin hnh bng cc c cu: y hm khun, bn quay, bn lt v rt mu.
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Ly mu bng c cu y hm khun:
3 2 1 5 4 3 2 1 5
H.3.9. Ly mu bng c cu y hm khun a/ Ly mu bng cch nng hm khun b/ Ly mu bng cch nng hm khun v tm mu
Phng php y hm khun bng cht nng (H.3.9.a): Khi dm cht xong, tm mu 1 c gi c nh vi bn my 5, cc cht nng 2 t t i ln y vo cnh hm khun 3, mu c ly ra khi khun. Phng php ny n gin, nng sut cao, nhng khun d v ch thch ng vi cc mu n gin chiu cao thp. Phng php y hm khun bng cht nng v tm (H.3.9.b): Nh c tm 4 gi hn hp nn khun t b v hn song phi ch to tm cho tng tm mu nn tn km hn. Ly mu kiu bn quay: Sau khi lm xong khun (a), bn quay 4 c nng ln v quay mt gc 1800, lt khun xung pha di, tip tc nng bn 5 ln ly khun, tho kp hm khun ra khi bn quay v t t h xung, cn tm c bn quay gi li (b).
4 5 a H.3.10. Ly mu bng bn quay b
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Ly mu bng bn quay c cng vng ln, khun v tr lt nn t v khun nhng kt cu phc tp. Phng php ny thch hp khi lm khun di. Ly khun kiu bn lt: Sau khi lm khun xong (a), bn lt 1 gc 1800, bn 4 nng ln ly hm khun v tho kp hm khun ri t t h xung, cn tm mu 2 c bn lt gi li (b). Ly mu bng bn lt kt cu phc tp, chim mt bng nhng t v khun, thch hp khi lm khun di.
2 3
1 4
a H.3.11. Ly mu bng bn lt
3.2.7. H thng rt, u hi, u ngt

a/ H thng rt: H thng rt l h thng dn kim loi lng t thng rt vo khun. S b tr h thng rt quyt nh cht lng vt c v gim c s hao ph kim loi vo h thng rt. Hao ph do h thng rt gy nn t n 30%. Cc b phn chnh ca h thng rt th hin trn hnh v: Yu cu i vi h thng rt: Ton b lng khun phi c in y kim loi. Dng kim loi chy phi u, cn, khng va p. H thng rt phi chc khng b v.
1 1- Phu rt 2- ng rt 3- Rnh lc x 4- Rnh dn H.3.12. H thng rt
2 3 4
b/ u hi: Dng kh trong lng khun thot ra, i khi dng b sung kim loi cho vt c. C 2 loi u hi: u hi bo hiu v u hi b sung chng thng c t v tr cao nht ca vt c.
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c/ u ngt: Dng b sung kim loi cho vt c khi ng c. Thng dng khi c gang trng, gang bn cao, thp, hp kim mu, gang xm thnh dy. u ngt phi c t vo ch thnh vt c tp trung nhiu kim loi v kim loi ng c chm nht v co rt nhiu nht.
H.3.13. u ngt
3.3. c gang xm
Gang c nhiu loi, nh gang trng, gang do, gang bin tnh, gang cu, song trong k thut c ngi ta ch yu s dng gang xm. Gang xm c k hiu: Gx. v d: Gx15-28. Thnh phn ho hc: 2,53,5% C; 0,83% Si; 0,61,3% Mn; 0,21% P; < 0,12%S. Trong C trng thi t do gi l graft.
3.3.1.Vt liu nu v m liu:

Khi nu gang xm phi dng nhng nguyn nhin liu sau: nguyn liu: kim loi; nhin liu cung cp nhit; tr dung to x; trong sn xut c gi l vt liu nu. Mun nu ra loi gang c thnh phn ho hc ng yu cu, c nhit cao, vn hnh l d dng cn phi tnh ton phi liu cho mt m nu gi l m liu.
a/ Nguyn liu (khi lng kim loi):

Trong thc t lng nguyn liu thng dng trong mt m liu: Gang c (thi gang ch to l cao): 30 50% Gang vn (cc loi gang ph liu) : 20 30% Vt liu v l (ph liu t l c) : 30 35% Thp vn : 0 10% Fer hp kim (FeSi; FeMn...) : 1 2% Vt liu trc khi a vo l phi c ly theo mt t l nht nh; phi lm sch g v cc cht bn.
b/ Nhin liu:
Trong thc t thng dng cc loi nhin liu sau: Than cc: (1016)% khi lng kim loi/ M liu. Than gy (than c mc cc bon ho cao): nc ta thng dng than gy ng triu, Mo kh. Trong thc t thng dng: 20 22% khi lng kim loi/ M liu. Than : t dng v nhit tr thp, bn c hc khng cao.
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c/ Cht tr dung:
Cht tr dung dng lm long x cho d ni ln trn b mt v d dng loi b chng cng vi tp cht. Thng dng vi (45% khi lng kim loi/M liu); hunh thch (cha CaF2): (<8% khi lng kim loi/M liu) hoc x l Mctanh.
3.3.2. L nu gang
Thng dng l ng, l ch, l in. Nhng ch yu l dng l ng v l ch. L ng c s dng rng ri v cu to n gin, tiu hao nhin liu t, vn u t thp, d thao tc, cng sut cao (50025.000 kG gang lng/ gi). Song nhit gang ra l khng cao (14500C), thnh phn ho hc ca gang khng n nh. Cc gang hp kim cn cht lng cao thng c nu bng l in hoc l ni.
a/ L ng nu gang
L l loi l ng, hnh tr gm cc b phn ch yu l: b phn l, thn l, thit b tip liu v thit b gi nng, h thng gi v thit b lm ngui, ng khi c thit b dp la, l tin v ng dn gang v.v..
H.3.14. S cu to ca l ng nu gang
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L c t trn ct chng (1) ca b phn l. Thn l gm c v ngoi (2) lm bng thp tm dy 810 mm, pha trong xy gch chu la (3) (gch samt, gch dint hoc l gch nung gi). B phn tip liu (8) a than cc (5) v kim loi (6) vo l qua ca tip liu (4). L c 1, 2 hoc 3 hng l mt gi c cp gi t qut gi (19) qua ng gi (9) nm trn ni l. Trn nh ng khi (10) l thit b dp la (11) chng c g trn tr (7). Phn ni l l phn khng gian t y l (12) ti ng gi (9). y l c ph mt lp vt liu chu la nn cht. Gang t l ng chy qua l tin t ca (14) v t l tin qua ca (18) v mng mng rt (17) ra gu rt . X c tho ra ngoi bng ming (15). Ton b l c g trn 3 tr bng thp. + ng knh trong ca l: D =
Q. L. K 4,71. L1
(m). Q - cng sut l (tn/gi); L v
L1 - S m3 gi dng cho 1 kg nhin liu (6,56,8m3/kg) v 1m2 tit din l trong 1 pht, K - T l than trong m liu (%). + Chiu cao l: l c nh: Ho = (35)D m; l c ln: Ho= (2,54)D m. Qu trnh nu: Sau mi ln nu phi sa l: sa tng l, l ra gang, ra x, p y l ri cht ci t sy l trong 24 gi, khi ci to chy, dn than lt xung cho n khi cao hn mt gi chnh 1,21,5 m. Sau cht vt liu vo theo tng m liu mt theo th t: kim loi (thp vn, gang thi, gang vn v f r) - nhin liu - cht tr dung c lp i lp li nh th cho n y l. Ch 2040 pht cho vt liu nng ri thi gi vo. Thc cht ca qu trnh nu: Qu trnh oxy ho nhin liu v tp cht pht nhit v qu trnh trao i nhit gia kh nng v vt liu nu.
b/ L ch nu gang
Hin nay cc xng c nh u dng l ch nu gang. u im c bn l cu trc rt n gin d ch to, vn u t rt t. Nhin liu d kim, ch cn than c nh 20-30 mm, c th nu bng nhiu loi than . Song l ch c nng sut thp v thnh phn ho hc ca gang khng n nh. L ch ch ph hp cho cc xng c nh, mt hng c c nh (<60 kG), iu kin c kh ho thp.
nghing l ra gang D L x L ra gang
Mt gi
Hp gi
H.3.15. L ch nu gang a/ L ch quay; b/ L c nh
b/
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L ch thp hn l ng, khng c b phn dp la lng bi. Thn l chia lm 2 hoc 3 on d dng nng h v tho lp. L ch c 2 loi: quay nghing v c nh. L c cc thng s k thut sau: ng knh trong ca l: 400500 mm. Chiu cao ca l: H/D = 23 l hp l. Mt gi: gi vo l 110120 m3/m2.pht l c. Trng lng m liu < 60 kG; t l than/gang khong 2030%.
3.4. c kim loi mu

3.4.1. c im v cng ngh c ng
a/ c im
Hp kim ng c nhit chy thp (10830C), tnh chy long cao c th c c nhng vt c phc tp, r nt. Hn hp lm khun, li nh mn, cn sn bt graphit chng chy ct. V c tnh chy long tt nn c th phn b nhiu vt c vo mt hm khun c chung mt h thng rt, c c cc vt mng. V c co ln nn u ngt phi ln v t nhng ch tp trung kim loi. ng d b xy ho, ng thanh d b thin tch nn dng kim loi rt vo khun phi thp v nhanh, chy m v lin tc nn ng rt thng hnh rn, nhiu tng.
a/ Vt liu nu:
Vt liu chnh: Gm ng k thut, ng thanh v ng thau, hi liu. Hp kim ph: Hp kim ng + 1 nguyn t kim loi khc (50%Cu + 50%Al hoc 80%Cu + 20%Mn) Cht kh oxy: Dng hon nguyn oxyt kim loi trong hp kim (90%Cu + 10%P) v: 5Cu20 + 2P = 10Cu + P205; P205 to thnh x ni ln. Cht tr dung: Dng kim loi lng khi b oxy ho v tch tp cht ra thnh x. Thng dng: Than ci hoc thu tinh lng, thch cao, mui n.
c/ Qu trnh nu ng:
Nu ng : Sy l n 90010000C, ri cht mt lp than ci vo y ni v ph mt lp than ci ln trn. Tip tc nung n khi Cu nng chy. kh tt oxy sau khi Cu nng chy, cho dn Cu + P vo kh. Kh xong rt ly
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mu, ngui em b mu. Nu mu b nt chng t vn cn oxy v tip tc kh ht xy ri mi rt. Nu ng thanh: Sy l 7008000c ri tin hnh nh trn. Cn khuy u, khi lng Cu chy ht cho 1/2 lng Cu+P vo kh xy. Nu ng thau: Nh nu ng thanh nhng km d bc hi nn ph liu (c cha km) v cc cht d chy sau cng.
3.4.2. c im v cng ngh c nhm

a/ c im:
Thng c trong khun ct v trong khun kim loi. Nhm co nhiu nn hn hp lm khun phi c tnh ln tt, bn cao, tng cht dnh v cht ph. Nhm c tinh chy long cao nn c th c c ccvt c c thnh mng ti 2,5 mm v phc tp. Nhm d ho tan kh nn ng rt dng loi hnh rn, bc. u hi, u ngt ln n 250% khi lng vt c. Khng nn d khun sm qu v ngui nhanh ngoi khng kh d b nt.
b/ Cng ngh c nhm

Nguyn vt liu: Gm 40 60% vt liu c v 60 40% kim loi nguyn cht. Kim loi nguyn cht thng dng: 90%Al + 10%Mn; 50%Al + 50%Cu; 85%Al + 15%Si. Cht tr dung: nga s xy ho v to x. Thng dng cc loi: 44%KCl + 56%MnCl2 hoc 50%NaCl + 35%KCl + 15%Na3AlFe6. Nhng cht ny ph hu xyt nhm to x. L nu nhm: thng dng: L ni, l in tr hoc l cm ng. Qu trnh nu: Nu nhm kh khn do s oxy ho mnh lit v s bo ho kh khi nung trn 8000C. Nn thng nu di lp cht tr dung, tinh luyn H.3.16. L in tr nu nhm bng kh hoc mui ri bin tnh. Nu di lp cht tr dung: Cht 1/3 m liu vo l, trn ph mt lp cht tr dung ri tin hnh nu chy. Phn m liu cn li sy nng n 1001200C (thot ht nc) ri cho vo kim loi lng trong l. t chc u mn ta cho vo mt s cht bin tnh. Khuy u ri th mu, nu mu ngui m cn si bt th phi tip tc kh xy.
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Tinh luyn bng kh: Nu chy 1/3 m liu ri cho hp kim ph v phn cn li ca m liu vo l. Khuy u ri thi kh clo (hoc N2) vo kim loi lng, khong 5 15 pht tinh luyn: 3Cl2 + 2Al = 2AlCl3 + Q Cl2 + H2 = 2HCl + Q AlCl3 v HCl bay ln to thnh s si mang theo cc tp cht (Al2O3, SiO2 v cc kh khc thot ra ngoi. sau cng lm bin tnh, th v rt vo khun.
3.5. Cc phng php c c bit

c trong khun ct c bng, chnh xc thp, lng d gia cng ln, nhiu khuyt tt, gi thnh ch to cao nn hin nay xut hin cc phng php c c bit nh: c trong khun kim loi, c di p lc, c ly tm, c trong khun mu chy, c trong khun v mng, c lin tc v.v...
3.5.1. c trong khun kim loi

a/ c im:
Khun c th dng c nhiu ln (vi trm n hng vn) tu thuc vo khi lng vt c. Vt c c chnh xc v bng cao (cp 7, 8; RZ = 20 Ra = 0,63) T chc ht kim loi nh, mn (do ngui nhanh) nn c tnh tt. Tit kim c vt liu lm khun v iu kin lao ng tt. Gi thnh khun t nn dng sn xut hng lot. dn nhit khun ln nn khi c gang d b ho trng v gim kh nng in y ca kim loi v th kh c thnh mng v phc tp. Khun, li bng kim loi nn khng c tnh ln, ngn cn s co ca kim loi nhiu lm cho vt c d nt. Hin nay thng s dng rng ri c thp, gang, ng, nhm, magi khi ch to cc chi tit nh ng dn kh p lc cao, secmng- xilanh ca bm thu lc, van, pittng, trc khuu, cam ...
b/ Vt liu lm khun, li v kt cu khun

Vt liu lm khun: Thng dng thp hp kim, thp ccbon, hp kim ng. Vt liu lm li: kim loi hoc lm bng ct-t st. Kt cu khun: Nu vt c n gin th khun c lm 2 na nh c trong khun ct. i vi vt c phc tp: khun thng t nhiu phn ghp li vi nhau.
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c/ Qu trnh cng ngh c

Lm sch b mt khun, li; sy khun n T0 nht nh; sn ln b mt khun, li mt lp sn chu nhit dy 2mm. Sn ph ln lp sn m mt lp sn o bng du mazt, du hi hoc du thc vt. Lp rp khun v rt kim loi. ngui vt c mt thi gian ri d khun.
3.5.2. c di p lc
a/ c im

Vt c c chnh xc, bng cao (cp 6,7; RZ =10 Ra = 0,63). c c nhng vt c mng v phc tp. Vt c ngui nhanh cho nn c tnh cao; nng sut cao. Khun lm vic di p sut cao, dng chy kim loi ln nn khun mau mn v chng b hng. c di p lc dng ch to cc chi tit phc tp nh: van dn kh, v bm xng du, np bung p. Vt liu c p lc: Thic ch, km, magi, nhm, ng.
b/ My c p lc
Kim loi lng c vo xi lanh, Piston trn nn xung, piston di I xung, kim loi lng theo rnh dn vo khun c, sn phm c y ra nh c cu bn y.
H.3.17. S c p lc kiu pittng
3.5.3. c ly tm
a/ c im:
c ly tm l rt kim loi vo khun quay, nh lc ly tm m kim loi lng c phn b u trn b mt bn trong ca khun to thnh vt c. Lc ly tm: P = m.r.2 . c c nhng chi tit hnh trn xoay, rng m khng cn li.
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C th c c nhng vt c c thnh mng, c gn, hoc hnh ni mng. Vt c sch, t chc kim loi mn cht. Ch thch ng cho cc chi tit hnh trn xoay, rng. Cht lng b mt trong khng tt. Vt c d b thin tch. Khun cn c bn cao, chu nhit tt. My c ly tm cn c kn tt, kh nng cn bng ng cao. Kh xc nh chnh xc ng knh trong ca sn phm.
b/ Cc phng php c ly tm
c ly tm ng: Khun quay theo trc thng ng. Vt c thng c dng mt Parabonloit. Phng php ny dng c cc chi tit ngn. c ly tm nm ngang: Khun quay theo phng nm ngang. Vt c l mt ng hnh tr c chiu dy nh nhau. kim loi chy u vo khun nn t trc quay nghing mt gc 50.
1 3 2 1 2 3 b/
a/
H.3.18. S nguyn l cc phng php c ly tm a/ c ly tm ng; b/ c ly tm nm ngang 1. Rt kim loi lng; 2. Khun kim loi; 3. Phi c
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chng 4
Gia cng kim loi bng p lc

4.1. Khi nim chung
4.1.1. Thc cht, c im ca gia cng p lc
a/ Thc cht
Gia cng kim loi bng p lc l mt trong nhng phng php c bn ch to cc chi tit my v cc sn phm kim loi thay th cho phng php c hoc gia cng ct gt. Gia cng kim loi bng p lc thc hin bng cch dng ngoi lc tc dng ln kim loi trng thi nng hoc ngui lm cho kim loi t n qu gii hn n hi, kt qu s lm thay i hnh dng ca vt th kim loi m khng ph hu tnh lin tc v bn ca chng.
b/ c im
Kim loi gia cng th rn, sau khi gia cng khng nhng thay i hnh dng, kch thc m cn thay i c c, l, ho tnh ca kim loi nh kim loi mn cht hn, ht ng u, kh cc khuyt tt (r kh, r co v.v ...) do c gy nn, nng cao c tnh v tui bn ca chi tit v.v ... GCAL l mt qu trnh sn xut cao, n cho php ta nhn cc chi tit c kch thc chnh xc, mt chi tit tt, lng ph liu thp v chng c tnh c hc cao so vi cc vt c.
c/ Cc phng php gia cng kim loi bng p lc

Tt c cc dng GCAL u c th chia lm hai ngnh chnh: Cn, ko, p thuc ngnh luyn kim. Rn t do, rn khun, rp tm thuc ngnh c kh. Sn phm ca GCAL c dng nhiu trong cc xng c kh; ch to hoc sa cha chi tit my; trong cc ngnh xy dng, kin trc, cu ng, dng hng ngy ... V d: Tnh khi lng chi tit rn, dp trong ngnh ch to my bay chim n 90%, ngnh t chim 80%, ngnh my hi nc chim 60%.
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4.1.2. Bin dng do ca kim loi

a/ Bin dng ca kim loi
Nh chng ta bit, di tc dng ca ngoi lc, kim loi bin dng theo cc giai on: bin dng n hi, bin dng do v bin dng ph hu. Tu theo cu trc tinh th ca mi loi, cc giai on trn c th xy ra vi cc mc khc nhau. Bin dng n hi: di tc dng ca P ngoi lc, kim loi b bin dng; nu thi lc tc dng th bin dng s mt i v kim loi tr v v tr ban u. l bin dng m ng sut sinh ra trong kim loi cha vt qu gii hn n hi Bin dng do: khi ng sut sinh ra trong kim loi vt qu gii hn n hi. Bin L dng do l bin dng vnh cu, n lm thay H.4.1. th quan h i hnh dng ca kim loi sau khi thi lc gia lc v bin dng tc dng. Bin dng ph hu: Nu lc tc dng vt qu gii hn ban u ca kim loi th n lc lc khng cn tng na, bin dng vn tip din v dn n ph hu kim loi.
b/ Tnh do ca kim loi

Tnh do ca kim loi l kh nng bin dng do ca kim loi di tc dng ca ngoi lc m khng b ph hu. Tnh do ca kim loi ph thuc vo hng lot nhn t khc nhau: thnh phn v t chc ca kim loi, nhit , trng thi ng sut chnh, ng sut d, ma st ngoi, lc qun tnh, tc bin dng ... Tnh do ca kim loi ph thuc rt ln vo nhit , hu ht kim loi khi tng nhit , tnh do tng. Trng thi ng sut chnh cng nh hng ng k n tnh do ca kim loi. Qua thc nghim ngi ta thy rng kim loi chu ng sut nn khi c tnh do cao hn khi chu ng sut nn mt, nn ng hoc chu ng sut ko. ng sut d, ma st ngoi lm thay i trng thi ng sut chnh trong kim loi nn tnh do ca kim loi cng gim.
4.2. Cn kim loi

4.2.1.Thc cht ca qu trnh cn
Qu trnh cn l cho kim loi bin dng gia hai trc cn quay ngc chiu nhau c khe h nh hn chiu cao ca phi, kt qu lm cho chiu cao phi gim, chiu di v chiu rng tng. Hnh dng ca khe h gia hai trc cn
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quyt nh hnh dng ca sn phm. Qu trnh phi chuyn ng qua khe h trc cn l nh ma st gia hai trc cn vi phi. Cn khng nhng thay i hnh dng v kch thc phi m cn nng cao cht lng sn phm. My cn c hai trc cn t song song vi nhau v quay ngc chiu. Phi c chiu dy ln hn khe h gia hai trc cn, di tc dng ca lc ma st, kim loi b ko vo gia hai trc cn, bin dng to ra sn phm. Khi cn chiu dy phi gim, chiu di, chiu rng tng.
D R
A N
P
T T A
ho
A C A I B l B
A B h1
A B
H.4.2. S cn kim loi Khi cn dng cc thng s sau biu th: T s chiu di (hoc t s tit din) ca phi trc v sau khi cn gi l h s ko di: =
l1 F0 = l 0 F1
(mm). Lng p tuyt i: h = (ho - h1) Quan h gia lng p v gc n: h = D(1 - cos ) (mm). S thay i chiu di trc v sau khi cn gi l lng gin di: l = l1 - lo S thay i chiu rng trc v sau khi cn gi l lng gin rng: b = b1 - bo Cn c th tin hnh trng thi nng hoc trng thi ngui. Cn nng c u im: tnh do ca kim loi cao nn d bin dng, nng sut cao, nhng cht lng b mt km v c tn ti vy st trn mt phi khi nung. V vy cn nng dng cn phi, cn th, cn tm dy, cn thp hp kim. Cn ngui th ngc li
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cht lng b mt tt hn song kh bin dng nn ch dng khi cn tinh, cn tm mng, di hoc kim loi mm. iu kin kim loi c th cn c gi l iu kin cn vo. Khi kim loi tip xc vi trc cn th chng chu hai lc: phn lc N v lc ma st T, nu h s ma st gia trc cn v phi l f th: T = N. f f = tg. V l gc ma st, nn: T/N = tg = f Lc N v T c th chia thnh 2 thnh phn: nm ngang v thng ng: Tx = T.cos = N.f.cos Nx = Nsin Ty = T.sin Ny = P.cos Thnh phn lc thng ng c tc dng lm kim loi bin dng, cn thnh phn nm ngang c tc dng ko vt cn vo hoc y ra. c th cn c, phi tho mn iu kin: Tx > Nx f.N.cos > N.sin ; tg > tg hoc > Ngha l h s ma st f phi ln tg ca gc n . Hoc gc ma st ln hn gc n. Khi vt cn vo gia trc cn th gc n nh dn n khi vt cn hon ton vo gia trc cn th gc n ch cn bng 1/2. Hin tng ny gi l ma st tha. m bo iu kin cn vo cn tng h s ma st trn b mt trc cn.
4.2.2. Sn phm cn
Sn phm cn rt a dng, c phn ra bn nhm chnh: dng hnh, dng tm, dng ng v dng c bit.
a/ Loi hnh:
Cc sn phm dng hnh c chia ra dng hnh n gin (a), gm c thanh, thi tit din trn, vung, ch nht, lc gic, bn nguyt ... v dng hnh phc tp (b) c tit din ch V, U, I, T, Z ...
a. Dng hnh n gin
b. Dng hnh phc tp
b/ Loi tm:
Cc sn phm dng tm c phn loi theo chiu dy ca tm thnh: Mng: s = 0,23,75 mm; b = 6002200 mm. Dy: s = 460 mm; b = 6005000 mm; l = 400012000mm. Cun: s = 0,22 mm; b = 2001500 mm; l = 400060.000 mm.
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c/ Loi ng:
Cc sn phm dng ng c phn ra: ng khng hn v ng c mi hn. ng khng hn c cn t phi thi c = 5426 mm, chiu dy thnh ng S = 0,540 mm. ng c mi hn c ch to bng cch cun tm thnh ng sau cn hn gip mi vi nhau. Loi ny c ng knh ngoi n 720 mm v chiu dy n 14 mm.
d/ Loi hnh c bit:

Cc sn phm c bit gm cc loi c hnh dng c bit theo yu cu ring nh v t v cc loi c tit din thay i theo chu k.
4.2.3. Thit b cn
a/ Cc b phn ch yu ca my cn
2 3 4 5 6 5 4 7 H.4.3. S cu to my cn 1. Trc cn 2. Trc cc ng 3. Hp phn lc 4. Khp ni 5. Bnh 6. Hp gim tc 7. ng c
Gi cn: L b phn ch yu ca my cn bao gm: cc trc cn gi ln v gi ta c t trong ca s ca thn my, c h thng nn trc v cn bng trc. Trc cn: Gm ba phn: thn trc cn (3), c trc (2) v u ch thp (1). Thn trc cn c dng trc trn (a) hoc c cc rnh to l hnh (b), c trc lp , u ch thp l ch ni vi b phn truyn dn.
1 2 3 1 2 3
a. Trc cn thng H.4.4. Trc cn
b. Trc cn thp hnh
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Trc truyn: Truyn m men xon t hp phn lc n cho cc trc cn. C 3 loi trc truyn: Trc khp ni hoa mai c cu to n gin, gc nng khng ln dng rng ri cc my cn hnh, my cn tm v my cn c nh phi tiu chun. Trc khp ni vung: dng nhiu trong cc my cn c nh phi tiu chun, my cn hn hp va cn hnh va cn tm, hp l nht l khi dng cc loi my cn c ng knh trc 50200 mm. Trc khp ni vn nng: C kh nng truyn m men xon cho trc cn gc nghing = 00100. N c s dng nhiu trong my cn, c bit trong cc loi my cn phi, my cn ph, my cn tm dy, my cn ren v.v... Hp bnh rng ch V: Phn phi mmen xon ra cho cc trc cn. Cc bnh rng c ch to t thp 40Cr hoc 40CrNi, rng xin 2 pha c kh nng chu ti ln v chng c lc dc trc. Hp gim tc: c ch to t cc bnh rng xin c t mt n 3 cp, mi cp c t s truyn t 4 n 6, hp gim tc 3 cp t dng.
b/ Phn loi my cn
Cn c theo s lng trc cn:
a/
b/
c/
d/
e/
H.4.5. Phn theo s lng trc cn

a- my cn 2 trc, b-my cn 3 trc, c- my cn 2 trc kp, dmy cn nhiu trc, e-my cn vn nng.
Cn c theo cng dng: My cn phi; my cn thp hnh; my cn thp ng, my cn c bit. Cn c theo ng knh trc: Hng ln: >600 mm, va: =360550 mm, nh: = 240350 mm.
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Cn c theo s b tr trc cn:

a b. c
e d g
H.4.6. Cch b tr trc cn a-my cn n, b-my cn ng thng, c-my cn hai cp, d-my cn nhiu cp, e-my cn bn lin tc, g-my cn lin tc.
4.2.4. Cng ngh cn mt s thp thng dng

a/ Cn thp tm:
Cn thp tm dy: Khi cn thp tm dng trc cn trn, thng qua hai cng on: u tin l cn rng (a), tip theo l cn di (b). Khi cn rng, phi a vo theo gc nghing so vi ng tm trc cn, cn khi cn di phi c a vo thng gc. Cn thp tm dy c th dng my cn hai trc hoc 3 trc.
c d b a a b d c
a.
b.
d a
c b
a) Cn rng b) Cn di
d c
Cn thp tm mng: C th cn trng thi nng hoc ngui. Cn nng thng tin hnh trn my cn lin tc hay bn lin tc c vn tc n 15 m/s. Kim loi sau khi cn nng tip tc cn ngui c chiu dy nh hn. Khi cn ngui thng dng cht bi trn v cn trn my 2, 3, 5 trc v.v... V cn ngui tn ti hin tng bin cng nn phi trung gian gia cc ln cn trong l c mi trng bo v hoc l trung tnh.
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b/ Cn thp hnh
Cn thp hnh n gin: Qu trnh cn cc loi thp hnh n gin thng qua nhiu ln cn vi trc cn hnh, cc bc cn th tin hnh vi cc l hnh c bin dng khc nhau nh: l hnh vung, l hnh ch nht, l hnh thoi, l hnh -van,... cn cn tinh, l hnh c bin dng ca sn phm. Hnh sau trnh by s cn mt s loi thp hnh n gin.
a 90o 90o
90o b
90o
c H.4.7. S cn mt s thp hnh a) Cn thp trn b) Cn thp vung c) Cn thp gc
c/ Cn ng: Khi cn ng khng c mi hn (a), phi ban u l thp trn, my cn c hai trc cn, mi trc c hai phn hnh nn ct ngc nhau, quay cng chiu v t cho nhau trong khng gian mt gc = 4 6o. Trong qu trnh cn, phi va chuyn ng quay, va chuyn ng tnh tin dc trc ca n. vng bin dng, tm ca phi b bin dng nhiu v chu ng sut ko nn thay i lin tc lm xut hin cc vt nt v to thnh l, sau l c mi xoy sa li bin dng. Sau khi cn th, ng c a qua nguyn cng tu chnh sa chnh xc ng knh trong v ngoi.
K 3 2 nhn theo K
1
H.4.8. S cn ng khng c mi hn 1) Trc cn 2) Mi xoy 3) Phi
Khi cn ng c mi hn, dng thp tm ct thnh di sau cn cun thnh ng v hn gip mi cnh dc theo chiu trc ca ng.
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4.3. Ko kim loi

4.3.1. Thc cht, c im v cng dng
a/ Thc cht: Ko si l qu trnh ko phi kim loi qua l khun ko lm cho tit din ngang ca phi gim v chiu di tng. Hnh dng v kch thc ca chi tit ging l khun ko. b/ c im: Ko si c th tin hnh trng thi nng hoc trng thi ngui. Ko si cho ta sn phm c chnh xc cp 1214 v bng Ra = 0,63 0,32. c/ Cng dng: Ko si dng ch to cc thi, ng, si bng thp v kim loi mu. Ko si cn dng gia cng tinh b mt ngoi cc ng cn c mi hn v mt s cng vic khc.
1 2 3 P 4 a) b) 1 2 3 P
H.4.9. S ko si a/ Ko si b) Ko ng 1) Phi 2) Khun ko 3) Sn phm 4) Li sa l
Khi ko si, phi (1) c ko qua khun ko (2) vi l hnh c tit din nh hn tit din phi kim loi v bin dng theo yu cu, to thnh sn phm (3). i vi ko ng, khun ko (2) to hnh mt ngoi ng cn l c sa ng ng knh nh li (4) t trong.
4.3.2. Qu trnh ko si
Ty theo tng loi kim loi, hnh dng l khun, mi ln ko tit din c th gim xung 15% 35%. T l gia ng knh trc v sau khi ko gi l h s ko di:
K= d0 = 1+ d1 P(1 + f cot g )
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do, d1- ng knh si trc v sau khi ko (mm). - gc nghing ca l khun. - gii hn bn ca kim loi (N/mm2); 2 p - p lc ca khun p ln kim loi (N/mm ). f - h s ma st. Ko si c th ko qua mt hoc nhiu l khun ko nu t s gia ng knh phi v ng knh sn phm vt qu h s ko cho php. S lt ko c th c tnh ton nh sau:
d1 = kn = d0 lg d 0 lg d n n lg k = lg d 0 lg d n ; ta c: n = dn lg k d0 d d d d ; d 2 = 1 = 0 ; d n = n 1 = 0 2 k k k k kn
Lc ko si phi m bo: ln thng lc ma st gia kim loi v thnh khun, ng thi kim loi bin dng. ng sut ti tit din ra khi khun phi nh hn gii hn bn cho php ca vt liu nu khng si s b t. Lc ko si c th xc nh:
P = . F1 .lg F0 (1 + f cot g ) F1
(N)
- Gii hn bn ca kim loi ly bnh tr s trung bnh gii hn bn ca vt liu trc v sau khi ko. F0, F1 - tit din trc v sau khi ko (mm2). f - h s ma st gia khun v vt liu. Ko si dng ch to cc thi, ng, si bng thp v kim loi mu c ng knh t vi mm n vi chc mm. Ko si cn dng gia cng tinh b mt ngoi ng cn c mi hn v mt s cng vic khc.
4.3.3.Dng c v thit b ko si
a/ Khun ko: Khun ko si gm khun (1) v khun (2), bin dng l hnh ca khun gm 4 phn: on cn (I) l phn lm vic chnh ca khun c gc cn = 24o360 (thng dng nht l 260), on cn vo (II) c gc cn 90o l ni phi vo v cha cht bi trn, on thng (III) c tc dng nh knh v on cn thot phi (IV) c gc cn Vt 600 si ra d dng khng b xc. liu ch to khun l thp cc bon dng c, thp hp kim hoc hp kim cng, thng dng cc loi sau: CD80, CD100, CD130, 30CrTiSiMo, Cr5Mo.
1
II I
IV III
Khun ko
1) Khun 2) khun
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b/ My ko si My ko si c nhiu loi, cn c vo phng php ko c th chia lm 2 loi: my ko thng hay my ko c tang cun. Cng c th c phn loi theo s lng khun ko, s si c ko ng thi. My ko thng dng khi ko cc si hoc ng c ng knh ln khng th cun c ( = 610 mm hoc ln hn). Lc ko ca my t 0,275 tn, tc ko 1545 m/ph. tu kt cu ca my c th ko 1 hoc 3 sn phm cng mt lc. to chuyn ng thng c th dng xch, vt v cu, thanh rng v bnh rng, du p v.v...Trn hnh sau trnh by my ko si bng xch si c kp cht nh c cu kp (3), c ko nh hai xch ko (4) ni chuyn ng vi h thng dn ng.
1 2 3 4
H.4.10. S my ko si ko thng 1) Kim loi 2) Khun ko 3) C cu ko 4) Xch ko
My ko si c tang cun dng khi ko si di c th cun trn c. Trn my ko mt khun (a) dng ko nhng si hoc thi c = 610 mm. khi tang ko (3) quay, si c ko qua khun (2) ng thi cun thnh cun. Theo tc ko, tang cp si (1) lin tc quay theo cp cho khun ko. My ko si nhiu khun ko c s trt (b) th cc khun ko c tit din gim dn v gia nhng khun ko l nhng con ln (3). S quay ca trng (4) ng thi to nn tng lc ko ca cc khun.
1 a 1 2 3 4 2 3
b. H.4.11. My ko c tang cun a-My ko mt khun; b- My ko nhiu khun
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4.4. p kim loi

4.4.1. Nguyn l chung
Ep l phng php ch to cc sn phm kim loi bng cch y kim loi cha trong bung p kn hnh tr, di tc dng ca chy p kim loi bin dng qua l khun p c tit din ging tit din ngang ca chi tit. Trn hnh sau trnh by nguyn l mt s phng php p kim loi:
1 2 3 4 1 2 4 3 1 2 3 4 5
a/
b/ H.4.12. S nguyn l p kim loi
c/
a, b) p si, thanh c) p ng 1) Pistng 2) Xi lanh 3) Kim loi 4) Khun o 5) Li to l
Khi p thanh, thi ngi ta c th tin hnh bng phng php p thun hoc p nghch. Vi p thun (a), khi pistng (1) p, kim loi trong xi lanh (2) b p qua l hnh ca khun p (4) chuyn ng ra ngoi cng chiu chuyn ng ca pistng p. Vi p nghch (b), khi pistng (1) p, kim loi trong xi lanh (2) b p qua l hnh ca khun p (4) chuyn ng ra ngoi ngc chiu chuyn ng ca pistng p. Vi p thun kt cu n gin, nhng lc p ln v ma st gia kim loi v thnh xi lanh lm tng lc p cn thit, ng thi phn kim loi trong xi lanh khng th p ht ln (1012%). p nghch lc p thp hn, lng kim loi cn li trong xi lanh t hn (68%), nhng kt cu p phc tp. S hnh (c) trnh by nguyn l p ng, y l ng c to thnh nh li (5). Phi p c l rng t li (5), khi pistng (1) p, kim loi b y qua khe h gia l hnh ca khun (4) v li to thnh ng.
4.4.2. Khun p
V kt cu, khun p c ba dng: hnh cn (a), hnh phu (b) v hnh tr (c).
H.4.13. Kt cukhun p
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Khun p dng hnh cn, c gc cn thnh bn t 2030o, chiu di on hnh tr t 58 mm, c s dng nhiu v kt cu tng i n gin. Kt cu hnh phu, kim loi bin dng u hn nhng gia cng kh khn, cn kt cu hnh tr d gia cng nhng kim loi bin dng qua khun kh hn. Vt liu ch to khun l thp hp kim cha W, V, Mo, Cr v.v... hoc hp kim cng.
4.4.3. c im v ng dng
p l phng php sn xut cc thanh c tit din nh hnh c nng sut cao, chnh xc v nhn b mt cao, trong qua trnh p, kim loi ch yu chu ng sut nn nn tnh do tng, do c th p c cc sn phm c tit din ngang phc tp. Nhc im ca phng php l kt cu p phc tp, khun p yu cu chng mn cao. Phng php ny c ng dng rng ri ch to cc thanh kim loi mu c ng knh t 5200 mm, cc ng c ng knh trong n 800 mm, chiu dy t 1,58 mm v mt s prfin khc.
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4.5. Rn t do
4.5.1. Thc cht, c im v dng c rn t do
Rn t do l mt phng php gia cng p lc m kim loi bin dng khng b khng ch bi mt mt no khc ngoi b mt tip xc gia phi kim loi vi dng c gia cng (ba v e). Di tc ng ca lc P do ba (1) gy ra v phn lc N t e (3), khi kim loi (2) bin dng, s bin dng ch b khng ch bi hai mt trn v di, cn cc mt xung quanh hon ton t do.
1 P 2 3 N
H.4.14. S rn t do
a/ c im chnh xc, bng b mt chi tit khng cao. Nng sut thp Cht lng v tnh cht kim loi tng phn ca chi tit kh m bo ging nhau nn ch gia cng cc chi tit n gin hay cc b mt khng nh hnh. Cht lng sn phm ph thuc vo tay ngh ca cng nhn. Thit b v dng c rn t do n gin. Rn t do c dng rng ri trong sn xut n chic hay hng lot nh. Ch yu dng cho sa cha, thay th. b/ Dng c Nhm1: L nhng dng c cng ngh c bn nh cc loi e, ba, bn l, bn tp, sn, cht, mi t. Nhm 2: L nhng dng c kp cht nh cc loi km, t v cc c cu kp cht khc. Nhm 3: L nhng dng c kim tra v o lng: ke, thc cp (o trong o ngoi, o chiu su, cc loi compa.
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4.5.2. Thit b rn t do
Thit b rn t do bao gm: Thit b gy lc, thit b nung, my ct phi, my nn thng, my vn chuyn.v.v... Rn t do c th tin hnh bng tay hoc bng my. Rn tay ch yu dng trong sn xut sa cha, trong cc phn xng c kh ch yu l rn my. Theo c tnh tc dng lc, cc my dng rn t do c chia ra: my tc dng lc va p (my ba), my tc dng lc tnh (my p). Trong , my ba hi l thit b c s dng nhiu nht. Hnh sau trnh by s ca mt my ba hi. My ba hi c hai xi lanh, mt xi lanh kh (5) v mt xi lanh ba (9). Gia hai xi lanh c van phn phi kh (7) iu khin s cp kh nn t xi lanh nn sang xi lanh u ba.
7 8 9 10 11 12 13 14 6 5
4 3
2 1
H.4.15. S nguyn l my ba hi 1- ng c in 2- B truyn ai 3- Trc khuu 4- Tay bin 5- Xi lanh p 6-Pistng p 7- Van phn phi kh 8- Pistng ba 9- Xi lanh ba 10- e trn 11- e di 12- gi e 13-B e 14- bn p iu khin
Nguyn l lm vic ca my ba: ng c 1 truyn ng cho trc khuu 3 qua b truyn ai 2. Thng qua bin truyn ng 4 lm cho pittng p 6 chuyn ng tnh tin to ra kh p bung trn hoc bung di trong xi lanh ba 9. Tu theo v tr ca bn p iu khin 14 m h thng van phn phi kh 7 s to ra nhng ng dn kh khc nhau, lm cho pittng ba 8 c gn thn pittng ba v e trn 10 chuyn ng hay ng yn trong xi lanh ba 9. e di 11 c lp vo gi e 12, chng c gi cht trn b e 13. Ngoi my ba hi trong thc t cn s dng cc loi my sau y trong rn t do: My ba hi nc- khng kh p rn t do, My ba ma st kiu vn g, My ba l xo.
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4.5.3. Nhng nguyn cng c bn ca rn t do

Cng ngh rn t do mt sn phm no thng bao gm nhiu nguyn cng khc nhau. Tu theo yu cu v k thut, hnh dng ca chi tit gia cng v dng phi ban u m la chn nhng nguyn cng v th t tin hnh khc nhau. a/ nguyn cng Vut Nguyn cng lm gim tit din ngang v tng chiu di ca phi rn. Dng rn cc chi tit dng trc, ng, dt mng hay chun b cho cc nguyn cng tip theo nh t l, xon, un. Thng thng khi vut dng ba phng, nhng khi cn vut vi nng sut cao hn th dng ba c dng hnh ch V hoc cung trn. Cn m bo cc thng s k thut hp l: Kch thc chi tit ban u l b0,h0; kch thc sau khi vut l b, h; kch thc e L, B. s - gi l bc vut.
c b0 b h s h B L h0
H.4.16. S vut kim loi
tranh tt gp np cho sn phm th: s > h v cn m bo th no cho

b0 2 2,5 . tng nng sut vut th: s << b. h0
cho b mt sn phm c phng th: s (0,40,8)c Khi vut phi l thi thp c th tin hnh vut t gia ra dn cc khuyt tt ra hai u ri ct b. i vi thp cn th vut tng on mt t ngoi vo trong, v hai u chng ngui. Khi cn vut nhanh n tit din nh yu cu, th trc tin vut thnh tit din ch nht hay vung cho d, lc gn t n kch thc cn thit ngi ta mi tu chnh cho ng theo thnh phm.
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Khi mun chuyn i phi c tit din vung thnh chi tit c tit din trn vi chiu di thay i khng ng k th chn cnh ca phi b hn ng knh ca chi tit 23%. Khi phi c tit din hnh trn m chi tit c tit din hnh ch nht m mun chiu di khng thay i ng k th ng knh ca phi D c tnh:
D=
2a + b 3
nu
a 2 ; D = 1,3a b
nu
a 2 b
a,b - cnh ln v cnh nh ca tit din chi tit. Mt s phng php vut c bit: Vut trn trc tm: Nhm gim chiu dy v tng chiu di chi tit, ng knh trong ca phi hu nh khng i. Lng phi vo trc tm (c d = d trong ca phi c cn 312 Ba Chi tit mm/m) v tin hnh gia cng trn e dng ch V v ba phng. Nu trc tm ln th bn trong c l rng dn nc lm ngui nu l Trc tm ln vut u th trc tm phi e 0 nung trc khong 150200 C. Khi vut th vut dn tng on H.4.17. S vut trn trc tm t 2 u vo gia d ly chi tit ra khi trc tm. M rng ng knh trn trc tm: dng vut cc chi tit dng ng nhm tng ng knh trong, ng knh ngoi, gim chiu dy thnh ng m chiu di hu nh khng i. Trc tm c ng knh nh hn l phi t 50150 mm, chiu di cng tc a ly ln hn chiu di phi l khong 50100 mm. Trc tm cng b th nng sut vut cng cao nhng cng vng km. Ba gia cng c b > l.
ba
l a
H.4.18. S m rng l trn trc tm
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b/ Nguyn cng chn L nguyn cng nhm tng tit din ngang v gim chiu cao phi. N thng l nguyn cng chun b cho cc nguyn cng tip theo nh t l, thay dng th trong t chc kim loi, lm bng u, chuyn i kch thc phi. Chn ton b: l nung c chiu di phi, khi chn thng xy ra cc trng hp sau: Trng hp 1: khi
h0 2 th vt chn c dng hnh trng (a). d0 h Trng hp 2: khi 0 2 2,5 c th xy ra cc hin tng sau: d0
Lc p ln: vt chn c dng 2 hnh trng chng kht ln nhau (b). Lc p trung bnh: 2 hnh trng kp khng chng kht ln nhau (c). Lc p nh v nhanh: vt chn c 2 u loe ra (d). Trng hp 3: khi
h0 2,5 vt chn d b cong, cn nn thng ri chn tip (). d0
d0 h0
H.4.19. Chn ton b
Chn cc b Ch cn nung nng vng cn chn hay lm ngui trong nc phn khng cn chn ri mi gia cng. Cng c th nung nng ton b ri gia cng trong nhng khun m thch hp.
H.4.20. Chn cc b
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c/ nguyn cng t l
t lthng sut: Nu chi tit t mng v rng th khng cn lt phi trong qu trnh t. Cn phi c vng m d thot phoi. Nu chiu dy vt t ln th t n 7080% chiu su l, lt phi 1800 t phn cn li. Nu l t qu su ( > 2,5 ) th khi ht mi t ta dng cc tr m t n chiu su yu cu. Nu l t c ng knh qu ln (D>50100mm) nn dng mi t rng gim lc t. t l khng thng: c coi nh l giai on u ca t l thng, song bit c chiu su l t th trn mi t v tr m phi c khc du. khng dng c mi t rng. Nu l t ln trc ht dng mi t nh t, sau dng mi t ln dn cho n ng knh yu cu. V rng s bin dng trong khi t l khng thng rt kh khn. lu : Li ct ca mi t phi phng, sc u, c cng cao v nm trong mt phng vung gc vi trc tm ca n. Lc p ca ba phi phn b u v phi vung gc vi ng tm trc. Khi t n 1030mm th nhc mi t ln v cho cht chng dnh vo (bt than, bt grafit...) ri mi t tip.
h d
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4.6. Dp th tch
a/ nh ngha
Dp th tch l phng php gia cng p lc trong kim loi bin dng trong mt khng gian hn ch bi b mt lng khun. Qu trnh bin dng ca phi trong lng khun phn thnh 3 giai on: giai on u chiu cao ca phi gim, kim loi bin dng v chy ra xung quanh, theo phng thng ng phi chu ng sut nn, cn phng ngang chu ng sut ko. p
1
Giai on 2: kim loi bt u ln kn ca ba-via, kim loi chu ng sut nn khi, mt tip gip gia na khun trn v di cha p st vo nhau. Giai on cui: kim loi chu ng sut nn khi trit , in y nhng phn su v mng ca lng khun, phn kim loi tha s trn qua ca bavia vo rnh cha bavia cho n lc 2 b mt ca khun p st vo nhau.
3 6 5 4
H.4.20. S kt cu ca mt b khun rn 1-khun trn; 2- rnh cha ba-via; 3- khun di; 4- chui ui n; 5- lng khun; 6- ca ba-via
b/ c im
chnh xc v bng b mt phi cao (cp 6 - 7; RZ = 80 20) Cht lng sn phm ng u v cao, t ph thuc tay ngh cng nhn. C th to phi c hnh dng phc tp hn rn t do. Nng sut cao, d c kh ho v t ng ha. Thit b cn c cng sut ln, cng vng v chnh xc cao. Chi ph ch to khun cao, khun lm vic trong iu kin nhit v p lc cao. Bi vy dp th tch ch yu dng trong sn xut hng lot v hng khi.
4.6.2. Thit b dp th tch

Thit b dng trong dp th tch bao gm nhiu loi khc nhau nh thit b nung, thit b vn chuyn, my ct phi, thit b lm ngui, thit b kim tra v.v...Tuy nhin ay ta ch nghin cu mt s my gia cng chnh. Dp th tch i hi phi c lc dp ln, bi vy cc my dp phi c cng sut ln, cng vng ca my cao. Mt khc, do yu cu khi dp khun trn v
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khun di phi nh v chnh xc vi nhau, chuyn ng ca u trt my dp phi chnh xc, t gy chn ng. Trong dp th tch thng dng nht l s dng cc loi my sau: my ba hi nc - khng kh nn, my p trc khuu, my p thu lc, my p ma st trc vt.
a/ My p thy lc
Cc my p thu lc l cc loi my rn truyn dn bng dng cht lng (du hoc nc) c p sut cao. My c ch to vi lc p t 300 - 7.000 tn. to p lc p ln, trong cc my p thy lc n u p thng dng b khuch i p sut vi hai xi lanh: xi P2 lanh hi (1) v xi lanh du (3). Pittng (2) c hai 3 phn ng knh khc nhau, phn nm trong xi lanh hi c ng knh ln (D) v phn nm trong xi lanh du c ng knh b (d). Vi p sut hi p1, p sut d 2 du (p2) c tnh theo cng thc sau:
p 2 = p1 D2 d2
1 P1 D Hi B khuyt i p sut
My p thy lc c u im: lc p ln, chuyn ng ca u p m v chnh xc, iu khin hnh trnh p v lc p d dng. Nhc im ca my p thu lc l ch to phc tp, bo dng kh khn.
b/ My p trc khuu
My p trc khuu c lc p t 1610.000 tn. My ny c loi hnh trnh u con trt c nh gi l my c hnh trnh cng; c loi u con trt c th iu chnh c gi l hnh trnh mm. Nhn chung cc my ln u c hnh trnh mm. Trn my p c kh c th lm c cc cng vic khc nhau: rn trong khun h, p phi, t l, ct bavia v.v... S nguyn l c trnh by trn hnh sau: Nguyn l lm vic ca my nh sau: ng c (1) qua b truyn ai (2) truyn chuyn ng cho trc (3), bnh rng (4) n khp vi bnh rng (7) lp lng khng trn trc khuu (5).
3 4 5 6
7 8 10 9
H.4.21. My p trc khuu
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Khi ng li hp (6), trc khuu (8) quay, thng qua tay bin (8) lm cho u trt (9) chuyn ng tnh tin ln xung, thc hin chu trnh dp. e di (10) lp trn b nghing c th iu chnh c v tr n khp ca khun trn v khun di. c im ca my p trc khuu: chuyn ng ca u trt m hn my ba, nng sut cao, tn hao nng lng t, nhng c nhc im l phm vi iu chnh hnh trnh b, i hi tnh ton phi chnh xc v phi lm sch phi k trc khi dp.
4.6.3. Cng ngh dp th tch

Ty thuc vo mc phc tp ca kt cu vt dp, qu trnh dp c th tin hnh qua mt lng khun hoc qua nhiu lng khun. Thng thng vi cc vt dp phc tp, qu trnh dp tin hnh qua cc nguyn cng dp s b, dp bn tinh v dp tinh.
a/ Khi dp s b
Qu trnh dp c tin hnh vi cc lng khun sau: Lng khun vut: lng khun lm gim tit din ngang mt phn phi ng thi lm tng chiu di phi (H.3.22a). Lng khun p t: lng khun lm tng tit din ngang ca phi mt s ch nh gim tit din cc ch khc, chiu di phi c gi nguyn (H.3.22b). Lng khun un: lng khun lm thay i hng trc ca mt phn phi so vi phn khc ph hp vi dng ca vt dp (H.3.22c) .
a/
b/
c/
H.4.22. Lng khun dp s b
b/ Khi dp bn tinh
S dng lng khun thnh hnh: lng khun to hnh gn ging vi hnh dng vt dp (H.3.23d), nhng cn, gc ln ln hn khun dp tinh v khng c rnh bavia.
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c/ Khi dp tinh
S dng lng khun tinh: lng khun to hnh chnh xc vt dp c rnh bavia (H.3.23e).
d/
e/
H.4.23. Lng khun dp bn tinh v tinh
4.7. k thut Dp tm
a/ Thc cht
Dp tm l mt phng php gia cng p lc tin tin ch to cc sn phm hoc chi tit bng vt liu tm, thp bn hoc thp di. Dp tm c tin hnh trng thi ngui (tr thp ccbon c S > 10mm) nn cn gi l dp ngui. Vt liu dng trong dp tm: Thp ccbon, thp hp kim mm, ng v hp kim ng, nhm v hp kim nhm, niken, thic, ch vv...v vt liu phi kim nh: giy cctng, bnt, fp, aming, da, vv...
b/ c im
Nng sut lao ng cao do d t ng ho v c kh ho. Chuyn ng ca thit b n gin, cng nhn khng cn trnh cao, m bo chnh xc cao. C th dp c nhng chi tit phc tp v p, c bn cao..v.v...
c/ Cng dng
Dp tm c dng rng ri trong cc ngnh cng nghip c bit ngnh ch to my bay, nng nghip, t, thit b in, dn dng v.v...
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4.7.2.Thit b dp tm
Thit b dp tm thng c hai loi: my p trc khuu v my p thu lc. My dp c th tc dng n (my ch c mt con trt chnh dng t, ct, to hnh) tc dng kp (my c 2 con trt: 1 con trt dng p phi, con trt kia dng dp su) 3 tc dng (ngoi 2 con trt nh my trn cn c b phn y sn phm ra khi khun).
1 2 3 4
1234c cu cam con trt ngoi con trt trong phi kim loi
H.4.24. My p tc dng kp
a/ My p trc khuu
Truyn ng ca trc khuu l truyn ng cng, khong hnh trnh ca my khng ch chnh xc nn sn phm dp tm c cht lng cao v ng u. Khi ng c quay, trc khuu c th c iu khin bng bn p, khi khng lm vic con trt v tr cao nht d tho sn phm v a phi vo. Phn ln cc my p trc khuu u c th iu chnh hnh trnh ca con trt ph hp vi kch thc ca chi tit. Ngoi ra cn c nhiu c cu cp phi v ly sn phm t ng trong sn xut hng lot.
1
4
x x
3 2
x
5 6
8 10 9
12345678-
mt in b truyn ai b ly hp phanh hm trc khuu bin truyn ng b gim chn b thay i hnh trnh v cn bng con trt. 9- con trt cng tc 10- bn my
H.4.25. My p trc khuu K366
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4.7.3. Cng ngh dp tm

Cng ngh dp tm c c trng bi 2 nhm nguyn cng chnh: nguyn cng ct v nguyn cng to hnh. a/ nhm Nguyn cng ct Ct phi l nguyn cng tch mt phn ca phi khi phn kim loi chung. Nguyn cng ny c 3 loi: ct t, ct phi, t l.
a/ Ct t
L nguyn cng ct phi thnh tng ming theo ng ct h, dng ct thnh tng di c chiu rng cn thit, ct thnh ming nh t nhng phi thp tm ln. C cc loi my ct t sau: My ct li dao song song: Gc trc =230 Ct c cc tm rng B 3200 mm, chiu dy S n 60 mm. + + + + Ch ct c ng thng, chiu rng tm ct phi nh hn chiu B S di dao. ng ct thng, p, hnh trnh dao nh; Lc ct tng i ln: P = 1,3.B.S. c (N). B - chiu rng ct ca phi (mm); S - chiu dy phi ct (mm). c - Gii hn bn ct ca phi c = (0,60,8)b (N/mm2). My ct dao nghing: Li dao di nm ngang, li dao trn nghing mt gc = 260. + + + + 0 Gc ct = 7585 ; gc sau = 230. n gin khi mi dao S cho php = 900; gc sau = 0. Z h gia 2 dao Z = 0,05 0,2mm Lc ct khng ln, ct c cc tm dy; Ct c cc ng cong; ng ct khng thng v nhn. Hnh trnh ca dao ln. P = 1,3
0,5. S 2 . c tg
(N)
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My ct chn ng: My c 2 li dao nghing to thnh mt gc = 24300; gc trc = 670, khi ct li ct trn ln xung rt nhanh (20003000 ln/pht) v vi hnh trnh ngn 23 mm. Ct c tm c S 10 mm. My ct dao a mt cp dao:
D S h B B D S
D h B Z
a/ Dao a c tm trc song song
b/ My ct dao di nghing
c/ Hai dao nghing
My ct nhiu dao a. B Li ct l 2 a trn quay ngc chiu nhau; my c th c hai hoc nhiu cp a D ct. Gc ct 900; Z = (0,1 0,2)S ng knh dao a: D =(40 125)S (mm). Chiu dy dao: B = 15 30 (mm) Z Vn tc ct: v = 1 5 m/s Vt liu lm dao: 5XBC My ny dng ct cc ng thng v ng cong chiu di tu . Cc tm ct mng < 10 mm.
b/ Dp ct v t l
y l nguyn cng ct m ng ct l mt chu vi kn. V nguyn l dp ct v t l ging nhau ch khc nhau v cng dng. t l l qu trnh to nn l rng trn phi, phn vt liu tch khi phi gi l ph liu, phn cn li l phi i qua nguyn cng to hnh. i vi dp ct th phn ct ri l phi phn cn li l ph liu . Mt s thng s k thut cn lu : Chy v ci phi c cnh sc to thnh li ct, gia chy v ci c khong h Z = (5% 10%)S. Khi t mun c kch thc l t cho th kch Cc loi u chy thc ca chy chn bng kch thc ca l, cn
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kch thc ca ci ln hn 2Z. Chy vt lm pha trong to thnh rnh ct. Khi ct phi c kch thc cho th kch thc ca z ci bng kch thc ca phi cn ca chy nh thua 2Z. Lc ct hoc t P - Khi ng ct trn: P = 1,25.d.s.cp (N). - Khi ng ct bt k: P = 1,25L.s.cp (N). s - chiu dy phi (mm); d - ng knh phi hoc l t (mm). L - chu vi ng ct (mm); cp- gii hn bn ct (N/mm2). b/ nhm Nguyn cng to hnh L nguyn cng dch chuyn mt phn ca phi i vi phn khc m phi khng b ph hu.
a/ Nguyn cng un:

L nguyn cng lm thay i hng ca trc phi. Trong qu trnh un cong lp kim loi pha trn b nn, lp kim loi pha ngoi b ko, lp kim loi gia khng b ko nn gi l lp trung ho. Khi bn knh un cong cng b th mc nn v ko cng ln c th lm cho vt un cong b nt n. Lc ny lp trung ho c xu hng dch v pha un cong. V tr v kch thc lp trung ho c Lp trung ho Chy xc nh bi bn knh lp trung ho: S
=
r + . . S . S 2
r
r - bn knh un trong; S - chiu dy phi (mm); - bn knh lp trung ho; r - bn knh un trong.
x.S Ci
b/ Nguyn cng dp vut

Dp vut l nguyn cng ch to cc chi tit rng c hnh dng bt k t phi phng v c tin hnh trn cc khun dp vut. Khi dp vut c th lm mng thnh hoc khng lm mng thnh.
Dp vut khng lm mng thnh

Hnh dng tm phi: Nu chi tit l hnh hp y ch nht th phi c dng hnh bu dc hay elp, cn nu chi tit l hnh hp y vung hoc hnh tr y trn th phi l ming ct trn.
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Kch thc phi: Nu S < 0,5 mm th din tch phi bng din tch mt trong hoc din tch mt ngoi ca chi tit, cn nu S > 0,5mm th ly bng din tch lp trung ho ca chi tit (k c y). Trong thc t din tch phi (k c lng d ct mp) c tnh: D = 113 F = 113 f (mm) , , Trong : F - din tch b mt ca chi tit, mm2. f - tng din tch cc phn t ring ca b mt chi tit, mm2. Xc nh s ln dp vut: Khi dp vut tu theo tnh do ca vt liu mi ln dp cho php dp thnh chi tit c ng knh nht nh. H s dp cho php c tnh nh sau: m=
d ct D ph
Trng hp mun ch to mt chi tit dp gin c chiu su ln, ng knh nh th phi dp mt s ln, mi ln dp ch gim ng knh y theo h s cho php m = 0,550,95. H s dp gin ln th nht m1 < m2,m3,m4...,mn. v cc ln dp sau vt sinh ra hin tng bin cng v iu kin bin dng kh hn. S ln dp n ca phi c dng knh D thnh chi tit c ng knh dn:
m1 =
m2 =
d1 D
d1 = m1.D
d2 d1 d mn = n d n1
d2 = m2.d1 = m1.m2.D dn = m1.m2.m3...mn.D

dct d3 d2 d1
n gin tnh ton ta ly gi tr trung bnh:

mtb = n 1 m2 . m3 ... mn
Ta c th vit: dn = m1.mtb(n-1).D Ly lg c hai v ta s c :

n = 1+ lg d n lg(m1 . D) lg mtb
Qu trnh dp vut: Nhng chi tit c phi l tm dy th tin hnh trn khun khng cn vnh p, nhng nu phi l tm mng s xy ra hin tng nhn xp thnh sn phm nn dng thm vnh p.
1 4 3 2 d1 D
1 - chy p; 2 - khun p 3 - phi k.loi; 4 - vnh p
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Dp vut lm mng thnh

c thc hin khi h gia chy v khun nh hn chiu dy phi. ng knh gim t, chiu su tng nhiu v gim chiu dy thnh phi. rt ngn s ln dp gin, mt s ln dp u khng lm mng thnh, sau mi P dp gin lm mng thnh. c im: Khng cn vnh p chng nhn. S Khng cn thit b dn hng. S Ch cn dp trn my tc dng n . r Khi dp nhiu ln phi qua trung gian. S S gim chiu dy cho php trong gii hn:
0 ch 0
S0 S 100% = (40 60)% S0
z =( 0,3-0,8)S
c/ Un vnh
L phng php ch to cc chi tit c g, ng knh D chiu cao H, y chi tit rng. Phi un vnh phi t l vi d trc, sau dng chy v khun to vnh.
d
Bn knh ln ca chy v khun R = (510)S. H R Khe h gia chy v ci Z = (810)S. D D L b dng chy u hnh cu hoc hnh chp. khng xy ra nt mp vng l t th phi c h s un vnh hp l: Ku = d/D = 0,620,78
1
d/ Tp ming
L nguyn cng lm cho ming ca phi rng (thng l hnh tr) thu nh li. Phn tp nh li c th l hnh cn, cn v tr, na hnh cu v.v... Khun di lm nhim v nh v chi tit, khun trn c l hnh cn ng knh gim dn, phn cui ca khun trn l hnh tr. trnh xy ra hin tng xp ming tp th:
d K = 0 = 1,2 1,3 d
d0
Khi cn tp n chi tit c ng knh nh hn gii hn cho php th phi qua mt s ln tp.
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e/ Mit
Mit l phng php ch to cc chi tit trn xoay mng. c bit mit c dng ch to nhng chi tit c ng knh ming thu nh vo v thn phnh ra nh bi ng, l hoa...k tip sau nguyn cng dp vut. Cng ngh mit c ng dng Khun Phi i vi cc chi tit bng thp mm hay kim loi mu. Mit khng bin mng thnh i vi thp chiu dy khng qu Ta 1,5mm, i vi kim loi mu khng qu 2mm, cn mit mng thnh th ng dng vi vt liu c chiu dy ln hn Cn p (20mm). S vng quay ca trc chnh ph thuc vo vt liu: thp mm 400 - 600 v/ph; nhm 800 - 1200 v/ph; uara 500 - 900 S mit v/ph; ng 600 - 800 v/ph. Mit chi tit hnh cn th t s mit ly:
d min = 0,2 0,3 (dmin- ng knh nh D d nht ca hnh cn); mit nhng chi tit hnh tr: = 0,6 0,8 . D
Vi nhng chi tit khng th mit mt ln th phi mit bng mt s nguyn cng ni tip nhau trn cc li khc nhau nhng ng knh ch nh nht phi bng nhau.
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chng 5
k thut hn
5.1. Khi nim chung
a/ Thc cht
Hn l phng php ni hai hay nhiu chi tit kim loi li vi nhau m khng th tho ri bng cch nung nng kim loi vng tip xc n trng thi nng chy, sau ngui t do v ng c hoc nung n trng thi do, sau tc dng lc p ln.
b/ c im ca phng php hn:

Tit kim kim loi: so vi tn ri v tit kim t 1020%, c t 3050% ... Thi gian chun b v ch to phi ngn, gi thnh phi thp. C th to c cc kt cu nh nhng kh nng chu lc cao. bn v kn ca mi hn ln. C th hn hai kim loi c tnh cht khc nhau. Thit b hn n gin, vn u t khng cao. Trong vt hn tn ti ng sut d ln. Vt hn b bin dng v cong vnh. kh nng chu ti trng ng thp. Hn c s dng rng ri ch to phi trong ngnh ch to my, ch to cc kt cu dng khung, gin, dm trong xy dng, cu ng, cc bnh cha trong cng nghip v.v...
c/ Phn loi cc phng php hn

Cc phng php hn rt a dng, chng c phn loi theo 2 nhm c bn sau: Hn nng chy: kim loi mp hn c nung n trng thi nng chy kt hp vi kim loi b sung t ngoi vo in y khe h gia hai chi tit hn, sau ng c to ra mi hn. Nhm ny gm hn h quang, hn kh, hn in x, hn bng tia in t, hn bng tia laze, hn plasma v.v... Hn p lc: khi hn bng p lc kim loi vng mp hn c nung nng n trng thi do sau hai chi tit c p li vi lc p ln, to ra mi hn. Nhm ny gm hn in tip xc, hn ma st, hn n, hn siu m, hn kh p, hn cao tn, hn khuch tn v.v...
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5.2. Hn h quang bng tay

5.2.1. Thc cht v phn loi hn h quang
a/ Thc cht ca hn h quang
Hn h quang l phng php hn nng chy dng nhit ca ngn la h quang sinh ra gia cc in cc hn. Thc cht ca h quang hn l dng chuyn ng ca cc in t v ion trong mi trng kh gia hai in cc, km theo s pht nhit ln v pht sng mnh.
b/ Phn loi hn h quang bng tay

Phn loi theo dng in hn: hn h quang bng dng in xoay chiu v dng in mt chiu. Hn bng dng in xoay chiu cho ta mi hn c cht lng khng cao, kh gy h quang v kh hn song thit b hn dng xoay chiu n gin v r tin nn trn thc t hin c khong 80% l my hn xoay chiu. Hn bng dng in mt chiu tuy my hn t tin nhng d gy h quang, d hn v cht lng mi hn cao. Phn loi theo in cc: hn h quang bng in cc nng chy v in cc khng nng chy. in cc hn khng nng chy: c ch to t cc vt liu c nhit nng chy cao nh grafit, vonfram. ng knh in cc dq = 15 mm i vi in cc vonfram v dq = 612 mm i vi in cc grafit, chiu di que hn thng l 250 mm, u vt cn. in cc khng nng chy cho h quang hn n nh, b sung kim loi cho mi hn phi s dng thm que hn ph. in cc hn nng chy: c ch to t kim loi hoc hp kim c thnh phn gn vi thnh phn kim loi vt hn. Li que hn c ng knh theo l thuyt dq = 612 mm. Trong thc t thng dng dq=16 mm. Chiu di ca que hn L = 250450 mm; chiu di phn cp l1 = 305 mm; l2< 15mm; l3= 12 mm.
1 l1 2 l2 L
a/ Que hn nng chy 1- li kim loi; 2- thuc bc b/ Que hn khng nng chy
l3
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Lp thuc bc c ch to t hn hp gm nhiu loi vt liu dng dng bt, sau trn u vi cht dnh v bc ngoi li c chiu dy t 12 mm. Tc dng ca lp thuc bc que hn: Tng kh nng ion ha d gy h quang v duy tr h quang chy n nh. Thng thng ngi ta a vo cc hp cht ca kim loi kim. Bo v c mi hn, trnh s oxy ho ho tan kh t mi trng. To x lng v u, che ph kim loi tt gim tc ngui ca mi hn trnh nt. Kh xy trong qu trnh hn. Ngi ta a vo trong thnh phn thuc bc cc loi phe-r hp kim hoc kim loi sch c i lc mnh vi xy c kh nng to oxyt d tch khi kim loi lng. Phn loi theo cch u cc in cc khi hn:
a- u dy trc tip
b- u dy gin tip
c- u dy 3 pha
5.2.3 Ngun in v my hn
a/ Yu cu:
Ngun in hn trong hn h quang tay c th l ngun in xoay chiu hoc mt chiu. Nhn chung ngun in hn v my hn phi m bo cc yu cu chung sau: u (V) in p khng ti U0 phi < 80 v. 2 i vi my hn xoay chiu: A 1 U0= 5580 V, Hh = 3055 V. B i vi my hn mt chiu: U0= 2545 V, Hh = 1635 V. I (A) ng c tnh ng V-A ca my hn phi l ng dc lin tc. 1- ng c tnh tnh ca h quang C kh nng chu qu ti khi ngn 2- ng c tnh ng ca my hn mch I= (1,31,4)Ih. C kh nng iu chnh dng in hn trong phm vi rng. My hn phi c khi lng nh, h s hu ch ln, gi thnh r, d s dng v d sa cha.
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b/ My hn h quang xoay chiu

My hn h quang dng dng in xoay chiu c s dng rng ri trong hn h quang tay v chng c kt cu n gin, gi thnh ch to thp, d vn hnh v sa cha. Tuy nhin cht lng mi hn khng cao v h quang chy khng n nh so vi h quang dng dng in mt chiu.
H.5.1 .My hn xoay My hn c li t di ng l loi my thng dng nht hin nay c trnh by nh hnh v sau: My hn kiu ny c mt li t di ng (A) nm trong gng t (B) ca my A bin p. Khi li t (A) nm B hon ton trong mt phng ca gng t (B) th t thng u1 u2 do cun s cp sinh c mt uh phn r nhnh qua li t lm cho t thng i qua cun th W2 W1 cp gim, do in p trn H.5.2. S my hn xoay chiu c li di ng cun th cp (u2) gim. Khi di ng li t (A) ra ngoi (theo phng vung gc vi mt phng ca gng t B), khe h gia li t v gng t tng, t thng r nhnh gim lm cho t thng qua cun th cp tng v in p trn cun th cp tng. My hn c li t di ng c kt cu gn, iu chnh dng in hn v cp, khong iu chnh rng do hin nay c dng nhiu.
b/ My hn h quang mt chiu
My pht hn h quang: Hnh sau trnh by s nguyn l ca mt my hn mt chiu dng my pht c cun kch t ring v cun kh t mc ni tip.
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My hn gm my pht in mt chiu (M) c cun dy kch t ring (2) c cp in ring t ngun in xoay chiu qua b chnh lu (1). Trn mch ra ca my pht t cun kh t (3). Ngi ta b tr sao cho t thng (c) sinh ra trn cun kh t lun lun ngc hng vi t thng (kt) sinh ra trong cun kch t. ch khng ti, dng in hn Ih = 0 nn t thng c = 0, my pht c kch t bi t thng (kt) do cun dy kch t (2) sinh ra: kt = I kt .
W Rk
kt M n p c K
H.5.3. S my pht hn
Trong Ikt l dng in kch t, W v Rk l s vng dy v t tr ca cun kch t. Khi in p khng ti xc nh theo cng thc:
u kt = C. kt
ch lm vic, dng in hn Ih 0 nn t thng c 0, my pht c kch t bi t thng tng hp () do cun dy kch t (2) v cun kh t = kt c (3) sinh ra: Sc in ng sinh ra trong phn cm ca my ph thuc vo t thng kch t: E = C. = C.( kt c ) . Trong C l h s ph thuc vo my.
1
My hn dng dng in chnh lu: My hn dng dng in chnh lu c hai b phn chnh: Bin p p hn (1) v b chnh lu (2), bin tr (3) dng iu chnh cng dng in hn.
H.5.3. S my hn chnh lu 1 pha
My hn dng dng in chnh lu c h quang chy n nh hn my hn xoay chiu, phm vi iu chnh dng in hn rng, h s cng sut hu ch cao, cng sut khng ti nh, kt cu n gin hn. Nhc im ca my hn chnh lu l cng sut b hn ch, cc i-t d b hng khi ngn mch lu v dng in hn ph thuc ln vo in p ngun.
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5.2.4. Ch hn h quang in
a/ ng knh que hn:
ng knh que hn ph thuc vo vt liu hn, chiu dy vt hn, v tr mi hn trong khng gian, kiu mi hn... chn c th tra theo s tay cng ngh hn hoc xc nh theo cc cng thc kinh nghim i vi cc vt hn mng: Hn gip mi:
S + 1 [mm] 2 K Hn gc, hn ch T: d = + 2 [mm] 2 d=
Trong S - l chiu dy vt hn, K- l cnh ca mi hn gc.
b/ Cng dng in hn (Ih):

Cng dng in hn chn ph thuc vo vt liu hn, ng knh que hn, v tr mi hn trong khng gian, kiu mi hn...c th tra theo s tay cng ngh hoc xc nh theo cc cng thc kinh nghim: i vi hn sp: I h= ( + d q )d q Trong v l cc h s ph thuc vo c tnh kim loi vt liu hn. i vi thp = 6, = 20. Khi chiu dy chi tit S > 3d tng cng dng in khong 15% cn S < 1,5d gim 15% so vi tr s tnh ton.
c/ in p hn: in p hn thng t thay i khi hn h quang tay. d/ S lt cn phi hn:

hon thnh mt mi hn c th tin hnh trong mt ln hn hoc mt s ln hn. Khi tit din mi hn ln, thng tin hnh qua mt s ln hn. S lt hn c th tnh theo cng thc sau: n =
Fd F0 + 1 . Trong Fd l din tch Fn
mt ct ngang ton b mi hn (din tch p), F0 v Fn tng ng l din tch mt ct ngang ca ng hn u tin v cc ln tip theo.
/ Tc hn (Vh):
Tc hn ph thuc vo cng dng in hn v tit din mi hn, c th tnh theo cng thc kinh nghim sau:
Vh = d .Ih 3600 Fd
[cm/s]
d l h s p = 711[g/A.h]; l khi lng ring kim loai que hn [g/cm3] Ih l cng dng in hn [A]; F l tit din p ca mi hn [cm2]
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2.5.5. Thao tc hn:

Khi hn h quang tay, gc nghing que hn so vi mt vt hn thng t 7585 . Trong qu trnh hn, que hn c dch chuyn dc trc duy tr chiu di ct h quang, ng thi chuyn ng ngang mi hn to b rng mi hn v chuyn ng dc ng hn theo tc hn cn thit. Khi hn sp, nu mi hn c b rng b, que hn c dch chuyn dc ng hn, khng c chuyn ng ngang. Khi mi hn c b rng ln, chuyn dch que hn c th thc hin theo nhiu cch: thng thng chuyn ng que hn theo ng dch dc (a), khi cn nung nng phn gia nhiu theo s (b) v khi cn nung nng nhiu c gia v hai bn theo s (c).
o
b c a
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5.3. Hn h quang t ng v bn t ng
5.3.1 Thc cht v c im
a/ Thc cht:
Hn h quang t ng l qu trnh hn trong cc khu ca qu trnh c tin hnh t ng bi my hn, bao gm: gy h quang, chuyn dch in cc hn xung vng hn duy tr h quang chy n nh, dch chuyn im hn dc mi hn, cp thuc hn hoc kh bo v. Khi mt s khu trong qu trnh hn c t ng ha ngi ta gi l hn bn t ng. Thng khi hn bn t ng ngi ta ch t ng ha khu cp in cc hn vo vng hn cn di chuyn in cc thc hin bng tay.
b/ c im:
Nng sut hn cao v cht lng mi hn tt v n nh. Tit kim kim loi nh h s p cao. Ci thin iu kin lao ng. Tit kim nng lng v s dng trit ngun nhit. Thit b t, khng hn c cc kt cu hn v v tr hn phc tp.
c/ Phn loi
Hn h quang t ng v bn t ng c tin hnh vi in cc hn dng dy khng c thuc bc, bi vy trong qu trnh hn thng phi s dng cc bin php bo v mi hn. Theo phng php bo v kim loi mi hn phn ra: hn h, hn di lp thuc, hn trong mi trng kh bo v. Theo mi trng kh bo v c th phn ra: Hn TIG (Tungstene Inert Gas): Hn h quang dng in cc khng nng chy, bo v bng kh tr (Ar, He ...). Hn MIG (Metal Inert Gas): Hn h quang dng in cc nng chy, bo v bng kh tr. Hn MAG (Metal Active Gas): Hn h quang dng in cc nng chy, bo v bng kh hot tnh (CO, CO2, H2 ...)
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5.3.2. Hn h quang t ng
Hn h quang t ng c s dng trong sn xut hng lot cc kt cu hn bng thp v kim loi mu, hn cc mi hn n (ng thng, ng trn... ), v tr mi hn khng phc tp. Hn h quang t ng c th c thc hin trong mi trng kh bo v (kh tr: Ar, He; kh hot tnh: CO, CO2, H2 ...) hoc bo v bng tr dung (thuc hn ri).
H.5.5. My hn h quang t ng di lp tr dung bo v 1. H quang; 2. Dy hn; 3. Tang cun dy hn; 4. u hn; 5. Thng thuc hn; 6. Mng dn thuc hn; 7. ng ht thuc hn tha; 8. C cu ko dy; 9. Thuc hn; 10. Vng hn; 11. V x; 12. Mi hn; 13. Vt hn.
5.3.3. Hn h quang bn t ng
i vi cc ng hn phc tp, v tr hn khng thun li trong sn xut hng lot thng s dng hn h quang bn t ng. Khi hn h quang bn t ng vic dch chuyn dy hn dc ng hn c thc hin bng tay. Hnh bn trnh by s thit b hn bn t ng trong mi trng kh CO2.
H.5.6. My hn h quang trong mi trng kh bo v CO2 (MAG) 1. Dy hn; 2. Kh bo v CO2; 3. Cng tc; 4. Tm hn; 5. Mi hn
Kh CO2 c phun vo vng mi hn, di tc dng nhit ca ngn la h quang kh b phn hu theo phn ng: 2CO2 = 2CO +O2. Kh CO khng ho tan vo thp, hnh thnh mi trng bo v khi hn, trnh s oxy ha ca oxy ngi ta s dng que hn ph c hm lng Mn v Si cao.
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5.4. Hn v ct kim loi bng kh

a/ Thc cht, c im
Hn v ct bng kh l phng php s dng nhit ca ngn la sinh ra khi t chy kh chy trong dng xy nung kim loi. Thng dng nht l hn v ct bng kh xy - axtylen. Hn v ct bng kh c c im: Hn c nhiu loi kim loi v hp kim (gang, ng nhm ... ) Hn c cc chi tit mng. Thit b gn, nh, n gin Vn u t thp, khng cn ngun in. Nng sut thp. Vt hn b nung nng nhiu dn n c tnh gim. Hn kh c s dng nhiu khi hn cc chi tit mng bng thp, cc chi tit bng gang, ng, nhm v mt s kim loi mu khc, ct to phi t tm, ct t thanh thi v.v...
b/ Kh hn
xy k thut xy dng hn kh l xy k thut cha t 98,599,5 % xy v khong 0,51,5 % tp cht (N2, Ar). Trong cng nghip, sn xut xy dng phng php in phn nc hoc lm lnh v chng ct phn on khng kh . xy hn ch yu dng phng php lm lnh khng kh. Nh chng ta bit, trong thnh phn khng kh cha khong 78,03 % N2, 0,93 % Ar v 20,93 % O2, nhit ho lng ca chng tng ng l -195,8 oC, -185,7 oC v -182,06oC. Bng phng php lm lnh khng kh xung nhit di -182,06 oC nhng trn nhit ha lng ca N2 v Ar, sau cho N2 v Ar bay hi ta thu c xy lng. xy k thut c th bo qun th lng hoc kh. th lng, xy c cha bng cc bnh thp v gi nhit thp, khi hn cho xy lng bay hi, c 1 lt xy th lng bay hi cho 860 lt th kh iu kin tiu chun. Axtylen Axtylen l hp cht ca ccbon v hyr c cng thc ha hc l C2H2, khi lng ring iu kin tiu chun 1,09 kg/m3, nhit tr 11.470 Cal/m3. Axtylen c sn xut t t n CaC2. Khi cho t dn tc dng vi nc ta thu c Axtylen theo phn ng: CaC2 + 2H2O C2H2 + Ca(OH)2 + 30.400 Cal/mol Kh Axtylen c cc tnh cht sau: Nhit t bc chy khong 420oC ( p sut 1 at).
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D pht n khi p sut > 1,5 at v nhit trn 500oC nhit v p sut thp d trng hp to thnh cc hp cht khc nh benzel (C6H6), (C8H8) ... C kh nng ha tan trong nhiu cht lng vi ho tan ln, c bit l trong axtn: 23 lt C2H2/ lt. Cc tp cht cha trong kh axtylen l PH3 lm tng kh nng gy n v H2S l tp cht c hi, lm gim cht lng mi hn. Ngoi kh axtylen khi hn v ct ngi ta cn dng cc kh khc nh hyr, mtal, hn hp prpan - butan.
5.4.2. Thit b hn v ct bng kh

Cc thit b chnh ca mt trm hn hoc ct bng kh gm c cc loi sau:
H.5.6. S thit b ca mt trm hn kh a/ Trm hn kh vi bnh cha xy v bnh cha axtylen b/ Trm hn kh vi bnh cha xy vi bnh iu ch axtylen 1. Bnh xy; 2. Bnh cha axtylen (hoc iu ch axtylen); 3. Van gim p; 4. Van an ton; 5. M hn; 6. Van kho; 7. ng h; 8. Xe y.
Bnh cha kh dng cha kh oxy v kh axtylen, c ch to t thp tm dy 7 mm bng phng php dp hoc hn. Bnh c ng knh ngoi 219 mm, cao 1390 mm, dung tch 40 lt, trng lng 67 kg. Bnh cha oxy chu c p sut kh np 150 at v c sn mu xanh hoc xanh da tri. Bnh cha axtylen chu c p sut kh np ti 19 at, c sn mu vng hoc mu trng. Trong bnh cha bt xp (thng l than hot tnh) v tm axtn, lng dng khong 290 - 320 gram than hot tnh v 225 - 230 gram a xtn cho mt lt th tch bnh cha.
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Bnh iu ch axtylen: Bnh iu ch dng iu ch kh axtylen t t n. Trong thc t, ngi ta dng nhiu loi bnh iu ch kh khc nhau. Theo nguyn tc tc dng gia t t n v nc ta c cc loi ri vo nc, nc ri vo v tip xc vi nc. S nguyn l ca mt s bnh iu ch kh in hnh:
2 3 4 6 6
C2H2 C2H
1 5
1 1
C2H2
2 b) Kiu nc ri c) Kiu tip xc nc
6 a) Kiu ri vo
H.5.7. S nguyn l bnh iu ch kh A xtylen

1.Nc 2. t n () 3).Nn cp t n 4. Phu cp nc 5. Van iu chnh lng nc 6. ng dn kh ra
Van gim p: l dng c dng gim p sut kh trong bnh cha xung p sut lm vic cn thit v t ng duy tr p sut mc n nh. i vi kh oxy p sut kh trong bnh ti 150 at, p sut kh lm vic khong 34 at, cn kh axtylen p sut trong bnh ti 1516 at, p sut lm vic 0,11,5 at. Trn hnh sau trnh by s nguyn l ca mt s van gim p:
1 2 3 4 5
p1 p2
10 6 9 8 7
p1 p2
H.5.8. S nguyn l van gim p

1. ng dn kh cao p 2. L xo ph 3. Van 4. Van an ton 5. ng dn kh ra 6. Bung thp p 7. L xo chnh 8. Vt iu chnh 9. Mng n hi 10. thanh truyn
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Nguyn l lm vic: kh c dn vo van theo ng (1) v qua ng (5) i ti m hn hoc m ct. p lc kh trong bung h p (6) ph thuc vo m ca van (3). Khi l xo chnh (7) cha b nn, van (3) chu tc dng ca l xo ph (2) v p lc ca kh, ng kn ca van khng cho kh vo bung h p (6). Khi vn vt iu chnh (8), lm cho l xo chnh (7) b nn, van (3) c nng ln, ca van m v kh i sang bung h p. Tu thuc vo nn ca l xo chnh (7), nn ca l xo ph (2), chnh p trc v sau van, ca van (3) c m nhiu hay t, ta nhn c p sut cn thit trong bung h p. Nh c mng n hi (9), van c th t ng iu chnh p sut ra ca kh. Nu do mt nguyn nhn no , p sut kh ra (p2) tng, p lc tc dng ln mt trn ca mng n hi (9) tng, y mng n hi dch xung v thng qua con i van (3) b ko xung, lm ca van ng bt li, lng kh i vo bung h p gim, lm p sut kh ra gim. Ngc li, nu p2 gim, ca van (3) m ln hn, lng kh vo bung h p tng, lm p2 tng tr li. Dy dn kh: dng dn kh t bnh cha kh, bnh ch kh n m hn hoc m ct. Yu cu chung i vi ng dn kh: Chu c p sut ti 10 at i vi dy dn oxy, 3 at vi dy dn axtylen. mm cn thit nhng khng b gp. Dy dn c ch to bng vi lt cao su, c ba loi kch thc sau: ng knh trong 5,5 mm, ng knh ngoi khng quy nh. ng knh trong 9,5 mm, ng knh ngoi 17,5 mm. ng knh trong 13 mm, ng knh ngoi 22 mm. M hn v m ct: l dng c dng pha trn kh chy v xy, to thnh hn hp chy c t l thnh phn thch hp nhn c ngn la hn hoc ct theo yu cu. M hn c 2 loi l m hn kiu ht v m hn ng p.
H.5.9. S nguyn l cu to ca m hn kh 1. u m hn; 2. ng dn hn hp kh chy; 3. Bung ht; 4. Van iu chnh xy; 5. Van iu chnh C2H2
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M hn kiu t ht s dng khi hn vi p sut kh C2H2 thp v trung bnh. Kh C2H2 (p sut 0,011,2 at) c dn vo qua ng v qua van ng m (5), cn kh xy (p sut 14 at) c dn vo qua ng v qua van iu chnh (4). Khi dng xy phun ra u ming phun (3) vi tc ln to nn vng p sut thp ht kh C2H2 vo theo. Hn hp tip tc c ho trn trong bung ht (3), sau theo ng dn (2) ra ming m hn (1) v c t chy to thnh ngn la hn. Nhc im ca m hn t ht l thnh phn hn hp chy khng n nh. Ngoi ra cn c m hn ng p dng khi hn vi p lc kh C2H2 trung bnh. Kh xy v C2H2 c phun vo bung trn vi p sut bng nhau (0,51 at) v tip tc c ha trn trong ng dn ca m hn, i ra ming m hn t chy to thnh ngn la.
5.4.3. Cc loi ngn la hn

Khi hn kh xy-axtylen, tu thuc t l thnh phn ca hn hp chy c th nhn c ba dng ngn la hn khc nhau: a/ Ngn la bnh thng: Ngn la bnh thng nhn c khi t l
O2 = 1,11,2. C2 H 2
Quan st ngn la ta c th nhn thy ba vng r rt: vng nhn ngn la (I), vng gia (II) v vng ui (III). Vng nhn ngn la: trong vng ny ch yu xy ra phn ng phn hy C2H2: C2H2 2C + H2 Ngn la c mu sng trng, nhit thp v thnh phn kh giu cc bon. Vng chy khng hon ton: trong vng ny xy ra phn ng chy khng hon H.5.10. Ngn la hn kh a/ Cu to ngn la hn; b/ Ngn la bnh thng; ton ca ccbon : c/ Ngn la xy ho; Ngn la ccbon ho C2H2 + O2 2CO + H2 + Q Ngn la vng ny c mu sng xanh, nhit ngn la t cao nht, kh cha nhiu CO v H2 l nhng cht hon nguyn khng tham gia vo cc phn ng xy ho v cacbon ho nn cht lng mi hn tt. Khi hn nn cho vng hn nm trn trong vng ny. Vng ny cn gi l vng hon nguyn.
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Vng chy hon ton: trong vng ny xy ra phn ng chy hon ton: CO + H2 + O2kk CO2 + H2O + Q Ngn la vng ny c mu vng sm, cha nhiu CO2 v H2O v nhit thp hn vng gia. Vng ny khng hn c v c nhiu cht xy ho.
b/ Ngn la xy ha: nhn c khi t l O2/C2H2 > 1,2.

Nhn ca ngn la ngn li, vng gia d O2 v cha c CO2 nn c tnh xy ha v khng phn bit r vi vng ui. Ngn la xy ha ch dng khi hn ng thau, ct v ty b mt.
c/ Ngn la cc bon ha: nhn c khi t l O2/C2H2 < 1,1.

Nhn ca ngn la ko di nhp vi vng gia thnh mu nu sm, thnh phn kh d ccbon nn c tnh ccbon ha. Ngn la cc bon ha c dng khi hn gang, thp gi v thp hp kim.
5.4.4. Cng ngh hn kh

a/ Cc phng php hn kh
Tu thuc vt liu hn, chiu dy vt hn, c th s dng hai phng php hn khc nhau: hn phi v hn tri.
b/
H.5.11. S cc phng php hn kh

a. Hn phi; b. Hn tri
Khi hn phi (a), trong qu trnh hn ngn la hn hng v pha mi hn, m hn lun i trc que hn. c im ca hn phi l nhit ch yu tp trung vo vng hn, vng hon nguyn hng vo mp hn, mi hn ngui chm v c bo v tt, lng tiu hao kh gim. Phng php ny c ng dng khi hn cc tm dy hoc kim loi vt hn dn nhit nhanh. Khi hn tri (b), trong qu trnh hn ngn la hn hng v pha cha hn, que hn i trc m hn. Trong trng hp hn tri, mp hn c nung
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nng s b nn kim loi vng hn c trn u hn, ng thi quan st mi hn d, mt ngoi mi hn p. Phng php ny c dng khi hn cc tm mng hoc kim loi vt hn d chy. b/ Ch hn kh Khi hn kh, da vo tnh cht ca vt liu, kch thc, kt cu vt hn, v tr mi hn v kiu mi hn chn ch hn hp l, bao gm chn gc nghing m hn, cng sut ngn la v ng knh que hn ph. Gc nghing m hn so vi mt phng hn c chn t l thun vi chiu dy vt hn, vi nhit chy v h s dn nhit ca vt liu vt hn. 80 - 90o 0o V d hn ng = 6080o, hn ch 10o. Bt u hn gc nghing ln, kt thc gim. Cng sut ngn la: cng sut ngn la tnh bng lng kh tiu hao trong mt gi, c chn t l thun vi chiu dy vt hn, vi nhit chy v h s dn nhit ca vt liu vt hn. Khi hn thp ccbon thp, ng thau, ng thanh chn P = (100120).S [lt/h] i vi hn tri v P = (120150).S [lt/h] i vi hn phi, trong S l chiu dy vt hn [mm]. ng knh que hn: ph thuc vt liu hn v phng php hn. Khi hn thp cc bon chn theo cng thc kinh nghim sau: Hn tri: d =
S + 1 [mm]; Hn phi: 2 d= S [mm] 2
5.4.5. Ct kim loi bng kh

a/ Thc cht v iu kin ct c bng kh
Thc cht ca qu trnh ct kim loi bng kh l t chy kim loi ct bng dng xy, to thnh cc xt v thi chng ra khi mp ct to thnh rnh ct. S qu trnh ct kim loi bng kh c trnh by trn hnh sau: O2 Khi bt u ct, kim loi mp ct c nung nng n nhit chy nh nhit ca ngn la C2H2+O2 nung, sau cho dng xy thi qua, kim loi b xy ha mnh lit (b t chy) to thnh xt. Sn phm chy b nung chy v b dng xy thi khi mp ct. Tip theo, do phn ng chy ca kim loi to nhit mnh, lp kim loi tip theo b nung nng nhanh v tip tc b t chy to thnh rnh ct.
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ct bng kh, kim loi ct phi tho mn mt s yu cu nht nh: Nhit chy ca kim loi phi thp hn nhit nng chy. Nhit nng chy ca xt kim loi phi thp hn nhit nng chy ca kim loi. xt kim loi phi c chy long tt, d tch khi mp ct. dn nhit ca kim loi khng qu cao, trnh s tn nhit nhanh lm cho mp ct b nung nng km lm gin on qu trnh ct.
Tm li: Thp cc bon thp c < 0,7% C rt thun li khi ct bng kh v chng c nhit chy thp hn nhit chy. Thp cc bon cao do nhit chy xp x nhit chy nn kh ct hn, khi ct thng phi nung nng trc ti 300 - 600oC. Thp hp kim crm hoc crm-ni ken c xt crm Cr2O3 nhit chy ti 2.000oC nn rt kh ct. Nhm, ng v hp kim ca chng do dn nhit nhanh nn cng khng th ct bng kh, tr khi dng thuc ct. Gang khng th ct bng kh v khi chy to ra xt silic SiO2 c st cao.
b/ M ct
ct bng kh ch yu s dng cc m ct dng nhin liu kh. S cu to chung ca chng c trnh by trn hnh sau:
6 5 4 2
H.5.12. S m ct kh
1. ng dn kh axtylen 2. ng dn kh xy 3. van axtylen 4. van xy 5. van kh xy 6. ng dn kh xy. 7. ng dn hn hp kh C2H2- O2
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5.5. Hn in tip xc
5.5.1. Thc cht, c im
Hn in tip xc l mt phng php hn p lc, s dng nhit do bin i in nng thnh nhit nng bng cch cho dng in c cng ln i qua mt tip xc ca hai chi tit hn nung nng kim loi. Khi hn, hai mp hn c p 3 st vo nhau nh c cu p, sau cho P dng in chy qua mt tip xc, theo nh lut Jun-Lenx nhit lng sinh 1 ra trong mch in hn xc nh theo 2 2 cng thc: Q = 0,24. R. I . t . Nhit ny 4 nung nng hai mt tip xc t n trng thi do, sau cho lc tc dng 5 lm cho hai mt tip xc ca hai vt H.5.13. S hn in tip xc gip mi hn tip cn nhau, xut hin mi lin 1,2/ Vt hn ; 3/ C cu kp phi; 4/ Bn my; kt kim loi v s khuych tn ca cc 5/ My bin p nguyn t hnh thnh nn mi hn. Hn tip xc c nhng c im sau: Thi gian hn ngn, nng sut cao do d c kh ha v t ng ha. Mi hn bn v p. Thit b t, vn u t ln. i hi phi c my hn cng sut ln.
5.5.2. Cc phng php hn in tip xc

a/ Hn tip xc gip mi
Hn tip xc gip mi l phng php hn m mi hn c thc hin trn ton b b mt tip xc ca hai chi tit hn. Khi hn gip mi in tr, sau khi hai chi tit hn c p st vo nhau vi lc p s b t 1015 N/mm2, tin hnh ng in nung kim loi mp hn n trng thi do, ct in v p kt thc vi lc p t 3040 N/mm2 to thnh mi hn.
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b/ Hn im:
Hn im l phng php hn tip xc m mi hn c thc hin theo tng im trn b mt tip xc ca hai chi tit hn.
a/
b/ H.5.14. Cc phng php hn in tip xc a/ Hn tip xc gip mi; b/Hn im; c/ Hn ng
c/
Khi hn im hai pha, cc tm hn c t gia hai in cc hn. Sau khi p s b v ng in, dng in trong mch ch yu tp trung mt din tch nh trn mt tip xc gia hai tm nm gia cc in cc, nung nng kim loi n trng thi nng chy. Tip theo ct in v p vi lc p ln, to nn im hn. Khi hn im mt pha, hai in cc b tr cng mt pha so vi vt hn (b). S nung nng cc im hn do dng in chy qua tm di ca vt hn. tng cng dng in chy qua cc im hn, ngi ta b tr thm tm m bng ng. Sau khi im hn c nung chy, tin hnh p vi lc p ln ta nhn c hai im hn cng mt lc. c/ Hn ng Hn ng l phng php hn tip xc m mi hn l nhng im hn ni tip nhau lin tc. V thc cht, c th coi hn ng l mt dng ca hn im, trong qu trnh hn do vt hn dch chuyn lin tc gia hai in cc to thnh cc im hn ni tip nhau. Khi hn ng ngi ta s dng cc in cc kiu con ln, nh vt hn c th d dng chuyn ng dch chuyn im hn. Theo ch hn ngi ta phn ra ba kiu hn ng: hn ng lin tc, hn ng gin on v hn bc. Khi hn ng lin tc, trong qu trnh vt hn chuyn ng, in cc thng xuyn p vo vt hn v ng in lin tc. Phng php ny n gin v cng ngh nhng vt hn b nung nng lin tc, d b cong vnh, vng nh hng nhit ln v in cc b nung nng mnh, chng mn, nht l khi ng hn di.
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Khi hn ng gin on, vt hn chuyn ng lin tc, nhng dng in ch c cp theo chu k, thi gian cp t 0,010,1 giy, to thnh cc on hn cch qung. Khi hn bc, vt hn dch chuyn gin on, ti cc im dng vt hn c p bi cc in cc v cp in to thnh im hn.
5.6. Cc phng php hn c bit

5.6.1. Hn ma st
Hn ma st l phng php hn p lc. Nhit sinh ra do ma st gia 2 mt tip xc sinh nhit lng nung nng mi hn n trng thi de v dng lc p to mi hn. Hn ma st c nng sut cao, gi thnh h, c dng hn ni cc thanh, thi kim loi, cc dng c ct ...
1 P 2 3 4 P
H.5.15.S hn ma st 1. Gi kp; 2,3. Chi tit hn; 4. Mi hn
5.6.2. Hn siu m
Hn siu m l phng php hn p lc, di tc dng ng thi ln vt hn cc dao ng c hc vi tn s siu m vi lc nn thch hp mi hn t n trng thi do v to thnh mi hn. Dng cao tn t my pht siu m truyn vo bin t 1 to ra tn s siu m H.5.16.S hn siu m (dao ng siu m) truyn qua b truyn 1.Bin t; 2.B truyn dao ng; 2, n dng c 3 vo vt hn 4 lm cho 3.Dng c; 4.Tm hn; 5.n by mi hn t n trng thi do. Ti trng P qua n by v dng c 5 to lc nn lm cho cc phn t hn thm thu vo nhau to thnh mi hn. Hn siu m dng hn cc vt nh, mng (< 0,1 mm), nhng kt cu phc tp khng cn lm sch ch hn, thi gian hn ngn, cc phng php khc kh thc hin c.
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5.6.3. Hn plasma h quang

Trng thi plasma ca vt cht c ngun nng lng rt ln, trong vt cht t trng thi kh chuyn qua trng thi plasma to ra nhit hng chc nghn C nung nng chy mi hn. nhn c trng thi ion ca kh, ngi ta s dng ng phng h quang 1 H.5.17.S hn plasma h quang chy gia in cc 2 (vnfram) v ming 1.ng phng h quang; 2.in cc W; 3.Ming phun; 4.ng dn; 5.Dng tia plasma phun t trong ng hnh tr. p lc ca kh tr c tc dng ko di h quang lm xut hin dng tia hp c mc ion ho rt mnh v to ra nhit cao. Nhit ca ngn la plasma h quang c th dng hn hoc ct kim loi vi nhng chiu dy khc nhau.
5.6.4. Hn x in
Hn x in l phng php hn nng chy nh nng lng nhit ca vng x hn chy lng c in tr rt ln. Khi dng in i qua vng x lng, nhit lng to ra theo nh lut Jun-Lenx rt ln lm cho kim loi vt hn v in cc hn nng chy. in cc trong hn x in c nhim v gy h quang lm nng chy x hn v b sung kim loi cho mi hn. Hn x in l phng php ti u hn vt hn c chiu dy ln, hn p, hn phc hi cc chi tit my mn. Vng x lng 4 c in tr ln cung cp nhit lng nung nng chy mp hn ca cc vt hn 1 v cc hn 3. Khi ng c to thnh mi hn 8. Cc tm chn 2 km cc ng dn nc lm ngui v ng c kim loi lng vng hn to thnh mi hn 8. Gi in cc c ng dn in cc, c nhim v a in cc 3 H.5.18.S hn x in vo vng hn 5 v to ra h quang 6. 1.Tm hn; 2.Tm chn; 3.Dy hn; 4.X lng; Kim loi lng; 6.H quang; Trong qu trnh hn thuc hn c phu 7.Phu thuc; 8.Mi hn 7 cung cp vo bo v mi hn. Ngoi ra cn nhiu phng php hn c bit khc nh hn bng chm tia in t, hn cm ng, hn bng lade v.v...cng c ng dng trong cng nghip tin tin.
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chng 6
gia cng ct gt kim loi

Gia cng kim loi bng ct gt l mt qu trnh cng ngh rt quan trng trong ngnh c kh. l phng php dng nhng dng c ct gt trn cc my ct gt ht mt lp kim loi (lng d gia cng c) khi phi liu c c vt phm vi hnh dng v kch thc cn thit.
6.1. nguyn l ct gt kim loi

6.1.1. Nhng khi nim c bn v qu trnh ct
a/ Thc cht, c im
Gia cng ct gt kim loi l qu trnh ct i mt lp kim loi (gi l lng d gia cng) trn b mt ca phi c chi tit c hnh dng, kch thc, chnh xc, bng theo yu cu k thut trn bn v. Qu trnh c thc hin trn cc my cng c hay my ct kim loi (cn gi l my ci), bng cc loi dao tin, dao phay, dao bo, mi khoan, mi v.v...gi chung l dao ct kim loi. Gia cng ct gt c th dng gia cng th, gia cng tinh, gia cng ln cui t c bng, chnh xc cao. Gia cng ct gt kim loi d t ng ho, c kh ho cho nng sut cao dng trong sn xut n chic, hng lot v hng khi.
b/ Chuyn ng c bn khi ct gt
Trong qu trnh gia cng c kh, phi v dng c ct gt di chuyn tng i vi nhau nh nhng c cu my. C hai dng chuyn ng: Chuyn ng c bn l chuyn ng sinh ra vic ct gt v chuyn ng ph. Chuyn ng c bn c th chia ra: Chuyn ng chnh (chuyn ng ct): c tc ln hn tt c cc chuyn ng khc. Chuyn ng chnh ch yu thc hin qu trnh ct to ra phoi, k hiu l V hoc n. Chuyn ng bc tin (chuyn ng chy dao): c tc nh hn chuyn ng chnh. y l chuyn ng thc hin qu trnh ct tip tc v ct ht chiu di chi tit. Vic ct gt c tin hnh thng qua hai chuyn ng ny thng qua cc phng php ct gt thng dng nhiu l tin, phay, bo, mi, khoan:
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- Khi tin th phi c chuyn ng chnh V l chuyn ng quay trn, cn dao th c chuyn ng chy dao gi l bc tin S (chuyn ng thng dc trc phi). - Khi phay th ngc li, dao phay thc hin chuyn ng chnh V (chuyn ng quay trn) cn phi th thc hin chuyn ng vi bc tin S (chuyn ng thng).
H.6.1. S qu trnh ct gt kim loi v cc chuyn ng c bn (V. Chuyn ng chnh; S. Chuyn ng chy dao) a/ Tin; b/ Khoan; c/ Bo; d/ Phay; e/ Mi
- Khi khoan thng thng th mi khoan va c c chuyn ng chnh V (chuyn ng quay trn) va c c chuyn ng chy dao vi bc tin S. - Khi bo trn my bo ngang th dao bo c chuyn ng chnh V (chuyn ng thng ti - lui), cn phi c chuyn ng chy vi bc tin S (chuyn ng thng). Khi bo trn my bo ging, phi s c chuyn ng chnh V (chuyn ng thng ti - lui), cn dao bo th th c chuyn ng chy dao vi bc tin S (chuyn ng thng).
6.1.2. Cc thng s c bn ca ch ct
Nhng thng s c bn ca ch ct gt: vn tc ct, lng chy dao, chiu su ct.
a/ Tc ct V:
Tc ct l khong dch chuyn ca mt im trn li ct hoc mt im trn b mt chi tit gia cng sau mt n v thi gian. i vi my c phi hoc dng c ct quay trn (tin):
V =
. D. n
1000
(m/pht)
D - ng knh ca phi, (mm); n - s vng quay ca phi hoc ca dng c ct trong mt pht. i vi my c phi hoc dng c ct chuyn ng thng (bo):
V = L (m/pht) 1000. t
L - chiu di hnh trnh (mm); t - thi gian ca hnh trnh (pht).
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b/ Lng chy dao S:

l khong dch chuyn ca dao theo hng chuyn ng ph sau mt vng quay ca chi tit gia cng (mm/vng). Lng chy dao khi phay l s dch chuyn ca phi khi dao phay quay mt vng (So) hoc khi dao phay quay mt rng (Sz), hoc l s di chuyn ca phi trong mt pht (Sm). Ta c: So= Sz.Z (Z - s rng ca dao phay). Sm= So.n = So.Z.n (n - s vng quay ca dao trong mt pht). Lng chy dao khi khoan l khong dch chuyn ca mi khoan dc trc sau mt vng quay ca mi khoan.
c/ Chiu su ct t:
l khong cch gia b mt cn c gia cng v mt gia cng sau mt ln dao ct chy qua. bc tin S phi - Khi tin ngoi, chiu su ct o theo ng vung gc vi trc phi v c tnh d D theo cng thc:
t= Dd (mm) . 2
D - ng knh ca mt cn gia cng (mm). d - ng knh ca mt gia cng (mm).
chiu su ct t H.6.2.Cc yu t ct gt khi tin ngoi
- Chiu su ct khi phay o trong mt phng vung gc vi trc dao phay v bng chiu dy ca lp kim loi b ht i sau mt ln chy dao. - Chiu su ct khi khoan bng na ng knh ca mi khoan:
t= D (mm). D - ng knh mi khoan. 2
6.1.3. Dng c ct gt
a/ Cu to ca dng c ct:
Dao ct (dao tin, dao bo, dao phay...) l loi dng c ct dng rt rng ri gia cng kim loi. Dao gm u dao I v thn dao II. Thn dao dng kp trong gi dao.
mt thot I II li ct ph mt sau ph mi li ct chnh H.6.3.Cc b phn chnh ca dao tin mt sau chnh
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b/ Vt liu ch to dao ct gt:

ct gt c hiu qu, vt liu lm dng c ct gt phi t cc yu cu sau: cng phn li ct phi cao hn nhiu so vi vt liu phi. ct thp ccbon v thp hp kim thp, cng ca dao phi t 6265 HRC. Chu mi mn tt, c bn m bo v do cn thit chng li lc va p v lc un v.v... bn nhit cao m bo cng khi gia cng vi tc cao. Cc loi vt liu dng ch to dao ct: Thp ccbon dng c: sau khi nhit luyn t cng 6063 HRC song chu nhit thp. Nng n 2003000C thp mt cng. Ngy nay ch dng thp ny ch to dng c ct nh ca, da, c v.v...Cc mc thp thng dng: CD80, CD80A, CD100 ... Thp hp kim dng c: c tnh c hc cng tng t nh thp ccbon dng c nhng chng c tnh nhit luyn tt, su nhit luyn cao hn t bin dng v chu mi mn tt ... C th dng thp c mc 90CrSi, 100CrW ch to tar, bn ren. c bit ph bin nht l dng thp cao tc (thp gi) ch to cc loi dao ct nh dao tin, mi khoan v li ct ca dao phay...v tuy cng khng cao hn hai loi trn nhng bn nhit cao hn (n 6500C). Hin nay thng dng cc loi thp gi c k hiu 80W18Cr4VMo, 90W9Cr4V2Mo, 90W9Co10Cr4V2Mo v.v... Hp kim cng: l loi vt liu c tnh ct gt rt cao. chu nhit ln n 10000C, cng ca vt liu: 7092 HRC. Mc d rt t, nhng ngi ta vn dng rt nhiu v l loi vt liu khng phi nhit luyn, c th ct vi tc cao, nng sut cao. Loi WCCo8, WCCo10 dng ct gang, hp kim nhm c...Loi WCTiC5Co10, WCTiC15Co6...thch hp khi ct vt liu do. Ngoi ra ngi ta cn dng vt liu gm, kim cng ch to dao ct gt.
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6.2. My ct kim loi

My cng c l loi thit b dng gia cng ct gt kim loi rt thng dng trong cc nh my v phn xng c kh ch to cc my khc, cc kh c, dng c v.v...dng trong sn xut v i sng. Ngy nay cng vi s pht trin ca tin hc v in t, my cng c v cng ngh gia cng c hon thin mc rt cao. Cc my cng c lm vic hon ton t ng v lm vic theo chng trnh nh trc. iu ni ln rng nng sut v cht lng ca cc sn phm c kh ngy mt tng cao.
6.2.1. phn loi v k hiu

a/ Phn loi my cng c
- Theo khi lng chia ra loi nh di 1 tn, loi trung bnh di 10 tn v loi hng nng t 10 tn tr ln. C loi n 1600 tn. - Theo chnh xc ca my: chnh xc thng, cao v rt cao. - Theo mc gia cng ca my: My vn nng: c cng dng chung gia cng nhiu loi chi tit c hnh dng, kch thc khc nhau. Thng dng trong sn xut n chic, hng lot nh. My chuyn mn ho dng gia cng mt loi hay mt vi loi chi tit c hnh dng gn ging nhau nh dng trc, bc, vng bi v. v... Thng dng trong sn xut hng lot nh my gia cng bnh rng, vng bi, tin ren, v.v... My chuyn dng gia cng mt loi chi tit c hnh dng, kch thc nht nh. Loi ny dng trong sn xut hng lot ln v hng khi. - Phn loi theo cng dng v chc nng lm vic: my tin, my bo, khoan, phay, mi v.v...
b/ K hiu my
d dng phn bit cc nhm my khc nhau, ngi ta t k hiu cho cc my. Cc nc c k hiu khc nhau. Cc my sn xut Vit nam c k hiu nh sau: Ch u tin ch nhm my: T - tin; KD - khoan doa; M - mi; TH - t hp; P - phay; BX - bo xc; C - ct t ... Ch s tip theo biu th kiu my, c trng cho mt trong nhng kch thc quan trng ca chi tit hay dng c gia cng. Cc ch ci sau cng ch r chc nng, mc t ng ho, chnh xc v ci tin my.
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V d: T620A: T - tin; s 6 - kiu vn nng; s 20 - chiu cao tm my l 200 mm tng ng vi ng knh ln nht gia cng trn my l 400 mm, ch A l ci tin t my T620. Theo TCVN, my cng c c 5 cp chnh xc theo cc ch ci E, D, C, B, A. Trong E l cp chnh xc thng; B l cp chnh xc c bit cao; A l cp siu chnh xc .
6.2.2. Truyn dn v truyn ng trong my ct gt kim loi a/ Cc hnh thc truyn dn

- Truyn dn tp trung: L truyn dn m ng c in truyn vo trc trung tm chy dc theo phn xng truyn chuyn ng n tng my bng b truyn ai. Hnh thc ny n gin nhng hiu sut thp, cng knh khng an ton, mun sa cha mt my, phi ngng ton b phn xng. - Truyn dn nhm: Mt ng c truyn dn cho mt nhm my. - Truyn dn c lp: Mt my c truyn dn t mt hoc nhiu ng c. Mi ng c lm mt nhim v ring, do mt h thng iu khin ring nh ng c chnh, ng c chy dao thng ng, ng c chy dao nhanh, ng c thu lc, ng c bi trn, ng c lm mt. Hin nay loi ny c s dng nhiu, c bit l cc my t ng, bn t ng c hng chc ng c trn mt my.
b/ Cc hnh thc truyn ng

Truyn ng ai: gm 2 bnh ai (puli) ch ng v b ng. ai thang hay ai dt truyn chuyn ng quay trn gia 2 puli vi t s truyn:
i= D1 n (1 ) = n2 D2 1
- h s trt ly bng (0,010,02). n1; n2 - vn tc vng ca cc bnh ai. D1; D2 - ng knh ngoi ca puli 1, 2.
n1 D1
n2 D2
Truyn ng bnh rng: gm cc bnh rng tr hoc cn n khp vi nhau truyn chuyn ng quay gia cc trc song song hoc vung gc vi nhau nh cc cc bnh rng c s rng Z . Z1; n1 T s truyn: i =
Z 1 n2 = Z 2 n1
M X M X
Z1; n1
X
Z1; Z2 - s rng ca cc bnh rng. n1; n2 - s vng quay ca cc bnh rng.
Z2; n2
Z2; n2
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Truyn ng trc vt-bnh vt: l dng truyn chuyn ng quay gia 2 trc khng song song. Bnh vt c s rng Zbv n khp vi trc vt c s u mi K (K = 1, 2, 3). T s truyn ca loi truyn ng ny rt nh v tnh theo cng thc: i = K/Zbv dng thay i mc ln gi tr vng quay n gia 2 trc quay.
K Zbv
b/ H.6.4. Truyn ng trc vt-bnh vt a/ 1- Vt v tn; 2- Bnh rng vt v tn
Truyn ng xch
Z n T s truyn: i = 1 = 2 Z 2 n1
M
n1; Z1
Z1; Z2 - s rng ca cc bnh xch. n1; n2 - s vng quay ca cc bnh xch.
n2; Z2
Truyn ng trc vt me - ai c: y l mt dng truyn chuyn ng bin chuyn ng quay trn thnh chuyn ng tnh tin. Khi trc vt quay trn ti ch, ai c tnh tin ; khi ai c c nh, trc vt quay trn v tnh tin. Sau n vng quay ca trc vt vi bc vt tx ai c tnh tin c mt on S = tx.n:
H.6.5. Truyn ng trc vt me - ai c
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Truyn ng thanh rng - bnh rng: y cng l dng bin chuyn ng quay thnh tnh tin v ngc li. S n khp gia thanh rng c bc t = .m v bnh rng c s rng Z c tnh theo cng thc: S = t.Z.n = .m.Z.n (mm). m - s mun ca rng; n, Z - s vng quay v s rng ca bnh rng.
6.2.3. Cc loi c cu truyn ng trong my ct kim loi

a/ Truyn ng v cp:
y l truyn ng cho ta tc bt k gia 2 tc gii hn nmin v nmax. Trong my ct kim loi c mt s c cu truyn dn v cp sau: Bnh ai cn - ai dt (a):
D n i = 1 (1 ) = 2 D2 n1
n1 I D1 I n1 cn gt I n2 a D1 D2
D1, D2 - ng knh puli tng ng vi v tr dy ai Cp bnh ai cn - ai dt (b):

D n i = 1 (1 ) = 2 D2 n1
n2 II
D2
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D1, D2 - ng knh puli tng ng vi v tr dy ai. Bnh cn ma st v con ln (c):

i= D1 n (1 ) = n2 D2 1
n1 I D1 D2 n2 II
D1, D2 - ng knh bnh cn ti v tr con ln.
b/ Truyn ng phn cp:

L truyn ng cho ta tc nht nh gia 2 tc gii hn nmin v nmax. C cc c cu thay i tc nh sau: Thay i tc bng bng khi bnh rng di trt: 1 2 Dng thay i tc gia cc Z1 Z2 trc. Tu theo s lng bnh rng di trt n1 I nhiu hay t, trc b ng s nhn c cc gi tr vng quay khc nhau. Ti cc x x n2 II v tr n khp ca cc cp bnh rng s Z3 Z4 a/ cho ta mt t s truyn i tng ng. C cu thay i tc bng ly hp vu (b). 1 2 Trong c cu ny cc bnh rng Z1, Z2 Z1 Z2 khng di trt m chng ch truyn n1 I chuyn ng quay cho trc b ng II khi c khp vo ly hp M. Khi gt ly hp II x x n2 M sang tri hoc sang phi ta s c cc t Z3 Z4 s truyn: i1 = Z1/Z3 v i2 = Z2/Z4. H6.7. Thay i tc bng ly hp vu C cu Nooctng: Trn trc ch ng c mt khi bnh rng hnh thp c s rng t Z1Z6 nhn cng mt s vng quay n1. truyn sang trc b ng II cn Z6 Z1 Z2 Z3 Z4 Z5 c bnh rng trung gian Za lun lun n n1 khp vi bnh di trt Zb lp trn trc II. X X X X X X I Ti v tr nht nh s c i tng ng:
i= Zi Z a Zi * = Z a Zb Zb
A B C D E
X
H.6.6. Thay i tc bng bnh rng di trt
Za Zb
n2
Thng cc gi tr s rng ca mi bnh rng chnh lch khng nhiu nn vng quay nII cng chnh lch rt t. C cu ny thch hp thc hin thay i lng chy dao S my tin.
II
H.6.8. C cu Nooctong
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C cu o chiu Trong my ct kim loi thng s dng 2 loi c cu o chiu c kh: o chiu bng ly hp (a) v o chiu bng bnh rng di trt (b). Theo nguyn tc nu s trc chn th trc b ng quay ngc chiu vi trc ch ng. Nu s trc l s l, trc b ng v trc ch ng quay cng chiu.
b/ I Z1
X
Z2
X
nI
b/ I
Z1
X
Z2
X
nI
II III Z3 a/
Za nIII Z4 b/ III
II
Za nIII
Z3
Z4
H.6.9. C cu o chiu a/ o chiu bng ly hp vu; b/ o chiu bng bnh rng di trt
c/ Truyn ng gin on
Trong my ct kim loi thng s dng c cu Cult truyn chuyn ng ti - lui cho chuyn ng chnh dao ct (my bo ngang). Bnh rng 1, 2 v a 3 quay lm con trt 8 s trt ti-lui trong rnh trt ca tay quay 10 lm cho tay quay 10 lc xung quanh tm 0. Nh vy bn trt 4 c g dao 5 nhn c chuyn ng qua-li trn chi tit 6 c g trn bn g.
4 2 1 3 8 9 0 10 7 5 6
H.6.10. C cu Cult trong my bo ngang
d/ Xch truyn ng
Xch tc : gii thiu mt b truyn nhiu cp tc cho trc chnh. Phng trnh xch ng c tnh: nc.i1.i2.i3.i4...in = nc
z1 X X X z2 nc X c z5 z6 z3 z4 z k nc
H.6.11. Xch tc
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6.2.4. My tin
a/ Cng dng
My tin l loi my gia cng ct gt ph bin nht trong cc nh my c kh (4050%) bi v n c th gia cng c nhiu b mt: Mt trn xoay ngoi v trong. Cc mt tr, cn, hay nh hnh. Cc loi ren (tam gic, thang, vung...). Mt phng mt u hay ct t. Ngoi ra trn my tin c th dng khoan l, doa l, mi, thm ch gia cng cc mt khng trn xoay nh cc g...
b/ Phn loi my tin

Cn c vo khi lng ca my: Loi nh 500 kg. Loi trung bnh 4.000 kg Loi nng 50 tn. Loi siu nng 400 tn. Cn c vo cng dng ca my: My tin ren vt vn nng dng gia cng cc loi ren v cc cng vic khc ca my tin. My tin nhiu dao (Revonre): cng mt lc c nhiu li dao cng ct mt lc trong cng mt thi gian. My tin t ng v bn t ng: l loi m cc thao tc v nguyn cng c thc hin t ng hon ton hay mt phn. My tin chuyn dng: ch gia cng mt s b mt nht nh, loi hnh hn ch. My tin ng hay tin ct: c mm cp ln quay nm ngang hay thng ng gia cng cc chi tit c ng knh ln n 20 m.
c/ Cc b phn chnh ca my tin:
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trc (1): l mt hp kn c cha b phn quan trng l trc chnh v hp tc . Pha di hp trc chnh l hp xe dao (3) v hp ng c (9). ng (4): c th di chuyn trn bng my, c cha mi chng tm g phi khi tin, cng c th lp mi khoan, khot khi khoan hoc khot l. Hp bn xe dao (5): l b phn dch chuyn c theo hng dc hoc ngang to ra lng chy dao (bc tin) S. Pha trn bn xe dao c b g kp dao (7). Thn my (6): l b phn g t tt c cc b phn trn. Ngoi ra cn cha thm b phn lm ngui, thp sng, cha phoi v cc bng hay c cu iu khin.
d/ Mt s phng php gia cng trn my tin

Tin trn: L tin ngoi v trong mt chi tit c hnh tr trn dng trc trn hay trc bc. Cc bc c tin hnh: chun b dao; g vt gia cng ln my; tin th (ph); tin tinh.
a. Tin trc trn ngoi
b. Tin trc bc
c. Tin trc trn trong
Tin cn: c 3 phng php tin cn nh hnh v sau: Khi dng dao rng bn (a) ch tin on cn c chiu di ngn vi gc nghing bt k. Dao rng bn chu lc ln v ch c bc tin ngang S chy tay hay t ng. Xoay nghing bn dao trn mt gc (b): ch thch ng vi nhng chi tit c chiu di cn ngn. Gc nghing c tnh theo cng thc:
tg = Dd 2l
y D, d - ng knh u ln v u nh ca on cn. l - chiu di ca on cn.

l n S.n
a. Dng dao bn rng
b. Xoay nghing bn dao trn
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nh lch ng (c): li dng r ca ng, nh lch mt on h

L Dd h= mm. l 2
l Tm mi d D L c/ nh lch ng h Tm c
y h - phn lch tm. l - chiu di phn cn. L - chiu di tnh t 2 mi tm.
Tin ren: Tu theo dng ren v yu cu, ngi ta s dng 3 cch tin dao khc nhau. Phng php (a) ch dng ct ren nh, hai li cng ct s chu lc ln, nhng c hai mp u nhn. Phng php (b) v (c) khi n dao nghing theo mt mp, th ch c mt li tham gia ct, s gim lc nhng mp bn phi km nhn bng. Phng php ny c dng khi ct th c kch thc ln. Ch : cc loi ren vung hay hnh thang, giai on u cng thng ct tam gic, sau dng dao nh hnh sa ng .
s a. b.
s c.
Cc loi ren thng dng:
a. Ren tam gic
b. Ren hnh vung
c. Ren hnh thang
Gia cng b mt lch tm: c 2 phng php gia cng cc b mt lch tm: Phng php dng mi chng tm: Trn mt u phi khoan 2 2 l tm trng vi ng trc ca 1 mt lch tm v ng trc ca I ngng trc. Khi g l tm I-I ta II gia cng mt lch tm 2, khi g l tm II-II gia cng ngng trc 1.
I II
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Phng php gia cng trn mm cp: ngi ta to mt lch tm bng cch m mt ming kim loi c chiu dy A nht nh di mt vu ca mm cp. Chiu dy A c xc nh theo cng thc:
e A = 1,5e 1 2d
A O2 d O1 e
d - ng knh ca b mt c kp cht e - khong lch tm . Tin cc b mt c bit bng dao nh hnh: Ngi ta s dng cc loi dao nh hnh c li dao c mi theo ng cong ging nh hnh dng mt ngoi ca chi tit gia cng.
s Dao nh hnh
/ Cc dng c ch yu ca my tin
Mm cp: l b phn kp cht v t nh v phi khi gia cng. C cc loi mm cp chnh sau:
H.6.12.Cc loi mm cp
a/ Mm cp 3 chu; b/ Mm cp 4 chu; c/ Mm cp hoa
Mm cp 3 chu t nh tm: Khi dng cl quay vt quay 1, ba chu 2 cng dch chuyn vo tm mt lng bng nhau. Loi ny dng cp cc chi tit trn xoay. Mm cp 4 chu c lp: Mi chu c mt vt iu chnh ring. Loi ny dng thch hp vi cc phi khng trn xoay hoc gia cng b mt lch tm.
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Ngoi ra cn c mm cp tc v mm cp hoa mai dng g cc chi tit c hnh dng phc tp v chi tit c bt vo mm cp qua cc bulon - ai c. Mi chng tm: Dng tm cc phi c 4 < L/D < 10 khi tin. C cc loi sau: Loi thng (a): loi ny c gc = 600, trong trng hp g nhng vt nng th = 900. Mi chng tm khuyt (b): c dng trong trng hp ct mt u ca phi m khng vng dao. Mi chng tm cu (c): dng trong trng hp ng trc ca chi tit gia H.6.13. Mi tm cng khng trng tm a/ Mi tm thng; b/ Mi tm khuyt; c/ Mi trc vi ng trc ca tm cu; d/ Mi tm kha; e/ Mi tm quay mi tm. Mi tm quay (e) l dng mi tm lp vo bi dng khi tc quay ln. Mi tm kha (d): dng chng tm v cc chi tit rng. Gi (Luynet): Dng g cc chi tit nh v di H/D > 10 nhm tng cng vng cho phi gia cng nhm hn ch sai s hnh dng do lc ct gy nn. C hai loi gi : Gi c nh (a): c nh v ti mt v tr trn bng my. Cc vu ca gi c th ra vo nh cc trc vt. Gi di ng (b): loi ny di chuyn cng vi dao trong qu trnh gia cng, n c bt cht trn bn dao. Gi ng ch c 2 vu trc tip vi lc ct, H.6.14. Gi c nh (a) v gi di ng m bo trc khi b cong. Ngoi ra trong my tin ngi ta cn dng mt s dng c khc nh Tc dng truyn chuyn ng quay t mm cp n vt gia cng khi vt c g trn trc chnh hai mi chng tm. Trc tm g nhng chi tit c l sn c gia cng tinh.
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6.2.5. My khoan-doa
a/ Cng dng v phn loi
My khoan-doa dng gia cng l hnh tr bng cc dng c ct nh: mi khoan, mi khot v dao doa. My khoan to ra l th t chnh xc, bng b mt gia cng thp Rz160 Rz40. nng cao chnh xc v bng b mt l phi dng khot hay doa trn my doa. Sau khi doa, chnh xc t cp 4 hoc 5 v bng c th t Ra = 1,25 0,32. My khoan-doa c chuyn ng chnh l chuyn ng quay trn ca trc mang dao, chuyn ng chy dao l chuyn ng tnh tin ca dao. Trn my khoan c th dng dng c tar, bn ren gia cng ren. My khoan c cc loi sau: My khan in cm tay Cho php khoan cc l trn nhng chi tit m khng cho php cc loi my khoan c trc chnh c nh thc hin. My khoan bn: l loi my n gin, nh, t trn bn ngui. L khoan ln nht d 10 mm. My thng c 3 cp vng quay vi s vng quay ln.
H.6.15. a/ My khoan tay; b/ my khoan bn
My khoan ng: l loi dng gia cng cc loi l n c ng knh trung bnh d 50 mm. My c trc chnh mang mi khoan c nh. Phi phi dch chuyn sao cho trng tm mi khoan. My khoan cn: gia cng cc l c ng knh ln trn cc phi c khi lng ln khng dch chuyn H.6.15.c/ My khoan ng; d/ My khoan cn thun li c. Do to ca mi khoan c th dch chuyn quay hay hng knh khoan cc l c to khc nhau. Trong thc t cn c my khoan nhiu trc, my khoan su.
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b/ Dng c ct trn my khoan-doa

Mi khoan: Trong ct gt kim loi c cc loi mi khoan rut g, mi khoan su, mi khoan tm... Cu to phn ct ca mi khoan c 2 li ct chnh v 2 li ct ph. Ngoi ra cn c phn li ct ngang. Phn c dao ghi ng knh mi khoan. Chui hnh tr dng cho mi khoan nh (< 10 mm). Chui cn dng cho loi c ng knh ln hn. S ct khi khoan theo hnh bn. Khi khoan tc ct tnh theo cng thc:
v=
dn
1000
m/pht
H.6.16. Mi khoan
a/ Tit din lp phoi; b/ Mi khoan tm; c/ Mi khoan rut g
d - ng knh mi khoan (mm). n - s vng quay ca mi khoan (v/pht). Chiu su ct t khi khoan trn phi cha c l l:
t= d (mm). 2
Lng chy dao ca khoan sau mi vng quay l Sz = 2S (mm/vng). Mi khot v doa: Dng c kht v doa dng m rng l khoan, tng bng, chnh xc b mt l trn xoay. Khc vi mi khoan, mi khot v dao doa c s li ct nhiu hn.
H.6.17. Mi khot, doa

d/ Mi khot; e/ Mi doa;
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Tar v bn ren: Ta r l dng c gia cng ren trong c th lp trn trc khoan hoc thao tc bng tay. ng vi mt kch thc, mt b tar c t 23 chic ct t th n tinh. Bn ren dng gia cng ren ngoi vi kch thc khng qu ln.
H.6.15. g/ Ta r; h/ Bn ren
6.2.6. my bo, xc
a/ c im, phn loi v cng dng
My bo, xc l nhm my c chuyn ng tnh tin kh hi, dng gia cng cc mt phng ngang, ng hay nm nghing; gia cng cc rnh thng vi tit din khc nhau: mang c, ch T, dng rng thn khai...My cng c kh nng gia cng chp hnh to ra cc mt cong mt chiu. Chuyn ng chnh ca my l chuyn ng tnh tin kh hi: gm mt hnh trnh c ti v mt hnh trnh chy khng. Chuyn ng chy dao thng l chuyn ng gin on. Gia cng trn my bo, xc c nng sut thp, chnh xc thp v nhn km.
b/ Cc loi My bo, xc
Tu theo nhng c trng v cng ngh, my bo c chia thnh: my bo ngang, my bo ging, my xc (bo ng) v cc my chuyn mn ho. My bo ngang: dng gia cng nhng phi khng ln (< 600 mm). Bn my cng vi phi di chuyn theo chiu ngang trn mt bng ca thn my, cn u trt ca my cng vi bn dao v dao bo chuyn ng ti-lui trn mt bng c dng ui n. Hp tc v c cu Cult dng di chuyn bn trt.
H.6.18. My bo ngang
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113
My bo ging: dng gia cng cc phi ln nh thn my. Bn my cng vi phi di chuyn theo chiu dc (chuyn ng chnh) cn dao bo kp trn gi dao th di chuyn theo chiu ngang. Trn my bo ging c th gia cng nhng phi di ti 12 m trn 3 mt cng m lc. My xc: My xc l mt loi my bo ng c u my chuyn ng theo chiu thng ng. My xc dng gia cng trong cc l, rnh, mt phng v mt nh hnh ca phi c chiu cao khng ln v chiu ngang ln.
H.6.19. My xc
c/ Dao bo v K thut bo
Tu theo v tr ca li ct m dao bo c phn thnh dao bo phi v dao bo tri; tu theo v tr ca u dao so vi thn dao chia thnh dao bo ngoi, dao bo mt mt, dao bo ct, dao bo nh hnh, dao bo thng, dao bo cong. Dao bo c ch to bng thp hp kim dng c (thp gi) H.6.20. Dao bo v nguyn cng bo, xc hoc hp kim cng. Nhng nguyn cng thng c thc hin trn my bo l gia cng cc mt phng ngang, mt phng thng ng, mt phng nghing, mt c bc, mt nh hnh; gia cng cc loi rnh thng thng, rnh ch T, rnh ui n v.v...
nng - 2002
114
6.2.7. my phay
a/ c im, cng dng
My phay l loi my c nhiu chng loi v c t l ln trong cc nh my c kh. Phay trn my phay l phng php khng ch t nng sut cao m cn t c nhn b mt tng i (Ra2,5 Rz40), chnh xc xp x vi khi gia cng trn my tin (cp 6 cp 11). My phay dng ph bin gia cng mt phng, mt nghing, cc loi rnh cong v phng, rnh then, l, mt ren, mt rng, cc dng b mt nh hnh (cam, khun dp, mu, dng, chn vt tu thu, cnh qut, cnh tucbin...), ct t v.v... Trong sn xut hng lot v hng khi, phay c th thay th cho bo v phn ln cho xc. Trong sn xut n chic v hng lot nh phay c nhiu cng dng, c th thay th cho bo - xc, do dao phay c nhiu li cng ct, tc phay cao v c nhiu bin php cng ngh, nn nng sut ca phng php phay cao hn hn bo - xc v gi thnh sn phm thp.
b/ phn loi my phay

My phay vn nng: l loi c trc chnh thng ng hoc nm ngang c th gia cng c nhiu dng b mt khc nhau. My phay chuyn dng: ch gia cng mt s loi b mt nht nh gm my phay bnh rng, my phay ren, my phay thng... My phay ging: dng gia cng ng thi nhiu b mt ca cc chi tit ln. Ngoi ra cn cc loi my phay chp hnh, my t hp, my phay iu khin theo chng trnh s...
H.6.21. My phay nm vn nng 1. Trc chnh; 2. Bn dao dc; 3. Bn dao ngang; 4. Bn my; 5. ; 6. Thn my; 7. Hp tc ; 8. Hp chy dao; 9. Dao phay; 10. B cha dung dch trn ngui.
H.6.22.My phay ng
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c/ Dao phay
Trong my phay, chuyn ng chnh l chuyn ng quay trn ca dao phay nn cu to ca dao thng ph hp vi s quay trn ca trc dao nm ngang hay thng ng. Tu theo dng b mt gia cng c cc loi dao sau: Loi dao gia cng mt phng gm dao phay tr, dao phay mt u. Loi dao gia cng rnh gm dao a, dao phay 3 mt ct, dao phay ngn... Loi dao gia cng bnh rng nh dao phay mun, dao phay ln rng ...
H.6.23. Dao phay v s mt s nguyn cng phay
d/ S ct khi phay
Khi dao phay quay trn theo tc ca trc chnh c tnh theo cng thc: v =
dn
1000
m/pht
d - ng knh ca dao phay (mm). n - s vng quay ca trc chnh (v/ph). Lng chy dao S: V dao phay c Z li ct nn sau mt vng hoc mt pht cc li u tham gia ct mt lng bng nhau, do ngi ta chia ra: Lng chy dao rng Sz (mm/rng). Lng chy dao vng Sv (mm/vng). H.6.24.S ct khi phay Lng chy dao pht S (mm/pht). 1. Dao phay; 2. chi tit gia cng Trong : z - s rng ca dao phay, n - s vng quay ca dao trong mt pht.
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Chiu su phay t (mm): chiu su lp kim loi b ct trong mt hnh trnh phay. Chiu rng phay B (mm): l chiu rng gia cng sau mt hnh trnh phay o theo phng song song vi trc dao. Chiu dy ct a (mm): l khong cch gia hai v tr k tip nhau ca qu o chuyn ng ca mt im trn li ct o theo phng vung gc vi li ct chnh. Chiu dy ct thay i t amin n amax (hoc amax n amin).
e/ Cc phng php gia cng phay

Theo chiu quay ca dao v hng tnh tin ca phi ta chia ra 2 phng php phay: Phay thun (a): l phng php m chiu quay ca dao trng vi hng tnh tin ca phi ti im tip xc M. Khi phay thun, chiu dy tit din ct thay i t amax n amin ( 0). Li dao khng b trt v gy lc p, p cht phi ln bn my. Nhng s va p ca phi v li dao ln d gy gy rng dao. Nn phay thun ch phay tinh. H.6.25.Phay thun Phay nghch: ti M vect vn tc v hng chy dao ngc nhau. Nh vy tit din ct t gi tr amin n amax. Do li dao ct t di ln c xu hng nng phi nn gy ra rung ng; dao thng b trt khi dao cn, nhng li trnh c lp bin cng mt ngoi. Phay nghch thch hp khi phay th.
H.6.26.Phay nghch
f/ u phn trn my phay

y l mt loi g quan trng dng trn my phay. Nhim v ca n l chia u hay khng u cc vt gia cng trn phi. u phn t trn bn my phay nm ngang (hoc ng) dng khi cn phay cc loi rnh thng, xon trn phi bng dao phay mun, dao phay ngn...
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117
C 2 cch phn : phn gin on v phn lin tc. Khi chia u ngi ta dng phn gin on n gin (chia chn) hoc phn vi sai (chia khng chn). Trn hnh (H.6.27b) bao gm trc chnh (1) kp phi; cp bnh vt - trc vt (2) c mt trong cc t s truyn sau:
i= K 1 1 1 1 = ; ; ; Z bv 40 60 90 120
Cc cp bnh rng tr hay cn thng c i = 1. a phn (3), trn c hai mt u c cc vng l c s l xc nh sn (v d: 24, 25, 28, 30, 34, 37, 38, 39, 41, 42, 43. Mt kia l 46, 47, 49, 51, 53, 54, 57, 58, 59, 62, 66). Tay quay (4) dch chuyn c theo hng knh tng ng vi cc vng l khc nhau. Khi quay tay quay (4), trc (5) mang cp bnh rng H.6.27. u phn tr i = 1 quay theo v truyn chuyn a/ S chung; b/ S nguyn l u phn ng quay n trc vt - bnh vt v lm trc chnh (1) mang phi quay. Mi u phn c c trng bng nghch o t s truyn ca trc vt - bnh vt c k hiu N (N = 40, 60, 90, 120). Khi phn n gin, s vng quay n ca tay quay (4) bng:
n= N (z - s rnh cn gia cng). z
Nh vy nu z l s rnh chia u, th sau khi gia cng xong 1/z (mt rnh), phi phi quay vng n v tr phay tip theo. Trng hp tng qut ta c:
n= N a a. m = A+ = A+ (vng) Z b b. m
Trong : A - s vng quay nguyn (y ), a/b - s phn s khng chia ht, m - s nguyn chn sao cho m.b c gi tr ng bng l trn mt vng no a (3). V d: Cn gia cng bnh rng c Z = 27 vi c trng ca phn N = 40. Ta c:
n= N 40 13 2 26 = = 1+ = 1+ Z 27 27 2 54
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Vy sau khi gia cng xong mt rnh ta s quay tay quay (4) mt vng trn, sau ta quay thm mt gc c cha 26 l trn vng l 54. Tip tc nh vy ta s gia cng xong 27 rng c chia u khng c sai s. l trng hp phn n gin. Khi khng th phn n gin v khng th chn m thch hp ta dng phn vi sai. Lc ny phi s dng b bnh rng a, b, c, d ni t trc chnh n tay quay b tr sao cho lng sai s l ti thiu.
6.2.8. my mi
a/ Khi nim
Mi l phng php gia cng m dng c ct l mi. Mi c th gia cng th ct b lp th cng mt ngoi cc loi phi, nhng a s trng hp l gia cng tinh cc b mt (mt tr, mt phng, rnh, l, mt nh hnh, ren, rng, then, then hoa...). Mi dng gia cng cc vt liu cng nh thp ti, gang trng ...cng c th gia cng th ct phi, ct bavia, mi th ... Chuyn ng chnh khi mi l chuyn ng quay trn ca mi:
v=
. D. n
601000 .
(m/s)
Trong D - ng knh ca mi, n - s vng quay trc chnh mang (v/ph) Chuyn ng chy dao khi mi c th l chy dao vng, chy dao dc, chy dao ngang, chy dao thng ng, hoc chy dao hng knh. Khc vi cc phng php ct gt khc, mi c c trng ring mi ht mi nh mt li dao ct, lc ct v tc ct ln (n 50 m/s), nhit vng gia cng rt cao (hng ngn ), hin tng trt d xy ra, b mt gia cng b bin cng. Mi l phng php gia cng nng cao chnh xc (cp 12) v bng (Ra = 0,320,16). Khi nghin hoc mi bng phng php c bit c th t c bng, chnh xc cao hn.
b/ mi
Vt liu ht mi l thnh phn ch yu ca , chng gm cc loi kim cng nhn to, cc xyt nh xyt nhm thng, xyt nhm trng, ccbit silic, ccbit boric... Ht mi c ch to vi kch thc ht khc nhau ch to cc loi khc nhau. Cht dnh kt lin kt cc vt liu ht mi thng dng cht dnh kt v c nh keramit, hu c nh baklit hoc cao su. Trong thc t thng s dng cc loi loi mi c hnh dng nh sau:
nng - 2002
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H.6.28. Hnh dng mi
c/ Cc chuyn ng c bn ca my mi
Tt c cc loi my mi u c chuyn ng chnh l chuyn ng quay trn ca mi v (m/s), cn chuyn ng chy dao c th c hai, ba loi khc nhau: Chuyn ng chy dao vng Sv (a) - l chuyn ng quay trn ca chi tit vc (m/ph). Trng hp chi tit ln khng quay c (d) th chuyn ng chy dao vng l chuyn ng quay hnh tinh ca . Chuyn ng chy dao dc Sd (b) - l chuyn ng thng kh hi ca bn my mang chi tit S (m/ph). Chuyn ng chy dao ngang Sn(hay chy dao hng knh Sk theo chu k ca bn my Sn (mm/hnh trnh kp). H.6.29.Cc chuyn ng c bn khi mi
nng - 2002
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d/ Cc loi my mi v phng php mi

- My mi trn trong: dng gia cng tinh cc loi l - My mi trn ngoi dng mi b mt ngoi ca chi tit (a). - My mi phng dng gia cng mt phng bng mt ngoi tr hoc mt u bt, cc, chu. - My mi nh hnh dng mi cc b mt nh hnh nh mi mt ren, mt rng, mi mt cn, then, then hoa... - My mi chnh xc v siu chnh xc km theo cc ph tng, g, dng c o nh my nghin, my nh bng, my mi doa, my mi siu chnh xc, my mi thu lc... - My mi trn khng tm dng mi mt tr ngoi v trong cc chi tit n gin, khng c bc vi nng sut cao. My c th gia cng lin tc, khng phi dng H.6.30 My mi trn trong my g kp.
nng - 2002
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chng 7
x l v bo v b mt kim loi
7.1. Khi nim chung
S ph hu kim loi, cc my mc thit b bng kim loi c th do nhiu nguyn nhn khc nhau nhng ch yu l do tc dng ho hc, tc dng in ho v tc dng c hc. S ph hu kim loi do ho hc hay in ho gi l s n mn kim loi hay s g. S ph hu kim loi do c hc gi l s mi mn kim loi.
7.1.1. Cc dng n mn kim loi (g)

G c nhiu dng khc nhau: Theo c cu bn trong c 2 loi: g ho hc v g in ho. Theo dng bn ngoi: g hon ton b mt, g b phn, g im. Theo mi trng gy g gm: g trong mi trng kh quyn, g trong dung dch, g trong khng kh, g trong t v.v...
7.1.2. Cc dng mi mn
S mi mn l s thay i khng mong mun v hnh dng v kch thc ca b mt chi tit v mt i mt lng kim loi do tc dng c hc ca cc phn t rn t b mt chi tit hoc t mi trng ngoi. S mi mn c hc c th xut hin 2 dng sau: Khi c chuyn ng tng i ca kim loi trn kim loi. Khi c chuyn ng ca mi trng phi kim trn b mt kim loi.
7.2. Cc phng php x l v bo v b mt kim loi

Thc cht ca x l b mt kim loi l to cho cc chi tit my c kh nng chng g, chng mi mn, tnh chu nhit v.v...bng cc phng php x l thch hp. C cc phng php x l b mt kim loi sau:
nng - 2002
122
7.2.1. X l nhit kim loi

A. Nhit luyn a/ Khi nim chung
Nhit luyn l mt qu trnh x l nhit kim loi lm thay i tnh cht ca chng bng cch nung nng n nhit xc nh, gi nhit mt thi gian sau lm ngui vi tc khc nhau theo mt ch xc nh nhm ci thin t chc, cho c tnh, tnh cng ngh mi, kh ng sut d, to cho kim loi nhng tnh cht theo yu cu. Qu trnh nhit luyn c c trng bi: Nhit nung (Tn) cn chn nhit nung v ch nung ph hp trnh cong, TC vnh, bin dng, nt. T Thi gian gi nhit (t1t2) nhit ng u trn ton b tit din ca sn II III I phm. 0 t t t(s) t Tc lm ngui khc nhau nh cc mi H.2.1. Qu trnh nhit luyn trng khc nhau v cho cc kt qu khc nhau vi cc phng php nhit luyn khc nhau.
0 n 1 2 3
b/ Cc phng php nhit luyn

- : l phng php nung chi tit n nhit xc nh (2003000C nu thp; 6007000C nu kt tinh li...), gi nhit, ri lm ngui chm (thng lm ngui trong l) vi mc ch kh ng sut d do qu trnh lm ngui khng u trc gy ra, lm t chc ng u, gim cng, tng do, dai, n nh cht lng, lm ng u thnh phn ho hc, phc hi li tnh cht ho l ban u. - Thng ho: l qu trnh nung nng nh nhng lm ngui trong khng kh tnh, nhm to ht nh, ng nht v cu trc vi bn v dai cao hn . - Ti: l phng php nung nng n nhit chuyn bin, gi nhit cho ng u ho v t chc ca vt liu ri lm ngui vi tc ln trong mi trng (nc, u, nc mui...) nhn c t chc khng cn bng c cng cao, tng thm bn. Ti c 2 phng php: ti th tch l nung nng ton b vt ti ri lm ngui; ti cc b, ti b mt l nung nng nhanh b mt n nhit ti, sau lm ngui nhanh hoc nung nng ton b ri lm ngui cc b phn cn ti.
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- Ram: Sau khi ti vt liu dn, d nt v nn thng phi ram kh ng sut gim cng, tng do, n hi, dai va chm. Ram l phng php nung vt liu n nhit ram (ram thp 1502500C; ram va 3004500C; ram cao 5006800C)
b. Ho nhit luyn
Ho nhit luyn l phng php lm bo ho mt s nguyn t ho hc trn lp b mt kim loi lm thay i thnh phn ho hc, do lm thay i tnh cht ca lp b mt
a/ Thm cc bon
Mc ch ca thm ccbon l lm bo ho ccbon ln lp b mt kim loi nhm lm tng cng cho lp b mt chi tit. Thng dng cho cc loi thp ccbon v hp kim c hm lng ccbon thp. Thm ccbon c th tin hnh th rn, lng, kh. Thm ccbon th rn c dng nhiu vi nguyn liu ch yu l than C = (8090)% + cht xc tc (BaCO3, CaCO3). Nung n nhit thm 9009500C, gi nhit mt thi gian ccbon nguyn t thm vo lm bo ho ccbon ln b mt chi tit thm. Lp b mt thm c (0,52)mm.
b/ Thm nit
Thm nit l phng php lm bo ho nit vo lp b mt chi tit kim loi nhm nng cao cng, dai va chm, tnh chng mi mn, chng mi... Vt liu thm nit thng dng amniac (NH3) nhit thm 4806500 NH3 3H + Nng.t Nit nguyn t c hot tnh mnh, thm vo b mt chi tit. Lp thm mng (0,20,3)mm; cng t c 6772 HRC.
c/ Thm xianua
Thm xianua l qu trnh lm bo ho ng thi c ccbon v nit ln b mt chi tit kim loi, nhm nng cao cng, tnh chu mi mn v gii hn mi ca lp b mt chi tit. Qu trnh thm nit c th nhit thp 5405600C hoc nhit trung bnh 8408600C v nhit cao 9009500C. Vt liu thm dng mui c gc CN nh NaCN, KCN...Chiu su lp thm < 0,10,2 mm.
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7.2.2. Cc phng php x l b mt khc

a/ Theo yu cu t c hnh dng t vi ca b mt, ngi ta thng dng cc phng php gia cng nh mi, nh bng. b/ Theo yu cu t v tnh cht c hc ca lp b mt, thng dng cc phng php nh ln p, phun bi v.v... c/ Theo yu cu t c v thnh phn ho hc, cu trc lp b mt, thng dng cc phng php x l nh xementit ho, nit ho, khch tn crm v.v... d/ Theo yu cu t c lp ph b mt c cc tnh cht vt l khc m thnh phn ho hc ging hoc khc vi vt liu nn, thng dng cc phng php nh m, phun kim loi ...
7.2.3. Bo v chng g
a/ Khi nim
Bo v chng g nhm m bo cc yu cu k thut ca kt cu khi lm vic lu di, nng cao hiu qu kinh t... c bit cc kt cu lm vic trong mi trng c cc hot ng ho hc mnh (khng kh, nc bin, nh sng mt tri...)
b/ Phng php bo v
- Bo v lu di: gm chn vt liu c kh nng chng g tt v chn phng php to lp chng g nh phun bi, ln p, to bng cao v.v... X l kt cu l chn kt cu n gin c bng b mt cao, c phn chuyn tip, thun li cho vic bo qun, chng g, x l v.v.. X l mi trng g cn kh hoc hn ch kh nng xm thc ca mi trng nh m, xy, xt... Bo v bng lp ph kim loi, phi kim, xt bng ho hc, in ho (trng ph men, m crm, trng km, ph xt nhm, phun kim loi, m in, ngm dung dch, qut sn...) Bo v chng g trong mi trng nhit i: cn kh thnh phn xm thc ca mi trng, cc sn phm g, nc v m mi trng, cn m niken, crm, sn tng hp, sn chng g c tnh kim, dng bao b ng gi... - Bo v tm thi: l qu trnh bo qun trong qu trnh sn xut, trong kho, khi vn chuyn nh lm sch bi trn du m, cht chng g, paraphin, bao gi, ng hp v.v...
nng - 2002

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Авторское право:

Доступные форматы

gio trnh: c kh i cng

Cc khi nim c bn v sn xut c kh

Thp, gang, ng, nhm v hp kim

Ch to phi Ph phm v ph liu Gia cng ct gt Ph phm v ph liu X l v bo v

c, cn, rn dp, hn...

Tin, phay, bo, khoan, mi...

Nhit luyn, ho nhit luyn, m, sn...

H.1.1.S qu trnh sn xut c kh

gio trnh: c kh i cng

1.1.2. Qu trnh thit k

1.1.3. Qu trnh sn xut

1.1.4. Qui trnh cng ngh

1.1.5. Dng sn xut

gio trnh: c kh i cng

1.1.6. Khi nim v sn phm v phi

1.1.7. Khi nim v c cu my v b phn my

gio trnh: c kh i cng

1.2. Khi nim v cht lng b mt ca sn phm

1.2.1. nhn b mt (nhm)

H.1.3. K hiu bng a/ K hiu bng theo Ra b/ K hiu bng theo RZ

gio trnh: c kh i cng

1.2.2. Tnh cht c l ca lp b mt sn phm

gio trnh: c kh i cng

1.3. Khi nim v chnh xc gia cng c kh

1.3.2. Dung sai

D (d) - Kch thc danh ngha ca chi tit.

gio trnh: c kh i cng

a/ Dung sai kch thc l

b/ Dung sai kch thc trc

H.1.5. Dung sai kch thc trc v l

gio trnh: c kh i cng

H.1.6. V tr cc min dung sai ca Trc v L

gio trnh: c kh i cng

1.3.3. Lp ghp v phng php lp ghp

gio trnh: c kh i cng

+ 0,021 + 0,028 + 0,015

1.3.4. Phng php o v dng c o

gio trnh: c kh i cng

gio trnh: c kh i cng

Vt liu dng trong c kh

y, F - din tch mt cu ca vt lm (mm2).

gio trnh: c kh i cng

cng Brinen dng o vt liu c cng thp (< 4500 N/mm2)

H.2.2. S th nghim o cng

Vin bi thp Vin bi thp Mi kim cng

gio trnh: c kh i cng

2.1.4. Tnh cng ngh

gio trnh: c kh i cng

gio trnh: c kh i cng

gio trnh: c kh i cng

gio trnh: c kh i cng

gio trnh: c kh i cng

2.3.2. Phn loi gang

gio trnh: c kh i cng

2.4. Kim loi v hp kim mu

gio trnh: c kh i cng

2.4.2. Nhm v hp kim nhm

gio trnh: c kh i cng

2.5. Hp kim cng

gio trnh: c kh i cng

gio trnh: c kh i cng

3.1.3. phm vi s dng

gio trnh: c kh i cng