HOC TRNH 1

NGUYEN LY CHUNG
Bai 1

C S LY THUYET VA NGUYEN LY CAT GOT

I. ac iem va vai tro cua gia cong cat got :

- Cat got kim loai la qua trnh cong nghe tao nen nhng san pham c kh co hnh dang kch thc o bong be mat theo yeu cau ky thuat t mot phoi lieu ban au nh s cat bo lp kim loai di dang phoi. - Gia cong cat got c thc hien nhiet o bnh thng cua moi trng (ca trc va sau nguyen cong nhiet luyen ). No cho o bong va o chnh xac cao hn cac phng phap gia cong han, uc, ren, dap nong - Phng phap gia cong bang cat got chiem 30% khoi lng cong viec gia cong c kh va trong tng lai co the nhieu hn.

II. Nhng khai niem va nh nghia c ban : 1. Chuyen ong trong qua trnh cat got :
- Moi mot loai may cat kim loai co quy ao chuyen ong tng oi gia dao va chi tiet khac nhau. Ngi ta phan ra ba loai chuyen ong : a> Chuyen ong chnh : (chuyen ong cat chnh) la chuyen ong c ban cua may cat c thc hien qua dung cu cat hay chi tiet gia cong. No co the la chuyen ong quay, tnh tien kh hoi hoac dang ket hp V du: Khi tien chuyen ong chnh la chuyen ong quay tron cua phoi ga tren mam cap; khi phay, khoan, mai chuyen ong chnh la chuyen ong quay tron cua dao phay, khoan va a mai; con khi bao va xoc la chuyen ong tnh tien kh hoi qua lai va len xuong cua dao

b> Chuyen ong chay dao: la chuyen ong cua dao hay chi tiet gia cong no ket hp vi chuyen ong chnh tao nen qua trnh cat got. Chuyen ong chay dao co the lien tuc hay gian oan. Chuyen ong nay thng c thc hien trong xu hng vuong goc vi chuyen ong chnh, cu the : - Khi tien, chuyen ong chay dao ka chuyen ong ngang doc cua ban dao khi cat: - Khi phay la chuyen ong ngang- doc- ng cua ban may mang phoi; - Khi bao la chuyen ong ngang (ng) cua ban may va chuyen ong len xuong cua au dao; - Khi mai la chuyen ong tnh tien ngang (doc) cua ban may mang phoi hay truc cua a mai. - Khi khoan la chuyen ong an xuong cua mui khoan. c> Chuyen ong phu: la chuyen ong khong trc tiep tao ra phoi nh chuyen ong tnh tien, lui dao ( khong cat vao phoi).

2. Che o cat:
*Van toc cat (Vc) la lng dch chuyen tng oi gia li cat va chi tiet gia cong trong mot n v thi gian (hoac lng dch chuyen tng oi cua mot iem tren be mat chi tiet gia cong va li cat trong mot n v thi gian) ta co : Vc = V + S a so cac trng hp tr so cua van toc chuyen ong chay dao S rat nho nen co the coi van toc cat la van toc chuyen ong chnh V V. V du khi tien ngoai chi tiet ng knh D (mm) so vong quay truc chnh n (vg/ph) th tr so cua toc o cat co the tnh theo cong thc:
V =

.D.n , ( m / ph ) 1000

Khi tien lo th D la ng knh lo sau khi gia cong, khi khoan D la ng knh mui khoan, khi phay D la ng knh dao phay, khi mai D la ng knh cua a mai. Neu chuyen ong chnh la tnh tien (bao, xoc ) th tr so van toc lay theo gia tr van toc trung bnh:
Vtb = 2.L.n 3 , ( m / ph ) 1000

Trong o: L: la chieu dai hanh trnh chay dao (mm). n: la so hanh trnh kep trong mot phut . *Chieu sau cat (t) : la chieu sau lp kim loai b ht i sau mot lan cat (hoac la khoang cach gia hai be mat a va cha gia cong ke nhau o theo phng vuong goc vi phng chay dao). V du: Khi tien th chieu sau cat c tnh: t = (D d)/2 (khi tien ngoai)mm t = (d D)/2 (khi tien trong)mm *Lng chay dao (S) la quang ng tng oi cua li cat so vi chi tiet theo phng chuyen ong chay dao sau mot n v thi gian, sau mot vong quay cua phoi hay

sau mot hanh tnh kep. Khi tien, lng chay dao S la lng dch chuyen cua dao theo phng chay dao doc theo be mat gia cong sao mot vong quay cua phoi (mm/vg) Khi bao va xoc lng chay dao S la lng dch chuyen cua dao hay ban may sau mot hanh trnh kep cua ban may (hoac dao) mm/h.t.kep. oi vi dao nhieu li cat nh dao phay co the tnh lng chay dao sau mot rang dao (mm/rg), lng chay dao sau mot vong quay cua dao (mm/vg), lng chay dao sau mot phut lam viec cua dao (mm/ph).

=> Tap hp cac yeu to van toc cat V, chieu sau cat t, lng chay dao S goi la che o cat. Mot che o

cat c xac lap tren he thong cong nghe bao gom : May Dao o ga va Chi tiet gia cong.

III. S hnh thanh cac be mat tren chi tiet trong qua trnh cat:
Bat ky phng phap gia cong nao, qua trnh ht bo dan lp lng d gia cong c (qua trnh cat) eu hnh thanh tren chi tiet 3 be mat co ac iem khac nhau. Xet tai mot thi iem nao o trong qua trnh gia cong (khi tien), ba be mat tren c phan biet nh sau:

+Mat se gia cong: la be mat cua phoi ma dao se cat en theo qui luat chuyen ong. Tnh chat cua be mat nay la tnh chat be mat phoi. +Mat a gia cong: la be mat tren chi tiet ma dao a cat qua. Tnh chat cua be mat nay la phan anh nhng ket qua cua cac hien tng c ly trong qua trnh cat. +Mat ang gia cong: la be mat tren chi tiet ma li dao ang trc tiep thc hien tach phoi. Cung la mat noi tiep gia mat a gia cong va mat se gia cong. Tren be mat nay ang dien ra cac hien tng phc tap. +Vung cat : La phan kim loai cua chi tiet va c tach ra gan mui dao va li cat nhng cha thoat ra ngoai. ay la vung ang xay ra cac qua trnh c ly phc tap.

IV. Cac mat phang c ban cua dao cat kim loai:
e xac nh cac goc o cua dao va khao sat ve lc cat, van toc cat, nhiet cat ngi ta qui nh cac mat phang toa o cua dao ( dao tien). He toa o c xac nh tren c s cua ba phng chuyen ong cat ( S, t, V) +Mat phang c ban 1 : c tao bi vect toc o V va vect chay dao S +Mat phang c ban 2 : c tao bi vect toc o V va vect chieu sau cat t. +Mat phang c ban 3 :(con goi la mat ay) c tao bi vect chay dao S va vect chieu sau cat t. La mat phang i qua mot iem cua li cat chnh va vuong goc vi vect van toc cat tai iem o . oi vi dao co tiet dien la hnh lang tru th mat ay song song vi mat ty cua than dao tren o ga dao. +Mat phang cat la mat phang i qua mot iem cua li cat chnh va tiep xuc vi mat ang gia cong. Mat cat cha vect van toc cat V. Hay mat phang cha li cat chnh va vect van toc cat ma no vuong goc vi mat ay (goi la mat phang cat got. Tiet dien chnh N N :la mat phang i qua mot iem cua li cat chnh va vuong goc vi hnh chieu cua li cat chnh tren mat ay .

Tiet dien phu N1 N1 :la mat phang i qua mot iem cua li cat phu va vuong goc vi hnh chieu cua li cat phu tren mat ay.

V. Nhng bo phan chnh cua dung cu cat:

Dao cat kim loai gi vai tro quan trong trong qua trnh gia cong, no trc tiep tac ong vao phoi lieu e tach ra phoi tao thanh be mat gia cong. Moi dao ( ien hnh la dao tien) thng gom hai phan:

*Than dao: dung e ga vao ban dao, no phai u o ben va o cng vng, Nham am bao v tr tng quan gia dao va chi tiet. *au dao: la phan lam nhiem vu cat got. au dao c hp thanh bi cac be mat sau: - Mat trc(1): la be cua dao tiep xuc vi phoi va phoi trc tiep trt tren tren o va thoat ra ngoai. - Mat sau chnh(2): la be cua dao oi dien vi mat ang gia cong. - Mat sau chnh(3): la be cua dao oi dien vi mat a gia cong. - Li cat chnh: la giao tuyen cua mat trc va va mat sau chnh, no trc tiep cat vao kim loai. o dai li cat chnh co lien quan en chieu sau cat va be rong cua phoi. - Li cat phu: la giao tuyen cua mat trc va va mat sau phu, mot phan li cat phu gan mui dao cung tham gia cat vi li cat chnh. - Li cat noi tiep: (ch co mot so loai dao tien) la phan noi tiep gia li cat chnh va li cat phu. Khi khong co li cat noi tiep dao tien se co mui. Mui dao co the nhon hoac lng tron (ban knh mui dao R = 1 2mm). Cac li cat co the thang hoac cong va mot au dao nen co the co mot hoac hai li cat phu . Mot dao co the co nhieu au dao nen co rat nhieu li cat. Tuy theo so lng cua li cat chnh, ngi ta chia ra : +Dao mot li cat : dao tien, dao bao +Dao hai li cat : mui khoan +Dao nhieu li cat : dao phay, dao doa, dao ca +Dao co vo so li cat la a mai, (moi hat mai co vai tro nh mot li cat)

VI. Thong so hnh hoc cua dao trang thai tnh (dao tien):

e am bao nang suat chat lng be mat gia cong, dao cat can phai co hnh dang va goc o hp ly. Thong so hnh hoc cua dao c xet trang thai tnh (khi dao cha lam viec). Goc o cua dao c xet tren c s : dao tien au thang at vuong goc vi phng chay dao, mui dao c ga ngang tam phoi. Cac thong so hnh hoc cua dao nham xac nh v tr

cac goc o cua dao nam tren au dao. Nhng thong so nay c xac nh tiet dien chnh N N, mat ay, tiet dien phu N1 N1 va tren mat phang cat got. +Goc trc : la goc tao thanh gia mat trc va mat ay o trong tiet dien chnh N N Goc trc co gia tr dng khi mat trc thap hn mat ay tnh t mui dao, co gia tr am khi mat trc cao hn mat ay va bang khong khi mat trc song song vi mat ay. Khi goc trc ln bien dang phoi nho, viec thoat phoi de dang, lc cat va cong tieu hao giam, nang suat tang. +Goc sau chnh : la goc tao thanh gia mat sau va mat phang cat got o trong tiet dien chnh. Goc sau thng co gia tr dng. Goc sau cang ln mat sau t b ma sat vao be mat gia cong nen chat lng be mat gia cong cang tot. +Goc cat : la goc tao bi gia mat trc va mat cat o trong tiet dien chnh

+Goc sac : la goc c tao bi mat trc va mat sau chnh o trong tiet dien chnh ta co quan he : + + =90o ; = + +Goc trc phu 1 : tng t nh goc trc, nhng o trong tiet dien phu N N, +Goc sau phu 1 : tng t nh goc sau , nhng o trong tiet dien phu N N +Goc mui dao : la goc hp bi hnh chieu li cat chnh va hnh chieu cua li cat phu tren mat phang ay. +Goc nghieng chnh : la goc cua hnh chieu li cat chnh vi phng chay dao o trong mat ay. +Goc nghieng phu 1 : la goc cua hnh chieu li cat phu vi phng chay dao o trong mat ay. Ta co : + + 1 =180o +Goc nang cua li cat chnh : la goc tao bi li cat chnh va hnh chieu cua no tren mat ay. Co gia tr dng, khi mui dao la iem thap nhat cua li cat . Co gia tr am, khi mui dao la iem cao nhat cua li cat. = 0 Khi li cat nam ngang ( song song vi mat ay). Cac nh ngha tren cung ung cho cac loai dao khac.

VII. Thong so hnh hoc cua dao trong qua trnh cat: 1. S thay oi gia tr cac goc va 1 khi ga truc dung cu cat khong thang goc vi ng tam chi tiet:

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Dung cu sau khi mai sac co cac goc nghieng chnh va goc nghieng phu Neu khi ga dao, truc dao khong vuong goc vi ng tam th: +Neu ga dao nghieng ve ben trai: *Goc nghieng chnh khi lam viec c = - (900 -) *Goc nghieng phu khi lam viec 1c = 1 + (900 -) +Neu ga dao nghieng ve ben phai: *Goc nghieng chnh khi lam viec c = + (900 -) *Goc nghieng phu khi lam viec 1c = 1 - (900 -)

2.S thay oi gia tr cac goc khi mui dao ga khong ngang tam may :
Cao hn tam (tien ngoai)

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Thap hn tam (tien ngoai) Ga cao hn tam (tien trong)

Ga thap hn tam (tien trong)

- Khi tien ngoai, neu mui dao ga cao hn ng tam cua may th goc trc cua dung cu khi lam viec tt se tang len, goc sau tt se giam i ; con khi ga dao thap hn

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ng tam cua may th goc trc khi lam viec tt se gam i, con goc sau khi lam viec tt se tang len. - Khi tien trong ket qua se ngc lai. ca hai trng hp tren, gia tr cua cac goc se thay oi mot gia tr bang goc. Goc o c tnh theo cong thc : Trong o: H : la o cao (thap) cua mui dao so vi tam may. R : la ban knh cua be mat c gia cong ( hay ban knh chi tiet ) = arcSinH/R 3. S thay oi gia tr cac goc cua dao khi co

them cac chuyen ong phu: Chuyen ong chay dao ngang va chuyen ong chay dao doc + Chuyen ong chay dao ngang (khi xen mat au, cat t..) Khi co chuyen ong chay dao ngang th quy ao cua chuyen ong cat tng oi la ng acsimet. Do co lng chay dao ngang nen hng cua vect toc o cat tong hp luon luon thay oi, lam thay oi goc o cua dung cu cat. Ta co : yc = y + 1 yc = y - 1

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Goc 1 c tnh theo bieu thc sau: Trong o : Sn : lng chay dao ngang sau mot vong quay cua chi tiet (mm/vg) D : la ng knh cua chi tiet iem khao sat (mm)

V du1 :
Tien cat c mot chi tiet hnh tru vi lng chay dao ngang Sn =0.2 mm/vong. Dao tien cat c sau khi mai co y =120. Tnh goc sau thc te khi cat en iem cach tam mot khoang r = 1mm. Giai : Tnh goc theo contg thc cho tren. Ta co : tg1= Sn/ 2.r =0.2 / 2 x 3.14 = 0.0318 Do o = 1049

tg1 =

Goc sau khi cat en iem cach tam 1 mm se la : yc = y - 1 =120 1049 =100 11. Nh vay do lng chay dao ngang be nen s thay oi goc sau khong ang ke, co the khong ang quan tam. V du 2 : Tien ht lng mot dao phay nh hnh co cac thong so sau: ng knh ngoai D = 75mm, so rang Z = 10, lng ht lng K = 4.5mm, can mai goc sau y la bao nhieu e lam viec ta co yc =80 Giai Ta co: yc = y - vi tg = Sn/D Lng ht lng K = 4.5mm, ngha la sau mot goc gia hai rang (3600/ z) th lng tien dao la 4.5mm Vay sau mot vong lng tien dao se la: Sn = K.Z = 4.5 x 10 =45 mm/ vong Khi o:

Vs Sn = V 0 D

tg =

45 = 0,190985 3,14 x 75

=10.812 0 =10048 V y = y - hay y = yc + Vay can mai goc sau: y = 80 +10048=18048 - Chuyen ong chay dao doc

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Khi co chuyen ong chay dao doc th quy ao cua chuyen ong cat tng oi la ng xoan oc, do o vect toc o cat tong hp se nghieng vi vect toc o cat trang thai tnh mot goc2 Ta co: xc = x - x xc = x + x Gia tr cua 2 c tnh t bieu thc:

Trong o: Sd: la lng chay dao doc sau mot vong quay chi tiet (mm/vg) D : la ng knh chi tiet tai iem khao sat Lng chay dao doc cang ln, ng knh chi tiet gia cong cang be th goc 2 cang ln. Do o khi cat vi lng chay dao ln nh khi cat ren bc ln nh ren nhieu au moi, th khi mai dao can phai chu y en goc 2 e am bao goc sau khi cat khong am.

V du 3 :
Tien mot truc vt hnh thang co Profin nh hnh ve, ng knh trung bnh cua truc vt dtrung bnh=40 mm, modun chieu truc m = 6. Goc Profin cua ren =200 Ngi ta tien hanh ten tng mat mot.

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Dao tien tinh mat trai ren co dang nh hnh sau, goc trc =0, = 700, = 00. Ga mui dao ngang tam may.e tien at yeu cau th goc sau tiet dien XX Phai la x0 =100 .Hoi phai mai dao vi goc n bang bao nhieu iem nam tren ng knh trung bnh ?

Giai: xe = x -x tgx = Sd/ 2. Tnh x vi Sd la lng chay dao theo chieu truc, luc nao bang bc chieu truc t0, do o Sd =to = m = 6. la ban knh vect tai iem ta xet = 20 mm Do o :

tg x =

6. = 0,15 2. .D.20

=>x =8053 tnh goc sau trong tiet dien NN n Ta a co quan he: ctgx ctgn.sin tg .cos V =0 nen ctgx = ctg. sin Hay : ctgn = ctgx. sin ay : x = xc =18053, goc =700

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Do o tgn = ctgxc. sin =tg18053.sin700 tgn = 0.31496. =>n=(17,48) 0 = 17026.

VIII. Cac thong so cua lp kim loai b cat :

* Chieu day cat a: la khoang cach gia hai v tr lien tiep cua li cat sau mot vong quay cua phoi hay mot hanh trnh kep cua dao (ban may) o theo phng thang goc vi chieu rong cat . * Chieu rong cat b: la khoang cach gia hai be mat cha gia cong va be mat a gia cong o doc theo li cat (tnh bang mm).

Neu li cat thang th b la chieu dai phan li ang tham gia cat, con neu li cat cong chieu rong cat b la chieu dai cung cong cua li cat ang tham gia cat. Thong so hnh hoc cua phoi co anh hng en lc cat va nhiet cat. Khi tang a th lc cat va nhiet cat tang, dao b mon nhanh con khi tang b th lc cat va nhiet cat tren n v dai cua li cat khong thay oi. Trng hp tien (dao ga ngang tam phoi, dao co =0, =0 ): t b = S in a=S.sin ; neu 0 th Sin a= S C os

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Nh vay, (neu : t = const; cang nho ) a se nho, b se ln- phoi se mong va dai. *Dien tch cat: va tch so gia chieu rong va chieu day cat .V du khi tien ( dao ga ngang tam phoi , dao co: = o ; = o) +Dien tch danh ngha : Fdn = a.b = s.t (mm)2 +Dien tch thc te: F = Fdn- F ; F dien tch nhap nho ma dao khong cat het. c tnh: - Khi li cat thang : F = F. (ABC) = 1/2AB x CH ; AB = S +CH x(cotg + cotg 1 ) CH = S/ cotg + cotg 1 => - Khi li cat cong :
= F 1 S2 . 2 cot g + cot g 1
S2 4

AB= S; CH = HI CI =
R R2

=> (CH R)2 = R2- S2/4 (CH)2 2CH x R + R2= R2 S2/4 Bo qua vo cung be (CH)2:CH S2/ 8R ; Lap ghep nh

tren. Co the nhan thay : CH = Rz Chieu cao nhap nho trung bnh be mat chi tiet gia cong ( thong so ve nham be mat) Neu tang th Rz tang (o bong be mat gia cong giam) va neu R tang th nhap nho be mat giam ( o bong se tang).

1 S3 F = ABxCH 2 16 R

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Bai2

VAT LIEU LAM DAO

I. Khai niem:
Muon ht i mot lp kim loai d tha ra khoi bemat can gia cong e at c hnh dang, kch thc va cac yeu cau ky thuat cua chi tiet, tren cac may gia cong kim loai bang phng phap cat got phai dung cac dung cu thng goi la dung cu cat.

II. Nhng ac iem va yeu cau c ban oi vi vat lieu lamdao: 1. ac iem lam viec:

- Khi cat dao lam viec trong ieu kien nhiet o cao (800 1000oC) co anh hng xau en c ly tnh cua vat lieu. - Trong qua trnh cat moi n v dien tch tren be mat lam viec cua dao phai chu lc rat ln ieu o ch gay nen hien tng rang nt va gay v dao khi cat. - Khi cat gia be mat tiep xuc cua dao va phoi vi chi tiet gia cong xay ra qua trnh ma sat rat ln. He so ma sat len en (0,4 1). - Nhieu trng hp khi cat dao phai lam viec trong ieu kien b va ap (nh phay,bao, xoc ) va s dao ong ot ngot ve nhiet o co anh hng rat xau en kha nang lam viec cua dao. - mot so phng phap gia cong (chuot,khoan) th ieu kien thoat phoi, thoat nhiet kho khan lam tang nhiet o, de gay ra hien tng ket dao.

2.Yeu cau oi vi vat lieu lam dao.

a.o cng: Thng vat lieu can gia cong trong che tao c kh la thep, gang co o cng cao, do o e co the cat c, vat lieu lam dao phan cat dung cu phai co o cng cao hn (60 65HRC) b.o ben c hoc: Dung cu cat thng phai lam viec trong ieu kien rat khac nghiet : tai trong ln khong on nh, nhiet o cao,

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ma sat ln, rung ong. De lam li cat cua dung cu st me. Do o vat lieu lam phan cat dung cu can co o ben c hoc (sc ben uon, keo, nen, va ap) cang cao cang tot. c.Tnh chu nong: vung cat, ni tiep xuc gia dung cu va chi tiet gia cong dung cu va chi tiet gia cong, do kim loai b bien dang, ma satnen nhiet o rat cao (700 800 oC), co khi at en hang ngan o (khi mai). nhiet o nay vat lieu lam dung cu cat co the b thay oi cau truc do chuyen bien pha lam cho cac tnh nang cat giam xuong. V vay vat lieu phan cat dung cu can co tnh chu nong cao ngha la van gi c tnh cat nhiet o cao trong mot thi gian dai. d.Tnh chu mai mon: Lam viec trong ieu kien nhiet o cao, ma sat ln th s mon dao la ieu thng xay ra. Thong thng vat lieu cang cng th tnh chong mai mon cang cao. Tuy nhien ieu kien nhiet o cao khi cat (700 800 0C) th hien tung mai mon c hoc khong con la chu yeu na, ma ay s mai mon chu yeu do hien tng chay dnh (bam dnh gia vat lieu gia cong va vat lieu lam dung cu cat) la c ban. Ngoai ra do viec giam o cng phan cat do nhiet o cao khien cho luc nay hien tng mon xay ra cang khoc liet. V vay, vat lieu lam phan cat dung cu phai co tnh chu mon cao. c.Tnh cong nghe: Vat lieu lam dung cu cat phai de che tao: de ren, can, de tao hnh bang cat got, co tnh tham toi cao, de nhiet luyen Ngoai cac yeu cau chu yeu neu tren, vat lieu lam phan cat dung cu phai co tnh dan nhiet tot, o dai chong va ap cao va gia thanh re.

III.Cac loai vat lieu lam dao:

e lam phan cat dung cu, ngi ta co the dung cac loai dung cu khac nhau tuy thuoc vao tnh c ly cua vat lieu can gia cong va dieu kien san xuat cu the. Di ay lan lt gii thieu lam phan cat dung cu theo s phat trien va s hoan thien ve kha nang lam viec cua chung.

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Nam 1894 1900 1900 1908 1913 1931 1934 1955 1957 1965 1970

Vat lieu dung cu Thep Cacbon dung cu Thep hp kim dung cu Thep gio Thep cai tien Thep gio(tang Co va WC) Hp kim cng Cacbitvonfra m Hp kim cngWC va TiC Kim cng nhan tao Gom Nitrit Bo Hp kim cng phu(TiC)

Ve,m/ph 5 8 12 15-20 20-30 200 300

Nhiet o gii han at tnh cat 0C 200-300 300-500 500-600 600-650 1000-1200 1000-1200 800

o cng HRC 60 60

60-64 91 91-92 100.000HV 92-94 8.000HV 18.000HV

300-500 100-200
300

1500 1600 1000

1. Thep Cacbon dung cu:

e at c o cng, tnh chu nhiet va chu mai mon, lng C trong thep Cacbon dung cu khong the c di 0,7% (thng t 0,7- 1,3%)va lng P, S thap (P< 0,035%, S < 0,025%) o cng sau khi toi va ram at HRC = 60 - 62. -Sau khi u o cng at ckhoang HB = 107-217 nen de gia cong cat va gia cong bang ap lc. -otham toi nen thng toi trong nc do o de gay ra nt v nhat la nhng dung cu co kch thc ln. -Tnh chu nong kem, o cng giam nhanh khi nhiet o at en 200o 300oC ng vi toc o cat 4-5 m/ph. -Kho mai va de bien dang khi nhiet luyen do o t dung e che tao nhng dung cu nh hnh, can phai mai theo prophin khi che tao.

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Di ay la ban neu thanh phan hoa hoc, c ly tnh va pham vi ng dung cua mot so mac thep Cacbon dung cu thng gap. Gia s ta co nhan hieuY10A -Ch Y: k hieu cua Cacbon. -Ch A:k hieu cua chat lng tot(ham lng P,S <0,03%) -So10: gia tr trung bnh cua cacbon trong thep(0,951,09%) Ngoai ra con co cac nhan hieu khac nh Y7,Y8 Y10,Y12 nhng chat lng kem hn(khong co ch A) nen hien nay t dung

2.Thep hp kim dung cu:

Thep hp kim dung cu la loai thep co ham lng Cacbon cao, ngoai ra con co them mot so nguyen to hp kim vi ham lng nhat nh ( 0.5 3%) Cac nguyen to hp kim nh: Cr, W, Co, V co tac dung: - Lam tang tnh tham toi cua thep - Tang tnh chu nong en 300oC, tng ng vi toc o cat cao hn thep cacbon dung cu khoang 20%. Thanh phan hoa hoc cua mot so nhan hieu thep hp kim dung cu %
Nho m I Nhan hieu Thep Cr05 85CrV Cr 9CrSi CrMn CrWMn CrW5 K hieu Lien xo cu XB X 9XC X XB XB5 0,8-,0,9 0,951,1 0,850,95 1,3-1,5 0,9-1,0 1,25-,1, 5 C 12,51,1 Mn 0,2-0,4 0,3-0,6 <0,4 0,3-0,6 0,450,7 0,8-1,0 <0,3 Si <0,35 <0,35 <0,35 1,2-1,6 <0,35 0,150,35 <0,3 Cr 0,040,06 0,450,7 1,3-,1,6 0,95-,1, 25 1,3-1,6 0,9-1,2 0,4-0,7 W 1,2-1,6 4,5-5,5 V 0,15-0,3 0,150,30

II

III IV

Chu thch: C cacbon, Mn mangan, Si silic, Cr crom, W vonram, V vanadi. Ky hieu cua lien xo cu: X Crom, T mangan, B vongam Thep hp kim dung cu nhom I thng dung chu yeu e che tao cac loai dung cu dung e gia cong go .

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Thep hp kim dung cu nhom II do co lng Crom ln ( 1 1.5 %) nen co tnh tham toi va cat got tot hn. Loai nay chu nhiet khoang 220 300oC. Thep hp kim dung cu nhom III co o tham toi cao, iyt thay oi kch thc khi nhiet luyen, nen thng che tao cac loai dung cu cat co o chnh xac cao va hnh dang phc tap: mui doa, ta ro, dao chuot va cac loai dung cu o Thep hp kim dung cu nhom IV co ham lng Vonfram ln, hat mn neno cng cao, tuy nhien o o tham toi thap dung e che taop6 cac loai dung cu cat can co li cat sac ben. Tuoi ben cao va e gia cong cac loai vat lieu cng. Nhn chung, thep hop75 kim dung cu chu yeu c dung dung e che tao cac laoi dung cu cam tay va gia cong toc o thap.

3. Thep gio: (HSS High Speed Steel thep cao toc).

Thep gio co tnh cat cao hn han cac loai thep nen tren, do o t khi thep gio ra i, no a tao ra mot cuoc cach mang ve cat got va nang suat gia cong, lam xuat hien mot the he cac may ban t ong va t ong toc o cao. Nen c ban cua thep gio van la thep cacbon, nhng co ham lng Cacbon cao hn, ac biet ham lng cac nguyen to hp kim Crom, Vonfram, Coban, Vana di tang len ang ke nhat la wonfram. Nhng nguyen to hp kim nay hp vi Cacbon tao thanh cac cacbt kim loai co o cng cao, chu mon tot, trong o cacbt wonfram (WC) ong vai tro nong cot. Cac cacbt nay nhiet o nho hn 600oC se khong thoat ra khoi mang mactensit nen vat lieu van gi c tnh cat tot. Tac dung chu yeu cua Crom la tang o tham toi, Vanadi tao thanh cacbt Vanadi co o cng cao, chu mon tot , Coban khong tao thanh cacbt ma hoa tan vao sat, khi lng Cacbon ln hn 5% th tnh chu nhiet cua thep gio nang cao. Ngoai ra con co cac loai thep gio co nang suat cao Ngoai ra, chat lng thep gio phu thuoc rat nhieu vao nhiet luyen. V vay khi nhiet luyen thep gio can chu y mot so iem chu yeu sau:

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Khong nung nong thep gio ot ngot en nhiet o cao, (nhiet o toi khoang 1300oC) ma phai tang nhiet o dan dan t 650oC, v thep gio co o dan nhiet kem. Thong thng thep gio c nung nong qua ba lo vi nhiet o lan lt 650 oC, 850 oC,va 1300oC Phai ram sau khi toi nhieu lan (3 lan) moi lan trong 1 gi ( nhiet o ram 560oC ). Sau moi lan ram phai e nguoi en nhiet o thng. Nhng tnh nang c ban cua thep gio la: -o tham toi ln, sau khi toi at o cng HRC = 63 66. -o chu nhet khoang 600oC tng ng vi toc o cat V = 25 - 35m/ph. So sanh gia P18 va P9: -Nang suat gia cong khac nhau khong ang ke. -P9 re hn P18 (v ham lng W ch bang mot na) -P18 chu mon tot hn, de mai sac, mai bong hn va co tnh ben cao hn P9.

4.Hp kim cng(HKC)

T nam 1915-1925 My va c a tien hanh th nghiem che tao hp kim cng. Lien Xo cu, hp kim cng ra i vao nhng nam 1930-1935. Hp kim cng la loai vat lieu lam phan cat dung cu c che tao theo phng phap luyen kim bot.

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Thanh phan chu yeu cua HKC la Cacbit cua mot so kim loai kho nong chay nh Vonfran,Titan,Tantan va c lien ket bi kim loai c ban Tnh cat cua HKC do cac pha Cacbit kim loai quyet nh . o ben c hoc do Coban tao nen. Nhng tnh nang c ban cua HKC so vi cac loai vat lieu lam dao khac nh sau: -o cng cao HRA = 80 90 (HRC >70-71) -o chu nhiet cao:800-10000C, do o toc o cat cho phep cua HKC co the at en V >100 m/ph. -o chu mon gap 1,5 lan so vi thep gio. -Chu nen tot hn chu uon (ham lng Coban cang ln th sc ben uon cang cao). Hp kim cng c che tao qua cac giai oan sau: -Tao bot Vonfram, Titan va Tantan nguyen chat. - Tao ra cac Cacbit tng ng t cac bot nguyen chat W, Ti, Ta -Tron bot Cacbit vi bot Coban theo thanh phan tng ng vi cac loai hp kim cng. -Ep hon hp di ap suat ln (100-140MN/mm 2) nung s bo en 900oC trong khoang 1 gi. -Tao hnh theo cac dang yeu cau. -Theu ket lan cuoi nhiet o cao1400- 15000C trong 1 en 3 gi tao thanh HKC Sau khi theu ket, HKC co o cng cao nen ch co the gia cong bang phng phap mai hoac bang cac phng phap ac biet (ien hoa, tia la ien) Hp kim cng la loai kim loai bot nen co o xop (khoang 5%) Hat cacbit cang mn, phan bo cang eu th tnh nang th tnh nang cua hp kim cng cang cao, chu yeu la o cng va tnh chu mai mon. o cng cua hp kim cng phu thuoc vao lng Cacbit Vonfram, Cacbit Titan va Cacbit Tantan. Lng Cacbit cang ln th o cng cang cao. Lng coban cang nhieu th o cng cang giam, tuy nhien o ben va tnh deo cang tang Co ba nhom hp kim cng thng gap nh sau: a. Nhom mot Cacbit k hieu K (ISO) hoac BK (Nga) thanh phan gom: Cacbitvonfram (WC) va Coban (Co) nhom nay chu yeu e gia cong vat lieu gion :gang, kim loai mau b.Nhom hai cacbit k hieu la P (ISO) hoac TK (Nga) thanh phan gom: Cacbit Vonfram (WC), Cacbit Titan (TiC) va Coban (Co).

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Nhom hai Cacbit co tnh chong dnh cao hn nen c dung e gia cong kim loai deo nh thep,(thng hnh thanh phoi day khi cat va co nhiet o cat cao mat trc). c. Nhom ba cacbit k hieu M (ISO) hoac TTK ( Nga) thanh phan gom: Cacbit Vonfram (WC), Cacbit Titan (TiC) va Coban (Co) va Cacbit Tantan (TaC) Loai nay thng c dung e gia cong cac loai vat lieu kho gia cong. nc ta, cung a tng san xuat th nghiem hp kim cng. Tuy nhien do chat lng cha on nh, mat khac gia thanh cao. ISO phan hp kim cng theo ba nhom chnh khi tao phoi: - Nhom k hieu P cho cac vat lieu cat ra phoi day. - Nhom k hieu M la loai van nang dung gia cong cac loai vat lieu cat ra phoi day va phoi xep. - Nhom loai K dung gia cong cac loai vat lieu cho phoi hat va phoi vun. at tnh chung cua hp kim cng khi tang o cng va tnh chu mai mon th se giam tnh deo. Khi tang tnh deo (tang lng Coban) se lam giam tnh mai mon va tnh chu nhiet. S phat trien cua hp kim cng xuat phat t cac nhom cong cu (v du: loai P10, P20, P30) theo hai hng. Mot hng la tang thanh phan Cacbt Titan (v du P03) lam tang tnh chu mon va cat c toc o cao. Hng th hai la tao c hp kim cng co o deo cao dung e cat cac loai vat lieu co o cng va va ap manh (v du, bao va tien tho) vi toc o cat thap, dien tch va lc cat ln hn. Cac loai hp kim cng P40, P50 e gia cong thep co thanh phan Coban (Co) tng oi ln. Hp kim cng c che tao thanh cac dang theo tieu chuan (cac manh hp kim cng). Cac manh o c han, kep len than dung cu tieu chuan. Ngay nay, cac manh hp kim cng c phu len mot lp mong vai miromet bang cac loai cacbt cng nh TiC, TiC/ TiN (Cacbt Titan, Nitrt Titan). Cac lp phu lam tang o cng, tnh chu mai mon va chu nhiet cua hp kim cng (o cng > 91 HRA, chu c nhiet o khoang1000 o C, ng vi toc o cat V>300m/ph.

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e s dung hp l va co hieu qua hp kim cng can chu y cac ieu kien sau: * Che o gia cong: - La chon hp kim cng cho vat lieu gia cong (cac nhom P,K) va theo yeu cau gia cong (gia cong, tho, tinh, lan cuoi). - Xac nh che o gia cong (toc o cat lng chay dao, chieu sau cat) phu hp cap vat lieu (chi tiet- dung cucat) va yeu cau gia cong can chu y en viec la chon tuoi ben kinh te. - Khong dung dung dich trn nguoi (gia congkho) hoac phai ti manh va nhieu. *oi vi dung cu: - Xac nh thong so hnh hoc theo ieu kien gia cong. - am bao kch thc than dung cu e khi gia cong khong co rung ong. - Mai sac hp ly va t t bang a mai san Cacbt Silc hoac a mai kim cng. *oi vi may cong cu: -May co o cng vng tot khong rung ong toc o cat cao va lc cat ln. ao bao kep chat tot dung cu va chi tiet. -Kiem tra cong suat cat va cong suat may e tranh qua tai.

5. Vat lieu gom:

Vat lieu gom c nghien cu t nhng nan1930 va a vao s dung sau 1950. Thanh phan chnh cua gom la at set ky thuat(Al2O3) gom hai pha cua oxt nhom: Al2O3 co =3,65g/cm3 va Ai2O3 vi =3,96g/cm3 e chuyen hoa hoa toan t Ai2O3 sang Al2O3 .Ngi ta nung at set k thuat nhiet o 1400-1600 0C. Sau o nghien nho thanh bot mn. Bot c ep thanh nhng manh dao co hnh dang va kch thc tieu chuan sau o em theu ket. Hien nay co 3 loai vat gom c s dung gom: a. Oxit nhom thuan khiet (99%Al 2O3): Hien nay Al2O3 con them khong di10% oxit kem (ZnO2) lam tang them sc ben. b.Vat lieu gom tron:

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Ngoai Al2O3 la chnh, con them cac Cacbit kim loai nh Cacbit Titan (TiC), Cacbit vonfram (WC), Cacbit Tantan (TaC), Nitrit Titan(TiN). Loai nay co sc ben cao, dung e tien tinh, phay tinh cac loai vat lieu nh gang cng, thep toi. c.Vat lieu gom khong Oxt: Loai nay c che tao t nitrit silic (Si3N4) co sc ben uon cao hn nhieu so vi hai loai tren, chu yeu c dung e gia cong nhom va hp kim nhom. oi vi vat lieu gom th o hat cang mn, sc ben uon cang tang *Cac tnh nang chu yeu cua vat lieu gom: + o cng va tnh gion cao. + Chu mon va chu nhiet cao nen thng dung e cat toc o cao . + Tnh dan nhiet kem nen khi cat khong dung dung dch trn nguoi . + Tnh deo kem do sc ben uong kem, v vay khong dung e gia cong khi co rung ong, va ap va lc cat ln . + Mai sac bang a mai kim cng. *Pham vi s dung cua vat lieu gom: - Toc o cat khong nho hn 100m/ph. - Khi gia cong thep, toc o cat: V=1 2 lan so vi khi cat bang HKC. - Khi gia cong gang, toc o cat V = 2 3 lan so vi HKC - Toc o cat tinh ln nhat khi gia cong thep xay dng co the at en 600m/ph, khi gia cong gang, V = 800m/ph. - V chu rung rong va va ap kem nen chu yeu c dung e gia cong tinh chieu sau cat va lng chay dao be. -V tnh dan nhiet kem nen khong dung dung dch trng nguoi khi cat. Rieng oi vi Nitritsilic (Si3N4) co sc ben va tnh dan nhiet cao hn Oxit nhom khoang bon lan nen co the dung dung dch trn nguoi. - Nh co tnh mon cao nen thng dung e gia cong lan cuoi e at o chnh xac kch thc va o nhan be mat cao. - Cac manh dao gom thng c kep c kh vao than dao va khong mai sac lai . * So vi HKC, manh dao gom co nhng u iem sau: - Nang suat cao hn v thi gian may giam do toc o cat cao khi cung mot tuoi ben. - Tuoi ben tang neu cat cung mot toc o cat .

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- Sai lech kch thc gia cong nho hn. - Chat lng be mat at c cao hn. - Gia thanh re hn.

6.Vat lieu tong hp (nhan tao) sieu cng:

Sau vat lieu gom, ngi ta tiep tuc nghien cu va che tao mot loai vat lieu lam dung cu mi. o la vat lieu tong hp sieu cng. Co hai loai thng gap la: kim cng tong hp va Nitrit Bo lap phng (con goi la El bo). a>Kim cng nhan tao: Kim cng nhan tao c tong hp t than ch (Graphit) ap lc va nhiet o cao. *Nhng tnh nang c ban cua kim cng: + o cng te vi cua kim cng cao nhat trong cac loai vat lieu hien nay, cao hn cua hp hp kim cng t 5 6 lan, o cng te vi cua hp kim cng khoang (120 180 ) 10sPa 1Pa= 1Nm2 + o dan nhiet cao gap hai lan hp kim cng. + o chu nhiet kem 8000C. + Gion, chu tai trong va ap kem. + Chu mai mon, tuy nhien khi gia cong thep C co ham lng Cacbon thap th lai b mon nhanh do hien tng khuech tan. Do he so dan nhiet cao, nen tuy chu nhiet kem, kim cng van co the cat c toc o rat cao. * Pham vi s dung : + Thng c dung lam a mai e mai sac dung cu cat bang hp kim cng. + Dung lam dao tien e gia cong gang va cac kim loai mau. b> Nitrit Bo lap phng (con goi la El bo): La hp chat gia Nit va nguyen to Bo. Tnh cat cua no tng t nh kim cng. - o cng te vi cua El bo la(600 800).108Pa . - Chu nhiet khoang 1500 20000C. - He so ma sat be . - Chong mai mon tot. - He so ma sat vi kim loai nho. * ng dung: - Gia cong tinh thep toi co HRC 39 66, va gang HKC, ac biet la thep gio.

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Bai 3

C S VAT LY CUA QUA CAT GOT

TRNH
I. Qua trnh hnh thanh phoi cat :
Khi cat li cat cua dao tac dung vao kim loai mot lc ( lc cat ), no gay ra mot s thay oi c ly tai vung cat cua vat lieu. - au tien di tac dung cua lc P kim loai b nen va bien dang an hoi -Dao tien sau vao ( lc P cang ln) gay nen ng suat ben trong kim loai ln hn gii han an hoi do o kim loai bat au b bien dangdeo ( cac phan t ben trong kim loai bat au b trt theo mat trt va phng trt) -Do bien dang cac tinh the tren phng nay b keo dai thanh hnh elp (goc cua mat trt so vi phng cua lc cat la 1) -Khi dao tiep tuc tien them => ap lc gia tang lam

ng suat tang vt qua gii han ben kim loai b bien dang ln va bat au b pha huy.

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Tren phan kim loai cua phoi mat trc daop xuat hiencac vet nt theo goc pha huy 2(2 1) - Khi dao tiep tuc tien, phoi b cat se trt tren mat trc cua dao, con dao tiep tuc ep len cac phan t kim loai tiep theo.

II. Cac dang phoi cat:

Cac nha cong nghe co the can c vao s hnh thanh phoi cat ma anh gia c cac thong so cua dung cu cat, cac yeu to che o cat c hp ly hay cha, mc o tieu hao nang lng nhieu hay t, chat lng be mat gia cong co am bao hay khong. Co cac dang phoi cat sau ay: *Phoi vun: phoi cat ra la nhng hat nho ri rat co hnh dang kch thc khac nhau. Phoi vun thng gap khi gia cong vat lieu gion hay cat vi van toc thap. S hnh thanh phoi khong lien tuc (phoi vun) lam lc cat thay oi gay ra va ap, rung ong chat lng be mat xau i, nhiet va lc cat ch tap trung mui dao. *Phoi xep : Mat phoi tiep xuc vi mat trc cua dao th nhan bong mat oi dien vi no co nhng nep gn (nc ne), phoi b t ra thanh tng manh hoac tng oan ngan. Dang phoi nay trhng xuat hien khi cat cac vat lieu deo va, (van toc cat, lng chay dao trung bnh va dao co goc trc ln). Khi cat ra phoi xep th be mat ra cong nhan bong hn. *Phoi day: Thng gap khi cat cac vat lieu deo hoac khi cat vi van toc cao, goc o mai dao hp ly. Phoi co dang day dai xoan (mat phoi tiep xuc vi mat trc

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cua dao nhan bong, mat con lai gn nt). Phoi day van con kha nang bien dang deo. Do co phoi day ma lc cat thay oi rat t, tieu hao nang lng giam, chat lng be mat gia cong cang tot. Can chu y rang ngay cung mot loai vat lieu gia cong nhng tuy theo ieu kien cat got, thong so hnh hoc cua dao, che o cat,.co the cho ta phoi vun, phoi xep hoac phoi day. V vay t cho quan sat phoi khi cat ngi th co the phan oan nguyen nhan e co nhng ieu chnh kp thi.

III. S co rut phoi:

S co rut phoi la ac tnh tieu bieu noi len mc o bien dang ve lng cua kim loai cat got. T nghien cu ve s co rut phoi tren phng dien the tch co the nhan biet c viec cat dien ra kho hay de, nang lng tieu hao nhieu hay t. Goi a,b,L, la kch thc can cat; ap,bp,c la kch thc phoi, th:

M a tr t c
bp

ap

Dao

Lp
Pho i

L> Lp a> ap b> bp he so co rut phoi theo: -Chieu dai: KL= L/ Lp >1 -Chieu dai: Ka= ap/a>1 Theo nh luat bao toan the tch: a.b.L = ap .bp.Lp Ta co :L/ Lp = ap /a hay: KL=Ka.

IV. Hien tng leo dao:

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* Hien tng : Khi cat kim loai mot khoang toc o nao o, tren mat trc cua dao xuat hien mot khoi kim loai co o cng kha ln, co to chc va tnh chat khac biet vi vat lieu chi tiet gia cong, vat lieu lam dao. Khoi kim loai nay luc to, luc nho khac nhau No xuat hien va bien mat hang chuc lan trong mot giay. o la hien tng leo dao. * Nguyen nhan: Tai vung vat lieu phoi tiep xuc vi mat trc cua dao ong thi chu tac dung cua ba lc: T- Lc ma sat gia phoi va mat trc cua dao. S- Lc lien ket gia cac lp kim loai thuoc phoi. W- Lc thoat phoi. nhiet o thap lc lien ket S ( noi lc ma sat) con ln, khi nhiet o tang len lc S giam dan nen : T> S +W va kim loai thuoc lp tiep xuc tach khoi phoi nam lai tren mat trc cua dao tao thanh khoi leo dao. Khi nhiet o cao hn na, lp kim loai gan en trang thai nong chay lam ca noi ma sat (S) va ca ngoai ma sat (T) eu giam nhng T giam nhanh hn S nen leo dao khong

T S

c hnh thanh, con leo dao trc o b nung chay roi b lc cua dong phoi cuon i. Leo dao co tac dung tch cc la bao ve li cat khoi b mon nhanh, lam tang goc trc ( ld > ) giam c lc cat. Tuy nhien leo dao lam li cat cun - tu va s hnh thanh bien mat cua no nhieu lan se gay ra rung ong trong qua trnh cat lam giam o bong, o chnh xac gia cong. Do o ta can phai tranh xay ra hien tng leo dao trong qua trnh gia cong. * Nhng nhan to anh hng en leo dao:

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V1

V2

+ Toc o cat: T thc nghiem vi mot so ieu kien nhat nh cho thay leo dao ch hnh thanh trong pham vi toc o cat t V1 en V2. +Vat lieu gia cong: Khi gia cong vat lieu gion phoi de pha huy va t ra sm nen kho hnh thanh leo dao. Leo dao thng c hnh thanh khi gia cong vat lieu deo. Tnh deo cua vat lieu khac nhau th khoang toc o e hien tng leo dao (V1,V2) va chieu cao leo dao (H1) cung khac nhau. +Goc trc cua dao ( ): Goc trc cua dao nho, phoi bien ong nhieu hn nen tan so hnh thanh va bien mat cua leo dao thap, chieu cao leo dao ln. + Anh hng cua chieu day cat (a): Khi chieu day cat ln, tan so hnh thanh va bien mat cua leo dao ln.

V. Hien tng cng nguoi.

Trong qua trnh gia cong dui tac dung cua lc cat, tren lp be mat chi tiet gia cong xay ra hien tng deo cac hat tinh the b keo lech mang va gia chung sinh ra ng suat. Tac dung nay lam tang the tch rieng va lam giam mat o kim loai o cng, o gion, gii han ben tang len con tnh deo dai b giam, tnh dan t thay oi, be mat kim loai c lam chac goi la hien tng cng nguoi. ac trng cua hien tng cng nguoi la cng o te vi.

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Mc o bien dang cng, chieu sau lp bien cng ty le vi mc o bien dang deo cua lp be mat kim loai. Hien tng cng nguoi gay anh hng xau, lam giam o bong, o chnh xac va c tnh tong hp cua lp be mat chi tiet gay cang tr en lan gia cong tiep theo. Cac nhan to anh hng en hien tng nay gom: - Cac thong so hnh hoc cua dao, cac yeu to cua che o cat lam tang mc o bien bang cua phoi, phoi th eu tang o cng nguoi. - Mc o mai mon cua dao tang th o cng nguoi tang; - Ban knh mui dao tang, o cng nguoi cung tang len. Muon giam hien tng cng nguoi ta phai la chon che o cat hp ly, thong so hnh hoc dao thch hp ket hp vi dung dch trn nguoi trong khi cat. ong thi vi hien tng lam chac lp kim loai be mat th con ton tai mot qua trnh ngc lai la lam cho kim loai suy yeu i va tr lai trnh trang ban au cha bien cng. Qua trnh nay phu thuoc vao nhiet o trong vung cat va khi nhiet o ln keo dai th kim loai be mat co the suy yeu manh. Tnh chat cuoi cung cua lp be mat tuy theo ty le tac ong hai yeu to lc va nhiet tai vung cat.

VI. ng suat d tren be mat gia cong:

ng suat d sinh ra tren lp be mat chi tiet gia cong c giai thch: Khi cat mot lp mong kim loai se ton tai mot trng lc => gay nen bien dang deo khong eu tng vung. Khi thoi cat, trng lc mat i th bien dang deo lam xuat hien ng suat d. Khi lp kim loai be mat b cng nguoi, the tch rieng cua no tang len, lp ben trong khong b bien dang van gi the tch bnh thng. Do co s lien he gia hai lp nen lp ngoai sinh ra ng suat d nen lp ben trong e can bang se sinh ra ng suat d keo. Trong vung cat, nhiet cat nung nong cuc bo lp be mat lam moun an hoi cua no giam xuong toi thieu.

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Sau o be mat chi tiet nhanh chong nguoi i va co lai. Nhng v co lien he vi lp ben trong nen lp ngoai sinh ra ng suat d keo, con lp trong e can bang sinh ra ng suat d nen. Khi cat nhiet sinh ra lam thay oi cau truc kim loai, kim loai chuyen pha lam the tch cua no b thay oi. lp kim loai co the tch rieng ln sinh ra ng suat d nen, ngc lai lp nao co cau truc the tch rieng nho se sinh ng suat d keo. Tom lai, khi gia cong c tren be mat sinh ng suat d tr so, dau va chieu sau phan bo cua no phu thuoc vao phng phap gia cong va che o cat. ng suat d lam giam chat long be mat chi tiet gia cong, lam giam kha nang chu moi, Han che khi s dung chi tiet may sau nay. Neu ng suat d qua ln, sau khi gia cong chi tiet b bien dang, v, nt khong dung c. e giam ng suat d can phai chon c che o cat, goc o dao hp ly va ti dung dch trn nguoi vao vung cat.

VII. Hien tng nhiet khi cat :

Trong qua trnh cat, cong tieu hao c chuyen thanh nhiet nang. Nhiet sinh ra trong qua trnh cat la mot hien tng vat ly quan trong trc tiep anh hng en tnh chat c ly cua vat lieu gia cong va o ben cua dao cu. Nhiet sinh ra lam giam nang suat va o chnh xac gia cong. Q = QF + Qd + Qc + Qmt QF Nhiet i vao phoi. Qd Nhiet i vao dao. Qc Nhietn i vao chi tiet. Qmt Nhiet i vao moi trng. (Khoang 75 80%) (Khoang 15 20%) (Khoang 4%) (Khoang 2%)

VIII. Hien tng rung ong khi cat:

Rung ong lam cho v tr gia dao cat va chi tiet gia cong thay oi theo chu ky. Khi tan so thap, bien o ln se sinh ra o song be mat, khi tan so cao, bien o nho se sinh ra o nhap nho be mat. Rung ong lam cho dao cu

36

mau mon. Ngoai ra do rung ong ma chieu sau cat, lc cat, tiet dien phoi bien ong lam tang sai so gia cong. Rung ong cua he thong cong nghe gom hai loai : rung ong cng bc va t rung. *Rung ong cng bc la do cac lc kch thch t ben ngoai truyen en. Tuy theo nguon lc kch thch rung ong cng bc co the co chu ky hoac khong chu ky. Nguon goc sinh ra lc kch thch la do sai so ca biet cua chi tiet trong may, cac mat tiep xuc co khe h, cac khau quay khong can bang, lng d gia cong khong eu, be mat gia cong khong lien tuc hoac rung ong do cac may xung quanh truyen sang . Bien phap e giam rung ong cng bc : - Tang o cng vng cua he thong cong nghe. - Yeu cau o chnh xac che tao lap rap may, o ga cao. - Phai can bang cac khau quay cao toc. - Tranh cat khong lien tuc. - Phoi can c chon loc va gia cong s bo. - Trang b them c cau giam rung ong. - Mong may u kha nang dap tat dao ong va c cach chan vi xung quanh. *T rung la loai dao ong khong giam c, no c duy tr bi mot nguon nang lng khong oi do ban than chuyen ong cat gay ra co ngha la khi nao ngng cat th t rung cung cham dt. T rung lam anh hng en chat lng gia cong, viec khac phuc no rat kho khan. Cho en nay van cha co gia thiet nao giai thch thoa ang ban chat cua hien tng nay. e han che t rung ong can giam nang lng truyen en va tang nang lng tieu hao. Bien phap giam nang lng truyen en : Thay oi hnh dang hnh hoc dao cat va che o cat e giam lc cat phng co rung ong. S dung dung dch trn nguoi hp ly e giam bt mom dao. +e tang nang lng tieu hao, can : Nang cao o cng vng cua he thong cong nghe, nang cao tan so t rung e lam tang sc can cua ma sat va giam bien o dao ong xuong. S dung cac trang b giam rung e thu bt nang lng dao ong . Nguyen ly cua trang b giam rung ong la : Da vao chi tiet dao ong mot khoi lng nho sao cho tan so cua

37

khoi lng nay bang tan so dao ong cua chi tiet. Trang b giam rung se tao ra mot dao ong lech pha vi dao ong cua chi tiet la 1800. Lc sinh ra se bang lc dao ong nhng ngc chieu nen can bang nhau va lam triet tieu dao ong.

IX. Dung dch trn nguoi:

e cai thien ieu kien cat got, nang cao nang suat, tang o bong be mat gia cong Ngi ta ti vao vung cat mot loai dung dch trn nguoi. Dung dch trn nguoi co hai tnh nang quan trong: - Lam nguoi e giam nhiet o vung cat, giam bien dang nhiet, - Boi trn e giam ma sat, giam lc cat e nang cao nang suat. Yeu cau oi vi dung dch trn nguoi la phai luon on nh co ngha la khong b bien chat trong mot thi gian dai, mat khac la khong anh hng en cong nhan nh gay mui hoi hoac an mon da tht quan ao ; khong ong ac hay ngng tu lam can tr cho viec bm ti ; khong lam g set hay an mon may, dao, chi tiet gia cong. Cac loai dung dch trn nguoi thong dung : Khi gia cong tho ngi ta thng dung dung dch nc co pha chat chong an mon nh: Axit Nitrt loang, Xut, Emuxi, . Con khi gia cong tinh thng dung dung dch cha cac chat hoat tnh nh Axt beo hu c, Axt beo, Kiem hu c, Dau thc vat. e ti dung dch trn nguoi vao vung cat ngi ta ngi ta s dung he thong bm ket hp vi voi phun. Lu lng dung dch trn nguoi c tnh toan va ieu chnh sao cho am bao c hieu qua lam nguoi va boi trn tai vung cat.

X. Hien tng va phng thc mai mon dao:

a. Hien tng mai mon dao khi cat kim loai : Trong suot qua trnh cat got mat trc cua dao luon tiep xuc va co chuyen ong tng oi vi mat a gia cong cua chi tiet. S tiep xuc gia cac phan t kim loai co nhng ac iem ang chu y: - S tiep xuc thc hien di ap lc ln. - Qua trnh dien ra nhiet o cao.

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- He so ma sat tai vung tiep xuc co chuyen ong rat ln ( =0.4 1 ) - Moi phan t kim loai cua dao ch tiep xuc vi phan t phoi hay chi tiet co mot lan va khong lap lai. T ly thuyet ve mai mon Summer Smiht va Delepiereux a khai quat thanh 4 nguyen nhan dan en mai mon dao nh sau : +Mai mon do qua trnh ma sat c hoc gay nen Khi cat cac be mat cua dao luon tiep xuc va chuyen ong tng oi vi phoi va chi tiet. Di tac dung cua tai trong cac phan t kim loai tai vung tiep xuc se phat sinh moi lien ket kim loai. Neu moi lien he nay ln hn o ben ban than moi kim loai tham gia tiep xuc th ban than cac phan t kim loai loai co o ben nho se b bc ra va loi i. +Mai mon do s xuat hien va mat i lien tuc cua cac khoi leo dao: Khi cat tai vung tiep xuc gan mui dao hnh thanh nen cac khoi leo dao co o cng cao hn o cng cua ban than kim loai tham gia tiep xuc. Mat khac do sinh ra va b loi i lien tuc dan en toc o mai mon tren cac be mat dao tang len. +Mai mon do hien tng khuech tan tai vung tiep xuc: Vat ly a chng minh : Co hai kim loai ep vao nhau neu ta ot nong tai vung tiep xuc th o xuat hien hieu ien the. Cac phan t kim loai cua hai vat tiep xuc se khuech tan vao nhau. Hien tng nay con goi la hien tng tham thau. +S xuat hien va phat trien cac vet nt te vi dan en gay v dao b. cac dang mai mon dao: - Mai mon mat sau - Mai mon mat trc - Mai mon li liem - Mai mon mui dao - Mai mon li cat Thong thng ca 5 dang mai mon ong thi xay ra tren dao cat. Song vi mot dao cho trc tai mot thi iem khao sat vi nhng ieu kien cat cu the th co 1 hoac 2 dang mai mon la ac trng. Loai mai mon ac trng thng phu thuoc vao vat lieu gia cong, vat lieu dao, phng phap cat va tnh chat cat got.

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+Mui dao b mai mon : V tr tiep xuc gia dao va chi tiet (theo phng t ) se thay oi dan en thay oi ng knh gia cong, mat khac ban knh mui dao (R ) thay oi se dan en s thay oi khi cat. +Mat sau khi b mai mon (goc sau Oo) lam tang s tiep xuc gia mat sau dao va mat ang gia cong cua chi tiet. S tiep xuc lam tang s ang ke tai trong lc va nhiet . +Mat trc dao b mai mon ( goc trc dao am ) lam tang mc o bien dang khi cat va cung dan en tang tai trong . +Mai mon li liem: lam tang goc trc tang len phoi de thoat, nhng ngc lai lam yeu dao (). o ln li liem nay tang en mc nao o dao khong con kha nang chu c lc cat c na se gay gay v dao. +Cun li cat: Dao cun se khong the ht bt lp kim loai ra khoi chi tiet ma ch trt tren be mat gia cong. c. Cac giai oan cua qua trnh mai mon dao: Ly thuyet mai mon noi chung va ket qua th nghiem ve mai mon dao a noi rieng a chng minh rang: qua

I
O

a T

trnh mai mon dao dien ra trong ba giai oan. +Giai oan bat au mai mon O co toc o mai mon ln dien ra trong thi gian ngan, mai mon chu yeu trong giai oan nay la sang bang c hoc cac nhap nho e lai khi gia cong c. +Giai oan mai mon bnh thng co toc o mai mon nho dien ra trong thi gian dai, giai oan tng t nh

40

giai oan lam viec bnh thng cua cac chi tiet may sau thi ky chay ra. +Giai oan mai mon khoc liet (sau) vi toc o ln dien ra trong thi gian ngan lien sau o la dao b chay hoac b gay v mat kha nang cat. iem c goi la iem mon ti han. o cng mai mon tng ng vi iem goi la o mai mon cho phep.

. Chat lng be mat gia cong.

1. o bong be mat gia cong. a. Khai niem ve chat lng gia cong: oi tng cua qua trnh cat got la chi tiet gia cong. Do anh hng nhieu yeu to co lien quan en qua trnh cat got cho nen chi tiet thc te c gia cong bao gi cung co sai lech vi chi tiet thc te. Nhng sai o phan lam 2 nhom: -Nhom sai lech ai quan (phat hien bang mat thng ) ve kch thc, hnh dang v tr tng quan gia cac be mat khai niem ve o chnh xac gia cong. -Nhom sai lech te vi : o nhap nho be mat, s thay oi tnh chat c ly lp be mat ,. khai niem ve chat lng be mat gia cong. b. Chat lng be mat a gia cong. * o nham va o bong be mat: Nguyen nhan s khac nhau gia be mat ly tng va be mat gia cong thc te. - Be mat a gia cong la s sao chep hnh dang li cat cua dao. - Co lng chay dao S lam cho cac vet cat khong lien tuc e lai phan kim loai cha cat. - Do s rung ong cua he thong cong nghe MGDC. - Do qua trnh bien dang va ma sat lam phat sinh nhng vet nt te vi. Ket qua cua nhng nguyen nhan tren a e lai tren be mat cua chi tiet sau gia cong nhng vet loi, lom.Vet loi, lom c goi lao nhap nho va tuy thuoc vao chieu cao cua cac nhap nho phan lam cac cap o bong. * Cac so o nham be mat : at trng 4 loai : +o khong bang phang (Rmax) la khoang cach o theo phng y t nh cao nhat ti ay nhap nho cua cac nhap nho trong khoang chieu dai 1 n v tnh la mk.

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+Chieu cao nhap nho trung bnh( Ra) la khoang cach trung bnh cua cac iem tren profin en ng trung bnh. Ra c xac nh theo cong thc:

1 n Ra = y i n i =1

1 2 hq = y dx l 0
+So o o nham hq c tnh theo bieu thc: +Chieu cao nhap nho Rz Chieu cao nhap nho Rz c xac nh bang cach chon tren chieu dai c s 5 nh nhap nho on nh va 5 ay nhap nho on nh. o chenh lech trung bnh gia cac nh va ay o chnh la Rz. V du: ta chon 5 nh 1,3,5,7,9 co khoang cach ti ng chuan la h1,h3,h5,h7,h9 5 ay 2,4,6,8,10 co khoang cach t ay ti ng chuan la h2,h4,h6,h8,h10 th:

Rz =

( h1 +h3 + +h9 ) +( h2 +h4 + +h10 ) ... ... 5

2. Hien tng cng nguoi: Hau qua cua bien dang an hoi va bien dang deo sau khi cat la tao tren be mat chi tiet 1 lp kim loai b nen khien cho be mat o tr nen ben va cng hn so vi

42

ban than cau truc cua kim loai o. o la hien tng cng nguoi, e anh gia hien tng cng nguoi ngi ta dung mot so thong so sau: - Mc o cng nguoi H

= H

H H0 x100 % H0

Trong o: H o cng lp mong be mat sau khi bien dang deo. H0 o cng lp mong be mat trc khi bien dang deo. - Chieu sau cng nguoi. - Tr so, chieu sau va dau cua ng suat d lp be mat. Khi gia cong do mui dao khong nhon l tng ma co ban knh R nen khi cat mat sau cua dao trt tren be mat gia cong cang lam tang mc o bien dang deo tren be mat chi tiet. Con s bien dang cua khoi kim loai vung pha trc mat dao se lam tang chieu sau cng nguoi. Tat ca cac thonh so ve che o cat, hnh dang hnh hoc cua dao lam tang s bien dang. Con khi dao b cun goc sau giam, khong dung dung dch boi tron nguoi,se lam tang mc o cng nguoi. Hien tng cng nguoi co anh hng xau en chi tiet v lp cng nguoi don de b ran nt ong thi gay kho khan cho lan gia cong sau.

HOC TRNH II

TIEN - CAT REN - BAO (XOC) GIA CONG LO

1-TIEN

I.Tnh chat cua tien:

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- Tien la phng phap gia cong cat got kim loai thong dung nhat. Trong cac nha may c kh, may tien chiem so lng ln nhat, khoang 30% en 40%. - Chuyen ong chnh khi tien la chuyen ong quay tron cua phoi, chuyen ong chay dao la chuyen ong thang cua dao tien theo phng doc truc hoac hng knh cua phoi. - Toc o cat trung bnh khi tien c xac nh theo cong thc: Trong o:

V =

n. .D ( m / ph ) 1000

D- ng knh trung bnh cua be mat can gia cong va be mat a gia cong [mm]. n- so vong quay cua phoi trong mot phut [vg/ph]. Lng chay dao (bc tien) c bieu th bang quang ng cua mui dao di chuyen sau mot vong quay cua phoi,

S t

co n v tnh la: mm/vong. Chieu sau cat c tnh theo cong thc:
t= Dd ( mm ) 2

Trong o: D ng knh cua be mat can gia cong[mm] d- ng knh cua be mat a c gia cong [mm]

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II. Kha nang cong nghe cua tien:

Tien chu yeu e gia cong cac be mat co dang tron xoay nh mat tru ngoai, tru trong, mat con ngoai, con trong, cac mat au, mat nh hnh tron xoay, ren trong, ren ngoai. o chnh xac cua gia cong tien phu thuoc vao cac yeu to sau ay: - o chnh xac cua may tien. - o cng vng cua he thong cong nghe. - Dung cu cat. - Trnh o tay nghe cua cong nhan. Chat lng be mat chi tiet gia cong phu thuoc vao cac

yeu to nh v tr be mat gia cong (mat ngoai, mat trong, mat au) va phng phap gia cong (tien tho, ban tinh, tien tinh). o chnh xac ve v tr tng quan nh o ong tam gia cac bac cua truc, gia mat trong va mat ngoai co the at ti 0.01mm tuy thuoc vao phng phap ga at phoi. Nang suat gia cong tien phu thuoc vao nhieu yeu to nh o chnh xac ve hnh dang, kch thc va v tr tng quan cua cac chi tiet, phng phap ga at, vat lieu lam dao, ket cau dao, vat lieu gia cong ,dung dch trn nguoi.v.v. Nhn chung nang suat cua tien la thap. Muon nang cao nang suat khi tien phai co nhng giai phap cong nghe thch hp cu the.

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III. Ga at chi tiet khi tien:

Khi tien ta co the co mot so cach ga at chi tiet nh sau: - Ga tren mam cap 3 chau t nh tam (mat ngoai hoac mat trong) oi vi chi tiet ngan, co l < 5d.
10 l 5 d

- Ga tren mot au vao mam cap 3 chau va mot au vao mui tam khi: - Ga tren mam cap 4 chau khong t nh tam. - Ga vao 2 lo tam co s dung kep toc khi l/d>10. - Ga tren cac loai o ga khi chuan la mat trong . - Ga tren cac loai o ga chuyen dung. Trong thc te, kieu ga mot au vao mam cap 3 chau t nh tam va mot au vao mui tam c s dung nhieu nhat. oi vi nhng truc dai, yeu, co l/d >12, ngoai viec truc c ga tren mam cap va mui tam con phai dung luy-net (gia ) e tang o cng vng cho chi tiet. Co 2 loai luy-net, o la luy-net tnh va luy-net ong (hnh 8.3a,b) Luy net tnh c ga co nh tren ban may tien .

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Luy-net ong thng c gan tren xe dao va no di chuyen theo dao trong qua trnh cat. Luy-net ong co o cng vng kem hn nhng do c di chuyen theo dao nen luon luon nam gan v tr cua dao cat nen phat huy c tac dung hn so vi luy-net tnh. Luy-net ong thng ch s dung khi tien truc trn va truc a gia cong s bo.

IV. Cac loai dao tien:

Tuy theo tng dang be mat can gia cong, tuy theo muc ch s dung va tuy theo phng phap tien ma ta co the s dung mot trong cac loai dao. Khi tien ta con co the s dung mot so loai dao khac nh mui khoan, mui khoet e gia cong lo va cac loai dao tien nh hnh e gia cong cac be mat tru co ng sinh trung vi bien dang li cat cua dao.

V. Lc cat khi tien:

Lc cat la lc tac dung t dao vao phoi e tach ra phoi tao nen be mat chi tiet gia cong. Nh a phan tch, qua trnh hnh thanh phoi la mot qua trnh c nhiet phc tap. Viec nghien cu lc cat la nghien cu nguyen nhan sau xa cua s hnh thanh phoi. Mat khac gia tr cua lc cat la thong so e xac nh lng tieu hao cong suat may, tnh sc ben cua than dao, o ga, * Tong hp va phan tch lc cat:

FT

NS

FS NT

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Khi cat, tren mat trc cua dao xuat hien lc phap tuyen NT va lc tiep tuyen FT (lc ma sat gia dao va phoi). Tren mat sau cua dao xuat hien lc phap tuyen NS va lc tiep tuyen FS (lc ma sat gia dao va phoi). Hp cac lc lai ta c lc cat P. Lc cat phu thuoc vao rat nhieu yeu to va thay oi trong mot pham vi rong theo kha nang cat cua may. e thuan tien cho nghien cu, ta thiet lap mot he toa o ecac va phan lc P thanh 3 lc theo 3 phng x, y, z. Trong o: Px _ Lc chieu truc, tac dung len c cau chay dao (con goi la lc chay dao). Py _ Lc hng knh, gay vong chi tiet gia cong, gay rung

n
PX

PZ PY

ong trong mat phang ngang xOy. Lc PY co anh hng trc tiep en o chnh xac hnh dang hnh hoc va chat lng be mat chi tiet gia cong. Pz _ Lc tiep tuyen co phng trung vi phng cua chuyen ong cat chnh. No co tr so ln nhat trong 3 thanh phan lc phan tch, con goi la lc cat chnh. Lc PZ dung e tnh hoac kiem nghiem ve cong suat cat (momen), tnh hoac kiem nghiem sc ben than dao. Trong ieu kien gia cong tien bnh thng vi dao co mui c ga ngang tam (vi S < t ; = =150 ; =0). Ta co: PZ : PY : PX = 1 : 0.4 : 0.25
P = Px2 + Py2 + Pz2 = 1,11Pz

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* Nhng nhan to anh hng en lc cat. Co the coi lc cat la mot ham cua cac yeu to: P = f(V, t, S, , , , R, , 1,,, , , ,). ay: V, t, S Cac yeu to cua che o cat; , , , R, , 1, _ Cac thong so hnh hoc cua dao cat; _ Lng mon cua dao; O _ Dung dch trn nguoi ; M _ Vat lieu gia cong ; N _ Vat lieu lam dao. * Mot so tnh toan lien quan en cac thanh phan lc cat. + Cong suat khi tien :

NC =
_ Cong suat cat :

PZ .V , ( KW 60 .1000

N dc =

_ Cong suat chay dao: Cong suat can thiet e chon ong c cho may gia cong

Px .n.S , ( KW ) 6 60.10

N dc =
:

N c + N cd

+ Momen cat cua truc chnh may tien :

M c = Pz
y= Py .l 3 KEI

D [ M ] x , Nmm 2
[Y ], ( mm )

+ o vong cua chi tiet gia cong khi tien. (chi tiet c coi nh mot dam chu lc tap trung PY): Trong cac cong thc tren: PX, PY, PZ _ tnh bang N;

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V Van toc chuyen ong chnh (m/ph); N _ So vong quay truc chnh may (vg/ph); S _ Lng chay dao (mm/vg); _ Hieu suat cac khau truyen ong trong may tnh t ong c; D _ ng knh chi tiet gia cong (mm); [M]x _ Momen xoan cho phep tren truc chnh (Nmm); l _ Chieu dai chi tiet gia cong (mm); I _ Momen quan tnh tiet dien chnh cua chi tiet gia cong (mm4); E _ Moun an hoi vat lieu gia cong (N/mm2); K _ He so phu thuoc dang lien ket ; [y] _ o vong cho phep cua chi tiet (mm).

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Bai 2

CAT REN

I/ Cac phng phap gia cong ren ac iem qua trnh gia cong:
Qua trnh tao ren, nhat la ren chnh xac cao la mot qua trnh phc tap va cong phu. Tuy theo dang ren, kch thc ren, o chnh xac cua ren va loai hnh san xuat ma ngi ta co the tao ren bang cac phng phap khac nhau.

Qua n ca

Pho i

Qua n ca

Gia

P n n

P ho i

Q u a cn a a o n d
S

Q u a c a n

A =C o n st

P
B c t e a a r n n n

P n
Po h i Po h i Q ac u a n

na
S

B c d c h a a on n n i

Va hc a n n

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+Cat ren bang dao tien ren: c tien hanh tren may tien ren van nang. o la phng phap gia cong ren van nang nhat va c dung pho bien. Bang cach tien ngi ta co the tien hanh tao ren co hnh dang tuy theo y muon kch thc bat ky. +Cat ren bang taro ban ren: c tien hanh bang tay hay tren may khoan kem theo o ga, tren may re von ve ,may t ong, may chuyen dung. +Cat ren bang dao rang lc thng tien hanh tren cac may R-von-ve, ban t ong va t ong. No la mot hnh thc tien ren vi dao tien co ket cau ac biet. +Cat ren bang dao phay c tien hanh tren may phay chuyen dung gia cong ren. Dung phay ren e cat ren tren cac chi tiet ln, ren nhieu au moi hoac ren tren cac chi tiet co ranh va chi tiet co thanh mong. No co the tao ren ngoai hoac ren trong at cap chnh xac 2-3 tren cac chi tiet hnh tru hoac con. Phng phap gia cong ren bang phay thng c dung trong san xuat hang loat . +Cat ren bang au cat ren : Dung au cat ren co the cat ren ngoai va ren trong tren may chuyen dung hoac tren may tien ren van nang. Tren than cua au cat ren co lap cac dao cat ren rang lc. cuoi hanh trnh cat, cac dao nay co the c ni nhanh ra khoi vung tiep xuc vi chi tiet, do o viec lui dao (hanh trnh chay khong) c tien hanh nhanh hn va se giam thi gian phu. Nang suat cua qua trnh cat ren bang au cat ren rat cao, do o cat ren bang au cat ren thng c dung trong san xuat hang loat ln va hang khoi. +Mai ren : Mai ren thng goi la gia cong tinh, gia cong chnh xac ren a qua toi cng. +Can ren : Co cac phng phap can ren nh sau: can ren hng knh, can ren tiep tuyen, can bang ban can, can bang vanh can. Can ren hng knh: Bc ren cua qua can c che tao bang bc ren can can. ng knh cua can D va so vong quay n nh nhau quay ngc chieu nhau, phoi can can at gia hai qua can trong vung can phoi t quay tai cho, mot trong hai qua can tien dan (A) vao phoi e can. Khi tien u chieu cao ren can can th ngng chay vao va chay ra ngc lai e lay phoi. Phng phap nay ep dan dan nen can c ren co kch thc ln, ng knh cua qua can khong phu thuoc vao ng knh ren can can, nhng co nhc iem la thi gian chay khong ln (qua can phai lui ra e lay san pham).

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Can ren tiep tuyen: Nguyen tac cua can ren tiep tuyen la,Vi kch thc bc ren ng knh ren nhat nh phai tnh toan thiet ke cac thong so hnh hoc qua can hoac so vong quay cac truc can sao cho phoi can va t quay va t chuyen ong qua vung can, khi o khoanh cach tam hai truc can khong oi (A=const). Phng phap nay nang suat cao, de t ong hoa cap , thi gian chay khong rat be(can lien tuc ), nhng han che ve kch thc phoi can do han che cong suat kem. Can ren bang ban can rat phu hp cho can ren ng knh be nh nan hoa xe ap ,inh vt.

/Tien ren
Tien ren la phng phap gia cong ren c dung rong rai nhat. No c tien hanh tren may van nang . Dung dao tien co hnh dang li cat thch hp , ngi ta co the tien ren tam giac , ren hnh thang , ren vuong , ren tron vv vi mc ren ng knh tuy y.

+Dao tien ren : Tuy theo yeu cau cua san xuat va cua may s dung ma ngi ta co the dung dao tien ren hnh vuong ,hnh thong thng hoac dao hnh lang tru mot va nhieu rang , dao ren hnh a rang lc.

53

Loai dao tien ren hnh thang c dung pho bien hn ca, v no n gian, nhng khi mon ta phai mai lai ca mat trc va mat sau nen tuoi tho kem. Dao tien ren hnh a va lang tru (mot rang hay rang lc) khi mon ch mai theo mat trc ,do o tuoi tho cao hn.

2 + 1
1

1 = 2

1 = 2

Khi tien ren, v tr tng oi cua phan cat cua li dao oi vi be mat gia cong co anh hng ti o chnh xac cua ren c cat va cac goc o cua dao trong qua trnh trnh cat. Noi chung be mat ren dung trong cac moi lap ghep trong nganh c kh thng la be mat vt Ac-si-met. Do o e am bao o chnh xac hnh hoc cua ren , dao tien ren phai co goc trc =0, goc mui dao tren mat trc bang goc dang ren va khi ga dao phai am bao mat trc cua dao nam trong mat phang ay i qua tam chi tiet khi gia cong tho, co the lay = 5-25 o tuy theo vat lieu gia cong va vat lieu dao. Do anh hng cua lng chay dao (bang bc ren) nen goc sau hai li ben cua dao tien ren b thay oi. Neu k hieu goc sau mai 1 va2, goc sau khi cat va c1 va c2, lng thay oi x th ta co: Neu k nhieu goc sau mai la 1 va2, goa sau khi cat la c1 vac2 , lng thay oi x th ta co : c1 = 1 + x c2 = 2 + x

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Goc sau x chnh la goc nang cua ng ren ng vi iem ren khao sat tren li cat . Neu ta lay iem man tren ng knh trung cua ren e

Tg x =
khao sat:

S .D

Trong o: S bc ren (mm) D ng knh trung bnh cua ren (mm) Chnh goc sau trong qua trnh cat c1 vac2 mi co vai tro quan trong khi cat ren tam giac th goc x thng nho (nho hn 2 -3 o) do o ta co the bo the bo qua ong thi e n gian cho gian cho che tao ta lay goc sau mai hai au li ben bang nhau va bang goc sau khi cat . 1=2=C . Khi cat ren hnh thang, ren vuong hoac cac ranh xoan co bc ln th thng goc x co gia tr ln. Luc o phai am bao goc sau toi thieu khi cat tiet dien chnh A-A va B-B khoang 2-3 o) .Ngha la khi mai ta phai am bao goc sau li trai (A) va li cat phai(B) nh sau: A=cA +N B=cB_N c1=1+x cA va cB la goc sau trong qua trnh cat o trong tiet dien phap vi li cat trai va phai N la lng chenh lech gia goc sau tnh va ong trong tiet dien phap. tgN= tgx sin .

180 0 0 = 2
Trng hp gia cong tho, e tranh phai mai lai hai goc sau khac nhau, ong thi e cai tao ieu kien cat li cat ben phai (tai ay goc trc co gia tr am), ta quay dao tien i quanh truc cua no mot goc . Khi o goc sau trong qua trnh cat li trai va phai bang nhau. c1=c2 Va 1= 2=0

: la goc hnh dang cua ren .

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+ S o cat ren khi tien ren: Cat ren vi nhng s o khac nhau co anh hng en o chnh xac va tuoi ben cua dao. ngi ta co the cat ren theo cac s o cat sau ay.

L p

Mah n

Phoh i p

S'

S'

S'

Theo s o hnh (a) tren sau moi lan chuyen dao, dao tien c chuyen dch thang goc vi ng tam chi tiet e cat lp kim loai tiep theo. Trng hp nay ca hai li cat cung tham gia cat, do o lc cat ln nhng o bong mat ren cao, thng c dung gia cong ren co bc P 2.5mm. Theo s o hnh (b) li dao ben phai hau nh tham gia cat. No ch ma sat vi be mat gia cong, do o mat ren khong bong, li dao chong mon. Song li ben trai lai cat lp phoi co chieu day cat ln, do o lc cat n v giam i, ieu kien thoat phoi tot hn.Thng ap dung cho viec gia cong tho ren co bc P 2.5mm S o hnh (c) ket hp ca hai s o a va b e tan dung u iem cua chung khi cat tho th theo s o b, en luc cat tinh th theo s o a, ren c cat se co o bong cao va ieu kien cat thuan l hn. + Che o cat khi tien ren. a- Lng chay dao ngang sz : Gia tr cua sz quyet nh so lan chuyen dao. Thng nhng hanh trnh trc lay sz ln con nhng hanh trnh cuoi lay sz nho e am bao o bong cua ren cao.

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Khi cat tho: sz =0,4 -0,25 mm Khi cat tinh: sz = 0,15 -0,1 mm b- Toc o cat: Khi tien ren bang dao tien thep gio, toc o cat tnh theo cong thc sau:

v=

Cv
x T msyv szv

Kv

m/ph

Trong o : T tuoi ben cua dao phut. S bc ren mm. Sz lng chay dao ngang sau moi hanh trnh chay dao mm.

v=

Cv .i qv
n T msyv bv

Kv

m/ph

Trong o : i so hanh trnh chay dao. b gii han ben cua vat lieu gia cong N /mm2. +Tnh thi gian may.

T0 =
Trong o :

L .i.q phut. n.s

L = l 1 + l2 + l

.l1 lng an ti l1 = (1-3) s mm. .l2 lng vt qua mm lay l2 = l1. .l chieu dai oan ren b cat mm. .i so lan chay dao e cat het chieu cao ren. .n so vong quay cua chi tiet trong mot phut vg/ph. .s bc ren mm. .q so au noi ren.

III - Cat ren bang ta-ro va ban ren:

Ta ro va ban ren la hai dung cu cat ren a c tieu chuau hoa va thong dung. Ta ro dung e cat ren trong, con ban ren e cat ren ngoai. Tuy theo hnh dang ket cau va o chnh xac che tao ma ta ro co the cat ren at ti o chnh xac cap 1, con ban ren thng ch e cat ren cap chnh xac 3. Ngi ta co the s dung chung bang tay (trong san xuat n chiec hay sa cha ) hoac tren cac may van nang, may t ong va may chuyen dung.

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1 - Ket cau cua ta ro.

Theo cong dung co the chia ta ro thanh cac nhom sau : Ta ro tay, ta ro may, ta ro ai oc, ta ro e gia cong ban ren, v.v... Nhng ve mat ket cau chung th chung eu giong

Pa c h a n t

Pa s ug h n a n Pa l v ha i c n me

Pa o h u n i

nhau. Ta ro co hai thanh phan chnh : phan lam viec va phan can (phan uoi). Tren phan lam viec lai c chia ra lam hai phan : -Phan cat co chieu dai : vi goc nghieng chnh la =25 300, lam nhiem vu cat lng d kim loai va tao hnh ren. - Phan sa ung : dung e sa ung profin cua ren ong thi co tac dung nh hng ta -ro trong qua trnh cat. Do o ngi ta con goi phan nay la phan nh hng. e giam ma sat gia be mat ren cua ta -ro va cua chi tiet gia cong, ong thi e giam o lay rong lo ren, ngi ta lam ng knh ren phan sa ung nho dan ve pha chuoi vi lng giam khoang 0,1 - 0,3 mm tren 100 mm chieu dai . - Phan can : dung kep ta-ro trong au kep e truyen mo -men xoan khi taro. cuoi phan chuoi co mot oan ngan co tiet dien vuong, e kep ta-ro trong tay quay khi lam viec bang tay. Ngoai ra phan can con la ni e ghi nhan hieu va so cua ta - ro trong bo . - oi vi ta-ro tay moi bo co t 2-3 chiec. ng knh cua ta-ro so 1 nho nhat roi en so 2 hoac 3 (neu la bo 3 chiec ). Ta- ro so cuoi cung trong bo co ng knh phu hp vi ng knh ren can gia cong. Muc ch la nham phan chia tai trong cho moi lan cat. Thong so hnh hoc cua taro: Goc trc cua taro chon trong khoang 0 - 30 0 tuy theo vat lieu gia cong .

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Goc sau tren phan con cat c tao ra bang cach mai ht lng rang theo ng knh ngoai. Tuy theo vat gia cong va kieu ta-ro ma = 3 -120 . oi vi nhng ta-ro co mai profin ren th ngi ta tao goc sau ca tren phan nh hng ng knh ngoai va hai li ben cua rang. Goc sau tren hai li cat o trong tiet dien vuong goc vi truc ta-ro khong ln lam, thng khoang 15-20 phut. Viec ht lng tien hanh ong thi vi qua trnh mai ren tren may mai ren. Goc nghieng chnh tuy theo loai ta-ro va ieu kien cat ma co gia tr khoang 3030 250. Ranh ta ro dung e cha phoi. Tuy theo ng knh ma so ranh co the t 3 - 6. oi vi ta-ro tieu chuan, e de che tao ngi ta thng lam ranh thang. Khi gia cong ren co o chnh xac cao nh ren cua ban ren hay ren trong lo sau, e de thoat phoi ngi ta lam ranh xoan. e gia cong ren trong lo sau th lam ranh xoan trai, con thong thng th lam ranh xoan phai. Goc xoan thng lay t 10 160. taro ranh thang, e hng phoi ve phia au ta-ro (khi gia cong ren trong lo thong) th ngi ta mai vat ranh tren phan con cat nghieng mot goc = 7 100 2. Ket cau ban ren tron:

Ban ren la dung cu e cat ren ngoai cua ren tieu chuan. Ve mat cau tao chung giong nh mot chi tiet co ren trong (ai oc), xung quanh c khoan t 3 en 5 lo e tao ra li cat va thoat phoi. Ngoai ra tren ban ren con co ranh chong xoay, lo e ty vt bat chat

59

Cac kch thc cua ban ren tron nh sau: ng knh ngoai cua ban ren d: ng knh nay a c tieu chuan hoa phu hp vi kch thc cua dung cu lap ban ren. Be day ban ren l: tuy theo kch thc bc ren ma co chieu day khac nhau, nhng t nhat cung phai u cho phan sa ung cua ban ren co t 5 en 6 nh ren. Trong phan lam viec cua ban ren co cau tao kieu rang lc, phan cat co ca hai au va o vat vi goc khoang 300 e cat dan chieu sau ren va nh hng cho ban ren i ung khi bat au cat. Phan dan hng va phan sa ung lam nhiem vu cat tinh am bao cho ren ung kch thc. Goc trc ban ren lay trong khoang 10250 phu thuoc vao vat lieu gia cong. Goc sau cua ban ren phan con cat va lay khoang 6090 o trong tiet dien vuong goc vi ng tam cua ban ren. Viec tao goc sau tren phan con cat ca hai au ban ren c thc hien bang cach ht lng (tien va mai) theo phng chieu truc cua ban ren. Rang tren phan sa ung khong co goc sau. 3- S o cat va cac yeu to cat khi cat ren bang ta-ro va ban ren.

Tuy theo yeu cau ve o chnh xac cua ren c gia cong ma ngi ta dung cac s o cat khac nhau.

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Theo s o hnh (a): cat be mat ren sau khi cat co do bong thap, nhng viec che tao phan con cat cua dung cu de dang, v ch co mot goc . Khi che tao ta-ro hay ban ren, ngi ta ch viec ht bo phan nh theo goc . Loai nay thng dung cho cac loai ta-ro e gia cong ren cap chnh xac thong thng va cho ban ren tieu chuan. Theo hnh (b): Ren tren phan con cat c che tao di dang ren con vi goc nghieng cua ren la 1 va goc nghieng cua be mat phan con cat la . Vi s o cat nay, be mat ren c cat ra se co o bong tot hn loai tren, nhng chieu day cat do li cat ra nho ma chieu rong cat lai ln. Do tai trong n v se tang len, them vao o ,viec che tao phan ren con se kho khan hn. Ket cau loai thng ch dung cho ta-ro e gia cong tho ban ren va mot so ta-ro tinh khac. Theo s o (c),ca 3 ng knh cua ren phan con cat eu co goc nghieng 1, ngha la co dang ren con co goc con la 2 1 .Ren c cat theo s o nay se at do bong va chnh xac cao. Li cat nh cat lp kim loai co chieu day a mong hn loai theo s o hnh b. Viec che tao loai ta-ro theo kieu s o cat nay cung phc tap nh loai th hai. No thng ch dung cho ta-ro e gia cong tinh ban ren va ca-lip ren trong lo. Chieu rong cat b la mot lng thay oi t lp cat no en lp cat kia. Chieu day cat la a o trong phng vuong goc vi li cat ( ay la vuong goc vi phng b). Song v goc thng nho, nen chieu day cat gan ung c lay la a vuong goc vi ta-ro. Neu ta- ro co Z ranh th tren chieu dai bang mot bc ren, chieu day cat tong se la Z.a. Chieu day cat do mot rang cat ra c tnh theo cong thc sau: t a= mm P Trong o : .t - chieu cao cua ren mm .P- so rang cat (hnh rang lc) tren tat ca cac mat cat thuoc phan con cat. Neu goi n la so rang tren mot mc cua ta -ro (hay ban ren ) th: p = n.Z t do o : a= n.Z V n = t1/ s nen co the viet nh sau :

61

a=

t.s t1 .Z

mm

V t/t1 = tg nen ta co : a=

Trong o : t1 chieu dai phan con cat mm s bc ren mm Z so ranh cha phoi (hay so mc). Theo cong thc (*) th chieu day cat a ty le nghch vi so mc Z va ty le thuan vi tg . Qua quan he nay,ta co the phan tch c anh hng cua goc hoac so ranh Z en lc cat n v, nhiet cat, o mon cua li cat...qua s thay oi cua chieu day cat a. Dien tch cat tong do tat ca cac rang cung cat khi taro lam viec(oi vi ren tam giac) tnh theo cong thc sau:

s tg Z

(*)

s.t 2 4. Mo men xoan va toc o cat khi cat ren bang ta-ro va ban ren:
F= Trong qua trnh cat, khang lc chnh tac dung len ta-ro va ban ren la mo-men xoan. Cac nhan to gay ra mo-men xoan la: mo-men cat do lc tao phoi Pz mo-men ma sat do s ma sat gia mat sau cua cac rang cat vao be mat ren c gia cong va mo-men ma sat cua phoi vao be mat ranh thoat phoi trong qua trnh thoat phoi. Lc chieu truc tren ta-ro khi ta-ro lam viec b triet tieu nhau tren cac mat ren oi lap. Trong trng hp chieu dai lo l ngan hn chieu dai phan con cat l1 , Th ban au mo-men xoan tang dan (theo ng cong AB) . en khi suot chieu dai lo l a c tiep xuc vi cac rang tren phan con cat, co ngha la so rang cua ta-ro tham gia lam viec at tr so ln nhat, th mo men xoan at gia tr cc ai iem B. Sau o, theo mc o i ra khoi lo cua phan con cat th mo-men xoan giam dan ( theo ng BC).Luc nay cac rang sa ung cha tham gia cat ,nhng v cac rang cang ve pha cuoi phan con cat th cat lp kim loai co dien tch cat cang nho (v chieu rong cat b nho dan), nen lc cat Pz nho dan , do o mo-men xoan giam. Khi cac rang sa ung bat au i vao lo ren th mo-men cat giam dan (theo ng CD).

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Trng hp chieu dai lo ren l ln hn chieu dai l1 cua phan con cat th sau khi mo men at en tr so cc ai iem B no se gi nguyen gia tr (theo ng BC) cho ti khi rang au tien tren phan con cat bat au ra khoi lo th mo-men cat giam dan (theo ng CD). Thc ra do co ma sat phan sa ung, nen khi cac rang cua phan con cat tuy a hoan toan ra khoi lo nhng mo-men xoan iem D van con co gia tr nhat nh (tuy nho). Mo-men xoan khi cat ren bang ta-ro va ban ren c tnh theo cong thc sau : N.mm (1) Trong o : D -ng knh ngoai cua ren mm. S -bc ren mm. Cm -he so co nh. Km -he so hieu chnh en anh hng cua vat lieu gia cong, o mon cua dao, dung dch trn nguoi . o bong mat ren cua taro cang cao th lc ma sat cang giam, do o Mx giam. Khi dung dung dch trn nguoi mo-men xoan giam i ang ke. S thay oi cua momen xoan khi cat ren trong lo thong bang ta ro a- Chieu dai phan con cat ln hn chieu sau lo ren. b- Chieu dai phan con cat nho hn chieu sau lo ren. So ranh cua ta-ro giam va goc trc tang se lam Mx giam. Neu khe h gia ng knh cua lo va ng knh trong cua ren ta-ro be hn 0,1 0,2 mm th Mx tang len rat

Dxm .sym .K m Mx =Cm .

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ln. Cong suat cat khi cat ren bang ta-ro va ban ren c tnh theo cong thc sau : M x .n Nc = kW 975000 Mx -mo-men xoan Nmm. n - so vong quay cua dung cu cat (hay chi tiet) vg/ph Toc o cat tnh theo cong thc sau : v=

C v . Dqv T .s
m yv

kW

(2)

T la tuoi ben cua dao phut. Trong thc te, khoang toc o cat trung bnh thng dung e gia cong tren may: oi vi ta -ro P9 va P18 co ti nc lam nguoi th: V = 6 15m/ph ; oi vi ban ren tron Y10 va Y12 th v = 3 6m/ph . Ga tr cua cac he so va so mu trong cac cong thc (1) va (2) cho trong cac so tay ve che o cat.

Bai 3

BAO VA XOC

I. Tnh chat chung cua bao va xoc:

Bao va xoc la hai phng phap gia cong kim loai co cac chuyen ong gan giong nhau trong qua trnh cat. oi vi bao, chuyen ong chnh la chuyen ong thang, tnh tien kh hoi gom mot hanh trnh co tai va mot hanh trnh khong tai. Chuyen ong nay co the do dao hoac ban may mang chi tiet thc hien. Chuyen ong nay thng co phng nam ngang. Xoc la trng hp ac biet cua bao co chuyen chnh do dao thc hien theo phng thang ng con chuyen ong chay dao do chi tiet thc hien. Do chuyen ong cat thc hien theo hai phng khac nhau nen tnh nang va kha nang cong nghe cung khac nhau. Nhn chung nang suat cua ca hai phng phap nay eu thap v cac l do sau:

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-S dung dao ch co mot li cat. -Ton thi gian cho hanh trnh chay khong tai. -Toc o cat b han che do qua trnh chuyen ong kh hoi. Khi thay oi chieu quay oi hoi momen quan tnh ln.

V = t

2.L.z [m / ph ] 1000

V = o

L.z.3 0 6 1 0 . 00

[m /

p h

e bien chuyen ong quay cua mo t thanh chuyen ong thang cua au dao bao can thong qua mot he c cau cult. Toc o chuyen ong thang kh hoi c xac nh nh sau:

Vc =

Trong o: Vt toc o trung bnh cua hanh trnh kep Vc toc o trung bnh cua hanh trnh cat. V0 toc o trung bnh cua hanh trnh chay khong. L o dai chuyen ong thang cua c cau Cult(mm). Z tong so hanh trnh kep sau mot phut. - goc gii han v tr cua c cau cult, c tnh: = 360-. ay c xac nh nh sau:

L.z.360 [m / ph ] .1000

cos

L = 2 2.R

R chieu dai canh tay on cua c cau cult.

II. Kha nang cong nghe cua bao va xoc.

Bao chu yeu e gia cong cac mat phang, ngoai ra con co the gia cong cac be mat nh hnh co ng sinh thang.

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Bao co the at o chnh xac toi a la cap 8 en cap 7 va o bong at la Ra = 2,5m. Xoc chu yeu e gia cong cac be mat trong, cac ranh then tren ong, tren banh rang.v.v.

III. Dao bao va dao xoc:

Cac thong so hnh hoc cua dao bao va dao xoc nhn chung rat giong dao tien.Tuy theo v tr cua li cat, dao bao cung c chia thanh dao bao phai, dao bao trai. Dao xoc co khac hn chut t v dao xoc uc ga song song vi truc chnh theo phng thang ng. Cac loai dao bao xoc gom mot so loai dao phu thuoc vao bien phap cong nghe va tnh chat cong viec nh dao bao li cat cong; dao gia cong be mat thang ng dao gia cong be mat nghieng; dao gia cong ranh; dao gia cong tinh; dao xoc.

Nhn chung ve ket cau, cac loai dao bao va xoc n gian, che tao de dang, gia thang khong cao.

IV. May bao va may xoc:

Tuy theo nhng ac trng ve cong nghe va kch thc cua may, may bao c chia thanh nhom may bao ngang, nhom may bao ging, may bao ng (may xoc) va

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nhom may bao chuyen dung. Trong moi nhom tren lai co nhieu kieu may vi kch thc va cac thong so ky thuat khac nhau. May bao ngang co chuyen ong chnh la chuyen ong cua au bao. Loai may nay thng co chieu dai hanh trnh ln nhat cua au bao la 600 mm, nen chu yeu gia cong cac chi tiet nho va trung bnh. May bao ngang thng s dung c cau cu lt e bien chuyen ong quay cua ong c thanh chuyen ong thang cua au bao. Chuyen ong chay dao do ban may thc hien va chuyen ong gian oan nh c cau coc trong may. May bao ging dung e gia cong cac chi tiet ln, co the len en 12 met. Chuyen ong chnh do ban may thc hien. Chuyen ong chay dao do au dao thc hien gian oan. May bao ging co the co t 2 en 4 o ga dao.

V. Cac thong so cat va tiet dien lp kim loai b cat:

Tren hnh bieu dien hng chuyen ong cua phoi va dao cung nh hnh dang hnh hoc cua lp kim loai b cat khi bao. Hnh dang lp kim loai b cat khi bao cung giong nh tien, phu thuoc vao hnh dang li cat chnh. Do o viec xac nh cac thanh phan cua tiet dien cat cung nh tien. Quan he gia chieu day cat va lng chay dao, chieu rong cat va chieu sau cat, cung nh dien tch tiet dien ngang cua lp kim loai b cat, c bieu dien bang cac cong thc: a = S. sin mm; b =
t sin

(mm)

f = a.b = S.t (mm2) Trong o : a chieu day cat b chieu rong cat S lng chay dao t chieu sau cat f dien tch cat

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S o cat khi xoc rang giong bao,ch khac la dao xoc thng co = 900 nen: a =S (mm) ; b=t (mm) 2 f = a.b = S.t (mm )

oi vi bao, khi toc o hanh trnh lam viec thay oi th toc o cat trung bnh vtb co the tnh theo cong thc: L .k (1+ m) vtb = m/ph 1000 Trong o : L chieu dai hanh trnh dao theo hng chuyen ong chnh (chieu dai nay bang chieu dai be mat gia cong, cong them vi lng an ti va lng vt qua cua dao mm). K- so hanh trnh kep cua au may bao hoac ban trt cua may xoc trong mot phut. M- t so van toc cua hanh trnh lam viec chay khong, trung bnh m = 0,75. Khi xoc th tr so m = 1 va do o toc o cat trung bnh co the tnh theo cong thc: 2L .k V= m/ph 1000 Thong so hnh hoc cua dao xoc va bao, ve c ban giong dao tien va phu thuoc ieu kien cat. Goc trc thng nho hn goc trc cua dao tien,v trong qua trnh cat co va ap (nham tang goc ). Tuy tng trng hp cu the, goc trc co the co tr so t -15 + 200. Mot so goc chu yeu khac cua dao co the chon nh sau :

68

20

= 6 160 ;

= 20 700 ;

1 = 0 150 ;

=6

Trong qua trnh cat, do tac dung cua lc Px , than dao thang co the b bien dang va b uon quanh iem O, khi o mui dao se chuyen ong theo quy ao tron ban knh R. Ket qua la be mat chi tiet b cat lem lam hut kch thc chi tiet gia cong. e tranh hien tng tren, thng ngi ta dung dao bao au cong. ac iem cua dao nay la mui dao va mat ta cua than dao cung nam trong mot mat phang. Do o ban knh R bang chieu dai oan nho ra cua au dao. Vi dao co ket cau than cong nh vay th khi b uon cong se khong sinh ra hien tng cat lem vao chi tiet gia cong.

VI- Lc cat va toc o cat khi bao va xoc:

Thc chat cua qua trnh cat khi bao va xoc cung giong nh gia cong tren may tien, ch khac la khi bao va xoc dao lam viec trong ieu kien co va ap. Do o tuy rang dao chay khong (trong chuyen ong tr lai), khong cat nhng ieu kien lam viec cua bao va xoc kho khan hn tien. Qua trnh tao phoi khi bao va xoc cung giong nh tien. Cho nen co the tnh lc cat khi bao va xoc theo cong thc tnh lc cat khi tien. Chung ta cung em lc bien dang khi cat va lc ma sat R chieu xuong 3 truc XX, YY, ZZ va chung ta cung c ba phan lc: Pz Theo phng cua chuyen ong cat chnh. Py song song vi phng chay dao. Px Thang goc vi Pz va Py tac dung vao than dao. Trong ba phan lc ke tren th Pz ln hn ca va goi la lc cat chnh. Nhng khi can tnh cong suat mot cach chnh xac th ngoai lc cat ra con phai tnh them lc ma sat tren song trt cua may theo cong thc. F = (Py +Gch + Gb) Trong o : F Lc ma sat tren song trt cua may (N). He so ma sat. Py Lc hng tam (N). Gch Trong lng chi tiet gia cong (N). Gb Trong lng ban may (N).

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Tai trong dung e tnh cong suat : P = Pz + F Cong suat cat khi bao va xoc c tnh theo cong thc sau :

P.vc kW. 601000 . Trong o: vc Van toc cat ng vi hanh trnh lam viec, van toc nay la van toc cho phep bi tuoi ben cua dao. Qui luat mon cua dao khi bao va xoc giong nh tien. V du khi bao thep bang dao thep gio, trc tien dao mon mat sau, ong thi mon ca mat trc, sau o tren mat trc cung tao ra ranh li liem pha trong li cat vi mot chieu sau nhat nh. C tiep tuc cat en khi mon dao mat sau en tieu chuan mon cho phep hs (khoang 2mm) th phai em dao i mai lai. Quan he gia tuoi ben T va toc o V cung co dang giong nh tien
Nc =

V1 T 2 = V2 T1

V1 , V2 ... la toc o cat cho phep ng vi tuoi ben T1 , T2 ,... So mu m noi len anh hng cua tuoi ben en toc o cat. Tr so m con phu thuoc vao chieu dai hanh trnh bao. Neu tang chieu dai hanh trnh bao th tr so m se tang va do o toc o se tang, khi o so va ap trong mot n v thi gian giam i va ieu kien cat se tot hn. Khi tuoi ben cua dao T = 60 phut th cong thc toc o cat cua bao va xoc tnh theo cong thc toc o cat khi tien ngoai : v60 =
Cv l
xv

Cac he so, so mu va he so ieu chnh toc o co the tra trong cac so tay. V trong qua trnh bao va xoc co va ap nen toc o cat tnh theo cong thc tren phai giam i khoang 20 - 40 % hoac nhan vi mot he so ieu chnh toc o ma gia tr cua no cho trong cac so tay cat got.

.syz

.K v

m/ph

VII- Che o cat khi bao va xoc:

Nh a trnh bay tren, may bao va may xoc v nguyen ly ket cau truyen chuyen ong, nen khong lam

70

viec c toc o cao khi cat. Do o phai u tien chon chieu sau cat ln, lng chay dao toi a cho phep roi mi chon toc o cat. Khi cong suat cua may b han che, th phai giam toc o cat va tang lng chay dao Trnh t xac nh che o cat nh sau: 1- Chon dao : Can c vao ieu kien ky thuat cua chi tiet gia cong ma chon vat lieu lam dao, cac thong so hnh hoc, ket cau than dao. 2- Xac nh chieu sau cat: Khi xac nh chieu sau cat phai da vao lng d va o chnh xac gia cong (gia cong tinh hay tho). 3- Xac nh lng chay dao cho phep : Khi bao mat phang tren may bao ngang th chon : S = 0,4 - 4 mm/ hanh trnh kep, khi gia cong tho thep va gang. S = 0,25 - 1,2 mm/ hanh trnh kep, khi gia cong tinh thep va gang . Neu bao tinh (dao rong ban) vi 1 = 0 va t 0,1 mm , th lay : S 20mm/ hanh trnh kep. 4- Tnh toc o cat: Theo cong thc phu thuoc vao tuoi ben cua dao. 5- Tnh toc o cat: Theo toc o cat a tnh, xac nh hanh trnh kep trong mot phut, t o chon so hanh trnh kep co tren may va toc o cat thc te. Toc o cat thc te tnh nh sau :

vc

may bao, do toc o hanh trnh cua au may thay oi nen Vc cung la toc o cat trung bnh ( vtb) nh tren. 6- Xac nh thi gian may: Thi gian cong nghe c ban (thi gian may) khi bao va xoc co the tnh theo cong thc: T0 = Trong o
B + B1 + B2 n.S

k.L (1+ m) 1000

m/ph

(ph)

: B - chieu rong cua be mat gia cong mm. B1- lng an ti cua dao mm. B1 = t.cotg . B2 - lng vt qua cua dao mm. S - lng chay dao mm/hanh trnh kep; n - so hanh trnh kep trong mot phut.

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B2

B1

Bai 4

GIA CONG LO

I. Tnh chat chung cua khoan, khoet, doa:

Khoan, khoet, doa eu la phng phap gia cong lo. Tuy theo hnh dang, kch thc lo, tinh chat vat lieu gia cong va chat lng yeu cau ma ta chon mot, hai hay ca ba phng phap neu tren e gia cong mot lo. V du: co lo ch can khoan, co lo khoan xong roi khoet nhng co lo khoan xong roi khoet va doa. Tuy khoan, khoet, doa co the at o chnh xac khac nhau nhng chung eu co chung cac chuyen ong sau ay:

72

-Chuyen ong chnh la chuyen ong quay tron cua dao (dung cu cat). -Chuyen ong chay dao la chuyen ong doc truc mang dao. -Toc o cat c tnh :

V =

n..D [ m / ph ] 1000

Trong o : D ng knh cua mui khoan, doa, khoet. n so vong quay sau mot phut. -Lng chay dao sau mot vong quay c tnh :S0 = Sz.Z Trong o : Sz dao. Z - so li cat cua dao. -Chieu sau cat khi khoan (phoi cha co lo) c tnh -lng chay dao cua mot li cat cua

t=

Khi phoi a co lo vi ng knh d th chieu sau cat

D [ mm] 2

t=

Dd [ mm ] 2
S0/ 2 t

t=D/2

c tnh :

II. Kha nang cong nghe cua khoan:

Khoan thng s dung e gia cong lo tren cac phoi ac (phoi cha co lo hay phoi co lo t trc). Khi khoan thng s dung dao la mui khoan ruot ga. Khoan co the gia cong cac lo co ng knh 0,1 en 80 mm, pho bien nhat la cac lo co ng knh t 35mm tr xuong. Vi cac lo ln hn th oi hoi may co cong suat rat ln, cac lo be qua th mui khoan khong am bao o cng vng. oi vi lo co ng knh ln nen khoan trc lo nho roi khoan thanh nhieu lan e giam chieu sau cat khi khoan.

so/2

73

Khi khoan cac lo ln va sau nen dung phng an chi tiet quay ong thi s dung cac loai mui khoan nong sung hoac mui khoan sau. o chnh xac gia cong khoan noi chung la thap ch at cap chnh xac 12 13 va Ra = 3,2 12,5m. oi vi cac lo co yeu cau o chnh xac cao th khoan ch la bc gia cong tho . Nguyen nhan at o chnh xac thap khi khoan la do ket cau cua mui khoan cha hp ly, khi che tao mui khoan hay co cac sai so nh o ong tam gia phan cat va phan chuoi, do khi mai hai phan cat cua mui khoan khong eu.v.v May khoan khong a dang nh may tien hoac may phay. Chu yeu co may loai sau ay : a- May khoan ban la loai may n gian nhat, kch thc nho, thng at tren cac ban nguoi, lo khoan ln nhat la 12mm . b-May khoan ng la loai may khoan co truc chnh ch chuyen ong doc truc cua no. Co the gia cong cac lo co ng knh 50mm . c- May khoan can la may ma truc dao ngoai kha nang dch chuyen doc truc con co the dch chuyen len xuong, ra vao va xoay quay than may. Vi cac chuyen ong neu tren cua truc mang dao nen co the khoan c lo tren bat ky toa o nao. Phu hp e gia cong cac chi tiet ln, cong kenh . d- May khoan nhieu truc la may co kha nang khoan ong thi nhieu lo nh mot au dao co ga nhieu mui khoan. Loai may nay phu hp trong san xuat hang loat. e- May khoan sau la loai may chuyen dung, co truc chnh nam ngang dung e gia cong cac lo co chieu sau ln .

1- Cau tao mui khoan xoan, cac thong so hnh hoc cua mui khoan:
Cau tao mui khoan xoan ruot ga

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Ve mat ket cau chung th mui khoan chia lam ba bo phan: 1-Phan can (uoi): la bo phan dung lap vao truc chnh cua may khoan e truyen mo men xoan va truyen chuyen ong khi cat. Mui khoan ng knh ln hn 20mm lam can hnh con, con ng knh nho hn 10mm th co can hnh tru, ng knh t 10 en 20 co the can hnh con hoac tru. 2-Phan co dao : la phan noi tiep gia can dao va phan lam viec. No ch co tac dung e thoat a mai khi mai phan chuoi va phan lam viec.Thng ay c ghi nhan hieu cua mui khoan. 3-Phan lam viec : gom co phan sa ung va phan cat :

a- Phan sa ung (tru nh hng) : co tac dung nh hng mui khoan khi lam viec. No con la phan d tr khi mai lai phan cat a b mon. ng knh cua phan nh hng giam dan t phan cat ve pha chuoi, e tao thanh goc nghieng phu 1. Lng giam thng la t 0,01-0,08 mm tren 100 mm chieu dai. Tren phan nh hng co hai ranh xoan e thoat phoi, vi goc xoan =18-300, thay oi tuy theo ng knh va ieu kien gia cong. Doc theo ranh xoan, ng vi ng knh ngoai co 2 day canh vien chieu rong f. Chnh canh vien

75

nay co tac dung nh hng mui khoan khi lam viec. Mat khac no co tac dung lam giam ma sat gia mat tru mui khoan va mat a gia cong cua lo. Phan kim loai gia 2 ranh xoan la loi mui khoan. Thng ng knh loi lam ln dan ve pha chuoi e tang sc ben cua mui khoan. Lng tang thng t 1,4-1,8 mm tren 100 mm chieu dai cua mui khoan, tuy theo vat lieu lam dung cu. b- Phan cat : la phan chu yeu cua mui khoan dung e cat vat lieu tao ra phoi. Mui khoan co the coi nh la hai dao tien ghep vi nhau bang loi hnh tru. Mui khoan gom co 5 li cat: 2 li cat chnh va; hai li cat phu va mot li cat ngang. Li cat phu la ng xoan, chay doc canh vien cua mui khoan, no ch tham gia cat tren mot oan ngan chng mot na lng chay dao.

Mat trc cua mui khoan la mat xoan. Mat sau cua no co the la mat con, mat xoan, mat phang hay mat tru, tuy theo cach mai mat sau. Thong so hnh hoc cua mui khoan xoan: Cach xac nh goc o cua phan cat mui khoan tien hanh cung nh oi vi dao tien, ngha la van dung cac mat toa o, cac goc o cua dao thng bieu dien tren cac tiet dien chnh. Neu khong ke en chuyen ong chay dao, th mat ay tai moi iem cua li cat la mat phang tao thanh

76

bi iem o va truc cua mui khoan, con mat cat la mat phang cha li cat chnh (khi li cat chnh thang) va tiep xuc vi be mat gia cong. Goc trc : Goc trc mui khoan c o trong tiet dien chnh N-N chung ta hay xem goc trc phu thuoc vao nhng thong so nao.

Neu lay iem A tren li cat cua mui khoan bo tr tren hnh tru co ng knh DA th oi vi iem nay, goc nghieng cua ranh xoan c xac nh bang cong thc:

Trong o : H- bc cua ranh xoan. A- goc nghieng cua ranh xoan iem A Goc trc tiet dien OO bang goc xoan A. Goc trc A tiet dien N-N co the bieu th qua goc A hay goc trc tiet dien O-O Muon vay tren tiet dien N-N va O-O, ta chu y tam giac ANO. Chieu canh AN xuong tiet dien N-N ta co: NB AN= hay NB = NA tg A tg A Chieu canh AO xuong tiet dien Q-O ta co : BD AO = hay D = AO tg A tg A

.DA tg A = H

77

NB = BD nen co : NA tg A = AO tg A AM = sin Trong tam giac AMO ta co : AO Nen ta co : tg A =

, v AN = AM

tg A sin

Thay the vao bieu thc cua tg A a tnh tren va chu y rang .D H = cuoi cung ta co : t g DA tg . tg A = D sin Do o, goc trc mot iem bat ky tren li cat cua mui khoan, phu thuoc vao goc nghieng cua ranh xoan ng vi ng knh D, goc nghieng va ng knh DA (DA la ng knh ng vi iem khao sat A). T cong thc tren ta thay rang, goc trc cua mui khoan la mot lng thay oi phu thuoc vao ng knh D A. : cang gan tam mui khoan, DA cang giam th goc A cang nho. Neu tren ng knh ngoai cung goc trc cua mui khoan co tr so khoang 18 -330, th gan li cat ngang goc trc se giam xuong gan bang khong, roi at tr so am li ngang. Cac cong thc tnh goc trc cua mui khoan trnh bay tren ch la nhng cong thc gan ung, v khi khao sat goc trc ta a coi nh khong co li cat ngang va coi nh li cat chnh i qua tam mui khoan. Goc sau : Goc sau cua mui khoan c o tren be mat cua quy ao chuyen ong cua cac iem tren li cat, tc la tren be mat hnh tru co truc trung vi truc mui khoan. e cu the hn ta xet hnh ve sau ay: Xet iem A bat ky nam tren li cat chnh cua mot mui khoan. Khi mui khoan quay tron quanh truc O-O th iem A se ve nen mot vong tron. Qua vong tron o, ta dng mot hnh tru ong truc vi mui khoan. Giao tuyen cua mat tru nay vi mat sau mui khoan se la mot ng cong C. Neu qua iem A ta ve 2 ng tiep tuyen: mot ng vi giao tuyen C, con mot ng kia vi vong tron do

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iem A ve ra trong mat phang cha vong tron o, th goc giua hai ng tiep tuyen nay la goc .

Vay goc sau tai mot iem bat ky tren li cat cua mui khoan la goc hop bi: .ng tiep tuyen (tai iem ang khao sat) cua tiep tuyen tao bi mat tru (ong truc vi mui khoan) va mat sau cua mui khoan, vi: .ng tiep tuuyen cua vong tron la quy ao cua iem khao sat khi no quay quanh truc cua mui khoan. Goc sau N cua mui khoan o tiet dien phap tuyen c xac nh gan ung bang cong thc: tgN= tg.sin Cung nh goc trc, goc sau tai nhng iem khac nhau cua li cat cung la mot lng thay oi, nhng goc sau ln dan ve pha tam mui khoan. ng knh ngoai cung thng = 8 -140 con gan tam = 25-350. o thay oi goc sau cua mui khoan con phu thuoc vao cach mai mat sau na. Goc sau li cat phu 1 c o trong mat phang thang goc vi truc cua mui khoan. mui khoan tieu chuan thng 1 =0. Goc trc va goc sau cua li ngang c o mat phang phap tuyen B3B3 hnh 7-5 Goc nghieng chnh : goc nay cung c xac nh nh dao tien. Goc mui khoan la 2 .Tuy theo vat lieu gia cong ma goc 2 co cac tr so dao ong trong khoang 801400. V du: Khi gia cong a hoa th2 = 800.

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Khi gia cong nhom th 2 = 1400. Khi gia cong thep va gang 2 = 116-1200. Mui khoan tieu chuan lay 2 =1 16-1200. Goc nghieng phu 1 mui khoan do o con ngc ma co, thong thng 1 = 20-40. Li cat ngang va goc nghieng cua li cat ngang . Goc nghieng cua li cat ngang la goc gia hnh chieu cua li cat ngang va li cat chnh tren mat phang vuong goc vi truc mui khoan. Mui khoan tieu chuan co = 550 . Thong thng li cat ngang khong cat (do goc trc co tr so am), ma t len be mat gia cong lam cho lc chieu truc sinh ra rat ln. Cac cai tien cua mui khoan hien tai la nham lam cho li cat ngang cang ngan cang tot . Goc nang cua li cat chnh. Goc cua mui khoan c xac nh nh dao tien. Goc xoan cua ranh thoat phoi . Goc la mot thong so quan trong oi vi mui khoan. Tr so cua no anh hng en qua trnh cat, s thoat phoi, lc cat, o ben va tuoi tho cua mui khoan . Tuy theo vat lieu gia cong ma ta chon tr so cua goc . oi vi ong thanh, ong thau , e-bo-nt 0 =8 - 12 oi vi thep va gang = 0 25 - 30 oi vi nhom, ong o = 0 35 - 40 Cung nh dao tien, khi lam viec do chuyen ong chay dao ma goc o mui khoan b thay oi. S thay oi nay phai c tnh en e am bao mui khoan lam viec on nh . T hnh 4-8 ta thay v co chuyen ong phu, ma vet mat cat va vet mat ay b thay oi. Ket qua la goc sau thc te c giam mot lng va goc trc thc te c ong thi cung tang mot lng . Hay c = - c = + s Vi tg = .DA

80

V lng chay dao s so vi ng knh mui khoan D nho hn rat nhieu nen goc thng la nho .

2- Cac yeu to cua che o cat khi khoan:

Cac s o cat chu yeu khi khoan gom : a- khoan lo khong thong trong vat lieu ac b- Khoan rong lo a co trc trong phoi Tren hnh ve nay a ky hieu cac yeu to cat trong hai s o khac nhau gom:

Cac yeu to cua che o cat khi khoan - Toc o cat v : o la toc o vong ng vi ng knh ln nhat cua mui khoan. Dn v= m/ph 1000 Trong o : .D - ng knh cua mui khoan ,mm

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.n - so vong quay cua mui khoan trong mot phut , vg/ph. - Chieu sau cat t : Khi khoan lo trong phoi ac : t = Khi khoan rong lo Trong o :

d- ng knh lo trc khi khoan

D 2 D d :t = 2

mm mm

rong mm. - Lng chay dao S : Lng dch chuyen cua mui khoan theo chieu truc sau khi mui khoan quay mot vong (mm/vg). V mui khoan co hai li cat chnh nen lng chay dao do mui li thc hien la:

sz =

Lng chay dao phut tnh theo cong thc: sph = s . n mm/ph. - Chieu rong cat b, chieu day cat a va dien tch cat f : Khi tnh ta bo qua khong tnh en anh hng cua li cat ngang. Ta co: D s b= mm ; a = sin 2sin 2 mm. Khi khoan lo vat lieu ac th: mm2 Khi khoan rong lo : f = a.b = f = a.b = D

s 2

mm/rang

s 4
(D d)s 4

mm2. Dien tch cat ng vi mot vong quay cua mui khoan la: F = 2f = 2ab 2 mm .

3- ac tnh cua qua trnh cat khi khoan:

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Qua trnh tao phoi khi khoan giong vi qua trnh tien. Khi khoan vat lieu deo noi chung ta co phoi day, phoi xep. Khi khoan vat lieu gion ta co phoi manh, phoi vun. Khi khoan li cat ngang lam viec trong khu vc co toc o cat thap, lai co goc trc am nen gay lc hng truc ln. Khi cat lui cat ngang ty len mat gia cong lam cho li cat mon rat nhanh. Li cat phu co goc 1 = 0, goc sac lai nho, mui dao chu nhiet kem nen chong mon. Con lui cat chnh th cac goc cat thay oi theo chieu dai li cat. T ngoai vao tam, goc trc giam rat nhanh, lam tang cong bien dang va ma sat khi tao phoi, ong thi lam tang nhiet lng va nhiet o vung cat. Khong gian thoat phoi khi khoan la na kn, phoi thoat ra kho va cham, thi gian tiep xuc va ma sat gia phoi, dao vi mat gia cong lau, hn na dung dch trn nguoi kho vao khu vc trc tiep gia cong va khi ti vung cat th a b phoi lam nong. Do o nhiet cat khi khoan ln, truyen nhiet kho khan, toc o khoan khong chon cao c. Ngoai ra toc o cat khi khoan khac nhau tren chieu dai li cat, anh hng xau en qua trnh tao phoi. Mui khoan kho ma oi xng hai li cat. Khi lap mui khoan vao may th ng tam mui khoan va ng tam truc chnh khong trung nhau. Do o sau khi khoan lo thng b loe ra mieng mot lng rong nhat nh.

4 - Lc cat khi khoan:

Cong cat khi khoan la do lc tac dung len li cat cua mui khoan sinh ra.Tuy rang tai moi iem cua li cat lc tac dung khac nhau, song e tien nghien cu ta coi hp lc cua cac phan to o tap trung iem A cach tam iem khoan mot oan bang D/4 Cung nh dao tien, lc tac dung len mui khoan cung c phan thanh ba thanh phan lc theo cac truc toa o ox, oy, oz . Cac thanh phan o la: a- Lc Py con goi la lc hng knh tac dung tren hai li cat chnh, co tr so bang nhau va ngc chieu nhau nen cung triet tieu lan nhau. Neu chu y ca hai li cat phu th phai ke ca hai lc Py na va chung cung triet tieu lan nhau. b- Lc chieu truc P0 co xu hng chong lai lc chay dao. Lc P0 bang tong cac lc chieu truc Px tac dung len li

83

cat chnh, lc chieu truc Px tac dung len li cat phu va lc chieu truc Pn tac dung len li cat ngang. Lc Px chiem khoang 40% lc P0. Lc Px chiem khoang 3% lc P0. Lc Pn chiem khoang 57% lc P0 .
x

Px Px Py A PyA

A
Pz

Pz

A
z

c- Lc tiep tuyen Pz gay ra momen cat chnh. Thc nghiem chng to rang 80% momen la do lc tiep tuyen tac dung tren li cat chnh, 12% la do lc tiep tuyen tren li cat phu, con lai 8% la do lc tiep tuyen tren li cat ngang. Hien nay cha co cong thc ly thuyet e tnh momen cat va lc chieu truc. Ngi ta nghien cu bang thc nghiem anh hng cua cac yeu to cat va ieu kien gia cong en mo men va lc cat roi t o lap nen cac cong thc thc nghiem co dang sau ay: Mo men cat : Mx = Cm . Dxm .sym Km x y Lc chieu truc : P0 = C0 . D p .s p K p0 N.mm N

Trong o : Cm, C0 - He so phu thuoc tnh chat vat lieu gia cong, hnh dang hnh hoc cua mui khoan va cac ieu kien khac. D-ng knh mui khoan mm S- lng chay dao mm/vg

84

Cac ga tr cua cac he so Cm,C0 cua cac so mu xm, ym, xp, yp ,cac gia tr cua he so ieu chnh Km, Kp0 co the tra trong so tay ve che o cat. 1-Anh hng cua goc xoan : T cong thc tnh goc trc a thiet lap tren ta thay rang khi = const va DA = D th A = k tg, hay noi khac i, goc trc tren phan cat cua mui khoan t le vi goc nghieng cua ranh xoan. Nh vay tang goc tang len th goc trc tang dan, cong bien dang deo va ma sat giam xuong lam cho mo men xoan Mx va lc chieu truc P0 giam xuong. Song qua thc nghiem, ngi ta a xac nh rang, neu tang len en 35% th luc o lc chieu truc P0 va mo men xoan Mx giam khong ang ke. o la v vi goc ln, phoi thoat ra se phai chuyen ong theo ng xoan dai hn, nen lc ma sat gia phoi va thanh ranh tang len. Ngoai ra khi tang len cung ong thi lam giam o ben cua mui khoan. V the mui khoan thep gio thng chon = 25-300 de gia cong thep va gang va = 400-450 e gia cong kim loai mau. oi vi mui khoan ng knh nho (D<10mm),e tang o ben va o cng vng cua chung ngi ta chon goc xoan = 18-280. 2-Anh hng cua goc nghieng chnh : Goc co anh hng khac nhau en lc chieu truc P0 va mo men xoan Mx. Tang goc (khi D=const) th chieu day lp cat tang len va chieu rong giam xuong (dien tch lp cat khong oi) do o bien dang cua phoi giam xuong. Mat khac, neu goc tang len se lam cho mui khoan kho an vao kim loai, lc hng truc P0 se tang len, v thanh phan lc hng tam tren li cat chnh tang len (Px = PN sin ). 3- Anh hng cua li ngang va phng phap mai sac li ngang: Do ket cau ac biet cua mui khoan ma hnh thanh li ngang (v khong the che tao mui khoan co ng knh loi bang khong). Nh (hnh II-31) ta thay goc nghieng chnh cua li ngang n = 900, do o thanh phan lc hng truc ay co gia tr ln (Px =PN sin n ) Px PN. Mat khac tai li ngang goc trc co tr am, cho nen li ngang cang dai th P0 cang ln. oi vi momen xoan Mx th li ngang ang

85

hng khong ang ke, v chieu dai li ngang nho hn chieu dai li cat chnh. Nh vay oi vi qua trnh cat th li ngang la mot yeu to co hai. e am bao o ben, mui khoan a che tao co ng knh bang (0,12 - 0,15)D, nhng e giam lc chieu truc ngi ta a co nhieu bien phap cai tien li ngang. 4-Anh hng cua goc nghieng cua li cat ngang: Ta biet goc quyet nh o dai cua li ngang. Neu tang goc th chieu dai li ngang se giam i, lc chieu truc P0 se giam. Song s thay oi cua goc co anh hng en tr so cua goc sau n li ngang. Goc tang se lam cho goc n giam. ieu o lam tang ma sat mat sau (ng vi li ngang ) vi be mat gia cong, do o li ngang b mon nhanh. Vi nhng ly do ke tren, trong thc te oi vi mui khoan D 15mm ta chon = 500, con oi vi mui khoan D >15mm th chon = 550 . 5- Anh hng cua dung dch trn nguoi: Khong gian thoat phoi khi khoan la na kn, viec thoat phoi khi khoan kho khan, ieu kien truyen nhiet khi khoan cung khong tot, nen khi khoan neu dung dung dch trn nguoi thch hp th lc hng truc va momen xoan giam i rat nhieu, v dung dch co tac dung lam giam ma sat gia phoi va ranh thoat phoi, ong thi tao ra ap lc ay phoi ra. Khi khoan lo sau th viec ti dung dch trn nguoi la ieu bat buoc . 6-Anh hng cua lng chay dao va ng knh mui khoan en lc hng truc va momen xoan : S anh hng nay co qui luat nh khi tien . Khi lng chay dao tang len th P0 va Mx tang , v du khi khoan th cac so mu ym va yp trong cong thc tnh lc cat co gia tr nh sau: Khi khoan thep : ym =0,8 va yp = 0,7; Khi khoan gang : ym = 0,8 va yp = 0,8; ng knh mui khoan co tac dung en lc cat giong nh chieu sau cat khi tien. Do o xp = 1. Trong cong thc momen, mot na ng knh d/2 la canh tay on cua cap ngau lc tac dung len li cat, do o ma so mu (x m = 1,9).

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Khi gia cong thep cac bon ket cau ( b = 750 N/mm2 ) th Cm = 33,8 va C0 = 84,7; khi gia cong gang xam th Cm = 23,3 va C0 = 60,5. 7. Anh hng cua toc o cat en P0 va Mx : Tang toc o cat th bien dang n v cua kim loai giam, ong thi cung lam cho nhiet o cat cac be mat tiep xuc tang len. Hien tng nay lam thay oi tnh chat c ly cua vat lieu gia cong vung cat, dan en s thay oi lc chieu truc P0 va momen xoan Mx. 8-Anh hng cua vat lieu gia cong: Thay oi tnh chat c ly cua vat lieu gia cong cung dan en s thay oi lc chieu truc va mo men xoan. Cung nh khi tien, ta bieu hien anh hng cua vat lieu gia cong en lc cat qua gii han ben b khi cat thep, con khi cat gang va vat lieu don th bieu hien qua o cng HB.

5 - Toc o cat khi khoan va cac nhan to anh hng en toc o cat:
Toc o cat khi khoan phu thuoc vao lng chay dao s, ng knh mui khoan D, tuoi ben T, chieu sau khoan lo l , cac thong so hnh hoc cua bo phan cat, vat lieu che tao mui khoan , vat lieu gia cong dung dch trn nguoi. Qua nghien cu cac nhan to anh hng en toc o cat, ta lap c cac cong thc thc nghiem co dang sau ay: Cv .Dxv V= m/ph Kv m yv Trong o : . Cv He so t le ng vi mot loai vat lieu gia cong nhat nh . Kv he so ieu chnh toc o o do cac ieu kien cat khac nhau. Di ay ta xet anh hng cua cac nhan to en toc o cat khi khoan. a. Anh hng cua lng chay dao: Khi tang lng chay dao th toc o cat phai giam xuong. Mc o giam c bieu th bang so mu yv . Tr so cua so mu nay phu thuoc vao lng chay dao, vat lieu che tao mui khoan va vat lieu gia cong . b. Anh hng cua ng knh mui khoan: Khi tang ng knh mui khoan th o cng vng cua mui khoan tang, ieu kien truyen nhiet cung c cai thien. Nhng khi tang ng knh mui khoan th v t = D/2 tang nen han che viec tang toc o cat.

T .s

87

c. Anh hng cua chieu sau lo khoan l: chieu sau lo khoan cang ln (khoan cang sau) th ieu kien cat cang xau. V lo khoan cang sau thoat phoi cang kho, dung dch trn nguoi cang kho a vao khu vc cat. Do o khi khoan lo co chieu dai l >3D th toc o cat khi khoan phai nhan vi he so ieu chnh toc o Kv lo (tra trong cac so tay ky thuat). Chu y : + Khi khoan gang xam co phoi vun th chieu sau cat khong anh hng ang ke en toc o cat . + Khi khoan lo l 5D th nen dung mui khoan sau. d. Anh hng cua vat lieu gia cong en toc o khi khoan: Anh hng cua vat lieu gia cong en toc o cat c bieu th bang he so ieu chnh KVL Ch tieu quan trong nhat ve tnh gia cong cua vat lieu thep khi khoan la gii han ben b khi khoan gang la o cng HB. Gia tr gan ung cua he so Kvl co the tnh theo cong thc thc nghiem sau ay:

750 Kvl = b

nv

Trong o : b gii han ben cua vat lieu N/mm2. nv so mu . Neu b < 550 N/mm2 th nv = -0,9 Neu b > 550 N/mm2 th nv = 0,9 Khi khoan gang xam

190 Kvl = HB

nv

Trong o : .HB o cng cua vat lieu gia cong (Brinen). .nv so mu. ga tr nv =1,3 e. Anh hng cua vat lieu lam mui khoan en toc o cat . Anh hng cua vat lieu lam dao c bieu th bang he so ieu chnh Kvd. oi vi mui khoan thep gio P18 va P9 th Kvd =1 con oi vi mui khoan che tao bang thep hp kim dung cu 9XC co Kvd = 0,65, mui khoan bang thep cac bon dung cu Kvd= 0,5 va mui khoan hp kim cng th Kvd = 2 - 3. g. Anh hng cua dung dch boi trn: e lam giam nhiet o khi khoan (ac biet la khoan thep) phai ti dung dch trn nguoi vi lu lng 4-5 l/ph.

88

Dung dung dch trn nguoi co the lam tang toc o cat len t 1,4 - 1,45 lan. Trong cong thc tnh toc o cat , he so ty le Cv co gia tr nh sau : + Khi khoan thep bang mui khoan thep gio: S < 0,2mm/vg ; Cv = 5,0 S > 0,2mm/vg ; Cv = 7,0 + Khi khoan gang bang mui khoan thep gio:S < 0,3 mm.vg; Cv = 10,5 S > 0,3mm/vg; Cv = 12,2 + Khi khoan thep bang mui khoan hp kim cng : S < 0,12mm/vg ; Cv = 750 S > 0,12mm/vg ; C v = 490

6- Chon che o cat hp ly khi khoan:

Phng phap xac nh che o cat khi khoan cung tien hanh nh tien, e xac nh che o cat va cac thong so hnh hoc hp ly cua mui khoan. phai xuat phat t cac ieu c ban sau : a. Lng chay dao nen chon ln nhat, nhng phai phu hp vi cac ieu kien ky thuat cua lo gia cong nh o bong, o chnh xac, cac nguyen cong tiep sau khi khoan. b. Toc o cat phai am bao tuoi ben ln nhat . Cu the che o cat c la chon theo trnh t sau: 1. Chon mui khoan: Mui khoan co the co nhieu hnh dang khac nhau tuy theo cong dung va vat lieu che tao mui khoan. mui khoan thep gio th cac thong so hnh hoc cua phan cat mui khoan a c tieu chuan hoa, con oi vi mui khoan gan hp kim cng tuy tng loai vat lieu gia cong ma hnh dang hnh hoc co the khac nhau. Khi chon hnh dang hnh hoc phai xet sao cho co li ve mat lc cat, toc o cat va tuoi ben cua dao. 2. Vi ng knh lo D<35mm th khoan 1 lan, khi o chieu sau cat la t = D/2. vi D > 35mm th khoan 2 lan, lan au dung mui khoan co ng knh D1 = (0,5 -0,7 ) D 3. Chon lng chay dao toi a cho phep .

89

Nh a biet lng chay dao phu thuoc vao rat nhieu yeu to : ieu kien ky thuat, o ben cua mui khoan, o ben va o cng vng cua c cau chay dao, chieu sau khoan. . . Lng chay dao cho phep bi o ben cua mui khoan co the tnh theo cong thc sau: Khoan thep

D0,81 s = 38,8 0,94 b

D0,81 s = 7,34 HB0,75

mm/vg

Khoan gang

mm/vg

Trong o : b gii han cua vat lieu gia cong . HB o cng cua gang c gia cong . 4- Vi D va s a chon cho trc tuoi ben T, tnh che o cat va so vong quay . 5- Xac nh lc chieu truc P0, momen xoan Mx va cong suat cat Nc. Neu nh a chon may trc th kiem nghiem P0, Mx, Nc theo D, s ,n ,v a chon. 6- Tnh thi gian may. Thi gian may T 0 c tnh theo cong thc: T0 =

Trong o : L - chieu dai hanh trnh cua mui khoan theo phng chay dao mm L = l + l 1 + l2 l - chieu dai (chieu sau) khoan mm l1 - lng an ti mm . Ta co : l1 =

L n.s

(ph)

l2 - lng vt qua mm. oi vi mui khoan tieu chuan co the lay l1+l2 = 0,3 D.

D cot g 2

III. Khoet 1. Kha nang cong nghe cua khoet:

Khoet nham muc ch nang cao o chnh xac cua lo sau khi khoan. Khoet co the at o chnh xac cap 9 12 va o bong at Ra=1,6 en 12,5m khoet co the ch la nguyen cong trung gian cho doa.

90

Dao khoet thng co nhieu li cat hn mui khoan tuy nhien oi vi cac trng hp gia cong lo co ng knh ln co the s dung loai dao co 1 hoac 2 li cat c gan vao truc hoac au dao. ac biet la khi gia cong pha

cac lo ln uc sau hoac ren, dap.

2- Ket cau cua mui khoet va qua trnh cat khi khoet:
a- Cac yeu to ve ket cau cua mui khoet:
P a la v h ie n m c P a c h a n n

P a c h a n t

C a od o

o d u e i t

Cau tao cua mui khoet rat giong mui khoan ch khac la chung co nhieu rang hn va khong co li cat ngang. Mui khoet thng co 3 - 4 rang. Neu ng knh nho hn 35 mm th lam 3 rang, con dng knh ln 35 mm lam 4 rang. Mui khoet cung gom cac phan: can dao, co dao, phan lam viec,...giong nh mui khoan. Goc trc cua rang mui khoet la goc lam bi mat phang tiep tuyen vi mat trc mot iem nhat nh va mat phang cha truc mui khoet i qua iem ang khao sat.

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Goc trc c o trong tiet dien chnh N-N, tiet dien AA va BB ta co goc trc 1 o trong tiet dien ngang. Con tiet dien FF tiet dien doc ta co goc trc 2 . Gia goc trc va goc trc 1, 2 va ta co quan he sau: tg = tg 1 .cos + tg 2. sin Goc nghieng chnh cua li cat la goc lam bi hnh chieu cua li cat tren mat phang qua truc cua mui khoet va phng chay dao. oi vi mui khoet thep gio chon = 45 - 600 , con oi vi mui khoet hp kim cng th = 60 - 750. Goc sau cua mui khoet cung thay oi tuy theo tng iem cua li cat chnh. Chon goc sau cung phai da vao chieu day lp cat. Thong thng mui khoet lam viec vi lng chay dao 0,4 - 1,2mm/vg va chieu day lp cat tng ng a = 0,28 - 0,85 mm , do o vi mui thep bang thep gio goc sau hp ly = 6 - 10 0 , con oi vi mui khoet hp kim cng th = 10 - 150 . Goc nghieng cua ranh xoan thoat phoi co quan he vi goc trc theo cong thc: tg = tg sin Do o , neu tang th goc troc tang , lc chieu truc P 0 va momen Mx giam xuong. Ngoai ra goc nghieng con anh hng en s thoat phoi. Do o khi dung mui khoet e gia cong thep ta chon = 20 - 300 mui khoet canh vien dung e nh hng mui khoet vao trong lo va e at c kch thc cuoi cung cua lo . Thc nghiem chng to rang hp ly nhat la chon chieu rong canh vien f = 12 - 1,3 mm. Neu chieu rong ma giam th li cat cua mui khoet se mon nhanh goc va li cat de b lay rong, nhng chieu rong canh vien chon qua ln se lam cho ma sat gia mui khoet va be mat gia cong tang, de ket phoi, rang dao mon nhanh va o bong be mat gia cong giam xuong. Goc nang cung nh dao tien co the co cac tr so am, bang khong hay dng. Goc bieu dien theo 1 , 2 va theo cong thc sau : tg = tg 1. cos - tg 2. sin Goc nam trong gii han t - 5 150 . e thoat phoi ve pha au dao (khi khoet lo thong) th chon < 0, con muon thoat phoi ve pha can dao chon >0.

92

Tuy theo ng knh mui khoet, vi muc ch tiet kiem kim loai lam dung cu, mui khoet co the c che tao rang lien hay rang chap, can lien hay can lap. Hnh4-16 cho ta ket cau mui khoet can lap. b- Cac yeu to khi khoet: Giong nh khi khoan rong, cac yeu to khi khoet gom: -Chieu sau cat t =

-Lng chay dao rang sx =

D d 2

mm

Trong o : z - so rang cua mui khoet s o- lng chay dao sau mot vong quay cua chi tiet mm/vg sph- lng chay dao sau mot phut mm/ph n - so vong quay sau mot phut vg/ph. -Chieu day cat a= sxsin = -Chieu rong cat b=
s sin z

s0 sph = z n.s

mm/vg

mm

t sin

mm.

Dien tch cat do moi rang cat ra: fx = ab =

Tong dien tch do z rang cat ra la: F= fx.z =

s, t s(D d) = z 2z

mm2

Trong o : d -ng knh lo trc khi khoet mm D-ng knh lo sau khi khoet mm. c- Lc va momen xoan khi khoet: Cung nh khoan, khi khoet co lc chieu truc P0 va momen xoan Mx.Song v li khoet cat lp kim loai co dien tch cat nho nen lc P0 va momen xoan Mx nho hn khi khoan nhieu. Do o viec tnh lc cat va momen xoan e tnh cong suat hieu dung cua may khoan ch co y ngha khi cat toc o cao bang mui khoet gan hp kim cng.

s(D d) mm2. 2

93

Momen xoan khi khoet c tnh theo cac cong thc sau: a-Vi mui khoet gan hp kim T15K6, gia cong thep cac-bon, thep hp kim crom, crom-ni-ken . Mx = 370.D0.75.t0.8.s0.95.b0.75 N/mm. b-Vi mui khoet gan hp kim cng BK8 dung gia cong gang xam va gang ren: Mx = 84.D0.85t0.8.s0.7.HB0.6 Cong suat hieu dung : Nc =
M x .n 975104 .

N/mm

kW

d-Tuoi ben va toc o cat khi khoet Tuy theo ieu kien gia cong, mui khoet co the mon theo mat sau, mat trc va theo canh vien. o mon theo canh vien trc tien phat trien cham, sau khi at en tr so tieu chuan (khoang 1-2mm) th phat trien rat nhanh. o mon theo mat trc thng tao ra ranh lom khong sau (20-30 micron). Khi dung mui khoet thep gio gia cong gang, ngi ta thng lay o mon canh vien (mon goc) lam tieu chuan. Tieu chuan mon hv = 0,8-1,5mm. Khi gia cong thep, tieu chuan mon theo mat sau la hs = 1,2-1,5mm, thep toi hs = 0,7mm. Tuoi ben cua mui khoet nam trong gii han T = 15-80 phut. ng knh mui khoet cang ln th chon tuoi ben cang ln Toc o cat khi khoet c tnh theo cong thc . V=

Cv..Dzv T .t
m xv

Cac he so va so mu tra trong so tay che o cat

.s

yv

.K v

IV. Doa: 1. Kha nang cong nghe cua doa:

Doa la nguyen cong gia cong tinh cac lo a c khoan hoac khoet. o chnh xac co the at t cap 7 en 9, o bong co the at c Ra=1,6 en 6,3m. Vi dao co chat

94

lng tot, che o cat hp ly, doa co the at cap 6 va Ra= 0,63 m. Khi doa co the thc hien bang doa cng bc hoac doa tuy ong. Doa cng bc la khi dao doa c lap cng vao truc may.Phng phap nay co hien tng lay rong lo, nguyen nhan la do tam cua truc dao va truc chnh cua may co o ao , do dao mai khong tot , do leo dao xuat hien mot so li cat , do vat lieu thanh lo gia cong khong ong eu . Doa tuy ong la dao c noi lac l vi truc may, nen loai tr c sai so gia tam truc may va truc dao. e khac phuc hien tng dao b mon do mai nhieu lan co the s dung loai dao doa tuy ong co kha nang t eu chnh kch thc ng knh. Tuy theo yeu cau chat lng va kch thc ma chon dao hp ly . Dao doa thng co nhieu li cat, ca li cat song song hoac nghieng vi truc dao mot goc rat be .

2 -Ket cau cua mui doa va qua trnh cat doa:

P a la v h ie n m c P a c h a n n

P a c a hg h a d n t n n

1 -Cac yeu to ve ket cau: Tuy theo ng knh lo gia cong ma mui doa co ket cau khac nhau. Co the co cac mui doa rang lien, doa rang chap (ieu chnh theo ng knh). Cac rang doa co the lam bang thep cac bon, thep hp kim dung cu, thep gio hoac hp kim cng. Cung nh mui khoan, khoet, mui doa cung co 3 phan: phan lam viec,co doa va chuoi. Phan lam viec la phan chnh cua mui doa,co chieu dai L. au mut phan lam viec co o ln tng oi ln (450) e mui doa de a vao lo.Tiep sau o la phan con cat nghieng mot goc . Phan nay co loi cat chnh e cat het lng d khi doa.Tiep theo la phan tru co chieu dai l2 ,dung e nh hng mui doa trong lo khi lam viec,

95

ong thi lam phan d tr khi mai lai mui doa. Tren phan hnh tru nay co cac li cat phu doc theo rang cua mui doa. Cac li cat phu co tac dung sa ung va lam tang o bong be mat lo , do o phan tru con co ten goi la phan sa ung. Sau phan sa ung la phan con ngc l3 . Phan nay co tac dung giam ma sat gia mui doa va be mat lo a gia cong va giam lng lay rong lo. oi vi li do tay th o con ngc la 0,005mm, oi vi vi li doa may la 0,04 -,06 mm tren ca chieu dai phan con ngc. Mui doa co so li cat ln (z= 6 - 18) . Li cat co the bo tr thang hoac nghieng oi vi truc doa . Do cong dung ma chia ra doa may, doa tay,. . . Hnh II-49 cho ta cac yeu to hnh hoc phan cat cua doa. Goc nghieng chnh cua mui doa tren phan con cat co tac dung nh mui khoet. oi vi mui doa may dung gia cong vat lieu deo th goc =150. Vi tr so nay cua goc am bao o bong gia cong cao nhat va o lay rong lo nho nhat. Khi doa tho cung nh khi doa lo khong thong, goc = 450 . Khi gia cong vat lieu t deo th = 50 . oi vi mui doa hp kim cng th = 30 - 450. Goc trc cua li cat o trong tiet dien chnh AA hnh 4- 21 c chon theo vat lieu gia cong va vat lieu lam dao. Goc trc cua mui doa tinh co tr so bang khong, con oi vi mui doa tho th goc trc chon t 5 - 100. Goc sau cung o trong tiet dien AA, c chon trong gii han t 6 - 120 . Khi gia cong vat lieu deo va gia cong tho th lay tr so ln, con khi gia cong tinh th lay gia tr nho. Tren phan sa ung, doc theo cac rang co canh vien f nam tren mat truc cua dao . Chieu rong canh vien f= 0,05 0,3mm. Canh vien am bao e mui dao hng ung vao lo va lam cho lo at c o bong va o chnh xac cao. Khi gia cong vat lieu deo e tranh hien tng ket phoi ta giam chieu rong canh vien xuong khoang 0,05 - 0,08 mm. Goc sau cua bo phan sa ung 1 =10 - 20 0 Mui doa thng c che tao vi rang thang v phoi cat ra la phoi vun. Song e thoat phoi c tot , tang chat lng be mat gia cong, nhat la khi doa nhng lo trong co ranh th ngi ta lam rang nghieng.

96

Khi gia cong lo thong, e thoat phoi ve pha au dao, ngi ta lam ranh xoan trai, con khi gia cong lo thong ngi ta lam ranh xoan phai. Khi gia cong thep cng th = 7 - 80 , khi gia cong gang ren va thep deo va th = 12 - 200. Khi gia cong kim loai mau th = 35 - 450. 2 - Cac yeu to cua qua trnh cat: Van e tuoi ben cua mui doa lien quan en viec giam o chnh xac do hut kch thc v mon va do s lay rong cua lo. Thng th ng knh lo sau khi doa khac vi ng knh thc te cua mui doa. Lng tang (hoac giam) cua ong knh lo so vi ng knh mui doa c goi la lng lay ong dng (hoac am). Neu dung mui doa co = 30 - 450 e gia cong lo de xay ra lay rong dng. Khi giam t 200 xuong 50 th lng lay rong lai chuyen sang v tr so am. Hien tng nay co the oc giai thch tang bien dang an hoi, v lc hng knh do goc giam xuong. Khi li cat i khoi th kim loai cua be mat lo phuc hoi tr lai gay nen s giam ng knh. Khi tang goc o cat t 2 - 7 m/ph, lng lay rong se chuyen t am sang dng. o la v toc o cat tang th lc cat giam va bien dang an hoi cung giam. Dung dch trn nguoi co anh hng ln en o lay rong v dung dch trn nguoi co tac dung cuon i nhng phan t nho cua phoi vun va leo dao bam tren li cat. Goc nghieng chnh co anh hng ln en ac trng mon cua mui doa. Thc nghiem chng to rang, khi gia cong thep vi = 5 0 th rang mui doa mon theo mat sau v lc hng knh tang. Neu tang goc th lng mon mat sau giam, nhng lng mon theo canh vien lai tang. Mui doa co = 450 se cat lp phoi co chieu day cat ln (az= sz . sin ), luc o canh vien mon nhieu nhat, ong thi mat trc cung mon thanh vet lom. Lc va cong suat cua mui doa nho v lp kim loai b cat i rat mong. Co the coi moi rang doa la mot dao tien lo va dung cong thc tien e tnh lc cat. Lc cat khi doa Pz = Pz. z (N) Trong o : .Pz lc cat tac dung len mot rang cua mui doa , tnh theo tien. .z So rang cua mui doa . Momen xoan tnh theo cong thc:

97

Mx =

Pz .D 2103 . Nc =

N.mm

kW 975104 . Toc o cat khi doa la mot ham so cua ng knh mui doa D, tuoi ben T, lng chay dao s va chieu sau cat t. Toc o cat con chu anh hng cua tnh chat vat lieu gia cong va nhieu nhan to khac na. Toc o cat khi doa oc tnh theo cong thc sau: V=

Cong suat cat :

M x .n

Cv .Dxv T .t
m xv

.s

yv

Kv

m/ph

3 - Xac nh che o cat khi khoet va doa: Viec xac nh che o cat khi khoet va doa vi ket cau va hnh dang hp ly nhat cua dung cu cat can xuat phat t cac ieu c ban sau ay: 1-T lng d gia cong phai u tien chon chieu sau cat ln nhat thng chon chieu sau cat bang lng d mot pha. 2-Lng chay dao ln nhat cho phep phai chon bi cac ieu kien gia cong lo ,am bao o chnh xac ,o bong gia cong va cac nguyen cong tiep theo. 3-T lng chay dao cong nghe cho phep,t tuoi ben hp ly nhat cua dung cu cat ma chon toc o cat Lng chay dao khi gia cong bang mui khoet thep dung cu co the tnh theo cong thc kinh nghiem sau: S = Cs .D0,5 mm/vg Trong o : Cs -He so ty le phu thuoc vao vat lieu gia cong va cac yeu to cong nghe. Tr cua so Cs co the tra theo cac so tay c kh D-ng knh mui khoet mm Lng chay dao khi gia cong bang mui doa thep dung cu tnh theo cong thc s = Cs .D0,7 mm/vg

98

HOC TRNH III

PHAY CHUOT CAT RANG MAI

Bai 1 PHAY
I. Khai niem chung ve phay:
Phay la phng phap gia cong kim loai s dung dao cat co nhieu li cat. Chuyen ong chnh la chuyen ong quay tron cua dao, chuyen ong chay dao la chuyen ong thang theo cac phng ngang, doc, va thang ng do ban may

S t

thc hien. Toc o cat khi phay c tnh theo cong thc:
V =

.D.n
10 00

99

[m /

p ] h

n v la met phut Trong o: D ng knh cua dao phay [mm]

V =

n- so vong quay cua dao [vong/phut]. Lng chay dao khi phay c xac nh bang mot trong ba yeu to: -Lng chay dao rang (Sz) la lng dch chuyen cua chi tiet trong thi gian mot rang (1 li cat) cua dao phay an vao kim loai, n v la mm/raang. -Lng chay dao vong la lng dich chuyen cua chi tiet khi dao phay quay c mot vong, k hieu la Sv va co n v la mm/vong. -Lng chay dao phut la lng dch chuyen cua chi tiet sau thi gian mot phut, ky hieu la Sm va n v la mm/phut. Nh vay moi quan he gia cac loai lng chay dao tren nh sau: Sm = Sv.n = Sz.Z.n [mm/phut]. Trong o: Z so rang (so li cat ) cua dao phay. n- so vong quay cua dao sau mot phut. Khi phay co the thc hien theo hai phng phap: -Phay thuan la khi hng tnh tien cua phoi trung chieu quay cua dao. -Phay nghch la phng hng chuyen ong cua phoi ngc chieu quay cua dao.

n..D 1000

n t M Nh h g c

n M T u ha n t

Khi phay thuan, chieu day cua phan cat thay oi t amaxen khong. Dao phay tao nen lc ep phoi xuong ban may. Khong gay hien tng trt khi an dao nen o bong be mat tot hn phay nghch. S va ap gia dao va chi tiet ln . Phu hp vi gia cong tinh. Khi phay nghch qua trnh cat t b va ap, may va dao t b hong hn, phu hp vi phay tho.

100

*u iem cua phay nghch la chieu dai cat tang t amin=0 en amax, nen lc cat tang t t, tranh c va ap, luc tac dung theo phng tien co tac dung lam khch gia ai oc va vt me cua ban may , khong tao ra o r khong gay ra rung ong. *Nhc iem la thi iem au khi rang mi vao cat, chieu day cat a min=0 nen xay ra hien tng trt gia li cat va be mat gia cong, lam cho o nhan be mat gia cong kem va lam dao mon nhanh. Do o phay nghch ch dung e gia cong tho. *u iem cua phay thuan la khong co hien tng trt luc li cat mi vao cat v chieu day li cat thay oi t amax en amin. Do vay dao t mon tuoi ben dao tang len, o nhan be mat cao. *Nht iem la khi mi vao cat co va ap, dao de v rung ong ln Lc cat theo phng tien dao lam cho s an khp gia vt me va ai oc ban may khong lien tuc Neu ta cat vi chieu day cat nho th lc va 165 nho anh hng en rung ong khong ang ke

II. Dao phay:

Khac vi dao tien ,dao phay co rat nhieu li cat, cac li cat nay co the che tao lien vi than dao, co the c che tao rieng goi la rang chap. Li cat c bo tr tren mat tru, mat au hoac ca mat tru va mat au. Tuy theo hnh dang , v tr li cat va cau tao, dao phay c chia thanh cac loai sau:

Dao phay m t tru a Dao phay go c

Dao phay ngo n Dao phay a

101

-Dao phay mat tru la loai dao ma li cat c bo tr tren mat tru cua dao. Co hai loai dao phay mat tru la dao phay rang thang va dao phay rang nghieng. Dao phay rang thang la dao phay co phng cua li cat chnh song song vi truc dao. Dao phay rang nghieng co li cat chnh tao vi truc dao mot goc nhat nh. -Dao phay mat au la dao phay co li cat c bo tr tren mat au cua dao. Dao phay mat au co the la rang lien hay rang chap. -Dao phay ngon co the co t 2 en 8 li cat. -Dao phay a . -Dao phay goc. Ngoai ra con co cac loai dao phay nh hnh, dao phay ranh then, dao phay lan rang moun dung e gia cong banh rang. Cac loai dao phay nen co goc sau t 10 en 200 va goc cat t 60 en 900. Khi phay cac vat lieu mem nen chon goc ln va goc cat nho hn.

III. Kha nang cong nghe cua phay:

Phay co the gia cong c nhieu dang be mat khac nhau, tuiy nhien di ay ta ch nghien cu ky hai loai be mat la mat phang va then hoa. Rieng phay banh rang se c nghien cu trong chng sau(chng gia cong banh rang). Cac mat phang gia cong c tren may phay la cac mat phang nam ngang, mat phang thang ng va mat phang nghieng . Khi gia cong cac loai mat phang nay co the s dung dao phay hnh tru , dao phay mat au, dao phay ngon hoac dao phay a. Trong san xuat loat ln,dao phay

102

mat au c s dung nhieu hn dao phay hnh tru v cac nguyen nhan sau ay: -Cho phep s dung dao co ng knh ln, cat c mat phang co chieu rong ln nen nang suat cao. -Truc ga dao khong can dai nen o cng vng cua truc dao tot hn, cho phep nang cao che o cat. -Nhieu li cat cung tiep xuc vi phoi nen qua trnh cat c em hn. -Cho phep s dung nhieu dao e gia cong nhieu be mat cung mot luc. -De che tao cac loai dao rang chap. -Mai dao de dang hn. Cac be mat ranh hoac bac nho thng dung dao phay a hoac dao phay ngon e gia cong. Ranh then va truc then hoa thng oi hoi o chnh xac gia cong kha cao nham am bao c tnh chat lap ghep cua moi ghep then hoac then hoa. Tuy theo dang then ma ranh then co the c gia cong bang dao phay a ba mat hoac s dung dao phay ngon. Khi phay truc then hoa co the s dung loai dao phay a ba mat bang cach phay hai mat ben bang hai dao phay a, sau o dung mot dao phay phan mat tru then hoa. Truc then hoa cung thng c gia cong bang dao phay nh hnh.

IV. Ket cau va thong so hnh hoc cua dao phay:

Tuy theo yeu cau tao hnh be mat gia cong ma co nhieu loai dao phy khac nhau. ay ta ch khao sat ket cau va thong so hnh hoc cua dao phay tru va dao phay mat au lam at trng v chung co nhieu iem giong nhau vi cac loai dao phay khac.

103

1.Dao phay tru:

oi vi dao phy tru gocf1 trc tao thanh bi ng tiep tuyen vi mat trc va mat chieu truc, tc ng knh i qua iem khao sat tren li cat. Goc trc o trong tiet dien chnh N N, goc sau co tac dung giam ma sat gia mat sau va chi tiet gia cong. Goc sau la goc gom gia tiep tuyen cua quy ao chuyen ong cua iem khao sat tren li cat quanh truc dao phay va mat sau. oi vi dao phay rang xoan goc sau o trong cac tiet dien N-N va M-M co dang sau: tg = tgN.cos tg = tg N.cos Trong o goc nghieng cua ranh xoan Chu y : Phay bang dao ophay rang tru la phay t do, v ch co mot li chnh tham gia cat got *Bc vong cua dao la khoang cach gia hai rang ke

TV =

nhau o theo cung tron Z la so rang cau dao D la ng knh dao phay (mm) *Bc chieu truc l;a khoang cach gia hai rang ke nhau o theo ng sinh cua hnh tru Ttr = Tv.cotg (mm)

.D Z

104

*Bc phap tuyen o theo phng vuong goc vi loi cat TN = Tv. cos 2. Dao phay mat au: dao phay mat au cac li cat hnh thanh nh cac daop tien ngoai co li chuyen tiep. Goc trc c o trong tiet dien chnh, goc sau c o trong mat phang quy ao chuyen ong, tc mat vuong goc vi truc dao. Quan he gai goc sau 1 tiet dien mat au va goc n tiet dien phap tuyen vi li cat nh sau : TgN = tg1.sin /cos Trong o la goc nang cua li cat chnh la goc nghieng chnh. Goc trc con c xet trong tiet dien doc truc 2, trong tiet dien mat au 1 Quan he nh sau : tgN = tg 1.sin + tg 2.cos Chon thong so hnh hoc dao phay cung xuat phat t tnh chat vat lieu gia cong thong so ket cau cua dao V du: oi vi dao phay mat au hp kim cng khi phay thep chon goc trc khoang 100 +100 . Khi phay gang = 5 100 . Goc nghieng chnh dao phay mat au thng lay bang 45 600, chon tuy theo o cng vng he thong may dao o ga chi tiet. Goc nghieng phu chon tuy theo cap o nhan can thiet thng lay bang 5 - 100 3. Cac yeu to cua lp kim loai b cat va che o cat khi phay: a. Che o cat: Toc o xac nh theo n. .D cong thc:
V =

Trong o:D la ng knh dao phay (mm) n so vong quay cua dao trong 1 phut. oi vi dao phay co mat lam viec nam tren ng knh khac nhau V du: oi vi dao phay nh hnh, dao phay goc xac nh toc o theo ng knh ln nhat cua dao. Khi phay ngoai chieu sau cat t con xet en chieu rong phay b. Chieu rong phay va chieu sau phay la kch thc lp kim loai c cat o trong phng truc dao phay. Chieu sau phayla kch thc cua lp kim loai b cat o trong phng thgang goc vi truc dao. Trong qua trnh phay ngi ta qui nh ba loai lng chay dao

1000

105

*Lng chay dao rang Sz la lng dch chuyen cua ban may sau khi dao quay c 1 rang (mm/rang). *Lng chay dao vong Sv la lng dch chuyen cua ban may khi dao quay c 1 vong (mm/vong). *Lng chay dao phut Sph la lng dch chuyen cua ban may trong thi gian 1 phut (mm/phut). Co moi quan he nh sau: Sph = Sv.n = Sz.Z.n b. Thanh phan lp cat: Trc khi xac nh chieu day cat va dien tch lp cat, ta can xac nh tr so goc tiep xuc tc la goc tam tng ng vi cung tiep xuc gia dao va phoi. *oi vi dao phay hnh tru: T tam giac OBC ta co D

t OC 2t 2 cos = = = 1 D OB D 2 2t = arccos1 => D

O B amax C atb

*oi vi dao phay mat au oi xng :

Sin

*Thanh phan lp cat oi voi dao phay tru rang thang: +Chieu day cat a: Khoang cach gia hai v tr ke tiep nhau cua quy ao hai rang lien nhau o theo phng phap tuyen tc la phng

t = 2 D

106

hng knh (coi ng xicloit gan nh ng tron) v lng chay dao qua nho so vi ng knh dao phay. Theo hnh sau iem B ng vi thi gian rang th nhat i ra khoi vung tiep xuc vi phoi, iem E oi vi rang th hai, goc tiep xuc. Cho cung EC bang oan EC.

S
E C B

/2

T tam giac BEC ta co : BC = amax = Sz.Sin Trong trng hp chung co the viet : ao = Sz. sin Trong o : goc tiep xuc tc thi. Chieu day trung amax + amin amax

atb =

bnh

Hoac tnh tng ng vi goc /2 atb = Sz.Sin/2

Theo lng giac ta co :

sin 2
Vay

1 = (1 cos ) 2 2
1 2t t 1 1 + = Sz 2 D D

atb = Sz.

+Chieu rong cat b: oi vi dao phay tru rang thang, chieu rong cat b bang chieu rong phay B. +Dien tch cat:

107

Xac nh dien tch cat ln nhat cua mot rang dao nh

f max = B.amax = B.Sz.Sin

sau:

t t2 2t Sin = 1 cos = 1 1 = 2 D D D2
2

f max

e xac nh dien tch cat tong cong can biet so rang ong thi tham gia cat Trong o: la goc tam gia 2 rang dao Z la so rang dao phay

t t2 = 2 B.Sz. 2 m= D D

oi vi moi rang dao dien tch cat tc thi tnh theo cong thc

360 0 = Z

Fi = B.Sz.Sin i
Trong o : i goc tiep xuc tc thi cua rang th i. Vay dien tch cat tong cong la: F = fi = B.Sz.(Sin 1 + Sin 2 + + Sinn)

F = B.S Z . sin i
1

v tr co dien tch cat tong cong ln nhat tr so cac goc tiep xuc nh sau: 1= ; 2= - ; 3 = - 2; .; m= - (m-1) * Thanh phan lp cat oi vi dao phay rang tru rang nghieng: oi vi dao dao phay tru rang nghieng chieu dai cat cung c tnh nh oi vi rang dao thang. Nhng chieu day cat khong nhgng thay oi theo v tr cung tiep xuc tc thi moi iem. Xet tai mot phan vo cung nho ben chieu dai li cat ta co dien tch cat bang:

108

df = adb = a
Hay

D d0 . 2 sin
D d0 . 2 sin

df = S z .Sin .

T o suy ra dien tch cat cua ca li cat:

f = f =

D.S z d . sin .d 0 2.sin c D.S z ( cos c cos d ) 2.sin

Va dien tch cat cua m rang ong thi tham gia cat:

F =

D.S z m f = ( cos c cos d ) 2.sin 1

V. Lc cat va cong suat cat khi phay:

oi vi dao phay tru rang thang co the phan lc can R1 ra lam hai thanh phan: Lc vong P (Tng ng vi truc Pz trong tien) tac dung theo phng tiep tuyen vi quy ao chuyen ong cua li cat va lc hng knh Py. Ngoai ra con co the phan lc R1 lam hai phan: lc ngang Pn va lc ng P. oi vi dao phay tru rang nghieng ben canh lc R1 trong mat vuong vi truc dao, con co lc chieu truc Po. Trong cac thanh phan lc noi tren can chu y nhat la thanh phan lc vongP. Thanh phan lc vong sinh ra cong cat chu yeu. Can c vao P e tnh cong suat cung nh e tnh toan cac chi tiet may cua c cau truyen chuyen ong chnh. Lc hng knh Py tac dung le cac o truc chnh lam vong truc ga dao. Lc ngang Pn e tnh c cau chay dao va ga lap kep phoi. Lc ngang co the sinh ra rung ong gia vt me va ai oc cua ban may co khe h.

109

Lc Pd co tac dung lam bat phoi ra khoi ban may. Xac nh cong thc tnh lc vong cua dao phay tru rang thang nh sau, cho lc P tac dung len mot rang: P = p.f Trong o: p la lc cat n v F la dien tch cat tren mot rang dao mot thi iem nao o. Lc cat n v c tnh theo cong thc :

P=

A n ax

Trong o A he so phu thuoc ieu kien gia cong vat lieu gia cong va thong so hnh hoc cua rang dao phay. n < 1 so mu phan anh mt o anh hng cua chieu day cat tc thi lc ax en lc p. Biet p va f xac nh c

P' =
P

A .az .B = A.B.a1 n x n ax

Trng hp tnh lc cat trung bnh Ta c Xet lc cat cua m rang ong thi tham gia cat: P.m

P =

atb = S z .

t 1 P' = A.B.S Z n . D

t D

1 n 2

m=

Ta biet : Trong o Va Khai trien

4 cos = 1 + + .... 2 1.2.3.4

2 2t = 1 2 D

2= cos 1 z 2

2t D

Neu ch lay hai so hang au ta co

1 =2 t D

110

Khi ay T o:

m=

Z t = . D
1 n 2

t P = P '.m = A.B.S 1n z D

t . z D

1 2

A 1 P = S Z n .B.Z .t
K hieu:

2n 2

.D

2n 2 2

CP =

Cong thc tren oc xac nh theo ly thuyet dang cong thc ung cho trng hp phay bang dao phay tru cung nh cac dao phay mat au , dao phay a Biet lc cat P, toc o cat V co the tnh cong suat tieu hao khi phay: Trong o : qN = qp+1 Cong suat cho chay dao thng khong qua 15% cong suat cat NC Phan tch cong thc ly thuyet va cong thc thc nghiem ta thay lc cat P: +Lc cat P ty le thuan vi chieu rong dao phay B va

A 2n n2 ; yP = 1 n; xP ; qP = 2 2

NC =

so rang dao phay z. +Anh hng cua lc chay dao en lc cat giong nh khi tien, so mu gan bang 0,75 +So mu cua t nho hn 1 trong khi oi vi tien xP = 1, ieu o co the giai thch khi phay va khi tien xet ve ban chat vat ly hai thong so chieu sau cat hai trng hp ay co khac nhau. Neu khi tien, chieu sau cat t at trng cho chieu rong cat th khi phay chieu sau cat lai xac nh chieu dai cung tiep xuc hay goc tiep xuc cung nh chieu day lp cat trung bnh. Do vay khi chieu sau cat tang len, lc cat n v se giam. +Tang ng knh dao phay, lc ca se giam la v so rang ong thi tham gia cat giam va chieu day cat cung giam.

P.V = CV .t xp .S yp .B.z.n. qN 60.1020

111

Cac thanh phan lc cat khac thng c xac nh theo 1 ty le vi lc vong . -Khi phay nghch: Py = (0,6 0,8)P ; Pn = (1,1 1,2)P ; Pd = ( 0,2 0,3)P. -Khi phay thuan: Py = (0,6 0,8)P ; Pn = (0,8 0,9)P ; Pd = ( 0,6 0,9)P. -oi vi dao phay mat au: Pn = (0,6 0,9)P. -oi vi dao phay tru rang nghieng can tnh lc chieu truc Po. Tuy theo goc nghieng . Po= (0,35 0,55)P co the khac phuc lc chieu truc bang cach dung hai dao phay ga tren mot truc vi cac phng rang nghieng ngc nhau.

VI. o mon va tuoi ben cua dao phay toc o cat:

Tuy theo ieu kien cat ma o mon xay ra, tren mat sau hay ong thi ca mat trc va mat sau cua rang dao. Dao phay tru, dao phay nh hnh, phay ranh thng cat phoi mong do o chu yeu b mon chu yeu theo mat sau. Khi phay nh hnh th cng o mon mat sau cang ln. Dao phay mat au thng cat phoi co chieu day ln, do o chieu dai cung tiep xuc thng ln do o phoi tiep xuc vi mat trc lau hn, v the xay ra mon ca mat sau va mat trc, nhat la khi gia cong thep toc o cao va dao co < 0 v o mon mat trc the hien ro hn ca. oi vi tat ca cac loai dao phay lay o mon theo mat sau lam tieu chuan, v no at trng cho tnh tang mon cua li cat. Tuoi ben cua dao phay phu thuoc toc o cat, kieu dao, ng knh dao, dang gia cong. Quan he gia toc o cat va tuoi ben co dang sau:

V =

oi vi dao phay thep gio m = 0,15 0,33 Dao phay dang hp kim cng m = 0,2 0,6 Toc o cat khi phay c bieu dien theo cong thc :

A Tm

CV .D qv 112 V = m xv yv Uv Pv .KV T .t .S Z .B .z

Trong o : Cv hang so phu thuoc nhom vat lieu gia cong. K v he so hieu chnh tnh en anh hng cua vat lieu gia cong, vat lieu dao, trang thai lp be mat gia cong, o mon cua dao, dung dch trn nguoi, hnh hoc cua dao. Phan tch cong thc tren ta co the rut ra ket luan : Khi tang ng knh D dao phay th bc vong cua dao tang len, so rang ong thi tham gia cat giam i, ong thi khoi lng than dao ln hn thi gian rang dao chay khong ngoai khong kh lau hn, do o nhiet cat sinh ra t hn, truen nhiet tot hn. V the tuoi ben cua dao c tang len hoac neu gi nguyen tuoi ben th co the tang toc o cat. Giam so rang dao phay, bc rang va than rang se ln, ieu kien lam nguoi se tot hn, do o co the tang toc o cat. Tang cac thong so B, t, sz se lam tang the tch lp cat, do o lc cat va nhiet cat tang len, e am bao tuoi ben khong oi toc o phai giam i.

VII. Xac nh che o cat khi phay.

Trnh t chon che o cat khi phay 1) Chon che o cat khi phay: Chon loai dao, ng knh dao, so rang, vat lieu 2)Chon chieu sau cat: Viec chon chieu sau cat phu thuoc vao lng d nh khi tien. Nen can lng chieu sau cat lay bang lng d e giam thi gian may. 3) Lng chay dao S: Cac yeu to quyet nh lng chay dao la: o nhan, o chnh xac gia cong, Tnh chat c ly cua vat lieu gia cong, vat lieu lam dao, tuoi ben cua dao phay o ben va o cng vng cua truc ga. on cng vng cua he thong may -chi tiet- dao, cong suat cua may, o ben cua c cau chay dao va o ao cua rang dao. Nh vay ta thay lng chay dao phu thuoc rat nhieu yeu to, cho nen khong the tm ra cong thc chung e xac nh lng chay dao, trong thc te Sz thng chon theo cac so lieu thc nghiem.

113

Khi phay ta chon lng chay dao vong Svong va Sv co anh hng quyet nh en o nhap nho be mat phay. Khi phay thep (o ben trung bnh) bang dao phay mat au hp kim cng vi =50 o nhan gia cong 2 co the chon S = 0.5 0.8 mm/ vg, o nhan 3 chon S = 0.2 0.3mm/vg. Khi gia cong bang dao phay tru thep gio, o nhan gia cong 5 at c khi tron S =1.5 2 mm/vg va o nhan khi chon S =1 2mm/vg. 4- Xac nh tuoi ben dao phay theo cac so tay ve che o cat. Trong o can chu y rang dao phay ladung cu cat tng oi at tien hn dao tien hay mui khoan, so lan mai sac cho phep lai han che nen tuoi ben cua dao phay nen chon ln. V du tuoi ben trung bnh cua dao phay tru va mat au 3 4, dao phay a la 2.5 3, dao phay ranh then 1 1.5 gi. 5- Theo cac so lieu a chon tren ma xac nh toc on cat . 6- Tnh lc cat PZ, lc chay dao PN, momen xoan va cong suat. Kiem tra kha nang may theo cac so lieu tnh toan ve lc va cong suat. 7-Thi gian may:
tm = l + l1 + l 2 L .i = .i S ph S Z .Z .n

Trong o: L Chieu dai trung bnh cua hanh trnh dao phay theo lng chay dao,mm l chieu dai be mat gia cong l2 lng an ti cua dao,mm l1 lng vt qua cua dao,mm i so lan chuyen dao. Lng an ti cua dao c tnh theo cong thc sau: + Khi gia cong bang dao phay tru:
l 2 = t ( D d ) mm

+ Khi phay oi xng bang dao phay mat au: l2=0.5(D-d)D2-B2 mm

+Khi phay khong oi xng bang dao phay mat au: l2=t(D-d) mm

114

I. ac iem va kha nang cong nghe cua chuot:

Xet ve cac chuyen ong trong qua trnh cat cua chuot th tng t nh bao va xoc, tuy nhien mot so trng hp chuyen ong chay dao la chuyen ong quay tron va c thc hien ong thi vi chuyen ong chnh. ieu khac biet nhat cua chuot so vi bao va xoc la ket cau cua dao chuot. Dao chuot co rat nhieu li cat. Tren mot dao co the co mot so li cat gia cong tho va phan li cat e thc hien gia cong tinh va sa ung. Chuot co the gia cong mat phang ngoai cac lo tron cac lo co ranh thang hoac ranh xoan, lo then, lo then hoa va cac dang lo nh hnh khac u iem cua phng phap chuot la : o chnh xac co the at cap 7, o bong be mat at Ra = 0.6 0.8m, chat lng be mat gia cong tot v van toc cat nho, bien dang deo khong ln. Nang suat cao v so li cat nhieu

Bai 2 CHUOT

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Mot lan cat co the va la gia cong tho va la gia cong tinh Co the gia cong c nhieu dang lo khac nhau Co the gia cong c cac lo co ng knh en 320mm, then hoa co ng knh en 420mm, chieu rong cua ranh en 100mm, chieu ai cua lo en 10 000mm Nhc iem cua dao chuot: Dao chuot kho che tao, at tien Ch gia cong c cac lo thong suot, thang va co ng knh khong thay oi oi hoi may phai co cong suat ln v lc chuot ln Chuot khong sa c cac sai lech ve v tr tng quan Khi chuot cac lo co chieu day thanh lo khong ong eu th lo de b bien dang.

C ago oh u a d l e ho c n ct c t

II.Ket cau cua dao chuot :

L1

L2

L3

L4

L5

ay ta lay dao chuot lo e nghien cu cau tao cua dao.

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Dao chuot gom 7 phan: au dao, co dao l 2 , con chuyen tiep l3, nh hng pha trc l4, phan cat l5, phan sa ung l6, phan nh hng pha sau l7. Phan au dao l1 dung e kep dao va truyen lc. Phan co dao l2 va con chuye tiep l3. Phan l4: nh hng pha trc dung nh tam chi tiet trc khi cat ong thi e bao ve dao khoi b qua tai do lng d ban au ln. Phan l5 la phan cat. Lam nhiem vu cat het lng d. Cac rang cat phan nay co ng knh tang dan gia cac rang cat, mot lng la 2SZ . SZ goi la lng nang cua rang dao chuot. Tren rang cat co cac ranh chia phoi ( ranh chia chia phoi rang sau va rang trc bo tr xen ke nhau) e chia phoi thanh nhng oan nho, do o giam bien dang va lc cat. Phan l6 la phan sa ung. No co tac dung sa ung kch thc lo va tang o bong be mat. Tren o co khoang 1 8 rang, kch thc ng knh cac rang sa ung eu bang nhau va bang kch thc lo muon gia cong. Tren ran sa ung khong co ranh chia phoi. Phan l7 phan nh hng sau, lam nhien vu nh hng chi tiet khi rang cuoi cung cua dao cha ra khoi mat lo. Muc ch la tranh h hong, be mat lo va gay ranh dao do chia tiet b lech. Tren toan bo dao chuoi, phan cat va phan sa ung la quan trong nhat. o chnh xac va o bong cua lo gia cong chu yeu la do ket cau va hnh dang hnh hoc cua rang dao quyet nh.

III- S o cat khi chuot:

tuy theo hnh dang, o chnh xac va kch thc chi tiet gia cong cung nh trang thai be mat cua phoi ma ngi ta dung cac s o cat khac nhau. s o cat co anh hng ln en s phan bo tai trong tren mat rang cat, tuoi ben cua dao va ket cau dao. Hien nay dung 3 s o cat c ban sau: - Chuot theo lp (hnh a) - Chuot an dan (hnh b)

117

- Chuot theo manh

b

(hnh c)
b
3 b

b 2

1. Chuot theo lp: Lp kim loai c cat ra co profin ong dang vi proin cua chi tiet gia cong. Profin rang dao giong profin cuoi cung cua be mat c cat. V du: (hnh a) chuoi lo vuong. Rang dao la hnh vuong. Chuot theo cach nay ta thay chieu day cat a rat mong, chieu rong cat b lai ln, cat nh vay o bong va o chnh xac cao. Nhng lc cat co the qua ln, vt qua gii han be cua dao va lc keo cua may va che tao dao phc tap. 2-Chuot an dan: Profin cua lp cat va li cat khong giong profin cua be mat gia cong. V du: (hnh b) Khi chuot lo vuong th chu vi cua li cat la tron va khi chuot be mat nh hnh th li cat la thang. Rang cuoi cung cua rang dao co hnh dang cua be mat gia cong. o bong va o chnh xac cua cac be mat gia cong vi s o chuot nay thap hn chuot lp v be mat gia cong cho chuyen tiep t lp cat no sang lp cat kia co nhng vet cat co cac rang rieng biet tao ra. Tuy vay chung co u iem la che tao n gian. 3- Chuot theo manh:
b a

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Cung nh chuot an dan profin khi dao chuot theo manh khong giong cua cac chi tiet. Moi lp kim loai co chieu day cat la a, rong la b c cat bi mot nhom rang (co t 2-3 rang). Do o con goi la s o cat theo nhom. Trong cung mot nhom co cac rang co chieu cao bang nhau (sz=0 ). V du: (hnh c) Mot nhom co ba rang. Rang th nhat cat lp kim loai co chieu day cat a, chieu rong 2b1, rang th hai cat lp kim loai co chieu day cat a chieu rong cat b2, rang th ba cat lp kim loai day la a, chieu rong cat 2b3. e tao hnh dang chi tiet phai co nhieu nhom rang cat nh vay. u iem cua nhom cat nay la chieu rong cat moi rang nho i do o co the tang chieu day cat a. neu tang a, bien dang n v cua lp kim loai cat giam do o tac dung len rang dao giam. Tuy vay, v a ln nen rang dao de b mon mat trc. Phng phap nay thng dung khi gia cong nhng chi tiet co lng d ln, chi tiet co vo cng (phoi uc, ren) va nhng chi tiet co thanh mong o cng vng kem. Nhc iem: che tao dao phc tap. IV- Thong so hnh hoc cua dao chuot: 1- Goc trc : o trong mat phang thang goc vi li cat. Tr so goc cat chon theo vat lieu gia cong, chieu day lp chuot, o bong va o chnh xac cua be mat gia cong. Thng lay =00 180 . Goc trc anh hng ln en en lc cat va o bong be mat gia cong trong khi o anh hng en o mon, tuoi ben cua dao rat t. Thc nghiem cho thay rang, neu tang goc trc 10 0 120 th o bong tang rat nhanh (vi az<0.03mm). neu tang qua 120 th anh hng cua no en o bong kjhong ang ke. Rang dao chuot du mai that can than th li cat cua no van co ban knh cong rat nho =0.008 0.01mm. Neu az<0.01mm th lp cat b nen ch khong tao ra phoi c. Ta thay ay vai tro goc trc mat tac dung oi vi qua trnh cat. Do bien dang cua kim loai tang khi cat vi s Z qua

119

nho lam giam o nong va o chnh xac gia cong. V vay khong nen chon sZ <0.02mm. e de dang che tao ngi ta thng lam phan cat va phan sa ung nh sau :=50 200 tuy thuoc vao tnh chat cua vat lieu gia cong. Nhng trong thc te dao chuot ch c mai sac lai theo mat trc. Do o oi vi rang sa ung khong lam nhien vu cat lng d thng lam =00 50 e ng knh cua dao lau b giam khi mai lai con rang cat th ln hn. 2 Goc sau : Goc sau anh hng ln en tuoi ben va kch thc cua dao chuot. V vay chieu day lp cat khi chuot rat nho(0,02 0,2)mm do o dao mon chu yeu mat sau. ang le phai chon ln, nhng nh vay th ng knh dao chuot giam i rat nhanh sau moi lan mai lai. Cho nen rang dao chuot goc sau thng nho. + oi vi rang cat: =2 3030 + oi vi rang sa ung:=10 20 + Dao chuot ngoai :=50 100 v no co the ieu chnh

Chi tie t

Sz

P
Rag dao n

knh thc gia cong. 3- Canh vien f: e tang tuoi tho cua dao chuot , tren rang sa ung ngi ta lam canh vien f<0.2mm, tren rang cat f<0.05mm. phan canh vien mai bong en 10 e giam ma sat vi be mat gia cong. 4-Cac yeu to cat: a-Chieu day cat a: chieu day cat khi chuot bang lng nang moi rang(a=sZ) nh tren a trnh bay, chieu day cat a do moi

120

rang cat a khong c nho hn 0.02mm. v a cang nho bien dang kim loai cang tang, a en lc cat v tang, o bong giam. Ngc lai a qua ln lam phoi kho cuon tron va cha ay ranh, de lam gay dao dan en lam giam o bong gia cong. A =0.02-0.03mm. tuy theo vat lieu gia cong. Vat lieu deo kem ben chon a ln va ngc lai. b- Chieu rong b: Chieu dai li cat tham gia cat. Dao chuot lo tron b=.D Dao chuot ranh then b = B . B chieu rong cat . Dao chuot lo then hoa b = n.B n so ranh then . e giam bien dang phoi, tren cac rang lam ranh chia phoi e phan phoi thanh tng oan, luc o chieu rong cat phai tr i mot lng bang chieu rong cua ranh chia phoi. c - Dien tch cat: Dien tch cat do moi rang cat ra f = a.b mm2 Tong dien tch cat do so rang ong thi tham gia cat got trong lo la F= f.z mm2 Trong o : z la so rang ong thi tham gia cat z = L/t L chieu dai mat c chuot T bc rang dao chuot (t = s) Do o dien tch thay oi t Fmin en Fmax gay rung ong trong qua trnh cat. e tranh hng tng nay, ngi ta lam dao chuot co bc khong eu nhau, nh vay khi cat dao khong b va ap li cat vao be mat gia cong theo chu ky. Cung co the dung dao chuot rang nghieng mot goc = 10 300 e giam rung ong. Chu y rang gia rang cat va rang sa ung can co rang cat tinh e am bao chat lng be mat gia cong cung nh am bao s giam dan tai trong tren loi cat cua dao chuot, v the chieu day cat giam dan t rang cat tho en rang cat tinh va cuoi cung en rang sa ung. So rang cat oc xac nh bi gia tr cua lng d gia cong va long nang moi rang az . so rang cat tinh lay t 2 en 5 rang. So rang sa ung lay t 4 en 8 rang va tuy rthuoc vao o chnh xac gia cong, o chnh xac cang cao th so rang sa ung cang nhieu. So rang ong thi tham gia cat thng lay t 4 en 5 rang khong vt qua 8 rang. V so rang ong thi tahm gia cat qua ln => dien tch cat ln may khong u cong suat, ong thi vat lieu che tao dung cu khong u ben khi ch lc cat qua ln. Bc rang t cua dao chuot co the xac nh theo cong thc thc nghiem (trnh bay sau).

121

V. Lc cat khi chuot :

Cac thanh phan lc cat khi chuot gom : Lc chieu truc Pz hng ngc vi phng chay dao Lc Py hng vuong goc vi be mat gia cong hay hng vao tam. Px hng vuong goc vi Py va Pz. oi vi dao chuot rang thang th Px = 0 , khi cho\uot cac be mat lo tron, lo vuong, then hoa, th Py triet tieu nhau. Lc chuot Pz c tnh Pz = p.b.a.zmax. Trong o p la lc cat n v (N/mm2) b la chieu rong cat a la chieu day cat. z so rang ong thi tham gia cat ln nhat. Cung co the xac nh lc cat khi chuot theo cong thc sau: +Chuot lo tru:

Pz = C p .Z max .S Zyp .D.K P

Px Pz

Py

+Chuot ranh then va then hoa: Trong cong thc tren :

Pz = Cp.Z max .S Zyp .D.b.n.K P

Cp hang so phu thuoc vat lieu gia cong Sz lng nang cua rang (mm) B chieu rong ranh then (mm) N so then Z so rang ong thi tham gia cat ln nhat

122

K he so hieu chnh ke en anh hng cua goc trc, o mon mat sau cua rang, dung dch trn nguoi cac so mu tra trong so tay che o cat khi gia cong c.

VI. S mai mon, tuoi ben va toc o cat khi chuot:

1. S mai mon: Khi chuot thep b 800N/mm 2 va 2gang co HB 180 vi a 0 , th mon chu yeu mat sau, khi chuot thep co o ben cao va gang cng vi a = 0,05 0,1 lai thay mon eu tren mat trc suot ca chieu dai li cat chnh. oi vi tat ca cac loai cac vat lieu cat vi chieu day cat a>0,1 mm th xay ra mon ca mat trc va mat sau. Noi chung, dao chuot mon theo mat sau la quan trong hn ca v no anh hng ln en tuoi ben dao lng d cho moi lan mai lai ( anh hng en tuoi tho cua dao) o mon theo mat sau chu yeu phu thuoc vao chieu day cat, goc sau , tnh c ly cua vat lieu gia cong va vat lieu lam dao: hs = C1 . 0,5 hs = C2 . 0,33 Dao chuot mon th o bong va o chnh xac be mat chi tiet giam, lc cat tang. oi vi dao chuot gia cong be mat thong thng th: hs = 0,15 0,2mm Dao chuot cat theo manh : hs = 0,33 2. Tuoi ben va toc o cat: Dao chuot la dung cu cat chuuyen dung kho ce tao, at tien, thng ch dung cac x nghiep che tao may ln. Do o viec xac nh tuoi ben hp ly cua dao chuot co anh hng ln en nang suat gia cong, o chnh xac va tuoi tho cua dao. Tuoi ben c chon phu thuot vao vat lieu gia cong, vat lieu dao, o chnh xac gia cong, thng ngi ta nh tuoi ben dao chuot : T = 120 480 phut Toc o cat khi chuot c tnh :L

V =

Trong o: Cv hang so phu thuoc vat lieu gia cong. T tuoi ben dao chuot (phut) Sz lng nang moi rang hay chieu day cat

CV Yv T m .S Z

m/ph

123

YV so mu noi len mc o anh hng cua tuoi ben, chieu dai cat vi toc o cat. V trong qua trnh cat, sat ln, ti dung dch trn nguoi kho khan, nen nhiet sinh ra ln. V vay chon van toc chuot thng nho. Dao chuot lam bang thep gio, thep hp kim dung cu nh P18, P9, XBT th nen chon toc o chuot la 2 12m/phut. Do o viec chon toc o thap chu yeu la theo chat lng be mat gia cong yeu cau chu khong phai theo o ben dao . Cong suat cat khi chuot:

NC =

PZ 60.103

Thi gian may khi chuot:

T0 =

L.K 103.V

L chieu dai hanh trnh chuot V toc o cat khi chuot K he so tnh en hanh trnh chay khong cua may K = 1,2 1,5 L = l1 + l2 + l3 + l1 chieu dai lo chuot l2 chieu dai phan rang cat l3 chieu dai phan rang sa ung chieu dai thoat dao 2 3 mm

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I. Khai niem chung ve banh rang:

Bai 3

CAT RANG

Banh rang la chi tiet co rang dung e truyen chuyen ong quay bang s tiep xuc lan lc cac cap rang an khp vi nhau. Banh rang thng dung gom co mot so nh sau: - Banh rang tru dung e truyen chuyen ong gia hai truc song song vi nhau - Banh rang con dung e truyen chuyen ong gia hai truc cat vi nhau - Banh vt truc vt dung e truyen chuyen ong gia hai truc cheo nhau Hai loai banh rang tru va banh rang con lai c chia ra lam hai loai la banh rang nghieng va banh rang co rang thang.

II. Yeu cau chung cua banh rang:

1. o chnh xac:

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o chnh xac cua banh rang c anh gia bang cac tieu chuan sau ay: +o chnh xac ong hoc. +Mc o lam viec em(hoac o on nh khi lam viec ) +o chnh xac ve tiep xuc +Khe h canh ben. Theo tieu chuan nha nc Viet Nam (TCVN 1067-84) th 3 ch tieu au c quy nh moi ch tieu co 12 cap chnh xac vi ky hieu la cac ch so t 1 en 12 trong o so 1 la cap chnh xac cao nhat. Trong thc te cac banh rang thng c che tao vi cap chnh xac t 4 en 11 . oi vi ch tieu th 4 th TCVN 1067 84 quy nh co 6 dang oi tiep khe h mat ben rang va c ky heu bang cac ch cai H,E,D,C,B,A trong o H co khe h nho nhat. 2. Vat lieu va nhiet luyen banh rang: Vat lieu e che tao banh rang phu thuoc vao tai trong , cong dung va toc o khi lam viec . Cac loai vat lieu thng c s dung gom thep cac bon, thep hp kim va gang. Banh rang bang gang ch s dung khi co toc o quay nho hn 3m/giay. Phoi cua banh rang thng s dung phoi ren. Phoi ren co c tnh tot va co kha nang tiet kiem c vat lieu va thi gian gia cong. Nhiem vu cua banh rang la truyen lc va khi lam viec banh rang ch tiep xuc vi nhau cac be mat rang v vay rang phai co o ben va o cng can thuyet . Mat khac banh rang khong c phep co vet nt va ng suat d cao qua mc cho phep. e banh rang co the lam viec c tot can phai co che o nhuyet luyen hp ly. oi vi thep cac bon thap , be mat rang thng c tham cac bon sau khi cat. 3. Chuan: Tuy theo ket cau , vat lieu o chnh xac va san lng ma ta chon chuan va phng phap gia cong chuan cho thch hp. oi vi banh rang co lo bao gi cung chon lo lam chuan e gia cong banh rang , v vay khi gia cong phoi phai chu trong en chat lng lo. oi vi cac banh rang lien truc th be mat co truc can phai chu y ve chat` lng v o la be mat chuan. Trong mot so trng hp can chu y en o thang goc gia mat au bang rang vi ng tam cua lo hoac ng tam cua truc.

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III. Cac phng phap va ac iem cua qua trnh gia cong rang:
Banh rang la mot chi tiet quan trong c dung pho bien trong truyen ong c kh noi chung. Hien nay viec tao hnh banh rang at o chnh xac yeu cau , chu yeu van bang phng phap cat got. oi vi banh rang moun nho co the c tao hnh bang phng phap can ( bien dang deo ) va co nhng banh rang co o chnh xac thap co the che tao bang phng phap uc. Tuy theo yeu cau san suat, o chnh xac va ket cau cua banh rang va ngi ta dung cac phng phap cat rang sau ay: 1. Phng phap chep hnh: Ban chat cua phng phap chep hnh la profin rang cua banh rang c chep lai theo profin li cat cua dao, cac dao dung trong phng phap nay gom co : dao phay a moun , dao phay ngon moun , dao chuot rang , au dao

soc rang Dung dao phay a moun, dao phay ngon moun co the gia cong dc banh rang hnh tru va hnh con rang thang cap chnh xac 9 va 10 . Cung co the gia cong c banh rang hnh tru nghieng da tren nguyen ly bao hnh khong tam tch. Tuy nhien o ch la tao hnh gan ung, o chnh xac gia cong thap, v profin cua cac dao phay a moun trong bo dao khong hoan toan tng ng vi profin banh rang gia cong cung modun va so rang cua no . Ngoai ra viec phan o lam qua trnh cat khong lien tuc, nang suat

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gia cong thap ma con giam o chnh xac gia cong (ve bc rang ). Tuy nhien nhng nhc iem tren, nhng chung van c dung trong san xuat nho va sa cha e gia cong banh rang chnh xac thap, v co the dung tren cac may phay van nang co au phan o. Trong phng phap chep hnh, dung cac dao chuot rang, can dao xoc rang th o chnh xac gia cong va cong suat gia cong at c cao, v qua trnh gia cong bang nhieu rang cat ong thi tuy nhien cung phai dung nhieu dao chep hnh nay ch dung trong san hang loat ln va san xuat hang khoi. 2.Phng phap bao hnh: Banh rang c gia cong theo phng phap nay co the at cap chnh xac 7-8 (bang dao phay lan rang va xoc rang ) va at cap chnh xac 5-7 (bang dao ca rang mai rang) qua trnh cat lien tuc nang suat gia cong cao. Phng phap nay dung chu yeu trong san xuat hang loat. Trong phng phap bao hnh profin banh rang gia cong c tao nen trong qua trnh la hnh bao cac v tr lien tiep (cac nhat cat) cua profin li cat cua dao. 3. ac iem cua qua trnh cat rang: Qua trnh cat rang theo phng phap bao hnh co mot so ac iem sau: - Tiet dien lp cat thay oi theo chu ky trong thi gian gia cong. - Nhng oan khac nhau tren li cat chu tai trong khac nhau, v kch thc lp cat ng vi tng oan lp cat khac nhau. Cung nh do lp cat va lng chay dao eu khac nhau. - Tr so goc trc va goc sau thay oi doc theo li cat cua dao, can lu y tranh hien tng ma sat cac oan co goc sau nho Ngoai thong so hnh hoc hp ly can phai am bao o chnh xac profin li cat khi mai lai . - Mot so dao cat rang phai thc hien cac chuyen ong qua phc tap khi lam viec. IV.Cat rang bang dao phay a moun: 1. Dao phay a moun: La loai dao nh hnh ht lng, profin rang dang than khai, profin cua dao phay a moun chang nhng phu thuoc vao moun, goc ap lc ma con phu thuoc vao: so rang z cua banh rang c gia cong. e giam bt so lng dao phay tieu chuan ng vi moi moun co mot bo dao phay( gom 8 dao hoac 12 dao) e am bao gia cong

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khoang so rang t 12 en . Dao phay a moun dung tren cac may phay van nang.Sau khi phay xong mot ranh rang, dung au phan o e quay phoi i mot rang. 2.Che o cat:

- Chieu sau phay t thng chon theo moun: t=2,25m m=1 6 tien hanh cat mot lan xong mot ranh rang. m=7 12 cat hai lan. m=14 20 cat ba lan. -Lng chay dao nphut1 oi vi dao thep gio c xac nh theo cong thc sau: Cs K S ph = m 0.5 o: Trong Cs: He so tnh en anh hng cua vat lieu gia cong K : He so ieu chnh khi phay banh rang nghieng m : Mo un Lng chay dao khi cat tho bang dao phay hp kim cng cho S = 0,1 0,2mm/rang. Khi gia cong thep th Sv = 0,18 0,24mm/vong. Toc o cat khi dung dao thep gio: +oi vi qua trnh cat tho V= 25 30 m/ph +oi vi qua trnh cat tinh V= 30 40 m/ph oi vi dao hp kim cng, e phay thep chon V = 160 200m/ph, va 2phay tho gang chon V = 80 100m/ph Thi gian gia cong xong banh rang c tnh theo cong

T=

(l + l1 + l 2 ) z (l + l1 + l 2 ) z + + t. z S ph Sk

thc : Trong o: L1 la lng cat vao t.( D t ) mm l1 = t la chieu sau phay D la ng knh dao phay

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l la chieu dai banh rang l2 la lng thoat dao (2 3 mm) z la so rang cua banh rang gia cong Sph la lng chay dao khi cat m/ph Sk la lng chay dao cua hanh trnh chay khong t la thi gian phan o mot rang ( t = 0,05 phut). 3. Tuoi ben cua dao: Dao phay a moun chu mon chu yeu mat sau. o mon cho phep theo mat sau oi vi dao gia cong tho hS = 0,8 1mm, oi vi dao gia cong tinh hS = 0,2 0,4mm. Tuoi ben cua dao thng chon T = 150 180phut.

V. Gia cong banh rang bang dao phay lan rang:

1 Dao phay lan rang:

Gia cong banh rang theo phng phap phay lan rang la s dung dao phay lan rang. Phng phap nay da tren nguyen ly an khp gia truc vt vo tan va banh vt. Trong o truc vt la dung cu cat co so rang ( so au moi ren) t 3 5rang va co cac ranh e tao mat trc e thoat phoi va ht lng rang e tao goc sau. Khi phay banh rang tru rang thang th truc dao nghieng vi mat au cua banh rang mot goc . Goc co gia tr bang goc nang ren cua dao Khi phay banh rang tru rang nghieng co goc nghieng cua rang la th goc tao bi truc dao va mat au cua banh rang la : . Dau am (-) klhi dao banh rang co cung chieu xoan, dau (+) khi dao va banh rang ngc chieu xoan.

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Khi phay lan rang cung co the thc hien bang mot trong hai phng phap la phay thuan phay nghch (xem lai). Khi phay co the thc hien tien dao theo hai cach la tien dao theo hng truc va tien dao theo hng knh roi tien dao theo hng truc. Rang dao gom co hai li nh rang va hai li cat ben, mat trc la mat xoan acsimet. Goc trc va goc sau qui c o trong tiet dien thang goc vi truc dao: oi vi dao phay tinh chon: =00 oi vi dao phay tho: =5 100 Goc sau chon: =10 120 Goc sau quan he vi lng ht lng K bang cong thc sau:
K=

.D .tg z

Trong o: D ng knh dao phay. Z so rang dao phay. oi vi dao phay lan rang hp kim cng, khi mai sac can cha mot canh vien doc li cat vi chieu rong f=0.3 0.8 mm va goc trc tren canh vien o v= -5 100 khi gia cong gang. 2.Che o cat: a. Chieu sau cat:phu thuoc moun cua banh rang gia cong, cong suat may, o cng vng cua he thong chi tiet dao may va ac tnh gia cong(tho hay tinh). Nen tan li cat tho trong mot lan chay dao. Trng hp cong suat may va o cng vng cua he thong khong u th co the chon cat tho hai lan. Lan th nhat cat vi chieu sau 1.4m va lan th hai vi chieu sau 0.7m ( :moun). b. Lng chay dao: la lng dch chuyen cua dao phay doc truc chi tiet sau mot vong quay cua chi tiet gia cong ( phoi ). Viec chon la chay dao phay phu thuoc vao tnh chat vat lieu gia cong, moun, o bong va o chnh xac cua banh rang. Khi cat tho, lng chay dao phu thuoc vao o cng vng cua may va o ben cua dao. Khi cat tinh, lng chay chu yeu phu thuoc vao o nhan va o chnh xac cua banh rang. Lng chay dao khi gia cong thep 45 bang dao thep gio nh sau: Khi gia cong tho banh rang m=6 16 tren may co cong suat 5 9 kw.

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S = 1.8 2.8 mm/vg Khi gia cong tinh at 6 (khong qua gia cong tho) vi m=1.5 3 mm. S = 0.5 1.0 mm/vg c.Toc o cat: Gia cong tho banh rang t thep 45 bang dao phay thep gio P18, m=7 26 th toc o tnh theo cong thc sau: 350 m / ph T s m 0. 1 Trong o: Tla tuoi ben cua dao phay lan rang Gia cong tinh khong qua nguyen cong tho v=
0.33 0.5

560.m 0.5 v = 0.5 0.85 m / ph T s

m=1.5 3 Gia cong tinh bang dao phay hp kim cng vi lng chay dao S=1 3 mm/vong C v = 0.74 v 0.33 m / ph T s

L.z ph n.s.q Trong o: L chieu dai hanh trnh cua dao L = l 1 + l2 + l3 L1: lng cat vao L2: chieu dai banh rang L3: lng thoat dao N : so vong quay cua dao trong mot phut S : lng chay dao Q : so au moi cua dao
3.Thi gian may. T0 = 4.Lc va cong suat cat: Dien tch cat khi phay lan rang la mot lng thay oi, do o lc cat khi gia cong cung la mot lng thay oi. Lc vong trung bnh co the xac nh theo cong thc thc nghiem P = CP.mxp syp Trong o: Cp hang so phu thuoc vat lieu gia cong

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M moun cua banh rang gia cong S lng chay dao Cac he so CP, xp, yp thay theo bang sau: Vat lieu gia cong Thep 20 Thep 40 Gang HB=212 223 Cp 30 24,4 10,9 Xp 1,0 1,0 1,37 Yp 0,75 0,75 0,8

Lc vong trung bnh cung co the xac nh t tr so cong suat cat Cong suat cat khi gia cong bang dao phay lan rang mot au moi, vat lieu gia cong la thep 45, c tnh bang cong thc :
0,124.S 0,9 .m1,7 D Trong o: D la ng knh ngoai cua dao phay NC =

5. o mon va tuoi ben cua dao: o mon cho phep dao phay lan rang cho theo mat sau. Gia cong tho thep, o mai mon mat sau qui nh trong gii han hs= 1,0 1,5cm. Khi gia cong tinh hs= 0,2 0,4mm. Tuoi ben cua dao nam trong khoang T=180 540 phut. Mo un cang ln nen chon tuoi ben cang ln.

VI. Cat rang bang dao xoc rang:

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1. Dao xoc rang va cac chuyen ong cua dao xoc rang:

Nguyen ly cua xoc rang cung tng t nh nguyen ly phay lan rang o la s lan cac rang cua dung cu cat theo cac rang cua chi tiet. Hnh dang cua dao xoc rang co hai loai o la dang mot banh rang tron xoay va dang thanh hay con goi la dang rang lc. Nguyen ly lam viec cua dao xoc rang bang dao xoc dang tron xoay c mo ta nh tren hnh sau: Dao xoc (1) c noi vi tanh trt (2). Thanh trt nay chuyen ong kh hoi doc theo truc cua no nh c cau cult

nd z c = nc z d
(3) qua thanh (4). C cau culit (3) co kha nang ieu chnh chieu dai hanh trnh cua thanh trt (2). Dao va chi tiet co chuyen ong ngc chieu nhau theo ty so truyen c xac nh tuy theo so rang cua dao va chi tiet:

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Trong o: nd so vong quay cua dao nc so vong quay cua chi tiet zc so rang cua chi tiet

5 4 1 2

zd so rang cua dao Khi dao thc hien hanh trnh chay khong th gai dao va chi tiet co chuyen ong hng knh e dao khong ma sat vao be mat rang cua chi tiet. Chuyen ong nay nh vao c cau (5) thc hien. Xoc rang la phng phap gia cong tho banh tang. Nang suat cua phng phap nay khong cao. 2. Che o cat: a. Chieu sau cat: c chon tng t nh trng hp gia cong bang phay lan rang b. Lng chay dao: Khi xoc rang la lng chay dao vong sau moi hanh trnh kep cua dao xoc, o la chieu dai chay theo vong lan cua phoi. Khi cat tho banh rang m =6 8 vat lieu bang thep, dao thep gio may co cong suat : Nc = 2,6 5Kw th Svong=0,3 0,5 (mm/htk) Khi cat banh rang m = 2 3 mm vi o nhan theo yeu cau 6. Svong=0,25 0,3 (mm/htk) Lng chay dao hng knh e dao xoc i vao cat het chieu cao cua rang lay theo ty le sau: Sk=0,1.Svong (mm/htk)

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c. Toc o va tuoi ben: Noi chung cac dao cat rang, cat vi lp kim loai mong do o thng b mon chu yeu theo mat sau. Lng mai cho phep theo mat sau cua dao xoc la : Khi gia cong tho: hs = 0,8 1mm Khi gia cong tinh: hs = 0,1 2mm Tuoi ben cua dao xoc rang khi gia cong tho lay T= 360 phut, gia cong tinh T=180 phut . Toc o cat khi xoc rang bang dao xoc thep gio tnh 90 V = 0,3 0,5 .kV T .SV theo cong thc sau:

90 Cat tho thepV = 0, 2 0,5 0,3 .kV 45: T .SV .m

Cat gang xam:HB = 190.V = 190. 113 .k V 0, 2 0,5
T .SV

54 Cat tho gang xam: V = 0, 2 0, 25 0,15 kV T .SV .m

d. Thi gian may T0: (phut) Cong thc nay tnh cho trng hp gia cong vi mot 2,1m .m.z T0 = + SV .k SV .k lan chuyen dao (chon chieu sau cat bang ca chieu cao rang gia cong). Trng hp cat nhieu lan, phai tnh thi gian may cho tng lan chuyen dao va tong cong cac thi gian ay lai. Trong cong thc tren, thanh phan th nhat la thi gian cat vao (chay dao hng knh) cho het chieu cao rang, thanh phan th hai la thi gian can e gia cong xong toan bo banh rang. n la so hanh trnh kep trong 1 phut gia tr
2.L.n 1000 n tnh theo toc o cat c xac nh t cong thc : 3. Lc cat va cong suat cat: Trong qua trnh cat, lc xoc rang thay oi, v the e tnh toan co the dung cac tr so lc trung bnh va lc cc ai VTB =

136

Khi gia cong thep 45 lc cat trung bnh tnh theo cong

PTB = 924.m 0,95 .S v

thc:

0 ,81

.v 0, 26 .z 0, 21

Tnh lc cc ai Pmax = (1,3 1,5)PTB Khi cat banh rang an khp trong lc cc ai tnh theo cong thc :

Pmax

9,18.21,33k 1+ k = .C SV .m.z 0, 05 0,17 k 2+k

Trong o C hang so phu thuoc vat lieu gia cong Cong suat tnh theo cong thc :

NC =

Pmax .VTB 60.1020

VII. Ca rang:
Ca rang la phng phap gia cong tinh banh rang tru trong o dao co hnh dang la mot banh rang tru hoac mot thanh rang an khp khong khe h vi banh rang can gai cong. Hai truc cua dao va chi tiet luon luon ga cheo nhau ong thi gia chung co chuyen ong an khp trong o dao quay tron la chuyen ong chu ong con chi tiet chuyen ong b ong. Dao ca rang co ng knh ln hn chi tiet , tren mat dao co cac ranh e tao nen cac li cat va ranh thoat phoi. Vi cac chuyen ong nh tren, be mat rang cua dao cao len be mat rang cua chi tiet lam tach ra mot lp phoi mong. o la qua trnh cat khi ca rang. Thi gian ca rang c tien hanh 2 3 phut, neu lau hn th mat rang de b lom (do nhieu nguyen nhan phc tap). Nang suat cua phng phap ca rang noi chung la cao. Banh rang gia cong co the at cap chnh xac 6 en 7 va o bong Ra = 0,32 1,25m. Phng phap nay ch gia cong c cac banh rang cha toi co o cng nho hn 35HRC.

VIII. Mai rang va ve au rang:

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1. Mai rang: Mai rang la la nguyen cong gia cong tinh e gia cong cac banh rang co yeu cau chat lng cao, co o cng be mat cao. Mai rang thng s dung khi gia cong cac banh rang co moun t 2 en 10mm. Nang suat khi mai rang thap ma gia thanh san pham lai cao nen ch s dung khi can thiet. Banh rang sau khi mai co the at cap chnh xac 6 en 7 va o bong be mat rang Ra = 0,32 1,25m. Mai rang c thc hien tren hai nguyen ly c ban o la mai nh hnh va mai bao hnh. a.Mai nh hnh:

Mai nh hnh la phng phap gia cong s dung a mai co bien dang phu hp vi dang rang cua chi tiet. Khi mai co the s dung mot a e mai mot ben cua canh rang sau o mai canh ben con lai cua mot ranh rang. Neu s dung a mai co bien dang giong ranh rang cua banh

M a bao hnh ba g avt xoa i n n

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rang can gia cong th khi mai se mai ca hai canh ben cua mot ranh rang. b. Mai bao hnh: Mai bao hnh s dung a mai co dang giong nh truc vt (giong dao phay lan rang). Khi mai, a chuyen ong quay tron con chi tiet (banh rang) quay cng bc theo mot xch truyen ong chnh xac. o chnh xac cua phng phap nay phu thuoc vao xch truyen ong va phu thuoc vao viec sa a mai. Phng phap bao hnh co the at o chnh xac cao va thng s dung khi gia cong cac banh rang co moun nho. 2. Ve au rang: oi vi nhng banh rang di trt e thay oi ty so truyen, au rang thng c ve tron hay vot nhon e ra vao khp de dang. Khi ve au rang co the dung loai dao co dang nh hnh sau, va thng thc hien tren may chuyen dung.

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Bai 4 MAI
I. ac iem va tnh chat cua mai:
1. ac iem cua qua trnh mai: Qua trnh mai kim loai co tac dung e gia cong tinh cung nh gia cong tho cac chi tiet may va dao cat. Mai khong nhng dung e gia cong cac mat tron ngoai va tron trong ma con gia cong cac mat phang, mat con, mat nh hnh co hnh dang khac nhau cua chi tiet. So vi cac dang gia cong khac, mai co nhng ac iem sau ay: - Toc o mai ln (20 40m/s) ac biet co the len en 50 70 m/s hay cao hn na. - a mai bao gom nhieu hat mai lien ket vi nhau bang chat ket dnh. Coi moi hat mai nh mot li cat. Cac hat mai khong giong nhau ve hnh dang hnh hoc, kch thc v tr, do vay cac goc cat cua hat mai cung khong giong nhau va kho at c tr so hp ly. - Nhiet o cat trong qua trnh mai tng oi cao (1000 1500oC) v toc o cat ln ong thi chieu dai phoi nho va goc trc am sinh ra bien dang kim loai nhieu. - Khac vi cac loai dao cat khac a mai khong co li cat khong lien tuc, cac hat mai nam cach biet nhau tren mat lam viec cua a. Moi hat se cat mot phoi rieng, do o co the xem qua trnh mai nh la qua trnh cao. - Trong thi gian lam viec a mai co kha nang t mai sac mot phan nao. Mot so hat mai sau khi cat xong co the t troc ra khoi mat a lam xuat hien cac hat mai mi sac ben hn. 2.Tnh chat chung cua a mai:

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Ve nguyen ly, mai co tnh chat tng t giong nh phay, ch khac nhau ve kch thc va so lng li cat dao phay va a mai. a mai la loai dao co vo so li cat, moi hat co kch thc khoang 0,003 en 3mm. Cac hat mai co hnh dang khac nhau, phan bo bat ky nh chat ket dnh cua a mai. Ban chat cua qua trnh mai la s co sat te vi be mat vat ran bang nhng hat mai co van toc cao. Mai co the gia cong c cac loai vat lieu rat cng nh lai khong phu hp khi gia cong cac loai vat lie qua mem. Toc o cat cua mai ln hn rat nhieu so vi phay, co the at t 10 80m/s. Mai la nguyen cong gia cong tinh, mai tho co the at cap chnh xac cap 9 va o bong be mat Ra = 0,2 1,6m. Mai tinh mong co the at cap chnh xac 3 en 4 va Ra = 0,025 0,4m.

II.Cac phng phap mai:

Mai co the gia cong c nhieu dang be mat khac nhau nh mat phang, mat tru trong, mat tru ngoai, cac mat con, cac be mat nh hnh tuy theo hnh dang be mat gia cong ma ta chia thanh cac phng phap sau: - Mai mat tru ngoai - Mai mat tru trong - Mai mat phang - mai be mat dnh hnh. 1.Mai mat tru ngoai: Khi mai mat tru ngoai ta co the thc hien bang mot trong hai phng phap la mai co tam va mai khong tam.. a) Mai co tam:

La chi tiet c ga vao hai lo tam hoac mot au vao mam cap va mot au kia vao mui chong tam. Mai co

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tam gia cong c truc trn, truc bac, be mat con, ranh tren cac be mat tru ngoai, goc ln. Khi mai co tam, chi tiet va a quay ngc chieu nhau. toc o quay cua a rat ln gap khoang 100 lan so vi toc o cua chi tiet. Mai co tam thng thc hien chay dao doc, chieu sau be rat be t 0,005 en 0,2 mm. Muon co chieu sau cat c ln hn th a mai can c vat con mot phan vi goc con = 2 3o. oi vi truc ngan co ng knh ln th nen thc hien chay dao ngang. Phng phap nay oi hoi o cng vng cua chi tiet tot, chieu rong cua a ln va ac biet la phai sa a that chnh xac. Phng phap chay dao ngang con s dung khi mai be mat nh hnh tron xoay. Khi gia cong mat au va mat tru ngoai cua truc bac bang mot a con co the thc hien an dao xien. Trong trng hp nay ta thay toc o cat cac iem tiep xuc gia a va chi tiet khong eu nhau, do do a mon khong eu v vay mat tru de b con va mat au khong c thang goc vi mat tru. Trng hp khi mai mat con th ta co the ga chi tiet hay a mai nh hnh sau b). Mai khong tam: Mai khong tam la s dung be mat ang gia cong e lam chuan nh v cho chi tiet gia cong. S o cua mai khong tam c mo ta tren hnh

3 4
S o m a k h o g ta . i n m

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Trong o chi tiet (1) c at gia hai a mai (3) va (4). a mai (3) lam nhiem vu banh dan va truyen chuyen ong cho chi tiet . a (4) co ng knh gap oi a dan va co toc o quay ln hn 100 lan so vi a dan. Chi tiet (1) con c nh tanh (2). Thanh (2) luon gi cho h = 16 d chi tiet co tam cao hntam cua hai a mai mot khoang la trong o d la ng knh chi tiet Nhng h khong c phep vt qua 10 15mm. Thanh dan thng c vat e tao ieu kien cho chi tiet c ap sat vao banh dan. Khi mai khong tam, chi tiet thc hien chuyen ong doc t ong nh goc nghieng gia truc banh dan va truc chi tiet,. Goc nay co gia tr la = 1 60. e tiep xuc gia a dan va chi tiet c tot hn, banh dan thng co dang hypepoloit. ac iem cua phng phap mai khong tam la: - Giam c thi gian phu (thi gian ga at) va thi gian cong chuan. - De t ong hoa qua trnh cong nghe. - o cng v ga at cao hn mai co tam. - Chu yeu dung e gia cong truc trn. 2. Mai tru trong: Khi mai tru trong th ng knh cua a mai phai nho hn ng knh cua lo mai. Thng chon ng knh a bang 0,7 0,9 ng knh lo can mai. Mai mat tru trong cung c tien hanh bang hai phng phap o la mai co tam va mai khong tam. a.Mai co tam:

Chi tie t a a mi

Mai lo co tam co hai cach ga at chi tiet. Cach th nhat la chi tiet c kep chat tren mam cap va quay tron. Truc a cung quay tron la chuyen ong chnh va thc hien ca chuyen ong chay dao doc hoac chuyen ong chay dao ngang. Phng phap ga at nay thng dung e

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mai chi tiet nho, cac mat tron xoay cac vat de ga tren mam cap. Phng phap th hai la chi tiet c ga co nh tren ban may. Truc mang a thc hien tat ca cac chuyen ong gom : chuyen ong quay tron cua a, chuyen ong chay dao doc hoac ngang va chuyen ong hanh trnh cua a xung qunh tam lo gia cong e cat het be nat chu vi lo. Thc chat chuyen ong hanh trnh cua a phng phap th hai la thay cho chuyen ong quay tron cua chi tiet gia cong cua phng phap th nhat. Phng phap th hai nay thuan tien khi gia cong cac chi tiet ln nh: than ong c, cac loai hop, cac chi tiet cong kenh. b. Mai lo khong tam: Chi tiet c gi va tao chuyen ong quay nh hai banh va banh a dan,. Banh a dan co ng knh ln hn nhiei so vi banh . a mai chuyen ong quay tron va cac chuyen ong chay dao. Khi mai khong tam, be mat ngoai cu chi tet la mat chuan nh v nen trc khi mai phai gia cong tinh hoac ban tinh be mat nay. Phng phap nay cho nang suat cao, kha nang at o chnh xac va o ong tam cao, chu yeu e gia cong cac bac co thanh mong. Phng phap nay co the gia cong c lo con khi ta nghieng truc a so vi truc cua lo mot goc nhat nh. Goc nay phu thuoc vao o con cua lo. 3. Mai mat phang:

a m ai

a m ai

Ch tie i t Ch tiet i

Khi mai mat phang co the s dung a mai mat tru hay a mai mat au.

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Mai bang a mai mat tru cho o chnh xac va o bong be mat cao v thoat phoi, thoat nhiet va ti dung dch trn nguoi vao khu vc gia cong c de dang. a mai chuyen ong quay tron, ban may mang chi tiet chuyen ong thang theo chieu doc e cat het chieu dai chi tiet sau o chuyen ong ngang e cat het chieu rong chi tiet. Ban may cung co the chuyen ong quay tron. Phng phap nay co nang suat khong cao v dien tch tiep xuc gia a mai va chi tiet khong ln. Khi mai mat phang bang a mai mat au, dien tch tiep xuc gia a va chi tiet gia cong ln nen nang suat cao hn so vi mai bang a mai mat tru. Tuy nhien viec thoat phoi, thoat nhiet va ti dung dch kho khan hn nen o chnh xac va o bong be mat lai kem hn. e giai quyet viec thoat phoi thoat nhiet va ti dung dch c de dang ta co the nghieng mat a so vi mat phang gia cong mot goc t 2 40 nhng co o bong be mat lai kem hn nhieu v tren be bat co cac vet mai va b lom xuong. Mai mat phang la phng phap gia cong tinh mat phang a phay hay bao va co the a qua nhiet luyen (toi). Mai mat phang co the at cap chnh xac 5 7 va o bong Ra = 0,2 - 1m. trng hp mai tinh co the at cap chnh xac 3 4 va Ra = 0,025 0,4m. o chnh xac cung nh o bong va cong suat cua mai phu thuoc vao mot so yeu to nh o cng vng cua may mai, o ln cua hat mai, loai chat dnh ket va che o cat khi mai. 4. Mai nh hnh: Mai nh hnh la s dung a mai co bien dang giong nh bien dang cua be mat gia cong co the la be mat tron xoay hoac mat nh hnh thang (ranh). Khi mai ch co the tien dao ngang oi vi mat tron xoay va tien dao doc vi chi tiet co mat nh hnh thang. Khi mai phai sa a that chnh xac theo hnh dang at yeu cau.

III. a mai:
a mai la mot dung cu cat ac biet v co vo so li cat va cac dung cu cat khong hoan toan giong nhau ve kch thc va hnh dang. a mai c tao thanh t cac hat mai va chat dnh ket. Hat mai la thanh phan chnh cua a mai, moi hat mai co nhiem vu nh mot li cat nen no phai co yeu cau nh cac loai vat lieu lam li cat. Hat mai c che

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tao t cac loai vat lieu nh kim cng, cacbit Silit (SiC), Oxit nhom (Al2O3), cacbit bo (B4C) hat mai c san suat theo cac kivh thc (c) hat khac nhau t 5m en 3200m e che tao cac loai a khac nhau. Kch thc hat phu thuoc vao kch thc ray e sang va phan loai o ln cua hat. Chat ket dnh dung e lien ket cac hat mai va tao nen hnh dang cua a mai. Chat dnh ket quyet nh o ben, o cng va o ben cua a mai. Chat dnh ket thng dung gom chat ket dnh vo c nh keramit, chat ket dnh hu c nh bakelit, caosu o cng hoac o mem cua a mai khong phu thuoc vao vat lieu che tao hat mai ma la kha nang tach ri cua cac hat mai khi co lc tac dung cua lc cat e tao nen tren be mat cua a mot lp hat mai mi. a cng la loai a ma cac hat mai kho tach khoi a mai. Loai nay dung e gia cong cac loai vat lieu mem v vat lieu mem khong oi hoi cao ve o sac cua li cat. a mem la loai a de tach cac hat mai ra khoi a mai va tao nen be mat cua a cac hat mai mi va cac li cat mi nen li cat sac ben hn. Thng dung e gia cong cac vat lieu cng. Mot ac trng na cua a mai ma cac loai dung cu cat khac khong co o la o xop. o xop cua a mai la ty le phan tram phan rong trong mot n v the tch cua a mai. a mai co o hat ln th o xop cang ln va ngc lai. Hnh dang cua a mai rat a dang, tuy theo muc ch s dung va tuy theo loai may ma a mai san suat theo hnh dang va tnh chat khac nhau. Trong moi loai hnh dang cua a cung co nhieu loai a mai vi tnh chat khac nhau nh o hat, o cng, o xop va o ln ve kch thc. 1. Vat lieu hat mai: Vat lieu dung lam hat mai co thien nhien va nhan tao. Vat lieu nhan tao nh: cacbitsilic va cacbitbo. Hat mai bang kim cng co loai nhan loai nhan tao va cung co loai thien nhien. o cng te vi cua mot s vat lieu hat mai nh sau: Kim cng 98690 N/mm2 CacbitBo 36300 48 070 N/mm2 CacbitSilic 29460 N/mm2

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Corum ien 20200 N/mm2 Corum ien c hnh thanh t Oxit nhom Al2O3 luyen t bocxit co ba loai: corum ien thng, corum ien trang, corm n tinh the. +Corum ien thng (Cn) c dung pho bien nhat thng co cac mau thay oi nau sam en hong. +Corum ien trang: (Chng trnh) co chat lng tot hncorm ien thng v co cha ty le Oxit nhom cao hn khoang 97 98,5%. +Corum n tinh the co o ben va co tnh cat cao. Thanh phan Oxit nhom 97 99%. Pham vi s dung: Corum ien thng dung lam a mai e mai tho ban tinh va tinh thep, gang deo hay dung cu bang thep dung cu. Corum ien trang dung cho nguyen cong mai ban tinh va tinh cac thep cng cung nh cung nh mai sac dao cat bang thep dung cu. Cacbuasilic la hp chat gia Silic va cacbon ( nhiet o 2200 23000C). co hai loai cacbuasilic xanh cha 98 99% Silic va cacbuasilic en cha 97 98 % Silic. Chat lng cacbuasilic xanh tot hn v cha nhieu silic hn. cacbuasilic xanh dung e mai sac dao HK cng, dao s. cacbuasilic en dung e gia cong vat lieu co gii han ben thap va cac kim loai deo, gang xam, nhom, ong, vat lieu phi kim loai. CacbicBo cng va gion hn cacbitsilic. No gom 70 90% B4C con lai la Bo, graphit va cac tap chat khac. Kim cng dung e mai sa9c1 mai bong dao hp kim cng cung nh mai cac vat lieu co o cng cao. 2. C hat: C hat ac trng cho kch thc cua hat mai. Phan loai kch thc hat mai bang cach cho chung lan lc lot qua cac lo cua cac ray t to en nho. Theo kch thc lo ray ma ngi ta phan loai o hat cua hat mai. oi vi bot mai xac nh bang kch thc hien vi hay bang phng phap mlang ong trong nc. Tieu chuan lien xo qui nh nh sau: Hat mai co c hat t 200 - 16m Hat mai co c hat t 12 - 3m Hat mai co c hat mn t M40 M5 Di ay la kch thc cua hat mai tng ng vi c hat cua no: C hat Kch thc cua lo ray m

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200 2000 2500 100 1000 1250 50 500 630 32 315 - 400 25 250 315 16 160 200 M40 40 M5 5 La chon c hat cua a mai tuy theo mo chnh xac va o nhan be mat gia cong, tnh chat vat lieu gia cong va dien tch tiep xuc cua be mat a vi be mat chi tiet gia cong. Khi mai tho nen dung a mai co c hat ln hn khi mai tinh. Khi gia cong kim loai mem va deo, e tranh a b tranh cun, nen chon a mai co c hat ln. Khi gia cong kim loai hay vat lieu cng,dung a mai co c hat be. Dien tch tiep xuc gia a maiva chi tiet gia cong cang ln a mai cang can co hat ln. 3. Chat ket dnh: Viec lien ket cac hat mai e tao hnh dang va kch thc cua a mai la nh chat ket dnh. Hien nay chat ket dnh c dung pho bien nhat lahai loai vo c ( Keramic) va hu c (Bakelit va Vunganhit). +Chat ket dnh Keramic (G). Chat ket dnh Keramic c tao t at set trang chu la, Spat va hoat thach, oi khi con them vao phan, thach anh, nc thuy tinh. a mai co chat ket dnh Keramic co o ben hoa hoc cao, chu c am va nhiet o cao, am bao c profin cua a mai. Nhng a mai nay lam viec vi toc o thap V 35mm/s va co nhc iem la o gion cao.. +Chat dnh ket Bakelit (B). La chat nha nhan tao che tao t nha Cacbonic va Fomalin, nen co the lam viec toc o cat ln en 50m/s, mot so trng hp ac biet co the en 70m/s. nhiet o tren 1800, chat dnh ket Bakelit mat tnh ben cua no. V vay a mai kieu nay khong chu c nhiet o cao, ong thi khong chu c tac dung cua kiem, cho nen trong dung dch trn nguoi o kiem khong c qua 1.5 . +Chat ket dnh vunkahit (V) gom 70 cao su va 30 lu huynh. a mai co chat ket dnh vunkahit co o ben va tnh an hoi cao hn ca a Bakelit, ngoai ra no con gi c tot profin cua a, v vay chat dnh Vunkahit c dung

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e che tao a mai nh hnh va cac loai a cat t co chieu day mong 0.3 0.5mm (vi ng knh 150 200mm ). Nhc iem cua a mai nay la o xop kem, mat a b l nhanh , chu nhiet kem ( nhiet o >2000C Vunkahit b chay) nen khi s dung nhat thiet phai dung dung dch nguoi lanh. nhiet o 150oC Vunkahit b mem ra, hat mai de an sau vao chat ket dnh, ap lc cua hat mai len be mat gia cong giam, nen c s dung trong cac nguyen cong mai bong, mai tinh. 4. o cng: Trong thi gian lam viec,hat mai b cun i , lc tac dung vao hat mai tang len, en mc nao o co the lam cho hat mai troc ra khoi be mat a mai. o cng cua a mai la kha nang chong lai s troc cua hat mai, trong thi gian lam viec. a mai goi la mem khi hat mai de troc ra va a mai cng khi hat mai kho troc hn. Theo tieu chuan Lien Xo, quy nh cac cap toc o cng a mai nh sau : o cng mai Ky hieu Mem M M1,M2,M3 Mem va CM MV1,MV2 Trung bnh C TB1,TB2 Cng va- CHI TIET CV1,CV2,CV3 Cng T C1,C2,C3 Rat cng T RC1,RC2,RC3 ac biet cng C1,C2 Trong tng nhom o cng, o cng tang dan theo th t 1, 2, 3 a mai co chat ket dnh Keramic va Bakelit c che tao vi tat ca cac cap o cng neu tren. a mai co chat dnh ket Vunkahit ch che tao cac cap o cng MV, IB, GV, C. o cng cua a mai c o bang phng phap: Phun cat (vi ap suat 1.5at), khoan lom vao mat a mai (tac dung tai trong len mui khoan 25 35kg) va an lom vao mat a mai bang bi thep ng knh 6.35mm (theo chieu sau cua vet lom e xac nh o cng). Tuy nhien cac phng phap tren cha bieu hien hoan toan kha nang lam viec cua a mai. Thng anh gia chat lng a mai la tuoi ben cua a hoac lng tieu hao khi cat i c 1cm 3 vat lieu gia cong. Khi mai vat lieu cang cng, hat mai mon cang nhanh can chon a mai mem, (e hat mai de

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troc ra tao kha nang t mai sac mot phan) va ngc lai vat lieu gia cong cang mem ,can chon a mai co o cng` cao hn, khi mai vat lieu deo (nhom, ong)ngoai hien tng mon cac hat mai, mat a mai con b l i (do phoi bt kn cac khe h gia cac hat) do vay can chon a mem. Mat tiep xuc gia a mai va cac chi tiet gia cong cang ln, hat mai mon cang nhanh can chon a mai cang mem. 5. Cau truc a mai: T le ve so lng cua hat mai , chat dnh ket va khoang trongtrong motn v the tch cua a mai la ac trng cua cau truc a mai. Cau truc cua a co k hieu t 0-12. So hieu cua cau truc cang ln th a mai cang xop ngha la t le khoang trong cang ln. Cau truc t 14 goi la cau truc chat , t 5-8 la cau truc trung bnh va t 9-12 la cau truc xop. Trong mot n v the tch a mai, hat mai cang ln, cau truc cua a cang chat . a co cau truc xop, khoang h gia cac hat mai ln mat a mai kho b l (phoi kho b ket vao khoang h gia cac hat mai). Mat khackhi a quay vi toc o cao de tao nen dong kh lu thong gia cac khe h o, cung nh dung dch lam nguoi cung de tham thau qua cac khe h cua hat mai e lam nguoi trc tiep be mat gia cong vung mai . Tuy vay a mai co cau truc xop cung co nhieu nhc iem la sc ben kem, khong gi c lau profin cua mat a. Viec chon cau truc cua a mai theo cach sau : trong mai tnh va mai nh hnh, chon a co cau truc chat, bi v can bao am profin mat a mai. a mai co cau truc chat trung bnh dung e mai thep a toi, mai sac dung cu cat va mai phang, mai tron ngoai bang mat tron cua a. Cau truc xop dung khi mai kim loai mem va deo, khi mai phang mat au cua a.

IV. Che o cat va thanh phan lp cat:

+Toc o cat: Khi mai nen chon toc o ln (toc o cat thng b han che bi sc ben cua a mai). Khi mai tron ngoai thng chon toc o maiV=35 40 m/s. Toc o quay chi tiet gia cong trong khoang: Vc/tiet=20 85 m/p khi gia cong tho Vctiet=15 50m/p khi gia cong tinh +Chieu sau cat:

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Hay lng chay dao ngang o trong mot hanh trnh kep cua chi tiet . Khi mai tho thep chon t = 0.01 0.07mm/htk va khi mai tinh thep t =0.0050.02mm/htk. +Lng chay dao doc: Chon tuy theo o rong cua a mai , khi mai tho s =(0.2 0.3)B (mm/vong chi tiet). Khi mai cac chi tiet co chieu dai tng oi ngan, ac biet khi mai nh hnh dung phng phap mai hng knh. Khi ay lng chay dao ngang t= 0,02 0,07mm ng knh a maiphai nho hn lo gia cong, be mat tiep xuc gia a mai va chi tiet tng oi ln, tai trong len hat mai cao hn. V a mai co kch thc lo nho, o cng cua truc a khong u Dung dch trn nguoi kho vao en vung gia cong. oi vi mat phang va tuy theo chieu dai cua chi tiet gia cong, chon chieu sau cat t trong khoang 0,05 0,1mm, chon t ln khi chi tiet cng vng ln, cac thanh phan che o cat khac chon gan giong nh mai tron ngoai. +Chieu day cat: Trong qua trnh gia cong co the xem a mai la mot dao quay co nhieu li cat +Tiet dien cat: Dien tch cat khi mai co the tnh nh sau: Goi the tch kim loai cat ra sau mot phut : V=1000.VC.S.t Dien tch lp cat trung bnh: mm3 V V .S .t Ftb = = CD L 60.Vd Trong o: L la chieu dai hat mai di chuyen trong mot phut S la lng chay dao doc

V. Lc cat va cong suat cat khi mai:

Lc cat khi mai thng nho (khong qua 300 400N) bi v lp cat phoi rat mong. Cong suat mai co the ln v toc o cat ln. Khi mai tron ngoai lc cat cung co the phan thanh ba lc thanh phan pz, py , px nh khi tien. ac biet khi mai, goc trc hat mai pthng3)am nen lc hng knh ln hn lc (1.5 . p
y z

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tiep tuyen Lc hng truc p x rat be so vi pz. Tnh lc pz co the theo cong thc kinh nghiem sau : - Khi mai vi a mai co ng knh D=500 mm chieu
p z = c p .v c .s 0,7 .t 0,6
0,7

rong a B=40mm oi vi oi vi Khi mai 18XHBA vi B = 50mm.

pz = 124.Vc
0 , 72

thep a toi cp = 21,6 gang cp =19,6 cao toc thep a toi nhan hieu 30XF CA va a mai co ng knh D = 400mm , chieu rong

.S 0,6 .t 0,85
0, 75

Vd

Lc cat khi mai bang a mai kim cng be hn khi mai thong dung, v hat mai kim cng co ban knh cong li cat be hn, mat khac kha nang t mai cua a kim cng co chat ket dnh Bakelit rat tot. Cong suat ong c quay a mai xac nh theo cong thc sau:
Nd = Pz .Vd 10 3.

Trong o : Hieu suat ong c. Cong suat ong lam quay chi tiet cung tnh theo cong thc tng t.

VI Chon che o cat khi mai:

Xac nh che o cat khi mai theo trnh t sau: 1. Tuy theo ieu kien mai ma chon a. 2. Xac nh chieu sau cat ( lng chay dao ngang ). 3. Xac nh toc o quay cua chi tiet gia cong. Chon toc o quay cua chi ytiet gia cong phu thuoc vao nhieu yeu to cong nghe . Toc o cang ln, ieu kien truyeng nhiet cang tot, v chi tiet tiep xuc vi a mai tronmg thi gian ngan hn, do vay chi tiet t co b vet chay. Ben canh u iem o, con nhc iem lam bien o dao ong tang, lc li tam tang, mui tam mon nhanh hn. Khi mai vat lieu cang cng, de b chay va nt, can tang toc o quay cua chi tiet.

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Mai chi tiet co yeu cau o chnh xac cao, can chon vc thap. 4. Hieu chnh so vong quay tnh toan cua chi tiet cho phu hp vi so vong quay co san cua may. 5. Xac nh l6ng5 chay dao doc: Thng lay S=( 0,3 0,6 )B B : chieu rong a mai. 6. Xac nh toc o quay cua a mai: Viec tang toc o cat b han che bi cong suat may va sc ben cua a. Theo toc o cat a chon , hieu chinjh3theo so vong quay co san cua truc chnh a mai . 7. Xac nh lcpz va cong suat tieu ton` khi mai. 8. Tnh thi gian gia cong c ban
T0 = L.i .Km n.s h t

Trong o :
i=

L : chieu dai chi tiet can gia cong mm. h: lng d mai mm. t: chieu sau mai mm. s : lng chay dao doc sau mot vong quay cua chi tiet mm/v. n: so vong quay cua chi tiet trong mot phuc v/ph. Km : he so tnh en so lan chay ra lan cuoi phu thuoc vao o cng vng cua may ( Km = 1,5 2,5 ).

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HOC TRNH IV THIET KE DAO CAT 1- C S E THIET KE DAO CAT. I. S can thiet phai thiet ke dao cat:
Trong qua trnh cong nghe gia cong c, dung cu cat la yeu to rat quan trong, no anh hong trc tiep va co tnh chat quyet nh en chat lng va nang suat gia cong. Dao cat co hp ly th chat lng be mat gia cong mi cao va cho nang suat cao; ong thi dao s dung c lau, tc tuoi ben cua dao se cao. - Hnh dang li cat cua dao anh hng trc tiep en hnh dang chi tiet. - Vat lieu lam dao anh hng en ieu kien cat, nang suat gia cong, tuoi ben cua dao. - Ket cau than dao co hp ly, th ieu kien cat mi c bao am, cac thong so cat c bao am trong qua trnh cat. - Ngoai ra, cac thong so phan cat cua dao con anh hng en ieu kien phat sinh nhiet, anh hng en lc cat, tc anh hng en ket cau va o cng vng cua may, o ga... Do o, viec la chon con dao hp ly cho tng trng hp gia cong cu the, la mot ieu vo cung phc tap va kho khan. No oi hoi ngi th phai co be day kinh nghiem, cung nh kien thc ve nguyen ly cat va mot so yeu to lien quan...nham giup ngi th biet tnh toan, la chon, che tao c con dao that hp ly trong qua trnh s

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dung. Co nh vay, mi bao am c nang suat va chat lng gia cong cao.

II. Trnh t thiet ke dao cat:

Thiet ke dung cu cat bao gom: viec xac nh hnh dang va kch thc cua no, ve nen ban ve che tao va quy nh cac ieu kien ky thuat. Tren c s yeu cau ky thuat cua ban ve chi tiet gia cong, ac iem ve hnh dang ket cau cua chi tiet...ma tien hanh thiet ke dao theo trnh t cac bc sau : a-/ Chon va xac nh s o cat (s o phan bo tai trong). b-/ Chon vat lieu phan cat, phan than, phan can dao. c-/ Chon thong so hnh hoc phan cat: goc trc,goc sau,goc nghieng chnh, goc nghieng phu, goc nang li cat, v.v... d-/ Xac nh pro fin dao : viec tnh toan hnh dang va kch thc cua li cat co the bang phng phap giai tch, o th hoac ket hp. e-/ Xac nh (chon hoac tnh) ket cau dao va cac thong so ket cau. f-/ Ve ban ve che tao : the hien ay u hnh dang, kch thc va cac tiet dien. g-/ Quy nh ieu kien ky thuat cua dao. (ay la mat lenh cua nha thiet ke e a en o chnh xac ve che tao).

III. Nhng chu y khi thiet ke dao :

Khi thiet ke dao cat, can chu y en cac ieu sau ay : a-/ Phan cat cua dao phai bao am u o cng vng, sc ben va kha nang truyen nhiet tot ( ieu kien lam lanh tot). b-/ Ket cau than dao phai bao am o cng vng khi co lc cat, bao am viec ga kep dao len may nhanh chong va chac chan. c-/ oi vi nhng dung cu cat co ranh thoat phoi phai bao am yeu cau : . Thoat phoi de dang . . ieu kien cuon phoi tot. . u khong gian cha phoi. . ong thi, phai bao am o ben cua dao tot. d-/ Bao am tnh cong nghe cua dao c tot.

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e-/ Chon s o mai sac dao hp ly, mai lai de dang va co kha nang phuc hoi lai dao khi b h hong.

IV. Yeu cau ky thuat khi thiet ke dao cat:

Nham bao am cac ieu kien nh: . Chat lng dung cu cat. . o cng vng cua dung cu. . ieu kien o chnh xac, o bong gia cong... Nhng yeu cau ve chat lng cua dao, c quy nh trong ieu kien ky thuat.(tren ban ve che tao dao ch ghi mot so ieu kien ky thuat chu yeu, con cac ieu kien khac can ghi ro trong thuyet minh). Khi thiet ke dao, e quy nh ieu kien ky thuat cho dao, nha thiet ke phai can c vao yeu cau ve chat lng dao, ong thi phai chu y en kha nang ky thuat trong ieu kien thc te san xuat nh : thiet b, vat lieu, trnh o ky thuat cua cong nhan, dung cu kiem tra,...e t o, mi co the a ra cac ieu kien ky thuat hp ly. Cac ieu kien ky thuat chung bao gom : a-/ Quy nh vat lieu lam dao : phan lam viec, phan than. b-/ o cng sau khi nhiet luyen. c-/ o nhan: mat trc, mat sau, chuan nh v, chuan o lng, chuan lap ghep... d-/ Quy nh cac khuyet tat cho phep tren cac be mat quan trong: khong co vet ran nt, vet chay,v.v... e/-Dung sai cac goc o dao (, , ,...). f/- Sai lech cho phep cua cac kch thc: - Kch thc chung. - Kch thc c ban. - Cac mat nh v va kep chat. - Kch thc profin dao. - Bc rang. - o cone. - Mo uyn. - Mot so kch thoc khac co anh hng en viec nh v va kep chat dao: + ng knh lo ga, o con, o o van cua lo ga... + o vuong goc cua tam lo va mat au. + S phan bo li cat so vi truc va hnh dang dao. g/- Ghi nhan hieu dao: can ghi ro : - Ten hay ky hieu nha san xuat. - Vat lieu lam dao (phan cat).

156

- Cac kch thc c ban. Muc ch e khi cong nhan s dung khong b nham lan. h/- ieu kien ong goi, ieu kien th nghiem dao (phan nay ghi trong thuyet minh, trong ban ve che tao khong ghi).

Bai 2- THIET KE DAO TIEN THONG DUNG I. ac iem, cong dung va phan loai dao tien:
Dao tien la loai dung cu cat c dung pho bien nhat trong nganh cat got kim loai. No lam viec thng gap tren cac loai may tien, may bao, may xoc, may r von ve, may doa, may tien t ong, ban t ong va mot so may khac na. Dao tien c dung pho bien, trong nhieu lanh vc, nen chung co nhieu dang khac nhau ve ket cau va thong so hnh hoc. Ve ket cau chung, dao tien thong dung la mot loai dao n, phan trc tiep tao ra phoi gom mot li cat chnh, mot hoac hai li cat phu. Khi lam viec, dao c coi la mot dam chu uon bi lc PZ . Do o, khi tnh toan chu yeu tnh ve ket cau than dao va thong so hnh hoc phan cat. Dao tien co the phan chia ra cac loai chu yeu sau :

157

+ Theo kieu may : co dao tien, dao bao, dao xoc, dao tien nh hnh, dao tien cho may t ong,... + Theo dang gia cong : dao tien pha, dao tien mat au, dao cat t, dao tien ranh, dao tien lo, dao tien nh hnh, dao tien ren,v.v... + Theo tnh chat gia cong : dao tien tho, dao tien tinh, dao tien rong ban,... + Theo ket cau au dao : dao au thang, dao au cong. + Theo phng chay dao : dao trai, dao phai, dao hng knh, dao tiep tuyen,... (Xem lai hnh dang cac loai dao tien trong phan dao tien)

II. Kch thc, ket cau than dao:

1- Vat lieu lam than dao: Thong thng phan than dao va phan ga at dao c che tao cung mot loai vat lieu, goi chung la vat lieu lam can dao. Theo kinh nghiem th hau het cac loai dao che tao co phan cat va phan can rieng, th vat lieu phan can dao c che tao bang thep 45 hoac thep 40X, nham bao am o ben va o cng vng tot. 2- Ket cau than dao: Can thiet phai xac nh kch thc tiet dien cua than dao e bao am cho dao lam viec an toan. Khi chon ket cau than dao phai bao am cac yeu cau sau : - u o cng vng e tranh b bien dang khi co cac lc tac dung. - Ga kep de dang, nh v tot. Tiet dien than dao thng la ch nhat, vuong, tron, a giac...Than dao ch nhat de ga at, co sc ben uon tot. Than dao tron de che tao, kho ga at, sc ben chong uon kem, thng dung cho tien lo, tien ren trong... Khi tnh toan tiet dien than dao, ngi ta da vao lc cat chnh PZ , o nho cua au dao ra khoi o ga dao va vat lieu lam can dao. Lc cat PZ co the c tnh: PZ = P . f (N) Vi: P: lc cat n v (N/mm2 ) f: tiet dien lp cat (mm2) Hoac tnh PZ khi tien theo giao trnh nguyen ly cat (xem lai cac phan trc)

158

 Lc PZ gay ra moment uon tai tiet dien nguy hiem :

Ch tiet i Dao tie n

Pz

S o ve lc PZ tac dung len dao tien. T s o tren, ta co the tnh c moment uon cua dao khi cat : M = PZ . l (Nmm) Vi : PZ : lc cat chnh (N) l : chieu dai au dao nho ra khoi o dao (mm) e dao khong b gay, th moment can thiet cua dao phai nho hn moment uon cho phep [M] : M [M] = W. []u Vi : W :moment chong uon (mm3) []u :ng suat uon cho phep (N/mm2) T ay co the tnh c moment chong uon. Lay gia tr cc ai W bang : W = [ ] = [ ] (mm3) u u Ma moment chong uon lai tuy thuoc vao tiet dien moi mat cat : + oi vi than dao co tiet dien hnh ch nhat : W=
PZ .l 6.PZ .l BH 2 = [ ] BH2 = [ ] 6 u u M PZ .l

Thong thng ngi ta lay : H = 1,6 B (mm) B.(1,6.B)2 = [ ] u

6.PZ .l

, nen :

B=

6.PZ .l 2,56.[ ]u

(mm)

Vi : B : chieu rong tiet dien can dao (mm).

159

 H : chieu cao tiet dien can dao (mm). []u : ng suat uon cho phep (N/mm2). + oi vi than dao co tiet dien vuong : W=
PZ .l B3 = [ ] 6 u 6.PZ .l B= 3 [ ]u

(mm)

Vi : . B : canh tiet dien than dao (mm) + oi vi than dao co tiet dien tron :
.d3 W= 32 PZ .l d3 = ( ) = [ ] 10 u 32.PZ .l (mm) .[ ]u

d =

Vi d : ng knh than dao (mm) Cac cong thc tren, co the dung e tnh toan hoac kiem tra kch thc va o ben cua dao tien. Khi tnh, ta bo qua cac lc PY , PX nen cac cong thc tren tnh gan ung. Khi thiet ke dao, ngoai viec tnh toan nh tren, ngi ta con co the chon kch thc than dao tien can c vao lp phoi cat hoac chieu cao tam may : VAT LIEU MUI DAO HP KIM THEP GIO CNG CH VUO DIEN CHIEU DIEN CHIEU NHAT NG TCH SAU TCH SAU CAT CAT CAT CAT (mm) (mm) (mm) (mm) 10 x 16 12 1,5 3 12 x 20 16 2,5 4 16 x 25 20 4 6 4 5 20 x 30 25 8 10 6 6 25 x 40 30 10 13 9 7 30 x 45 40 25 18 16 8 40 x 60 50 40 25 25 12 50 x 80 65 60 36 Chu thch : - Cac tr so cho trong bang la tr so ln nhat. - Cac tr so nay nen dung cho dao tien 0 vi = 45 va cat thep co b 750 N/mm KCH THC THAN DAO (mm)

160

GA DAO

TREN O 4 DAO TREN BAN DAO

TIET DIEN THAN DAO CH NHAT VUONG CH NHAT VUONG

CHIEU CAO TAM MAY (mm) 150 12 20 16 12 20 16 260 300 180 200 x 12 x 20 16 x 25 20 x 30 16 20 25 x 16 x25 20 x 30 20 x 30 20 25 25 350 400 25 x 40 30 25 x 40 30

III. Vat lieu va thong so hnh hoc phan cat:

1 - Chon vat lieu phan cat: Tuy thuoc vao vat lieu gia cong va yeu cau o chnh xac gia cong, ma chon vat lieu phan cat cua dao cho phu hp. ( xem lai phan vat lieu lam dao ). 2 - Cac thong so hnh hoc phan cat: Cac thong so hnh hoc phan cat cua dao, co anh hng rat ln en qua trnh cat kim loai nh : nhiet cat, lc cat, o mai mon, chat lng be mat va nang suat gia cong,... Xac nh cac thong so hnh hoc phan cat cua dao bao gom : viec xac nh v tr, hnh dang cac mat trc, mat sau cua dao oi vi mat ay, tr so cac goc o cua dao va hnh dang li cat,v.v... 1-/ Thiet ke hnh dang mat trc cua dao: Mat trc dao tien n thng co hai dang : mat trc phang va mat trc cong: Mat trc phang, dung e gia cong vat lieu cng va don; mat trc cong, dung e gia cong vat lieu deo, mem, hay cng va. Tren mat trc con co canh vien f, e lam tang sc ben cua li cat. Thng f = ( 0,2 1) mm , tuy theo lng chay dao S , neu S 0,25 mm th khong lam f. + Dao thep gio : ac trng sc ben uon cao, de mai sac, chu c nhiet o khong cao.

161

- Mat trc phang, = 00 : ng dung cho cac dao tien nh hnh, co hnh dang phc tap. - Mat trc phang, > 0o , khong co canh vien : dung e gia cong thep can, thep uc, thep dung cu, gang, v.v... co b 8 N/mm2 , HB 220 ( = 100 160 ). - Mat trc phang, co canh vien : dung e gia cong vat lieu tng oi cng : thep co b 800 N/mm2 , HB > 220, vat lieu don nh gang, ong thanh,... f = (0,2 0,3) mm : gia cong tinh. f = (0,8 1) mm : gia cong tho. - Mat trc cong, khong co canh vien : dung e gia cong vat lieu deo, co bc tien nho, chieu day cat a < 0.2 mm. - Mat trc cong, co canh vien, f = 0 50 , = 30 250 , R = 3 18 (mm). Dung e gia cong cac loai thep deo co b 800 N/mm2, kim loai mau, deo, hp kim nhe. + Dao hp kim cng: co ac trng : chu c nhiet o cao, don, chu va ap kem, kho tao c li sac. - Mat trc phang, vi goc trc dng, = 100 280 : gia cong nhom, hp kim ong, e bo xt, gang xam, ong thanh, thep co b 800 N/mm2 . - Mat troc phang, vi goc trc am, = - 50 : gia cong thep can, thep uc, co b > 800 N/mm2, gia cong co va ap, trong ieu kien he thong cong nghe cng vng. - Mat trc phang, co canh vien, f = (0,2 4) mm, f = 0 , = 60 100 : gia cong gang deo, thep uc co b 800 N/mm2 , cung co the b > 800 N/mm2 trong trng hp he thong cong nghe kha cng vng. - Mat trc cong, vat canh, = - 50 -100 ; vet cong lom co R = (2 6) mm, b = (2 2,5) mm, h = (0,1 0,5)

M o gc a a c n ov t t M h c a a p a g ov t n t
f
f

M h k o gv a pa g h a t n n t

T t e ie h n p

T g n , t e c n ie ie a g h hu h n p t T t e ( a h o p o ie h r eu h i) n p n n

162

mm e cuon phoi va be phoi. Dung e gia cong vat lieu co b (700 1000 ) N/mm2 . Cac dang mat trc cua dao tien 2-/ Cac thong so hnh hoc hp ly cua phan cat: Cat kim loai la mot qua trnh phc tap, v co nhieu yeu to anh hng en qua trnh cat : tnh chat vat lieu gia cong, vat lieu lam dao, che o cat va ieu kien gia cong,...Tat ca cac yeu to nay ong thi anh hng en qua trnh cat. Do o chon thong so hnh hoc phan cat hp ly la viec lam phc tap. Qua thc nghiem, ngi ta tong ket c nhng anh hng cua cac thong so hnh hoc phan cat cua dao en cac yeu to cua qua trnh cat nh sau : Yeu to qua trnh cat - Ma sat gia cac be mat cua dao va phoi - Bien dang cua be mat gia cong - Bien dang cua phoi - Tuoi ben cua dao - o ben cua li cat - Tr so lc cat thanh phan - Phng cac phan lc - o nhan be mat gia cong - ac tnh mon cua dao - Mc o va tr so mon cua dao - Dang phoi - Chieu day cat - Chieu rong cat - Phng thoat phoi x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x
1

a/- Goc trc : Anh hng cua c gii thieu trong bang tren. Tac dung chu yeu cua la tao ieu kien thoat phoi (lam giam bien dang cua phoi), anh hng en tr so va phng cua lc cat, chat lng be mat gia cong, tuoi ben cua dao. - Vat lieu cang deo th chon cang ln : lc cat nho, thoat phoi de... - Vat lieu cang don co khuynh hng giam e tang goc cat, tang o ben cua dao.

163

- Dao thep gio co the chon ln hn so vi dao hp kim cng hay vat lieu chu ben uon kem. - Gia cong tho nen chon ln ( nho ), gia cong tinh nen chon nho e tang goc sau trong ieu kien = const. - Dao hp kim cng: gia cong tho, co the am, song he thong cong nghe phai u cng vng. + oi vi dao tien thep gio : goc trc tren canh vien thong nho: f = 50 80 Mat trc phang : chon = 80 150 . Mat trc cong : chon = 250 300 + oi vi dao hp kim cng: goc trc tren canh vien thng chon: f = -3o -100 Gia cong vat lieu don : gang, ong thanh...chon = 80 150 Gia cong vat lieu cng > 100 Kg/cm2 chon = -50 -250 Chon goc trc cua dao tien co the tra bang trong cac so tay ky thuat. b/- Goc sau : Goc sau co anh hng ln en mot so yeu to cua qua trnh cat nh trong bang tren a neu. ac biet la anh hng en tuoi ben cua dao va o nhan be mat gia cong. Goc sau 1 phu thuoc vao bc tien S va tr so . e tranh ma sat mat sau th phai nho hn : tg = Trong o : S _ bc tien (mm/vong) D _ ng knh chi tiet gia cong (mm) . Khi S tang th lc cat tang, tang, nen tang : e giam lc cat th phai tang cho phu hp vi . ieu nay dan en b giam va o ben cua mui dao giam. Ngi ta co khuynh hng chon min. . Khi S giam th lc cat giam, giam va giam nen tang : luc nay lc cat nho, e giam ban knh mui dao va giam ma sat, ngi ta co khuynh hng chon max . . Gia cong vat lieu gion, cat phoi mong, dao chu yeu b mon mat sau: chon tang. . Tien tinh nen chon tang e giam ma sat.
S D

164

. Goc sau phu 1 : thong thng chon 1= . Rieng dao tien ranh 1 = 10 20 Mot so gia tr goc sau cua cac loai dao thong dung : Khi : S o.25 mm S > 0.25 mm - Dao tien thong va tien mat au : = 120 = 60 80 - Dao cat t, tien ranh : = 120 150 = 80 100 - Dao tien lo : = 120 150 = 80 100 Chon co the tham khao trong cac so tay ky thuat. c/- Goc nghieng chnh : Goc nghieng chnh anh hng en o nhan be mat gia cong; anh hng en chieu rong, chieu day lp cat; en phng va tr so lc cat PY , PX ; en o ben cua dao... Nguyen tac chon: + Neu o cng vng cua he thong cong nghe cao th chon giam, e tang o ben cua dao. + Neu o cng vng cua he thong cong nghe giam th chon tang e giam lc cat. Tuy nhien cung co gii han cua no tuy theo ieu kien cu the : - ieu kien he thong cong nghe cng vng, vi < 6 th = 100
-

l D

300
l = 6 D

ieu kien cng vng trung bnh, vi 450 .

12

th = 300

- ieu kien cng vng kem : th = 600 750

l . D > 15

l = 12 15 D

80 90
0

th =

en 900

- Tien mat au :
-

= 300 700 oi khi len

Tien lo bac, khong suot 900 d /- Goc nghieng phu 1 : Goc nghieng phu anh hng en o nhan be mat gia cong, o ben cua dao va lc cat. Khi 1 giam th o nhan tang nhng rung ong tang.

165

+ Khi he thong cong nghe cng vng lay : 1 0 = 10 15 . + Khi he thong cong nghe kem cng vng lay 0 1 = 20 300 . e /- Goc nang li cat chnh : Goc nang anh hong en hnh dang cua phoi, phng thoat phoi, sc ben cua li cat. + = 0 phoi thoat ra theo hng vuong goc lui cat chnh. + > 0 phoi co khuynh hng thoat ra i vao hng be mat gia cong : gia cong tho. + < 0 phoi thoat ra co khuynh hng i ra xa be mat gia cong : gia cong tinh. + ieu kien be phoi tot ma khong can c cau be phoi : dao co = -50 -100, = 600 700 th = 100 150 . + Dao thep gio : tien tinh, ban tinh = 00 Gia cong tho lng d khong eu = 0 0 50 . Bao va tiien cac be mat khong lien tuc = 100 200 . + Dao hp kim cng : gia cong vi lng d eu, khong va ap : = 00 50 Gia cong vi lng d khong eu, cat khong lien tuc : = 120 150 Khi gia cong thep da toi : 0 0 = 25 35 . Khi nho ( 60 ) th anh hng cua goc nay en qua trnh cat khong ln, thng = 00 hoac = 40 50. Khi tang len th chat lng be mat gia cong giam, neu > 60 th PZ va PY tang va PX giam g /- Hnh dang li cat chnh va ban knh cua mui dao r : Hnh dang li cat chnh cua dao tien n co the thang, cong, gay khuc,.... No anh hng en chat lng be mat gia cong, lc cat, o ben cua dao: + Li cat cong : Neu ban knh li dao r tang th Ra giam tc la o nhan be mat tang, tuoi ben cua dao tang, ong thi PY va PZ cung tang ( PX giam ) lam rung ong tang. Do do, dao co r ln ch dung khi gia cong tinh va he thong cong nghe cng vng. +Thng chon : Dao tien r = 0,5 3 mm Dao bao r ln hn ( 2 2,5 ) lan so vi dao tien.
0

166

+ Li cat cong kho che tao. e khac phuc, de che tao dao ngi ta mai li cat gay khuc tao them goc nghieng chnh phu 0 nham tang o ben cua dao : 0 200

2 =0

Dao cai tien IV. Thiet ke phan kep manh li cat vao than dao : Khi gia cong bang cat got, so lng dao tien c dung ngay cang tang len, cho nen viec dung dao han gap nhieu kho khan: ton vat lieu lam than dao, nguyen cong han ton thi gian, nang suat thap. Van e at ra la phai co phng phap nham khac phuc cac nhc iem tren. T o ngi ta ngh ra cach kep dao bang c kh va lc cat, o la nhng phng phap rat tien li va c s dung nhieu nc co nen cong nghiep phat trien. ac iem cua cac phng phap nay la: cac manh dao c che tao theo tieu chuan va co hnh dang rat a dang, theo yeu cau cong dung va tnh nang s dung cua tng loai dao. Qua trnh lam viec, manh dao b mon, en luc khong dung c na, ta thao ra thay manh khac, hoac xoay sang canh khac cua dao e tiep tuc s dung. 1 - Phng phap han: Han co cac dang: - Dang h : de lam nhat, han khi manh li cat co tiet dien ln. (Ha) - Han na kn: oi vi manh li cat co kch thc trung bnh. (Hb) - Dang kn: oi vi cac manh li cat mong hoac co kch thc nho. (Hc) + u iem:

167

- Tien li khi s dung: thay dao nhanh, t mat thi gian thay va ieu chnh manh li cat. + Nhc: - Khi mai li cat se b pham vao than dao. - Ton nhieu vat lieu lam than dao: moi manh li cat ton mot than dao. - Cac vet han de b ran nt trong qua trnh cat. - Phai ton cong mai cac vet lom, bo phan e cuon, be phoi. - Thi gian chuan b dao ton nhieu thi gian (do han) 2 - Phng phap kep bang c kh: Co cac dang sau: - Kep bang vt kep - Kep bang cam lech tam - Kep bang vt + on bay Hien nay ngi ta a dung nhieu manh hp kim cng hoac s co dang nhieu canh. + u diem: - De phuc vu, de thay manh hp kim, de sa cha khi can thiet. - Khi mai dao ch can mai manh li cat, nen can dao co the s dung rat nhieu lan. + Nhc: - Che tao phc tap. - S mai lai dao kho khan hn v phai bao am goc o dao trc khi kep manh li cat vao than dao. 3 - Dao kep bang lc cat: S dung lc cat e kep manh hp kim vao than dao tien, phng phap nay rat thuan li. Trong qua trnh cat, lc kep la do hp lc cua hai lc thanh phan PN va PZ : P R = Pz + Pn Hng cua lc Pn ac trng bi goc : + Neu < : manh hp kim b dap xuong. + Neu > : manh hp kim b tung len. ieu kien e dao lam viec bnh thng la: < < Pn Theo thc nghiem: tg = va tang theo o mon cua Pz li cat va s giam chieu day cat.

168

4 - Phng phap ket hp: Ket hp gia hai phng phap c kh va han: Manh li cat c han vi au dao ri va lam bang thep dung cu. au dao ga vao than dao bi ranh mang ca co dang hnh nem, khi cat nh ranh hnh nem tao lc gi kep au dao.

V. C cau be phoi :
Cuon phoi va be phoi la mot van e rat quan trong khi cat cao toc cac kim loai deo bang dao hp kim cng. Khi cat cao toc, vi lng chay dao ln, phoi ra nhanh thanh nhng day dai cuon vao dao va chi tiet gia cong, vao thanh may,... lam anh hng en nang suat, chat lng va an toan lao ong.,... Do do, viec be phoi la rat can thiet. Hien nay khi tien dung mot so phng phap sau ay e be phoi: - La chon hnh dang hnh hoc cua dao va che o cat. - Mai ranh chan hoac ranh li liem tren mat trc cua dao. - Lam c cau be phoi. 1 - Da vao hnh dang hnh hoc phan cat cua dao: + u iem: - Khong can thiet b phu. - Dao mai thong thng. Phng phap nay da tren c s anh hng cua goc va goc en dang phoi. V du : Khi tang len, neu t va S khong oi th a tang len, phoi cng hn, khi xoan lai de b gay thanh nhng oan nho. Goc co tac dung ieu chnh phng thoat phoi, khong anh hng nhieu en viec be phoi, ac biet la = 450 600 Mot so lieu cu the e chon cac thong so c gii thieu bang sau : Kieu dao (HKC) Dao tien thong Dao xen 0 45 60 70 90 0 10 - 10 -3
0

-5 -2 -5 0

f (mm) 4 * 2,5 * * 4

+18 +12 0

169

mat au

90

+15

-5

+15

1,5

* Khi t 4 va S 0,3 mm/ vong. ** Khi vong.

t 10 ac biet khi S 4 mm/ s

2 - Be phoi nh ranh mat trc: Ranh c gia cong bang phng phap mai hay dung tia la ien Manh dao c at nghieng mot goc -10 -1,50 cho phep cat vi che o trong pham vi rong khi cung kch thc ranh. (S= 0,25 0,6 mm/ vong). Kch thc ranh phu thuoc vao vat lieu gia cong. V du: Thep Cac bon co: CT 10 45 suy ra f = 0,1 0,5 ; B = 7 5 mm = 1 4; t= 1,5 0,8 Nhc iem cua kieu be phoi nay la mai ranh kho, tieu ph hp kim cng nen s dung b han che, no c dung trong trng hp lap c cau be phoi kho khan. Kch thc ranh cong cho trong bang sau : Kch thc (mm) B R t f 0,3 2,5 2,5 0,3 0,2 0,5 3,5 4 0,4 0,3 S (mm/vong) 0,7 5 5 0,7 0,45 0,9 7 6,5 0,95 0,55 1,2 8,5 9,5 1 0,6 1,4 9,5 10 1,2 0,8

3 - C cau be phoi khong ieu chnh: Mieng be phoi thng che tao t manh hp kim cng c han len mat trc cua dao Qua trnh cat phoi ra vi toc o ln ap vao c cau be phoi va b gay. Goc gia mieng be phoi va be mat trc phu thuoc vao goc nghieng cua mieng be phoi bf va goc trc goc anh hng ln en qua trnh be phoi. Thc nghiem chon:

170

bf = 450 khi o chon = 1350 - Goc tao gia mieng be phoi va li cat chnh anh hng en dang phoi va phng thoat phoi, no phu thuoc vao chieu sau t va goc Neu t 6 mm Khi = 450 chon = 50 = 600 chon = 100 = 900 chon = 200 Tr so k phu thuoc chu yeu vao lng chay dao s va mot phan nao t va v, thng : k = 3 8 mm. Nhc iem: Mom nhanh mieng be phoi, mai kho, khong van nang, cha tan dung het mieng hp kim cng. 4. C cau be phoi co ieu chnh: C cau be phoi tren khong the ieu chnh c theo cac thong so yeu cau, do o mot c cau be phoi van nang nay, co the ieu chnh theo cac chieu e tao nen nhng thong so thch hp khi cat got. Thao vt 3 au be phoi 1 co the quay vong quanh truc nam ngang; au 2 co the quay theo truc ng nh vay co the ieu chnh theo yeu cau cac goc o. Ngoai ra khi mon au be phoi 1 ta co the thay the de dang. Nhc iem cua c cau nay la cong kenh va phc tap, ngoai cac c cau tren con nhieu c cau be phoi khac co nguyen tac lam viec giong c cau tren. 5. ieu kien ky thuat : Thng c quy nh chu yeu la phan cat (o bong, sai so goc o). Than dao che tao t thep 45, 40X, CT6. Cac be mat ta khi ga va mai dao thng at o bong 5. - Mat trc at 8 dao thep gio 9 dao hp kim cng - Mat sau 7 - Tren be mat phan cat khong co vet st, nt ne. - o cng sau khi toi phan cat: HRC = 62 65. than dao: HRC = 30 40. - Sai so goc o : 10 20.

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Bai3-THIET

KE DAO TIEN NH HNH

I- Dao tien nh hnh:

1- Khai niem: Dao tien nh hnh s dung e gia cong cac be mat nh hnh tron xoay, trong san xuat hang loat ln, hang khoi, ac biet tren may t ong va ban t ong. So vi dao tien thong thng co cac ac iem sau : - Dao tien nh hnh co hnh dang ng vien li cat chnh phu hp vi bien dang be mat gia cong. - Bao am s ong nhat ve hnh dang va chnh xac ve kch thc cua chi tiet gia cong, v no khong phu thuoc vao cap bac tay nghe cua cong nhan, ma no phu thuoc chu yeu vaoo chnh xac che tao dao. - Cho nang suat cao, tuoi tho cua dao ln (do lng d gia cong thng nho), mai sac dao tng oi n gian hn. 2- Phan loai : Dao tien nh hnh co the chia ra cac loai sau ay : + Theo ket cau : dao tien nh hnh co the chia ra dao hnh tron va dao hnh lang tru. + Theo cach ga tng oi cua dao oi vi chi tiet gia cong co : dao nh hnh hng knh va dao nh hnh tiep tuyen. Dao hng knh co hng chay dao theo hng ban knh cua chi tiet; con dao tiep tuyen chay dao theo hng tiep tuyen vi be mat gia cong. Dao nh hnh tiep tuyen thng dung e gia cong nhng chi tiet chu uon kem, chieu cao hnh danh chi tiet khong sau. + Theo v tr truc dao va truc chi tiet gia cong : co dao ga thang va dao ga nghieng. 3- Sai so hnh dang chi tiet khi tien bang dao tien nh hnh: Cac chi tiet nh hnh, co bien dang thng gom nhng be mat noi ket vi nhau nh : mat tru, cone, cong..., o chnh xac khi gia cong phu thuoc vao hnh dang ket cau dao va cach ga at dao. Ta se nghien cu o chnh xac cac be mat nay, khi gia cong bang dao tien nh hnh. +oi vi dao lang tru :

172

- Khi gia cong mat tru khong co sai so : khi gia cong chi tiet hnh tru, li cat nam ngang tren ng sinh cua hnh tru (song song vi truc cua chi tiet) th se khong co sai so tren chi tiet gia cong. - Gia cong mat con (non) co sai so do cat mat cat con bang mat phang khong i qua ng tam chi tiet : e tao ra mot hnh non tro xoay chnh xac, ta cho mot ng sinh cat truc non tai mot iem (O1) va hp vi truc mot goc , ng sinh nay di chuyen luon luon ta tren vong tron co tam (O2) nam tren truc non. Trng hp ng sinh o khong cat truc non ma cheo vi truc non mot goc , khi ng sinh o quay nh tren th se tao ra be mat Hyperbolloid tron xoay. Dao tien nh hnh lang tru do khi gia cong mat con (non) ch co mot iem c s, ma li cat cheo vi truc cua chi tiet, v vay be mat chi tiet nhan c la mot be mat hyperbolloid lom, co sai so 1 Cach khac phuc : . Che tao li cat co dang hyperbolloid loi, ieu nay rat kho khan khong the thc hien c, . Nang li cat len mot goc , e cho li cat trung vi ng sinh (li cat co 2 iem c s), goi la dao co oan c s nam ngang tam chi tiet, . oi vi be mat phc tap, ta chia li cat thanh nhieu oan va a ve dang co oan c s. + Dao hnh tron : - Gia cong mat tru khong co sai so. - Gia cong mat con : co sai so nh dao lang tru, nhng lai co them sai so do sai so hnh dang li cat khi che tao nh hnh gay ra : Nh ta a biet, neu dung mot mat phang cat qua truc mot hnh non, th ta luon luon nhan c ng sinh la ng thang. Nhng neu ta cat hnh non bang mot mat phang khong cat qua truc hnh non, th giao tuyen se la mot hyperbol. Trong thc te, oi vi dao tien nh hnh hnh tron (da), khi che tao, ban than dao a co dang con; mat khac, do co goc trc , nen khi che tao mat trc cua dao, ta a cat dao bang mat phang khong qua tam, ma cach truc dao mot oan H nao o. Giao tuyen cua mat trc va mat con luc nay se la ng Hyperbol ch khong phai la ng thang. Khoang cach gia cung hyperbol va ng thang ly thuyet la sai so 2, ay la sai so tat mhien do che tao. Sai so nay cua dao se gay tren chi tiet sai so 2.

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Vay khi gia cong bang dao hnh tron th chi tiet se co sai so la: = 1 +2 Cach khac phuc : 1 nh dao lang tru, con 2 th rat phc tap, khong khac phuc c. (Hnh IV-8.d) 4. So sanh dao lang tru va dao hnh tron: a. Dao lang tru: +u: - Do kep dao bang ranh mang ca nen o cng vng hn cao hn. - Goc co the thay oi c. -o ben li dao, thoat nhiet tot. -o chnh xac cao hn, sai so khong ang ke. + Nhc: - Che tao kho. - Khong dung e tien lo c. b. Dao tron: + u: - Co the tien ngoai va tien lo. - Che tao de v dang tron xoay va mai de. + Nhc: - Kho kep chat, ng vng kem. - Goc khong ieu chnh c ( v phu thuoc vao chieu cao H) - o chnh xac kem hn.

II. Thiet ke dao tien nh hnh:

1- Mot vai nh ngha: + iem c s: la iem nam xa nhat oi vi chuan kep, hay tam cua dao. ay la iem e chung ta da vao o chon cac goc o can ban cua dao va tnh toan cac iem khac. Chon nh the nao e cac iem khac cua dao co the lam viec c. + Chieu cao hnh dang chi tiet: (hct) La hieu so cac ban knh tai cac iem tren be mat chi tiet so vi ban knh cac iem c s. + Chieu cao hnh dang dao: (hd) La hieu so khoang cach gia cac ng vien cua li cat, o trong tiet dien vuong goc vi mat sau cua dao va song song v truc tam cua chi tiet. 2- Thiet ke dao tien nh hnh: Trnh t thiet ke dao: - Chon loai dao (da vao ket cau chi tiet, thiet b gia cong, ieu kien hien co...) - Chon vat lieu lam dao (tuy thuoc vao vat lieu gia cong).

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- Can c vao vat lieu gia cong e chon goc trc va goc sau tai diem c s. - Tnh chieu cao profin ln nhat cua chi tiet: D Dmin tmax = max 2 Can c vao tmax chon kch thc ket cau dao (tra bang trong cac so tay thiet ke). - Can c vao cac d kien tren e xac nh hnh dang li cat (ve profin dao). Mot so bc can lu y : a- Chon kch thc ket cau cua dao: + Kch thc ket cau cua dao tien dnh hnh c xac nh tuy theo chieu cao profin ln nhat cua chi tiet gia cong (tmax), chieu dai ket cau chi tiet co the chon theo cac bang sau: + ng knh dao tien lo nh hnh khong c ln hn 0,75 ng knh cua lo gia cong. + Chieu rong li cat cua dao c chon nh sau: Ld = Lct +a+b+c Trong o: - Lct : chieu rong profin cua chi tiet. - a: li cat phu a:=2 - 5mm - Chieu rong li cat ng v v tr cat t phoi lay ln hn hay bang chieu rong li daocat t b>= 3 8mm - c: Chieu rong li cat phan xen mat au chi tiet: c = 1 - 3mm neu mat au chi tiet co vut, th lay ln hn phan vut t 1 - 1,5mm. b- Thong so hnh hoc phan cat: +S can thiet phai tnh toan hnh dang dao: Neu lay hnh dang chi tiet lam hnh dang dao th chieu cao hnh dang dao bang vi chieu cao hnh dang chi tiet: hd = hct Nh vay th: iem (1) dao gia cong = iem (1) cua chi tiet iem (2) dao gia cong = iem (2) cua chi tiet. Trng hp nay th : = 0, = 0 : dao khong the cat got c. Van e at ra la: e dao cat c kim loai th chung ta phai tao ra tren dao co: 0, 0. Vay hd hct do o khong the lay hnh dang chi tiet lam hnh dang dao ma phai tnh toan hnh dang dao.

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Viec xac nh hnh dang dao, tc xac nh chieu cao hnh dang dao tai cac iem so vi iem c s c xac nh trong tiet dien vuong goc vi mat sau cua dao (N -N) + Thong so hnh hoc phan cat: - Chon goc trc va goc sau cua dao tien nh hnh ( bang thep gio hay thep hp kim dung cu) tuy theo vat lieu gia cong va chieu day cat va chon theo cac so tay ky thuat . Dao tien nh hnh cat vi phoi mong, cho nen goc sau lay ln hn so vi dao tien thng. - Goc : Dao tron tao bang canh ga dao co tam cao hn tam chi tiet mot oan h = r.sin. Vi r: ban knh cua dao iem c s. - Dao lang tru: ieu chnh c, do ieu chnh dao theo o ga ( tao nen do ga nghieng dao theo tiet dien vuong goc vi truc chi tiet) - Goc va chon theo cac bang thng la tai diem c s. Con va ng vi cac iem tren cac ban knh khac nhau th co tr so khac nhau. Cang gan chuan kep ( dao lang tru) hay cang gan tam dao ( dao hnh da) th cang tang va ngc lai goc th giam. Nhng iem nam cao hn iem c s th lay tang len va giam. Neu chon iem c s khong phu hp th co the giam en 0 va nho hn 0. V vay nen kiem tra lai , neu qua nho th phai chon lai iem c s. - Goc tai iem X bat ky co the tnh nh sau: + Dao tron :X = - X + X + Dao lang tru : X = - X ay: = + r sin sin X = rx Cx * sin tg X = r Cx * cos

Cx =

rx * sin( x) sin

+ Tnh toan profin dao: e xac nh bien dang dao tien nh hnh thng dung 2 phng phap: Phng phap o th va phng phap giai tch. Phng phap o th cho nhanh chong ket qua nhng o chnh xac phu thuoc vao hnh ve. Con phng phap giai tch chnh xac nhng lau ( mat nhieu thi gian)

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# Phng phap o th: Dung o th e ve profin dao da vao hnh dang, kch thc chi tiet cho trc. Theo phng phap nay, muon tm hnh dang lui cat ta phai tm mat trc qua iem c s. Giao tuyen gia mat trc vi cac vong tron cua chi tiet, chnh la hnh dang li cat tiet dien tren mat trc. e tm hnh dang chi tiet tren tiet dien vuong goc vi mat sau (hay tiet dien chieu truc), ta ve nhng ng sinh song song vi ng sinh tai iem c s, a ve nghieng mot goc . Cach ve : + Dao nh hnh lang tru : . Xac nh iem c s : da vao hnh dang chi tiet. . Chon goc o dao: va cho iem c s : da vao vat lieu gia cong (tra trong cac so tay). . Qua iem c s, dng ng thang (P) tao goc . (P) se cat cac vong tron bien dang phoi tai cac iem (i). o la nhng iem cua dao e gia cong cac iem (i) cua chi tiet. . Qua iem c s dng ng sinh tao goc . T cac iem (i) dng cac ng sinh song song vi ng sinh va dng . Ta co be mat sau cua dao lang tru. . Dng mat phang N-N vuong goc vi mat sau cua dao lang tru va lien he vi hnh chieu bang t cac iem (i) giong xuong, ta ve c hnh dang dao. + Dao nh hnh tron (dao hnh da): . Xac nh iem c s: da vao hnh dang chi tiet. . Chon goc va cho iem c s: da vao vat lieu gia cong (tra cac so tay ky thuat). . Ve 2 tia t iem c s vi goc tng ng la va . Tia cat cac vong tron bien dang chi tiet tai cac iem (i). . Ve ng thang ng cach ban knh ln nhat cua chi tiet mot khoang K = (3 12)mm (co the tra bang), gii han chieu dai mai mat trc cua dao, ng nay cat tia tai iem B. . T B ke ng phan giac goc (tao bi tia va ng thang ng va dng). Giao iem gia ng phan giac vi tia la tam O2 cua dao. . T tam O2 lan lt quay cac vong tron co ban knh Ri = iO2 . Ta c cac ban knh ng vien cua li cat chnh: Ri .

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. Xac nh bien dang li cat trong tiet dien chieu truc N-N , ta ve c hnh dang dao vi chieu cao profin dao o trong tiet dien chieu truc ti bang hieu cac Ri ke tiep. # Phng phap giai tch : Dung phng phap tnh toan ket hp vi hnh ve e xac nh profin cua dao tien nh hnh, gom : xac nh profin dao tiet dien theo mat trc va tiet dien vuong goc vi mat sau (oi vi dao tron la tiet dien chieu truc). oi vi dao ga nghieng con phai tnh chieu rong profin dao. (Dao khong ga nghieng, chieu rong profin dao hoan toan trung vi chieu rong cua chi tiet). + Dao lang tru : ay, nham xac nh chieu cao profin dao tiet dien tren mat trc Ti va tiet dien vuong goc vi mat sau ti. Quan sat mot chi tiet hnh con nh hnh ve : Xac nh chieu cao profin dao tiet dien tren mat trc Ti : . au tien xac nh iem c s (1). . Chon va , da vao vat lieu gia cong. . Tai iem c s xac nh chieu cao hnh dang chi tiet ln nhat : d dmin tmax = max , t tmax chon ng knh dao tai iem c 2 s va chon cac kch thc ket cau khac (tra trong cac so tay ky thuat). . Tnh chieu cao profin dao mat trc Ti : Qua s o: t cac vong tron gii han kch thc chi tiet tren hnh chieu ng, tai iem c s (1) ta dng ng thang (P) tao goc . (P) cat cac vong tron con lai tai cac iem (i). (P) cach tam O1 cua chi tiet mot khoang A. Theo phng (P) ta ve c cac kch htc tng ng B,C,T i . Ta co : A = r . sin B = r . cos C = ri . cos i i = r i Ti = C - B va ti = Ti . cos ( + ) T ay ta giong xuong mat phang hnh chieu bang, se ve c profin dao tiet dien vuong goc vi mat sau cua dao. Vi :
A

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Nhan xet : Chieu cao hnh dang dao tiet dien vuong goc vi mat sau cua dao lang tru ti , bang chieu cao hnh dang dao tiet dien mat trc Ti nhan vi cos ( + ). + Dao hnh tron : - Chieu cao profin dao tren mat trc cua dao hnh tron (dao da), cach tnh theo cac cong thc nh oi vi dao lang tru. - Chieu cao profin dao tiet dien chieu truc c xac nh theo cac cong thc sau: . Goc dao tron c hnh thanh do ga nang tam dao cao hn tam phoi mot khoang: h = R . sin . Con chieu cao mai dao H c tnh : H = R . sin ( + ) Va chieu cao profin dao tai tiet dien chieu truc se bang : t i = R - Ri Vi R a chon. Ri = sin( + ) i i ma tg (i + i ) = vi : E = D - Ti va : D = R . cos ( + ) + Dao co mat trc nang mot goc :(Hnh IV-14) Khi gia cong be mat con bang dao tien nh hnh lang tru hoac tron xoay (dang da), eu sinh ra sai so profin gia cong. e nang cao o chnh xac cua chi tiet gia cong, can thiet phai thiet ke dao tien nh hnh co oan c s nam ngang tam chi tiet. Yc la ta xoay mat trc cua dao mot goc nang . Goc khong the chon bat ky, ma no phu thuoc vao khoang cach chieu truc L gia cac iem gii han (1) va (2) cua phan con a cho trc va tr so nang q cua iem (2) tren iem (1), tai tiet dien vuong goc vi vet cua giao tuyen gia mat trc vi mat phang mai di mot goc . oi vi dao lang tru va dao dang da co the xac nh : tg =
q t.sin = = tg . tg L L H E H

Vi : .t -chieu sau hnh dang cua phan con chi tiet a chon : t = r2 - r1 . 2 -goc nh cua mat con chi tiet. . -goc trc cua li cat.

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Tnh toan hnh dang dao tren oan c s 1-2 : - oi vi dao nay, ban knh dao tai iem c s (1) cung chon theo bien dang ln nhat cua chi tiet tmax va ta c R1 . - Ta se tnh ban knh R2 tai iem c s (2) : T tam giac O212 ta co : R 2 = sin 2 .h- Khoang nang tam dao tron so vi tam chi tiet. Vi h = R1 . sin 1 trc) tg 2 = E 2
h h

(R1 va 1 c chon t

.E2 - khoang cach t iem c s (2)

en tam dao O2. ma E 2 = E1 - t .E1 - khoang cach t diem c s (2) en tam dao O2. .t - chieu cao hnh dang phan con chi tiet. E1 = R1 . cos 1 t = r 2 - r1 Chieu cao hnh dang dao tiet dien phap tuyen se la : ti = R 1 R2

Bai 4 C S THIET KE MOT SO LOAI DAO KHAC

1. 2. 3. 4. 5. 6. Mui khoan: Mui khoet: Mui doa: Dao phay: Ta ro ban ren: Cac loai dao ac biet:

Sinh vien t tm hieu cac loai sach

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