i

B GIO DC V O TO
I HC THI NGUYN







NGUYN TH QUC DUNG





NGHIN CU
QU TRNH TIN THP HP KIM QUA TI
BNG DAO PCBN


LUN N TIN S K THUT












Thi nguyn 2012



i
B GIO DC V O TO
I HC THI NGUYN





NGUYN TH QUC DUNG




NGHIN CU
QU TRNH TIN THP HP KIM QUA TI
BNG DAO PCBN

CHUYN NGNH: CH TO MY
M S: 62 52 04 01


LUN N TIN S K THUT


NGI HNG DN KHOA HC
PGS.TS PHAN QUANG TH









Thi nguyn 2012



i








LI CAM OAN

Ti xin cam oan y l cng trnh nghin cu ca ring ti. Tr nhng phn
tham kho c ghi r trong lun n, nhng kt qu, s liu nu trong lun n l
trung thc v cha tng c ai cng b trong bt k cng trnh no khc.

Tc gi



ii

LI CM N

Li u tin, ti xin c cm n PGS.TS. Phan Quang Th, Hiu trng trng
i hc K thut Cng Nghip, thy hng dn khoa hc ca ti v s nh hng
chin lc, s hng dn tn tnh cng nhng ng gp qu bu ca thy trong qu
trnh ti lm NCS v vit lun n.
Ti mun by t lng bit n su sc n tp th cn b ging vin, cc gio s,
tin s trng i hc K thut Cng nghip, c bit l b mn K thut C kh, v
nhng tnh cm v s gip nhit tnh m ti nhn c trong sut thi gian
nghin cu.
Ti mun c cm n s gip v t ca bn b, ng nghip ti cc phng
th nghim trng HKT Cng Nghip, trng HSP Thi Nguyn, trng H
Khoa hc T nhin, trng HBK H Ni, vin Khoa hc Vt liu Vit Nam, cc
k s ca cc nh my cn thp Lu X, NasteelVina, Vit-, cng ty TNHH C
kh Vnh Thi, trung tm gia cng trng H Cng Nghip H Ni dnh nhng
iu kin lm vic tt nht cho ti v c s vt cht, dng c, my mc, gip ti
hon thnh c nghin cu ca mnh.
Ti mun c by t s bit n ca mnh n Ban Gim Hiu, khoa o to sau
i hc, khoa C kh trng i hc K thut Cng nghip dnh nhng iu
kin thun li nht ti hon thnh lun n ny.
Cui cng, ti mun c dnh tnh cm bit n cho gia nh v tnh yu v s
ng h v b ca h trong nghin cu ca ti.





Nghin cu sinh
Nguyn Th Quc Dung


iii
MC LC
Trang
Li cam oan ............................................................................................................... i
Li cm n ................................................................................................................. ii
Cc ch vit tt .......................................................................................................... vi
Danh mc cc thut ng v k hiu .......................................................................... vi
Danh mc cc bng biu ............................................................................................. x
Danh mc cc hnh v v th ................................................................................ xi
Phn m u ................................................................................................................ 1
Chng 1. TNG QUAN V CNG NGH TIN CNG ................................. 5
1.1. Khi nim chung .................................................................................................. 5
1.2. Vt liu dng c ct PCBN .................................................................................. 6
1.3. Qu trnh to phoi khi tin cng .......................................................................... 9
1.3.1. Cc hnh thi phoi khi ct kim loi ................................................................... 9
1.3.2 C ch hnh thnh phoi khi tin cng .............................................................. 10
1.4. Lc v ng sut trong ct kim loi ..................................................................... 12
1.4.1. M hnh tnh ton lc ct ................................................................................ 12
1.4.2. M hnh tnh lc khi ct nghing .................................................................... 14
1.4.3. ng sut trong dng c ct ............................................................................. 15
1.4.4. S phn b ng sut trong vng bin dng ..................................................... 16
1.4.5. Lc ct khi tin cng ....................................................................................... 17
1.5. Nhit ct trong qu trnh tin cng .................................................................... 19
1.5.1. Cc ngun nhit trong ct kim loi ................................................................. 19
1.5.2. Cc phng php o c nhit trong ct kim loi ..................................... 19
1.5.3. Nhit ct khi tin cng bng dng c PCBN .................................................. 20
1.6. Mn v tui th dng c CBN ........................................................................... 21
1.6.1. Cc dng mn v c ch mn dng c PCBN ................................................ 21
1.6.2. Cc nhn t nh hng n mn dng c PCBN ........................................... 23
1.7. Kt lun chng 1 .............................................................................................. 24
Chng 2. NGHIN CU C TRNG CA QU TRNH TO PHOI KHI
TIN THP HP KIM QUA TI BNG DAO PCBN ..................................... 26
2.1. Phng php nghin cu s hnh thnh phoi ..................................................... 26


iv
2.2. nh hng ca cng phi n hnh thi phoi khi tin thp hp kim qua ti
bng dao PCBN ......................................................................................................... 26
2.3. nh hng ca vn tc ct n hnh thi phoi ................................................... 29
2.4. C ch hnh thnh phoi khi tin thp hp kim qua ti bng dao PCBN ............ 32
2.5. Kt lun chng 2 .............................................................................................. 36
Chng 3. NGHIN CU C TRNG V LC CT KHI TIN THP
HP KIM QUA TI BNG DAO PCBN ............................................................ 37
3.1. Bin thin lc ct theo chiu di ct khi tin thp hp kim qua ti bng dao
PCBN ........................................................................................................................ 37
3.2. nh hng ca tc ct n cc thnh phn lc ct khi tin cng trc giao
thp 9XC bng dao PCBN. ....................................................................................... 40
3.3. Phn tch nh hng ca iu kin ct n cc thnh phn lc ct khi tin cng
trc giao thp 9XC bng dng c PCBN. ................................................................. 41
3.4. Kt lun chng 3 .............................................................................................. 43
Chng 4. XC NH TRNG PHN B NHIT TRONG DNG C
PCBN KHI TIN THP HP KIM QUA TI ................................................... 45
4.1. Xc nh trng phn b nhit trong dng c PCBN khi tin cng trc giao
bng phng php phn t hu hn (FEM) .............................................................. 45
4.1.1. M hnh tnh nhit ........................................................................................... 45
4.1.2. Cc thng s xc nh t thc nghim ............................................................ 48
4.1.3. Tnh ton tc sinh nhit ring .................................................................... 50
4.1.4. Trng phn b nhit trong dng c PCBN khi tin cng trc giao thp 9XC
bng dao PCBN xc nh bng phng php phn t hu hn ................................ 55
4.2. Trng phn b nhit trong dng c PCBN khi tin cng trc giao thp 9CX
xc nh bng phng php thc nghim ................................................................. 58
4.2.1. Thit b v ch th nghim .......................................................................... 58
4.2.2. Trng phn b nhit trong dng c PCBN ................................................... 59
4.3. Kt lun chng 4 .............................................................................................. 61
Chng 5. MN DNG C PCBN V CHT LNG B MT KHI TIN
THP HP KIM QUA TI................................................................................... 63
5.1. Mn v c ch mn dng c PCBN khi tin thp hp kim qua ti ................... 63


v
5.1.1. nh hng ca cng vt liu gia cng n mn v c ch mn dng c
PCBN ........................................................................................................................ 63
5.1.2. nh hng ca ch ct n mn v c ch mn dng c PCBN .............. 68
5.1.3. Bin thin chiu cao mn dng c PCBN theo chiu di ct khi tin thp hp
kim qua ti ................................................................................................................. 71
5.2. Cht lng b mt gia cng khi tin thp hp kim qua ti bng dao PCBN ..... 73
5.2.1. Nhm b mt gia cng..................................................................................... 73
5.2.2. Lung vt liu bin dng do v lp bin cng b mt gia cng.................... 74
5.3. Kt lun chng 5 .............................................................................................. 78
Chng 6. TI U HA A MC TIU CH CT KHI TIN THP
HP KIM QUA TI BNG DAO PCBN ............................................................ 80
6.1. Xy dng m hnh ton ...................................................................................... 80
6.1.1. Thit b v ch thc nghim ....................................................................... 81
6.1.2. Xy dng m hnh hi qui m t nhm b mt ............................................... 82
6.1.3. Xy dng m hnh hi qui m t mn dng c .............................................. 85
6.2. Ti u ha a mc tiu ch ct khi tin thp 9XC qua ti bng gii thut di
truyn (GAs) .............................................................................................................. 88
6.2.1. Xc nh bi ton ............................................................................................ 88
6.2.2. Kt qu thc hin gii thut di truyn cho bi ton ti u n mc tiu ........ 90
6.2.3. Kt qu thc hin gii thut di truyn cho bi ton ti u a mc tiu .......... 90
6.3. Kt lun chng 6 .............................................................................................. 93
KT LUN V PHNG HNG NGHIN CU TIP THEO ....................... 94
DANH MC CC CNG TRNH CNG B LIN QUAN N LUN N 96
TI LIU THAM KHO ......................................................................................... 98





vi
CC CH VIT TT

K hiu ngha
PCBN Nitrit Bo lp phng a tinh th
CBN Nitrit Bo lp phng
BN Nitrit Bo
SEM Knh hin vi in t qut
QSD C cu dng dao nhanh
EDX Phn tch nhiu x Rnghen
RTD Cm bin nhit in tr
FEM Phng php phn t hu hn
GA Gii thut di truyn

DANH MC CC THUT NG V K HIU

K hiu n v ngha
c - Bin dng
0
t MPa Gii hn trt
- Bin dng trt
1/s Tc bin dng
t MPa ng sut trt
G MPa M un n hi trt
- H s ma st
A mm
2
Din tch tip xc
A
R
mm
2
Din tch tip xc thc
V m/p Vn tc ct
t
1
mm Chiu dy ct

t
2
mm Chiu dy phoi
| rad Gc trt
o , rad Gc trc ca dng c
y A mm Chiu dy vng bin dng


vii
V
s
m/p Vn tc trt trn mt phng trt
V
c
m/p Vn tc phoi trn mt trc dng c
y
k MPa ng sut gii hn

- Bin dng gii hn

y
1/s Tc bin dng gii hn
w, b mm Chiu rng ct
F
C
N Lc tip tuyn
F
T
N

Lc dc trc
F
R
N Lc tng hp
F
S
N

Lc ct nm trong mt phng trt
F
SN
N

Lc vung gc vi mt phng trt
F
F
N Lc ma st trn mt trc ca dng c
F
N
N Lc php tuyn vi mt trc ca dng c
F
x
, F
y
, F
z
N Cc thnh phn lc ct
| rad Gc ma st
rad Gc nng ca li ct chnh
kg/m
3
Khi lng ring ca vt liu gia cng
c J/kg.
0
C Nhit dung ring ca vt liu gia cng
R
T
- H s phn phi nhit
, ,
x y z
k k k W/m.
0
C H s dn nhit theo ba phng x, y v z
q W/m
3
Tc sinh nhit ring th tch
, ,
T T T
x y z
c c c
c c c
- Bin thin nhit theo cc phng x, y v z
h W/m
2
.C H s truyn nhit i lu
T
o
C Nhit xc nh theo khng gian v thi gian
T

o
C Nhit mi trng xung quanh
, ,
x y z
l l l - Cc cosin ch phng ca php tuyn ngoi trn cc bin
V mm
3
Th tch ca vt th rn
u
x
,u
y
m/p Thnh phn vn tc ca vt liu theo hai phng x v y
S
T
, S
q
, S
h
- Cc bin phn bit to nn din tch ca phn t kho st


viii
T
i
, T
j
, T
k

o
C Nhit ti cc im nt
k
AB
MPa ng sut ct trn mt phng trt
A
s
mm
2
Din tch mt phng trt
( ) x
t
MPa ng sut tip trn mt trc
V
(x)
m/p Vn tc ca lp phoi di cng
s
t MPa Gii hn chy trt trung bnh trn b mt tip xc
l mm Chiu di tip xc gia phoi v dng c
sec
t MPa ng sut chy trt trong vng bin dng th hai
sec
1/s Tc bin dng trong vng trt th hai
q
21
W/mm
2

Tc sinh nhit do ma st gia phoi v mt trc
q
22
W/mm
2
Tc sinh nhit do bin dng do ca phoi trong min
bin dng th hai
q
3
W/mm
2
Tc sinh nhit trn mt tip xc gia dao v phi
K
c
- H s lc ct khi dng c mn
F
tf
,F
cf
N Lc ct dc trc v lc ct tip tuyn khi dng c mn
y - Hm hi qui thc nghim
x
j
- Cc bin m ha ca thng s z
j

b
j
- H s hi qui ca cc bin c lp
b
ju
- H s hi qui ca cc bin kp
N - S th nghim
k - S yu t c lp
m - S th nghim lp li ti tm
X
T
- Ma trn chuyn v ca ma trn k hoch
bj
t - Chun s Student
2
pf
t - Tr s tra bng ca chun s Student
p - Mc c ngha ca m hnh hi qui
f
2
- Bc t do lp
S
b
- lch trung bnh ca phn b b
l - S h s c ngha trong phng trnh hi qui
2
ll
S - Phng sai lp ca cc th nghim lp li tm


ix
0
a
y - Gi tr ca thc nghim lp li th a
0
y - Trung bnh cng ca cc thc nghim lp li
2
d
S - Phng sai d
F - Chun s Fisher ca m hnh hi qui thc nghim
2 1
pf f
F - Gi tr tra bng ca chun s Fisher
f
1
- Bc t do d
( )
k
f x E e - Vc t ca cc hm mc tiu f
i
(x)






x
DANH MC CC BNG BIU

Bng 1.1. So snh cc tnh cht c l ca PCBN vi mt s vt liu dng c c tnh
nng ct cao ................................................................................................................. 8
Bng 2.1. Thnh phn ha hc ca thp X12M ........................................................ 27
Bng 2.2. Thnh phn ha hc ca thp 9XC ........................................................... 27
Bng 3.1. Kt qu th nghim xc nh cc thnh phn lc ct. ............................... 42
Bng 4.1. Thng s mnh dao PCBN tin cng thp 9XC. ...................................... 48
Bng 4.2. Cc thng s tnh ton trng nhit xc nh t thc nghim. ........... 49
Bng 4.3. Cc thng s tnh ton xc nh cc ngun nhit ..................................... 55
Bng 4.4. Kim loi ph v im nng chy tng ng ............................................ 58
Bng 6.1. Gi tr nhm b mt ti cc im th nghim theo quy hoch .................. 82
Bng 6.2. Gi tr din tch b mt gia cng ti cc im th nghim theo qui hoch85
Bng 6.3.Cc gi tr ti u Pareto v ch ct tng ng tm c t qu trnh ti
u ha ........................................................................................................................ 91











xi
DANH MC CC HNH V V TH

Hnh 1.1. Cu trc t vi ca vt liu PCBN ................................................................ 6
Hnh 1.2. nh hng ca thnh phn v kch thc ht CBN n tnh cht ca vt
liu PCBN ................................................................................................................... 7
Hnh 1.3. Cc dng mnh dao PCBN .......................................................................... 8
Hnh 1.4. Dng hnh hc li ct dng c PCBN ....................................................... 9
Hnh 1.5. C ch hnh thnh dng phoi n nh ......................................................... 9
Hnh 1.6. Cc dng phoi phn on. ......................................................................... 10
Hnh 1.7. Cc giai on ca qu trnh to phoi do trt cc b trong ct kim loi .. 11
Hnh 1.8. Cc giai on hnh thnh phoi rng ca trong gia cng thp 100Cr6 ....... 12
Hnh 1.9. Vng trn lc khi ct trc giao ca Ernst v Merchant ............................ 13
Hnh 1.10. S mi quan h gia cc thnh phn lc khi ct nghing .................. 14
Hnh 1.11. Bin thin ng sut php v tip trn mt trc dng c ....................... 16
Hnh 1.12. Bin thin ng sut php v tip trong mt phng trt ......................... 17
Hnh 1.13. Cc khu vc bin dng l ngun sinh nhit ............................................ 19
Hnh 2.1. Cu trc t vi ca thp X12M cng khc nhau ................................. 27
Hnh 2.2. Cu trc t vi ca thp 9XC cng khc nhau.................................... 27
Hnh 2.3. Thit b v s th nghim kho st mn v c ch mn dao PCBN. ... 28
Hnh 2.4. Hnh thi phoi khi tin thp 9XC cng khc nhau............................ 28
Hnh 2.5. Hnh thi phoi khi tin thp X12M cng khc nhau ......................... 28
Hnh 2.6. Hnh thi phoi khi tin thp 9XC ng vi vn tc ct khc nhau. ............ 29
Hnh 2.7. Hnh thi phoi khi tin thp X12M ng vi vn tc ct khc nhau .......... 30
Hnh 2.8. Hnh thi phoi khi tin trc giao thp 9XC vi vn tc ct khc nhau ..... 31
Hnh 2.9. Mt ct ngang ca phoi khi ct trc giao v khi ct nghing.................... 31
Hnh 2.10. Cu trc gc phoi thp 9XC vn tc ct khc nhau ............................. 32
Hnh 2.11. Phn b bin dng trong phoi dy n nh v phoi rng ca .................. 33
Hnh 2.12. Kim tra cng ti cc v tr bin dng khc nhau gc phoi ............ 33
Hnh 2.13. cng phoi thay i theo c ch hnh thnh phoi ............................... 34
Hnh 2.14. Hnh thi phoi thay i theo cng vt liu phi v tc ct ........... 35
Hnh 3.1. S v thit b th nghim o lc ct ..................................................... 37
Hnh 3.2. D liu o lc ct khi tin cng thp 9XC v X12M ............................... 37
Hnh 3.3. th bin thin cc thnh phn lc ct theo chiu di ct ...................... 38
Hnh 3.4. Kim tra cng ca cc ht cacbit trong t chc thp X12M ................ 39


xii
Hnh 3.5. nh hng ca bn knh mi dao v chiu su ct n c ct ................. 39
Hnh 3.6. Bin thin ca cc thnh phn lc ct theo cng khi tin thp X12M
ng vi chiu di ct khc nhau ................................................................................ 40
Hnh 3.7. S th nghim tin cng trc giao ........................................................ 40
Hnh 3.8. th bin thin lc ct theo vn tc ct khi tin trc giao thp 9XC ..... 41
Hnh 3.9. Bin thin lc ct theo vn tc ct khi tin cng trc giao thp 9XC ...... 41
Hnh 3.10. nh hng ca cc nhn t v v s v tng tc gia chng n cc thnh
phn lc ct trong tin cng trc giao thp 9XC bng dng c PCBN. ................... 42
Hnh 3.11. Mt hi qui v th ng mc ca cc thnh phn lc ct F
z
v F
x
... 43
Hnh 4.1. M hnh bi ton tnh nhit v cc iu kin bin .................................... 45
Hnh 4.2. Cc iu kin bin s dng trong m hnh nhit ...................................... 46
Hnh 4.3. nh SEM chp mt ct gc phoi v vt tip xc trn b mt dng c khi
tin trc giao thp 9XC ............................................................................................. 48
Hnh 4.4. Bin thin nhit to thnh trn mt tip xc gia phoi v dng c. ......... 52
Hnh 4.6. Phn b ng sut trn mt tip xc gia dao v phi ............................... 54
Hnh 4.7. M hnh tnh ton trng phn b nhit trong tin cng trc giao ........... 55
Hnh 4.8. S tc dng ca cc ngun nhit trong m hnh tnh ton trng phn
b nhit. ..................................................................................................................... 56
Hnh 4.9. Trng phn b nhit khi tin thp 9XC bng dao PCBN trong trng
hp dng c sc ......................................................................................................... 56
Hnh 4.10. Trng phn b nhit khi tin thp 9XC bng dao PCBN trong trng
hp dng c b mn .................................................................................................. 57
Hnh 4.11. Phi thp 9XC dng trong th nghim. ................................................... 58
Hnh 4.12. Mnh ghp PCBN dng c v thn dao s dng trong th nghim. ...... 58
Hnh 4.13. Knh hin vi in t qut Jeol-JSM 5410 LV. ........................................ 58
Hnh 4.14. Phn tch EDX thnh phn lp ph ......................................................... 59
Hnh 4.15. nh SEM b mt ghp mnh PCBN c ph cc kim loi .................. 60
Hnh 4.16. Cc ng ng nhit trong dng c PCBN xc nh bng thc nghim .. 60
Hnh 5.1. Cc dng hng ca dng c PCBN. .......................................................... 63
Hnh 5.2. Hnh nh mn mt trc v mt sau ca dao PCBN ................................ 64
Hnh 5.3. Cc vng mn mt trc dng c PCBN khi gia cng thp X12M ......... 65
Hnh 5.4. Vt mn dng sng do tc dng ca cc ht cacbit trong vt liu phi. ... 65
Hnh 5.5. Phn tch EDX cc cht trn b mt dng c ............................................ 67


xiii
Hnh 5.6. nh vng mn mt sau ca mnh dao PCBN khi ct thp 9XC vn tc
khc nhau................................................................................................................... 68
Hnh 5.7. Cu trc t vi t chc vt liu vng phng rp di li ct ph v vng
vt liu nguyn thy ca dng c PCBN .................................................................. 69
Hnh 5.8. nh vng mn mt trc mnh PCBN ..................................................... 69
Hnh 5.9. Gc thot nhit trn mt sau di li ct chnh v ph. ......................... 71
Hnh 5.10. nh SEM vng mn mt sau mnh PCBN khi tin cng thp 9XC vi
chiu di ct khc nhau ............................................................................................. 71
Hnh 5.11. nh SEM mn mt sau mnh PCBN khi tin thp 9XC v X12M ........ 72
Hnh 5.12. th bin thin chiu cao mn mt sau theo chiu di ct ca mnh
PCBN khi tin thp 9XC ........................................................................................... 72
Hnh 5.13. Thit b o nhm Mitutoyo SI-201. ........................................................ 73
Hnh 5.14. th bin thin nhm b mt theo chiu di ct ................................... 73
Hnh 5.15. th bin thin nhm b mt theo cng khi tin thp X12M .......... 74
Hnh 5.16. nh chp topography b mt khi tin thp X12M ng vi cng phi
khc nhau................................................................................................................... 75
Hnh 5.17. nh chp topgraphy b mt khi tin thp 9XC cng 52HRC ng vi
vn tc ct khc nhau ................................................................................................ 76
Hnh 5.18. Kim tra cng t vi lp b mt gia cng khi tin thp 9XC v X12M
cng khc nhau ................................................................................................. 76
Hnh 5.19. Bin thin cng ca lp b mt gia cng nhn c khi tin thp 9XC
v X12M cng khc nhau. ................................................................................ 77
Hnh 5.20. Cu trc t vi lp b mt gia cng khi tin thp 9XC v X12M cng
57HRC vi chiu di ct khc nhau .......................................................................... 78
Hnh 6.1. Gi tr nhm b mt xc nh t thc nghim v m hnh hi qui. .......... 84
Hnh 6.2. Mt hi qui v th ng mc ca nhm R
a
theo cc thng s ch
ct ......................................................................................................................... 84
Hnh 6.3. Gi tr din tch gia cng xc nh t thc nghim v m hnh hi qui. .. 87
Hnh 6.4. Mt hi qui v th ng mc ca din tch gia cng S
c
theo cc thng
s ch ct .............................................................................................................. 87
Hnh 6.5. th mt bin ti u Pareto v gii php ti u tha hip ..................... 92





1
M U
1. TNH CP THIT CA TI
Tin thp hp kim qua ti c cng ln hn 45HRC hay tin cng, ang l mt
la chn rt hp dn thay cho nguyn cng mi bi cc u th: thi gian quay vng
ngn, qu trnh gia cng linh hot, tui th lm vic cao, chi ph u t thp v t tc
ng n mi trng. Trong qu trnh tin cng, nh dng c c li ct n nn
c th iu chnh chnh xc gc ct v do , d dng gia cng cc b mt phc tp
ca sn phm. Mt khc, mt s nghin cu ch ra rng, ng sut d gy bi tin
cng lm ci thin bn mi ca chi tit gia cng.
Tin cng bt u c ng dng trong nhiu lnh vc ch to c kh t nhng
nm 1980. Vi s ra i v pht trin ca cc loi dng c ct siu cng PCBN
(Nitrit Bo lp phng a tinh th), cc ng dng ca cng ngh tin cng tng
ln r rt trong cc ngnh cng nghip, c bit l cng nghip ch to t, ln,
cc thit b thy lc, bnh rng, cam, trc v cc chi tit c kh khc.
Mc d c nhng u im ni bt nh mt bin php gia cng linh hot, thn
thin vi mi trng, trong lnh vc gia cng chnh xc khi yu cu chnh xc
hnh hc ti mt vi micromet, vic ng dng ca tin cng cn b hn ch bi tnh
thiu n nh lin quan n cht lng cc b v tin cy khi gia cng. Nhc
im na do cng ca chi tit ln nn dng c b mn nhanh lm tng chi ph gia
cng. Thm vo , gin cao v dai va p thp ca vt liu dng c ct
PCBN cng i hi h thng cng ngh c cng vng v chnh xc cao.
Mc d vic nghin cu cc c trng ha l nhn bit v iu khin cc
nhn t nh hng ti hiu qu qu trnh tin cng v ang c tin hnh ti
nhiu ni trn th gii, cc kt qu cng b cho thy vic nghin cu vn cha
su sc v trit . Chnh v n nh thp lin quan n cht lng cc b v
tin cy khi gia cng nn tin cng chnh xc cn cha tha mn c yu cu ca
hu ht cc ngnh cng nghip. Mt khc, d c kh nng thay th cho mi trong
gia cng cc b mt chnh xc chu ng sut cao, ng hc khi tin rt khc so vi
qu trnh mi nn cn c nhng nghin cu su v y hn v nh hng ca
cc yu t cng ngh cng nh tc ng tng quan ca cc qu trnh ha l xy
ra khi tin cng.


2
Vit nam, cng ngh tin cng bt u c ng dng mt vi c s sn
xut. Tuy nhin, cho n nay vn cha c cng trnh nghin cu no v lnh vc
cng ngh ny c cng b. Vi vic s dng ngy cng ph bin ca cc loi
thp hp kim c bn v cng cao trong ngnh c kh ch to, cng vi s ra
i v pht trin ca cc loi dng c ct siu cng v cc my gia cng t ng,
cng ngh tin cng ang thu ht c s quan tm c bit. V vy, vic nghin
cu bn cht qu trnh, xc nh cc nhn t nh hng ti cht lng v tnh n
nh ca qu trnh gia cng nhm tm ra cc bin php nng cao hiu qu, m rng
phm vi ng dng ca cng ngh tin cng Vit Nam l cn thit v cp bch.
2. MC CH, I TNG V PHM VI NGHIN CU
Mc ch nghin cu
Mc tiu nghin cu ca lun n l nghin cu cc c trng vt l ca qu trnh
tin thp hp kim qua ti bng dao PCBN nh: c ch hnh thnh phoi, lc v nhit
ct, mn dng c. Trn c s cc nghin cu c tin hnh trong iu kin gia
cng rt gn vi thc tin sn xut, c th nhn bit mt s nhn t nh hng ti
hiu qu qu trnh tin cng l tui th dng c v cht lng b mt, xut c
nhng bin php nng cao hiu qu ca qu trnh tin cng.
Bn cnh , nghin cu cng tp trung vo vic tm kim tp hp cc thng s
ct ti u tha mn nhiu mc tiu lm c s cho vic iu khin qu trnh tin
cng sau ny.
i tng v phm vi nghin cu
i tng nghin cu ca qu trnh tin thp hp kim qua ti bng dao PCBN l
hai loi thp hp kim 9XC v thp X12M, c s dng kh ph bin trong ngnh
c kh ch to nc ta.
ti gii hn phm vi nghin cu cc vn sau:
+ Nghin cu tng quan v cng ngh tin cng v vt liu dng c PCBN.
+ Nghin cu cc c trng vt l khi tin cng hai loi thp hp kim 9XC v
X12M bng dao PCBN bao gm qu trnh to phoi, lc ct v nhit ct.
+ Nghin cu cc ch tiu mn dng c PCBN v cht lng b mt gia cng khi
tin thp cng thp hp kim 9XC v X12M.


3
+ Xc nh tp hp cc thng s ct ti u tha mn hai mc tiu i lp l nhm
b mt v tui th dng c khi tin thp hp kim qua ti bng dao PCBN.
3. PHNG PHP NGHIN CU
Nghin cu l thuyt kt hp vi nghin cu thc nghim. Vic nghin cu l
thuyt da trn s phn tch v tng hp cc kt qu cng b, a ra cc gi thit
v cc tnh ton bin i ph hp xy dng c s l thuyt v thit lp cc m
hnh thc nghim.
Nghin cu thc nghim c tin hnh vi h thng thit b thc nghim c
thit k, ch to c tin cy, s dng cc thit b o hin i c chnh xc
cao nhm kim chng cc m hnh l thuyt, tm ra cc mi quan h hoc i chiu,
kim chng vi cc kt qu nghin cu c.
4. NGHA KHOA HC V THC TIN CA TI
ngha khoa hc
Cc kt qu nghin cu ca ti s l c s khoa hc thit lp cc ch dn
cng ngh trong qu trnh tin cng, c bit trong vic iu khin, ti u ha qu
trnh. Kt qu nghin cu cng l c s khoa hc ng dng cng ngh tin cng
trong ch to cc sn phm i hi b mt lm vic c cht lng cao, gp phn
tng tnh n nh v tin cy ca mt phng php gia cng tinh sau nhit luyn,
nng cao hiu qu v m rng phm vi ng dng cng ngh tin cng.
ngha thc tin
Nhng kt qu nghin cu ca ti c th ng dng ti cc nh my, phn
xng sn xut c kh khi gia cng cc sn phm, chi tit c ch to bng cc
loi thp hp kim, ch yu l thp crm, yu cu cao v bn, cng v chu
nhit trong t, xe my, tu thy, my cng c, ng c, thit b v cc dy chuyn
cn thp trong nc.
Qu trnh ng dng cc kt qu nghin cu s cho php m rng phm vi gia
cng ca ngnh ch to my ni chung v ca cng ngh tin cng ni ring, gp
phn to ra nhng sn phm c cht lng tt, gi thnh h v nng cao kh nng
ng dng vo thc tin mt phng php gia cng tinh linh hot, thn thin vi mi
trng, chi ph u t thp, ph hp vi iu kin sn xut Vit Nam.


4
5. NI DUNG CC VN S I SU NGHIN CU
Ni dung nghin cu s i su vo cc vn sau:
- Nghin cu tng quan v cng ngh tin cng: Vt liu dng c ct PCBN, qu
trnh to phoi, lc ct, nhit ct v mn dng c khi tin cng.
- Lm r mi lin h ca hnh thi phoi vi cng vt liu v vn tc gia cng
khi tin thp hp kim 9XC v X12M bng dao PCBN. Phn tch hnh nh gc phoi
rt ra nhn nh v c ch hnh thnh phoi ph thuc vo hai qu trnh bin cng
v mm ha v nhit.
- Kho st bin thin lc ct ph thuc vo vt liu gia cng, vn tc ct v chiu
di gia cng khi tin thp hp kim qua ti bng dao PCBN. Nhn bit c mi lin
h gia c ch hnh thnh phoi vi lc ct.
- S dng phng php phn t hu hn gii bi ton truyn nhit v xc nh
trng phn b nhit cho qu trnh tin cng trc giao thp 9XC vi s h tr ca
phn mm ABAQUS. Bng cch ph cc kim loi nguyn cht c im nng chy
xc nh ly thng tin v nhit , kim chng kt qu m phng l thuyt bng
thc nghim.
- Phn tch cc c ch mn v dng mn dng c PCBN khi tin cng hai loi
thp hp kim 9XC v X12M. Kho st nh hng ca vt liu phi, vn tc ct v
chiu di gia cng ti mn dng c v cht lng b mt gia cng. Gii thch mi
lin h gia nhit ct v mn dng c.
- ng dng gii thut di truyn trong qu trnh ti u ha a mc tiu ch ct
xc nh tp hp cc thng s ti u khi tin cng thp 9XC bng dao PCBN. S
dng phng php phn tch hi quy xy dng cc m hnh lc ct, nhm b mt
gia cng v tui th dng c.
Phn kt lun chung v phng hng nghin cu tip theo.
Equation Chapter (Next) Section 1


5
Chng 1
TNG QUAN V CNG NGH TIN CNG
1.1. Khi nim chung
Tin cng l phng php tin s dng dao bng cc vt liu siu cng nh
Nitrit Bo, kim cng hoc gm tng hp thay th cho nguyn cng mi khi gia
cng thp ti c cng t 4570HRC [47], [58]. So vi mi, tin cng c nhiu
u th vt tri v kha cnh kinh t v sinh thi [77], [80]. u th ng k nht ca
tin cng l c th dng mt dng c m vn gia cng c nhiu chi tit c hnh
dng khc nhau bng cch thay i ng chy dao. Trong khi , mun mi c
hnh dng chi tit khc th phi sa li hoc thay khc. c bit, tin cng c
th gia cng c nhng bin dng phc tp m mi kh c th thc hin c.
Nu xt v chi ph u t th mt my tin CNC ch bng khong 1/2 n 1/10 my
mi CNC [16]. Cp chnh xc khi tin cng t IT57 v nhm b mt t R
z
= 24
m. iu kin gia cng c bit, tin cng c th t c chnh xc IT35 v
nhm b mt R
z
<1,5m [48], [96]. Ngoi ra, cht lng b mt khi tin cng cng
c mt s u im so vi mi nh: nh hng nhit n b mt gia cng nh do
chiu di v thi gian tip xc gia dng c v phi ngn, lp ng sut d nn b
mt c chiu su ln nhng vn gi c chnh xc kch thc, hnh dng v
tnh nguyn vn b mt [42], [48], [64], [91]. Bn cnh , tin cng cn c th
thc hin gia cng kh, khng cn s dng dung dch trn ngui nn khng nh
hng n mi trng v sc khe ngi lao ng [19], [74]. Tuy nhin tin cng
cng i hi my, h thng cng ngh c cng vng v chnh xc cao [29].
Mc d c nhng u th ni bt v t c s tng trng mnh m trong
trong nhng nm gn y, tin cng vn ang l mt cng ngh gia cng mi
cha c nghin cu y . Do tin cy ca qu trnh cha cao, cht lng
gia cng thiu n nh v chi ph dng c ct ln nn phm vi ng dng ca cng
ngh gia cng tin tin ny cn rt hn ch [57], [96]. V vy, vic b sung cc
nghin cu tm hiu v cc hin tng c l tnh ca qu trnh, nhn bit c cc
thng s iu khin nng cao hiu qu qu trnh cng nh ci tin cng ngh
ch to dng c ct v my gia cng s m rng tim nng ng dng ca cng
ngh tin cng [80].


6
1.2. Vt liu dng c ct PCBN
Vt liu dng c ct PCBN (Nitrit Bo lp phng a tinh th) l vt liu kt hp
gia cc ht Nitrit Bo lp phng (CBN) vi cht kt dnh c thiu kt nhit
1200
0
C v p sut 5,5GPa. Thnh phn
PCBN bao gm cc ht CBN vi kch
thc vi micromet (130m ty yu
cu v mt ) phn b trong mt cht
nn cha cacbit kim loi, nitrit hoc
xit (Hnh 1.1). Cu trc ng u ca
PCBN khc phc c cc nhc
im ca CBN n tinh th nh tnh c
th v d hng [11]. Hin nay, cht
kt dnh gm kim loi ang c s
dng rng ri v kt hp c s gn
kt do dai ca kim loi vi cng v bn nhit ca gm [102].
CBN l mt trong bn dng tinh th ca Nitrit Bo (BN) gm: Hexagonal
(HBN), Rhombohedral (RBN), Wurtzitic (WBN) v Cubic (CBN) [35], [54]. CBN
c tng hp thnh cng ln u tin vo nm 1957 v bt u c a ra th
trng di dng dng c ct v bt mi t nm 1969. Tnh cht t tng tc ha
hc vi nhm hp kim thp, cng cao v tnh n nh nhit cao, c bit
trong iu kin xy ha lm cho vt liu CBN tr thnh loi vt liu cng
nghip thch hp hn so vi kim cng. c coi l vt liu ca th k 20, hin nay
Nitrit Bo ang c ng dng rt hiu qu trong nhiu lnh vc khoa hc v cng
ngh nh vt liu k thut in t, vt liu k thut ht nhn, vt liu dng c ct,
vt liu bi trn v vt liu chu la [54].
c tnh ca vt liu PCBN ph thuc ch yu vo hm lng CBN, thnh phn
cht dnh kt v kch c ht. Cn c vo hm lng CBN m PCBN c chia
thnh hai loi: Vt liu PCBN vi hm lng CBN thp, khong 50% v vt liu
vi hm lng CBN cao, khong 8090% [102]. Hm lng CBN cng cao th kh
nng dn nhit cng ln v tnh chng mn cng tng. C ht CBN cng ln th kh
nng chng mn tng nhng cht lng li ct gim (Hnh 1.2) [96]. Trng thi
ca vt liu dng c PCBN trong qu trnh gia cng b nh hng bi rt nhiu
Hnh 1.1. Cu trc t vi ca vt liu
PCBN: (1) v (2)vng TiCN nh v ln;
(3)vng Al
2
O
3
v (4)vng hn hp ca
Al
2
O
3
[11].


7
nhn t bao gm: thnh phn
ca vt liu PCBN, vt liu
phi, bn cht qu trnh gia
cng, iu kin ct cng nh cc
thng s dng c ct. Tuy hiu
qu ca dng c ct ph thuc
vo nhiu yu t song cc
nghin cu n nay cho thy,
vi thnh phn CBN thp, dng
c ct PCBN t c hiu qu
tt hn trong gia cng vt liu
cng c v phng din tui th
dng c ln cht lng b mt.
Nh cc tnh cht qu gi nh cng cao, bn nhit v t tng tc ha hc
nhit cao, PCBN c th s dng ct vi tc cao cc hp kim thp v cc
vt liu kh gia cng nh: thp hp kim ti cng n 70HRC, thp rn vi cng
4568HRC, gang ti, cc loi siu hp kim Niken v Cban [56]. Tuy khng cng
bng kim cng song PCBN li c nhng u th ni bt vi vai tr dng c ct khi
gia cng thp ti, gang ti v cc loi siu hp kim v t c i lc ha hc vi nhm
hp kim ca st v tnh n nh nhit cao, nhit 1600
0
K khng tc dng
vi hp kim st v khng c s chuyn ha cu trc tinh th Nitrit Bo dng lc gic
(HBN) ging Graphit [54]. So vi hp kim cng v gm, tuy PCBN c gi thnh rt
cao, thng gp t 1020 ln v hn ch v dng hnh hc, song li c th p ng
cc yu cu t c mc cao v nng sut, chnh xc v ng u trong
gia cng ch to, c bit l cc yu cu ca qu trnh t ng ha trong gia cng
nh gim thi gian dng my, thi gian v s ln thay th dng c nn nhu cu tiu
th dng c PCBN lin tc tng mc hai ch s [56], [97]. Tuy nhin, d c
cng rt cao nhng do dai va p km nn hn ch vic s dng PCBN trong cc
qu trnh ct gt nng, c va p nhiu nh phay [97].
Hin nay, PCBN ang c s dng rng ri dng bt cho qu trnh mi, dng
thiu kt cho qu trnh ct nh ca, ct gt, nghin p, c bit trin vng trong qu
trnh tin cng [99].
Cht lng li ct

n

n
h
i

t

H

m

l

n
g

C
B
N

(
%

t
h

c
h
)

CBN cao
CBN thp
Kch thc ht CBN trung bnh (m)

Hnh 1.2. nh hng ca thnh phn v kch
thc ht CBN n tnh cht ca vt liu
PCBN [96].



8
Bng 1.1 trnh by mt s tnh cht c l ca vt liu dng c ct PCBN v mt
s vt liu dng c ct theo cc cng ty ch to dng c Kennametal, Sandvik,
Sumitomo v De Beerd. T y c th thy PCBN l loi vt liu dng c c tnh
nng thch hp nht cho vic gia cng bng ct gt cc loi vt liu c bn
cng cao [96].
Do iu kin ch to kh khn, cu to v hnh dng cc mnh dng c PCBN
b hn ch v thng c ch to ba dng (Hnh 1.3) [17]:
- Mnh dao c mi gn PCBN trn nn hp kim
cng (Hnh 1.3a).
- Mnh dao c lp b mt PCBN gn trn nn
hp kim cng (Hnh 1.3b).
- Mnh dao nguyn khi PCBN (Hnh 1.3c).
Chiu dy lp PCBN c ch to ba mc:
1,6; 3,2; 4,76 mm theo tiu chun ISO/ANSI [17].
Do c s dng ch yu trong qu trnh gia
cng tinh vi chiu su ct v lng chy dao nh
nn qu trnh ct khi tin cng ch din ra bn knh
mi dao hoc dc theo cnh vin li ct, vic ch
to dng hnh hc li ct dng c PCBN ng vai tr rt quan trng. Bn cnh ,
Hnh 1.3. Cc dng mnh
dao PCBN [97]: PCBN
mi li ct (a) ; PCBN
lp b mt (b) ; PCBN
nguyn khi (c).
Bng 1.1. So snh cc tnh cht c l ca PCBN vi mt s vt liu dng c c tnh
nng ct cao [96].
Tnh cht c l
Cacbit
Vonfram
Gm s
nhn to
PCBN
Kim cng
nhn to
Khi lng ring (g/cm
3
) 6.0-15.0 3.8-7.0 3.4-4.3 3.5-4.2
cng (HV 30) 1300-1700 1400-2400 3000-4500 4000-7000
Modul n hi (GPa) 430-630 300-400 580-680 680-890
Gii hn bn (Mpa
1/2
) 8-18 2-7 6.7 8.89
bn nhit (C) 800-1200 1300-1800 1500 600
H s truyn nhit (W/mK) 100 30-40 40-200 560
H s gin n v nhit (10
-6
K
-1
) 5.0-7.5 7.4-9.0 3.6-4.9 0.8



9
dng c ct PCBN thng c s dng gia cng vt liu c cng cao nn
dng hnh hc ph hp ca li ct s gip bo v dng c khng b h hng sm,
v hoc st m [27]. Dng hnh hc ca li ct cn nh hng ti tnh nguyn
trng, ng sut d v vic to thnh lp trng trn b mt gia cng [92].
Li ct dng c PCBN thng
c ch to vi dng hnh hc nh vt
cnh, ln trn cnh hoc kt hp.
Ngoi ra cn c dng ln cung van
hoc parabol (Hnh 1.4) [71]. Thc t
cho thy, cc dng c c li ct c
gia cng c tui th hn hn so vi cc
dng c c li ct sc nh to thnh
gc trc m lm tng sc bn cho dao
[27]. Mnh dao c li ct c ln gc c xu hng to lc ct nh hn do
mn mt sau t hn. Tuy nhin, hiu qu gia cng ca mnh dao ln gc li km
hn so vi mnh dao c vt gc hoc c cnh sc [91]. Hin nay, dng c c
vt cnh li ct thng c dng trong tin th v tin cng. Trong cc iu kin
ct khc nghit, li ct c th c ln gc thm vo vt cnh hoc vt cnh kp
bo v li ct khi b v hoc st m. Li ct ln gc thng c dng
trong qu trnh tin cng ln cui [92].
1.3. Qu trnh to phoi khi tin cng
1.3.1. Cc hnh thi phoi khi ct kim loi
Phoi hnh thnh trong qu trnh ct kim loi rt a dng song c th chia thnh
hai dng c bn [83]:
+ Dng phoi dy n nh (phoi
lin): vi ba loi ty theo c ch
hnh thnh bao gm: vng trt tp
trung gn nh mt mt phng, vng
trt c dng mng v vng trt
m rng c bin dng do bn di
b mt do dao mn (Hnh 1.5) [82].
Hnh 1.5. C ch hnh thnh dng phoi n
nh: Trt tp trung trn mt phng(a),
vng trt to thnh mng(b), vng trt
m rng bn di b mt gia cng(c) [82].



b) a) c)
a

a

Nhn t mt trc Nhn t mt bn
Mnh dao
Vt
cnh
Vt di
ln trn

Ln
cnh

trn
Vt cnh
v ln
Hnh 1.4. Dng hnh hc li ct
dng c PCBN [71].


10
+ Dng phoi tun hon: phoi ri, phoi ln sng, phoi rng ca (phoi xp) v
phoi to thnh vi lo dao.
i khi cn c dng phoi vi b dy thay i khng tun hon, c bit l khi
ct kim loi nguyn cht.
Khi nim phoi phn on thng c
dng m t c phoi ln sng v phoi rng
ca khng cn ph hp t khi s khc bit
gia hai loi phoi ny c nhn din. V d,
tn s chu k ca phoi ln sng thng
khong 100Hz trong khi chu k ca phoi rng
ca ln hn 24 ln. Hn na, phoi ln sng
khng c cc nh sc nhn nh phoi rng ca
(Hnh 1.6) [83].
1.3.2 C ch hnh thnh phoi khi tin cng
S khc bit c bn ca qu trnh to phoi khi gia cng thp cng v thp thng
thng l s hnh thnh phoi rng ca, ln u tin c Shaw pht hin vo nm
1954 [14]. Cc l thuyt khc nhau gii thch v c ch hnh thnh phoi rng ca
c th chia thnh hai dng: Dng th nht da trn s trt on nhit ban u, mt
trng thi mt n nh nhit do thng thy cc vt liu hn ch v kh nng
bin cng khi b bin dng tc cao hoc bin dng do ln [104], [103]. Dng
th hai cho rng do s mt n nh theo chu k da trn s xut hin v lan truyn
ca cc vt nt b mt t do ca phoi [14], [82], [83].
Theo quan im th nht, s thay i ca tc ct khi gia cng cc loi vt
liu kh gia cng gy ra s khng n nh ca qu trnh dn n phn ng c
nhit ca vt liu phi di iu kin ct gt. Kt qu l s trt cc b v dng
phoi tun hon c hnh thnh. Trt cc b lm lc ct thay i tun hon v gy
ra dao ng hoc va p trong qu trnh ct, c bit khi cng vng ca h thng
thp v nhit trn b mt tip xc gia phoi v dng c ln. Phoi hnh thnh do
trt cc b l dng phoi in hnh khi gia cng cc vt liu c h thng trt hn
ch (cu trc tinh th su cnh), kh nng dn nhit km, cng cao nh cc loi
thp hp kim cng, cc loi siu hp kim ca titan v niken. Tri li, phoi n nh
Hnh 1.6. Cc dng phoi phn
on: phoi ln sng (a) v phoi
rng ca (b) [83].
a)
b)


11
l dng phoi thch hp khi gia cng cc loi vt liu c h thng trt mnh (cu
trc tinh th bn cnh), tnh dn nhit tt, cng thp nh cc loi thp cc bon v
thp hp kim thng thng [104].
C ch hnh thnh phoi do trt cc b gm mt chui cc qu trnh vi hai giai
on c bn: Giai on th nht l s trt khng n nh v bin dng cc b
trong mt di hp vng trt th nht pha trc dng c. Giai on th hai l qu
trnh ph hy theo ng nghing hnh chm ca vt liu phi khi dng c tin v
pha trc vi bin dng khng ng k hnh thnh mt phn on phoi [104].
Qu trnh hnh thnh phoi do trt cc b khc hn vi qu trnh hnh thnh
phoi lin (Hnh 1.7). Trong trng hp hnh thnh phoi lin, hin tng bin cng
chim u th so vi hin tng mm ho v nhit. Khi trt din ra dc theo mt
phng trt chnh a, do b bin cng nn ng sut yu cu cho bin dng tip theo
tr nn ln hn v mt phng yu nht s chuyn sang mt phng tip theo. V vy,
trt s chuyn sang mt phng tip theo dn n mt s phn b bin dng ng
u trong phoi cp tng th. Trong trng hp hnh thnh phoi do trt cc b,
s mm ho v nhit chim u th hn s bin cng. Khi trt din ra dc theo mt
phng trt chnh a (Hnh 1.7), sc bn y nh hn nn mt phng ny vn l
mt phng yu nht v trt tip tc din ra y hay ni khc i, trt c gii
hn trong mt mt phng hp. V vy, s phn b bin dng trong phoi cp
tng th l khng ng u. Nh vy, bn cht ca c ch to phoi y ch l s
cnh tranh ca hai hin tng c nhit l bin cng v mm ha v nhit [103].
Theo quan im th hai, qu trnh hnh thnh phoi rng ca l do s mt n
nh theo chu k da trn s xut hin v lan truyn ca cc vt nt b mt t do
ca phoi tri qua cc giai on (Hnh 1.8) [73]:
Hnh 1.7. S cc giai on ca qu trnh to phoi do trt cc b trong ct
kim loi [104].
C
A A'
D
I
s
1
s
2
II
B
Dao
y
x
B
C
A
D
I
II
Dao
S
1
B
C
A
D
A'
I
II
S
1
S
2
Dao a
b
c
c
a
b
a'
l
s


12
Giai on 1: Khi ng sut ct t ti gi tr ti hn, mt vt nt t nhin xut
hin v pht trin v pha li ct.
Giai on 2: Do s xut hin ca vt nt, th tch phoi gia vt nt v cnh vin
li ct b y ln hu nh khng c bt k bin dng no. Khi dng c tin v pha
trc, khe h gia
vt nt v cnh vin
li ct s nh dn
lm chiu dy ca
phoi gim. Tc
trt ca phoi trn
mt trc ca dng
c v b mt vt
nt ln n ni ma
st lm nhit tng
n gn im chuyn ha A
3
. V th, mactensite c th c to ra di dng cc
lp trng xung quanh on phoi va hnh thnh. Bn cnh mt lp trng tng
t tn ti trn b mt gia cng do ma st ln vi mt sau ca dng c.
Giai on 3: Chiu rng ca khe h hp n mc m tc y ra v bin dng
do ca phoi l rt cao. Di tc dng ca nhit cao, hai lp trng trn phoi ha
nhp vi nhau to thnh phn cn li ca on phoi. Ti y, chiu dy phoi rt nh
v n ngui i rt nhanh. V th, s chuyn ha trong vng ny l on nhit.
Giai on 4: Phn on phoi c hnh thnh v in y vo ch trng gia vt
nt v mt bn trong ca phoi do bin dng ln. S phn b ng sut nn m b
gim xung trong giai on 2 v 3 ng vai tr quan trng tr li bt u mt vt
nt mi v cc hin tng ca chu k s c lp li.
Dng phoi to thnh c iu khin bi s cn bng gia tc ct v cng
ca phi thng qua mi lin h gia hai thng s trn l nhit ct [73].
1.4. Lc v ng sut trong ct kim loi
1.4.1. M hnh tnh ton lc ct
Lc ct cn thit to thnh phoi trong ct kim loi ph thuc vo gii hn
trt ca vt liu phi v din tch mt phng trt. Trong khi gii hn chy trt
Hnh 1.8. Cc giai on hnh thnh phoi rng ca trong
gia cng thp 100Cr6 (760HV), thng s ct v = 100m/p,
s=0,1 mm/vng, t =1mm, mi trng ct kh, dao PCBN
c cht gn kt ceramic [73].

Cc lp
trng
Vt nt
ban u
Giai on 1 Giai on 2 Giai on 3


13
ca cc kim loi v hp kim trong ct kim loi thay i rt t trong di rng tc
ct v chiu su ct thng thng th din tch mt phng trt li thay i nhiu
ph thuc vo iu kin ct nn nh hng ca din tch mt phng trt ti lc ct
ln hn nhiu so vi nh hng ca gii hn chy trt trong ct kim loi [94].
Trong trng hp ct trc giao, din tch mt phng trt c quan h vi chiu
dy lp ct t
1
, chiu rng phoi w v gc trt | theo biu thc:
1
w
sin
S
t
A
|
= (1.1)
Trong qu trnh ct, c th ch ng iu khin c cc thng s chiu su ct
(w) v lng chy dao (t
1
) nhng khng th iu khin c trc tip gc trt | .
Khi gc trt nh, lc trt c th ln gp 5 ln khi gc trt ln nht. V vy vic
nghin cu cc nhn t nh hng ti gc trt | s gip iu khin hoc d on
c lc ct [94].
xy dng cc biu thc d on nh lng v trng thi vt liu phi trong
qu trnh ct cng nh xc nh cc nhn t quyt nh chiu dy phoi, gc trt |
v lc ct tng ng, nhiu m hnh d on lc ct, ng sut d, hnh dng phoi
c pht trin nh m hnh ca Ernst v Merchant (1941), Lee v Shaffer
(1951), Kobayashi v Thomsen (1962), Rowe v Spick (1967), Wright (1982)...
Tuy nhin, cho n nay vn khng c m hnh no ng vi mi iu kin ct [42].
Cc m hnh tnh ton lc ct c trnh by trong Ph lc I.
Trong s cc m hnh cp trn,
khng m hnh no c s ci tin ng k
so vi m hnh ca Ernst v Merchant
[42]. Vng trn lc ca Merchant vn l
ct mc quan trng trong l thuyt v ct
kim loi. Theo m hnh ny, lc tng hp
gia dao v phoi F
R
l mt vector tng
hp ca cc thnh phn lc vung gc
(Hnh 1.9):
R S SN F N C T
F F F F F F F = + = + = + (1.2)
Trong : F
R
l lc tng hp; F
S
l lc ct nm trong mt phng trt; F
SN
l lc
|
u
A
Phi
Dao
Vng
bin dng
Phoi
o
FR
FF
FN
FC
FT
FSN
FS
|o
V
u
Vc
B
t
2
t
1
Hnh 1.9. Vng trn lc khi ct trc
giao ca Ernst v Merchant [42].


14
vung gc vi mt phng trt; F
F
lc ma st trn mt trc ca dng c; F
N
l
lc php tuyn vi mt trc ca dng c; F
C
l lc ct chnh; F
T
l lc dc trc.
Lc thnh phn tc dng trn mt phng trt v mt trc ca dng c c quan
h vi cc thnh phn lc ct chnh (lc tip tuyn F
C
v lc dc trc F
T
):
cos sin
sin cos
sin cos
cos sin
S C T
SN C T
F C T
N C T
F F F
F F F
F F F
F F F
| |
| |
o o
o o
=

= +

`
= +

=
)
(1.3)
Vi o l gc trc; | l gc trt.
1.4.2. M hnh tnh lc khi ct nghing
Trong qu trnh ct nghing, t l ca cc thnh phn lc ct F
z
, F
y
, F
z
ph thuc
vo chiu su ct v lng chy dao. iu ny c th c gii thch bi thc t
rng chiu su ct v lng chy
dao nh hng n hng thot
phoi v v vy n hng ca
lc ma st gia phoi v mt
trc dng c. Hnh 1.10 m t
lc tc dng ln mt trc dng
c c gc nng ca li ct
chnh =0 [107]. Vi mt trc
AOBC l to mt gc trc
vi mt phng y AOED
vung gc vi vc t vn tc
ct. Lc php tuyn N v lc
tip tuyn F tc dng trn mt
trc. H trc xyz c trc z song song vi phng vn tc ct v trc x song song
vi phng ca bc tin dao. H trc vung gc kln c trc n vung gc vi mt
trc v trc l trng vi li ct v to thnh gc nghing chnh vi trc x. Trc
m l giao ca mt nk vi mt AOED. S dng h trc ta kln trn c th xc
nh c mi quan h gia cc thnh phn lc php tuyn N v lc ma st F vi
cc thnh phn F
z
, F
y
, F
z
ca lc tng hp chiu ln h trc xyz nh sau:
Hnh 1.10. S mi quan h gia cc thnh
phn lc khi ct nghing [107].
Fz
R
F
y
Fx

u
y
O
n
l
m
s
F
T
X
T
Y
T
sz
s
m
s
my
s
mx
z
N
Nz
N
m
N
mx
N
my
E
B
C
D
A

t
2
t
2
k
x

15
+) os sin
z z z
F N S Nc S = + = + (1.4)
+) os sin sin
2 2 2
y y my my m m
F T N S Tc N S
t t t

| | | | | |
= + = +
| | |
\ . \ . \ .

sin cos cos
y m m
F T N S = + (1.5)
+) sin cos sin
2 2 2
x mx mx x m
F S N T S N T
t t t

| | | | | |
= =
| | |
\ . \ . \ .
(1.6)
os os sin
sin sin sin cos cos cos cos
cos cos cos sin sin sin cos
z
y
x
F Nc Fc
F F N F
F F N F
u
u u
u u
= +
= +
=
(1.7)
Nu c th o c cc thnh phn lc s xc nh c gc thot phoi trn mt
trc dng c:
sin os
sin ( cos sin ) cos
y x
z y x
F F c
tg
F F F

u

=
+ +
(1.8)
H s ma st bng t s gia lc tip tuyn vi lc php tuyn tc dng trn
mt trc dng c c xc nh:
2 2
[ sin ( cos sin ) cos ] ( sin cos )
cos ( cos sin )sin
z y x y x
z y x
F F F F F
F F F

+ + +
=
+
(1.9)
Khi 0 u = cos sin
y x xy
F F F + = v sin cos 0
y x
F F =
Do :
sin cos
cos sin
z xy
z xy
F F
F F

+
=

(1.10)
1.4.3. ng sut trong dng c ct
Vi cu to phc tp ca dng c v iu kin ct trong qu trnh gia cng, vic
nh gi chnh xc ng sut cc b tc dng ln dng c gn li ct l mt thch
thc i vi cc phng php phn tch hin c [94].
Trong mt qu trnh tin n gin, c hai loi ng sut chnh quan trng tc
dng ln dng c:
- ng sut php do lc ct chnh tc dng ln mt trc dng c ti vng tip xc
l ng sut nn, c th xc nh bng t s gia lc ct chnh v din tch tip xc.


16
- ng sut tip do lc n dao tc dng ln mt trc dng c, xc nh bng t
s gia lc n dao v din tch tip xc. V lc n dao nh so vi lc ct chnh nn
ng sut tip nh hn ng sut php tc dng trn cng din tch tip xc, thng
ch vo khong 30%-60% gi tr trung bnh ca ng sut php.
- Khi dng c mn, c c ng sut php v tip tc dng ln mt sau ca dng
c. Mc d din tch tip xc trn mt sau i khi c th xc nh r rng nhng rt
kh xc nh gi tr ca lc tc dng trn n. Cho n nay, vn khng c mt nh
gi ng tin cy no v ng sut trn mt sau dng c.
Ngoi ra, cn c cc ng sut khc tc dng ln thn dng c lin quan n cu
trc chung ca dng c v cng vng kt ni ti ni dng c c lp t khi gia
cng. Tuy nhin, v khng lin quan n qu trnh to phoi v tui th dng c nn
cc ng sut ny khng c xem xt [94].
1.4.4. S phn b ng sut trong vng bin dng
Gi tr ca ng sut trung bnh trong vng bin dng khi gia cng c th xc
nh da trn gi tr lc o c v din tch vng bin dng:
s
s
s
F
A
t = . Trng phn
b ng sut trong vng bin dng c lin quan trc tip n qu trnh sinh nhit, nh
hng n c ch hnh thnh phoi v xc nh yu cu i vi vt liu dng c.
S phn b ng sut trn vng bin
dng khi gia cng rt phc tp. Theo nghin
cu ca nhiu tc gi, trn vng tip xc ca
phoi vi mt trc dng c, ng sut ct
c
t
bng hng s trn mt na phn phoi tip
xc gn nht vi li ct v s gim dn n
khng trn na cn li, t gi tr bng
khng ti im C khi phoi ri khi b mt
dng c. ng sut php
c
o tng n iu t
im C ti li ct A (Hnh 1.11) [81].
ng sut php thay i trn mt trc
theo quy lut [106]:
( ) ( )
n
x l x o = (1.11)
Hnh 1.11. Bin thin ng sut
php v tip trn mt trc dng
c [81].

A C D
B
V
x
D'
Phoi
Dao
oc
tc
oc
tc
Vng dnh Vng tr- t
Phoi ri khi
mt tr- c dng c
l
l
1






17
ng sut php c gi tr cc i ti li ct: ( )
n
M
x l o o = = (1.12)
1
n
s
M
l
l l
t

o
| |
=
|

\ .
(1.13)
vi n l hng s, xc nh t thc nghim: n = 1922 cho thp cc bon thp [55];
l h s ma st trn mt trc.
ng sut tip bin thin theo quy lut:
( )
s
x t t = vi
1
0 x l s s (1.14)
(x) s
1
= (x)=
n
l x
l l
t o t
| |
|

\ .
vi
1
l x l s s (1.15)
Gn ng
1
2 l l ~ . Chiu di vng ng sut trt bng hng s gim tng i so
vi tng chiu di tip xc khi tng gc trc o ca dng c.
Trng thi phn b ng sut trn mt
phng trt cng tng t nh trn b mt
tip xc gia phoi v dng c [81]. Hnh
1.12 biu din s thay i ca ng sut
tip
s
t v ng sut php
s
o trn mt phng
trt. Trong vng AE (gn li ct nht)
s
t
khng ph thuc vo ng sut php
s
o trn
mt phng trt, trong khi trn vng EB
(gn b mt t do nht) t s
s
s
t
o
xp x bng
hng s v ph hp vi nh lut Amonton
cho b mt ma st trt. Hai vng ny c kt ni vi nhau nh mt vng
chuyn tip EE ni mt cc vt nt t vi tng n mc ni thng vi nhau.
1.4.5. Lc ct khi tin cng
Trong qu trnh tin cng, cng cao ca phi cng vi tc ct cao v iu
kin gia cng kh lm cho tc dng ca lc ct c nhng thay i ng k so vi
cc qu trnh gia cng thng thng. Lc ct trong gia cng cc vt liu cng khng
ln hn cc vt liu mm [66]. Gc trt ln v s hnh thnh phoi rng ca do
Hnh 1.12. Bin thin ng sut
php v tip trong mt phng
trt [81].

s
Phoi
E' E
A
Mt phng
tr- t
V
C
Dao
B
os
ts
os
ts




18
do km lm gim lc ct mc d bn cao ca vt liu cng. Trng hp gia
cng cc thp cng, gc trc m ca dng c cng ln th lc dc trc cng cao v
lc ct tip tuyn cng thp. S bin thin ca cc thnh phn lc ct cng b nh
hng bi s thay i cng vt liu gia cng. Strafford v Audy [87] khng
nh khi tin cng thp AISI 4340 c cng t 29 n 57HRC bng dng c gm
c s tng tng ng lc ct t 3080%. Trong mt cng b khc chng t
rng tc ct cng cao, lc dc trc v lc ct ring cng thp, khng ph thuc
vo mn dng c [12].
nh hng ca iu kin ct n qu trnh tin trin ca lc ct cng c
m hnh trong nhiu nghin cu. Bng vic tin hnh cc th nghim khi gia cng
thp AISI D2 cng 62HRC vi dng c ct PCBN, Arsecularatne v cng s
[12] kt lun c mt mi lin h cht ch gia lc ct v iu kin ct. Huang
v Liang [39] trnh by lc ct tng cng l tng ca cc thnh phn lc to
phoi v lc do mn mt sau. M hnh ny c nh gi bng thc nghim qu
trnh tin cng chnh xc thp AISI 52100 cng 62HRC vi hai loi dng c
PCBN hm lng CBN cao v thp. Kt qu cho thy, lc hng knh v lc tip
tuyn c gi tr nh hn, nhit trn b mt tip xc gia phoi v dng c c gi
tr cao hn khi s dng dao vi hm lng CBN thp. Chen [20] cng cng b khi
nghin cu thc nghim tin cng thp bng dng c PCBN, lc hng knh c
gi tr ln nht trong ba thnh phn lc ct. Ozel v cng s [68] cng kt lun,
lc ct khi gia cng bng dng c PCBN nhy cm vi s thay i ca cc thng
s hnh hc ca dng c v mn dng c. B mt ca sn phm khi gia cng bng
dng c PCBN cng tng ng nh b mt c mi. Thm na, lc ct cng
nh nhm b mt cn b nh hng bi thng s hnh hc ca dng c. Dng c
vi cnh li ct mi trn s lm gim lc ct nhng lm tng nhit trn mt
tip xc gia phoi v dng c. S dng cc kt qu t m hnh c nhit ca mt
phng trt khi ct trc giao c k nh hng ca bin dng, tc bin dng,
nhit v cng phi ban u, Yan v cng s [100] kt lun rng lc n dao
c gi tr ln ni tri trong cc thnh phn lc ct khi tin cng chnh xc bng
dng c PCBN. Lc ct, c bit l lc n dao, tng khi tng lng chy dao v
bn knh v trn cnh li ct.


19
1.5. Nhit ct trong qu trnh tin cng
1.5.1. Cc ngun nhit trong ct kim loi
Trong qu trnh ct kim loi, nng lng b tiu tn vo vic to phoi v thng
lc ma st gia phi v dng c. Hu ht nng lng ny chuyn ha thnh nhit
to ra nhit cao vng bin dng v nhng vng xung quanh ca phoi, dng c
v phi (Hnh 1.13) [26].
Nhit ct ng vai tr quan trng
trong quyt nh hiu qu gia cng. Nhit
trong vng bin dng c s, ni din ra
bin dng ln hnh thnh phoi c nh
hng n cc thuc tnh c hc ca vt
liu gia cng v do n cc lc ct. Nhit
trn mt trc dng c c nh hng ln
n tui th dng c ct. Nhit trn mt
sau dng c s nh hng n trng thi hon thin v cu trc kim loi ca b mt
gia cng. Nhit va phi s gim bt ng sut d trn b mt gia cng do gim
bt s chnh lch nhit trong khi nhit cao c th dn n lp chy hoc lp
cng trn b mt gia cng.
V c bn, trong qu trnh ct c th nhn bit c ba ngun sinh nhit [42]:
- Vng trt c s.
- Mt tip xc gia phoi v mt trc dng c.
- Mt tip xc gia phi v mt sau dng c.
Ngun nhit sau cng (mt tip xc gia phi v dng c) c th b qua nu
dng dng c sc.
1.5.2. Cc phng php o c nhit trong ct kim loi
Nhit trong ct kim loi bt u c quan tm v mt nh lng t nhng
nm 1920. Nhit dng c ct c th c xc nh bng cc phng php nh:
nhit in, ngu nhit, bc x hng ngoi, v bn s thay i v cu trc v
cng ca vt liu ph thuc vo nhit , xc nh mu thp ti, s dng cc vt
liu ch th nhit t vo cc b mt cn xc nh nhit v.v... song tt c cc
phng php u cha cho kt qu chnh xc. V d, phng php nhit in ch o
Hnh 1.13. Cc khu vc bin dng
l ngun sinh nhit [26].
Relief face
Deformation zone
Rake face
Vng bin dng
Mt trc
Mt sau


20
c nhit trung bnh trn ton b vng tip xc gia phoi v dng c, mt khc
c phi v dng c u phi l cht dn in nn mt s dng c nh gm khng
th p dng phng php ny. Vic gia cng cc l t cp ngu nhit s ph v v
c th lm thay i trng nhit trong ct kim loi. Vic v bn nhit bng
cch s dng cp ngu nhit cng rt rm r v phi dng nhiu dng c vi cc
cp ngu nhit t ti cc im khc nhau. K thut o bc x l thng hn ch
vic tip cn vo b mt cn o. Mu thp ti ca phoi ph thuc vo chiu dy ca
lp xy ha trn b mt phoi m chiu dy ny ph thuc vo thi gian nhit
cng nh s tp trung xy v lm cho s gii thch gp kh khn [42].
S pht trin gn y trong cng ngh ph cho php s dng mt phng php
mi o nhit dng c bng vic dng cc mng mng cm bin nhit in tr
RTDs (Resistance Temperature Detectors) t trc tip trn b mt dng c. Cc
cm bin ny c dy c trng khong chng vi nanomet, nh hng ca n
trong qu trnh ct l khng ng k. Hn na, vi chiu rng ch vi micromet, c
th t nhiu cm bin cnh nhau trong vng tip xc gia phoi v dng c. Tuy
nhin, trong qu trnh pht trin ca cm bin nhit in tr, lp ph mt ngoi
ang l mt im b tc. Tt c cc lp ph c th nghim u b trc ngay khi
ct v sau , cm bin b ph hy bi phoi [42].
Nh vy, vn khng c mt phng php n gin no c nhn bit o
c nhit trong phoi, phi v dng c, thm ch trong qu trnh ct trc giao.
iu ny c bit cng kh khn i vi vt liu dng c PCBN v vi cng cao
v khng dn in nn vic s dng phng php nhit in tr v gia cng l t
cp ngu nhit gp nhiu tr ngi. Thc t mi ch c mt vi nghin cu th
nghim o c nhit dng c PCBN bng vic t ngu nhit hoc cht ch th
nhit bn di mnh dao hay o bc x hng ngoi [60], [79], [88]. Chnh v
vy, cc m hnh phn tch d on nhit khi tin thp hp kim qua ti bng
dng c PCBN cng c quan tm nghin cu.
1.5.3. Nhit ct khi tin cng bng dng c PCBN
Cc nghin cu v nhit ct trong qu trnh tin cng cn cha nhiu. Hiu bit
v qu trnh sinh nhit v phn b nhit trong dng c ct khi tin cng vn cn
mc rt hn ch. Cc nhn t c nh hng ln nht n nhit ct khi tin cng l


21
tnh cht ca vt liu phi v dng c, cc thng s ca iu kin ct. Ngoi ra cn
c th c mt s nhn t khc nh ch lm ngui, kch thc phi [88]. Nghin
cu thc nghim cho thy quy lut thay i nhit trong qu trnh tin cng
khng tun theo l thuyt ct kim loi truyn thng. Cu trc t vi ca vt liu phi
gia cng c nh hng ln n nhit ct. V d, nhit trong tin cng thp ln
GCr15 bng dng c PCBN tng khi cng phi tng n 50HRC, vt qua gi
tr ny nhit ct s gim. iu ny c gii thch l do c ch to phoi thay i,
phoi rng ca xut hin lm tng kh nng dn nhit ra khi vng bin dng.
Trong khong cng ca phi t 3064HRC, nhit ct tng cng vi s tng ca
tc ct, lng chy dao. Tuy nhin nh hng ca tc ct n tui th dng
c PCBN nh hn nhiu so vi dng c bng gm v hp kim cng [59].
Vn tc ct c nh hng ln nht ti nhit ct khi tin cng. Chiu su ct v
lng chy dao c nh hng t hn [88]. Cng c bng chng cho thy nhit ct
gim khi tng chiu su ct t khi tin cng. iu ny bi v khi tng chiu su ct
s lm gc mt phng trt tng v ngun nhit trn vng trt c s s c nh
hng t hn n b mt gia cng do khong cch t mt phng trt n b mt
c ct ln hn [23].
1.6. Mn v tui th dng c CBN
1.6.1. Cc dng mn v c ch mn dng c PCBN
Mn v tui th dng c l tiu chun thng thng nht dng nh gi hiu
sut ca dng c ct, kh nng gia cng ca vt liu v l mt trong nhng ch tiu
c quan tm nht khi chn dng c ct v iu kin gia cng. Tng t nh cc
vt liu dng c ct thng thng, mn mt trc v mt sau l hai dng hng ch
yu ca dao tin PCBN. Tuy nhin, mn mt trc dng c PCBN bt u t rt
gn li ct [74] v li ct ca mnh dao PCBN khng b bin dng khi ct [94].
Trong khi c mt vi l thuyt khc nhau lin quan n cc c ch mn xut
hin trong qu trnh tin cng bng dng c PCBN, c mt s thng nht chung
cho rng mn gy ra bi s kt hp ca mt vi c ch. Cc c ch thng
thng nht c s dng gii thch qu trnh mn dng c PCBN bao gm
mi mn [46], [67], [74], dnh v khuch tn [49], [67], [105] v mn do tng
tc ha hc [33], [38], [61].


22
+) Mi mn: Mi mn gy ra bi cc ht cng trong phi v cng bi cc ht
CBN t vt liu dng c [31]. Khi lp vt liu dnh kt b mi mn bi vt liu
phi, cc ht CBN d dng b tch khi vt liu dng c v tr thnh cc ht mi
mn i vi vt liu dng c [61].
+) Dnh v khuch tn: Dnh xy ra khi vt liu phi hoc phoi nng chy di
tc dng ca nhit v ng sut cao vng ct v dnh vo b mt khng tip xc
ca dng c [13], [33], [61]. Din tch v chiu dy ca lp dnh ph thuc vo
iu kin ct v tc mn dng c bi v cc nhn t ny quyt nh nhit
vng ct. Cu trc, thnh phn v mc lp dnh c quyt nh bi vt liu
dng c [22], [49]. Nhiu nh nghin cu cho rng nhng hp cht c to thnh
khng cng nh vt liu PCBN lm cho qu trnh mi mn tng thm [22], [38].
Khuch tn c th xy ra khi nhit vng ct cao [33], [49], [105]. Cht
dnh kt trong dng c PCBN c cho rng d b mn dng ny nht v sn sng
phn ng vi vt liu phi to ra mt s thay i v cu trc [49]. iu ny lm
gim kh nng chng mn ca cht dnh kt v dn n tng mi mn dng c. Tc
khuch tn tng cng vi s tng ca nhit nhng do nhit ct vi dng c
PCBN tng i thp, thng nh hn 900
0
C nn c ch mn ny c cho rng
ch thc s ng k khi iu kin ct rt khc nghit [67].
+) Tng tc ha hc v lp vt liu dnh bm: Lp vt liu dnh bm thng
xuyn quan st thy trn b mt dng c PCBN sau khi ct kim loi l do phn ng
ha hc xy ra trn vng tip xc gia phi vi dng c hoc khng kh [13], [33],
[61]. Din tch v chiu dy lp dnh bm ph thuc vo iu kin ct v tc mn
ca dng c v cc nhn t ny quyt nh nhit trong vng tip xc [33], [49], [67],
[105]. Cu trc, thnh phn v mc cc lp dnh ph thuc vo vt liu dng c
PCBN [22], [49]. Lp dnh bm b mt c cho rng c kh nng bo v dng c
cho ti khi t ti nhit lm lp dnh bm tr nn mm v b mt i, lc tc
mn dng c s tng [61]. Lp dnh bm trn b mt dng c c nh hng n s tiu
tn nhit t b mt dng c vo mi trng v nh vy, lm nh hng n nhit ct.
Tng tc ha hc trong vng tip xc cng c th hnh thnh cc hp cht c im
nng chy thp, v d B
2
O
3
vi im nng chy 723
o
K. Trong iu kin nhit cao
hnh thnh mt pha lng vng tip xc gia dng c vi phoi v gp phn lm
gim h s ma st trong vng tip xc gia phoi v dng c PCBN [46]


23
1.6.2. Cc nhn t nh hng n mn dng c PCBN
Cc nhn t c nhn bit c nh hng quyt nh n tui th v hiu
sut dng c PCBN bao gm: thnh phn ca vt liu phi v dng c, thng s
hnh hc ca dao, iu kin gia cng v cng vng ca h thng cng ngh.
+) Thnh phn ca vt liu dng c: L nhn t quan trng c nh hng ng
k ti mn dng c. Vi hai loi vt liu PCBN c thnh phn CBN cao v thp, c
gi tr nhm b mt gia cng v mn dng c vt liu c thnh phn CBN cao u
ln hn vt liu c thnh phn CBN thp v CBN thp c kh nng chng mn
nhit tt hn [16], [22], [31], [38], [44], [46], [67]. Tc mn c quan h gn nh
tuyn tnh vi vn tc ct v s khc nhau v tc mn ca hai loi vt liu PCBN
tng theo vn tc ct [22].
+) Thng s hnh hc ca dng c: Cc thng s gc vt cnh li ct, chiu
rng vt cnh li ct, cung mi trn cnh li ct c nh hng quyt nh n
tui th ca dng c ct. Gc trc m s lm tng tui th dng c PCBN [16],
[47], [50], [51], [68], [84], [92]. Vic tng bn knh mi dao s lm tng mc
mn mt sau v lm gi tr ca cc thnh phn lc ct tng, ch yu l lc dc trc
v lc hng knh. Vic ch to sn cnh vin li ct khng lm thay i tc
mn dng c [43]. Chiu rng vt cnh li ct c nh hng n lc ct khi lc ct
tng cng vi s tng chiu rng vt cnh li ct [84]. Phn tch cng cho thy
dng mn thnh rnh trn cnh dng c PCBN l do cnh phoi gy ra [37], [43].
+) Vt liu phi: Mn dng c PCBN ph thuc vo thnh phn cu trc t vi ca
vt liu phi nh thnh phn v kch thc ca cc ht cacbit, thnh phn mactenxit
[22], [72], [74]. Nghin cu cng cho thy trong qu trnh bc vt liu tc cao,
mn dng c PCBN ph thuc vo loi, kch thc v thnh phn ca cc pha cng
trong phi v c cc ht CBN b tch ra t vt liu dng c [49], [61], [67].
+) H thng gia cng: Bao gm dng c ct, cn dao, g, trc chnh my gia
cng v nn mng t my [45]. iu kin tip xc gia phi v dng c quyt nh
c ch mn dng c PCBN v chng c iu khin bi nhiu nhn t. Ngoi
thnh phn vt liu dng c PCBN v vt liu phi, cc thng s hnh hc ca dng
c, cn c n nh ca h thng cng ngh [23], [25], [45], [93]. Bt k s
khng n nh no trong my gia cng cng s c nh hng tiu cc ti mn dng
c v lc ct, v n lt n quyt nh cht lng v chnh xc gia cng.


24
1.7. Kt lun chng 1
Mc d c nhiu nghin cu c tin hnh song cc nghin cu v qu trnh
tin cng cn cha khi qut ha cc kt qu t c v d on trng thi
ca cc loi vt liu trong cc iu kin gia cng khc nhau.
Nghin cu v qu trnh tin thp hp kim qua ti bng dao PCBN cn nhiu
kha cnh cn tip tc nghin cu lm r nh: Nghin cu qu trnh to phoi mi
c tin hnh mt vi vt liu, cha c nhiu kt qu ca cc nghin cu khc
nhau kim chng v i chiu. Nghin cu v nhit ct hu ht mi dng ni
dung tnh ton phn tch hoc m phng s, cha c kim chng bng thc
nghim. Mt vi nghin cu thc nghim v nhit ct khi tin cng cn cha tip
cn c vo vng ct nh s dng thit b o bc x hng ngoi, t ngu nhit o
nhit trung bnh y mnh dao hoc dng phng php nhit in bng cch
ph lp kim loi dn in ln dng c [59], [79].
Khi cng vng ca h thng cng ngh c m bo, vic iu khin cht
lng v hiu qu gia cng ch c th thc hin c bng vic nghin cu nh gi
cc thng t nh hng, c tnh gi tr lc ct, nhit ct v mn dng c, cc nhn
t ch yu lm thay i chnh xc v kch thc ca sn phm cng nh nhm
b mt hoc lm bin i c tnh ca vt liu gia cng [24], [53].
Xut pht t thc trng vic ng dng cng ngh tin cng cn nhiu hn ch,
cc nghin cu v tin cng hu nh cha c thc hin Vit Nam, ni dung
tip theo ca lun n s s tp trung nghin cu cc vn :
- Nghin cu qu trnh to phoi khi tin thp hp kim qua ti bng dao PCBN.
Lm r mi lin h gia hnh thi phoi v c ch hnh thnh phoi vi cng vt
liu v vn tc gia cng khi tin hai loi thp hp kim 9XC v X12M.
- Kho st bin thin lc ct ph thuc vo vt liu gia cng, vn tc ct v
chiu di gia cng. Nhn bit quy lut pht trin lc ct v cc nhn t nh hng
n lc ct khi tin thp hp kim 9XC v X12M qua ti bng dao PCBN.
- S dng phng php phn t hu hn gii bi ton truyn nhit v xc
nh trng phn b nhit trong qu trnh tin cng trc giao thp 9XC bng dao
PCBN thng qua tnh ton bng phn mm ABAQUS. Bng cch ph cc kim
loi nguyn cht c im nng chy xc nh ly thng tin v nhit , kim


25
chng m hnh l thuyt.
- Phn tch cc c ch mn v dng mn dng c PCBN khi tin cng hai loi
thp hp kim 9XC v X12M. Kho st nh hng ca vt liu phi, vn tc ct v
chiu di gia cng ti mn dng c v cht lng b mt gia cng. Rt ra mi lin
h gia nhit ct v mn dng c.
- ng dng gii thut di truyn xc nh tp hp cc thng s ct ti u tha
mn mc tiu nhm b mt v tui th dng c khi tin thp 9XC qua ti bng dao
PCBN. Xy dng cc m hnh lc ct, nhm b mt v tui th dng c bng
phng php hi quy thc nghim.



26
Chng 2
NGHIN CU C TRNG CA QU TRNH TO PHOI
KHI TIN THP HP KIM QUA TI BNG DAO PCBN
2.1. Phng php nghin cu s hnh thnh phoi
Nghin cu s hnh thnh phoi rt kh khn bi v tc gia cng thc t ln
v kch thc ca i tng cn quan st rt nh. S dng my quay tc cao vi
phng i nh ch gii hn vic quan st s thay i hnh dng bn ngoi ca
phoi trong qu trnh bin dng v c th dn n sai st khi gii thch cho cc hin
tng xy ra ti trung tm phoi. Kt hp my quay phim v s dng a silica trong
sut ghp vi vt liu phi c th quan st cc iu kin ti trung tm phoi nhng
cng ch gii hn di tc v kch c nh [94]. Dao saphia trong sut cho php
quan st b mt tip xc gia dao v phoi song khng th p dng cho cc hin
tng xy ra i vi vt liu dng c kim loi. Bng vic dng qu trnh ct t
ngt, tc l lm ng lnh qu trnh ct c th lu gi li rt nhiu chi tit quan
trng xy ra trong qu trnh ct. p ng mc tiu ny, cc loi cc c cu dng
nhanh c pht trin [15], [21], [98], [101]. Loi c cu dng nhanh s dng
thnh cng nht l dng lc y n y dng c ra khi v tr ct tc rt cao
theo chiu chuyn ng ca phi [18], [32], [72]. Tuy nhin, phng php ny rt
kh p dng iu kin trong nc do gp kh khn v vic tip cn cc vt liu
n. Mu thu c khi s dng c cu dng dao nhanh thng l phoi b t gn
trn dng c hoc mu phoi cn gn nguyn trn phi. Quan st mu trn knh hin
vi in t s cho cc hnh nh gi tr v qu trnh hnh thnh phoi nh bin dng, tc
bin dng, cc vng trt v gc to phoi [42].
phc v cho qu trnh nghin cu s hnh thnh phoi khi tin thp hp kim
qua ti s dng dao PCBN, mt loi thit b dng dao nhanh p dng nguyn l n
by v l xo c thit k v ch to nh trnh by trong phn Ph lc II.
2.2. nh hng ca cng phi n hnh thi phoi khi tin thp hp kim qua
ti bng dao PCBN
Nghin cu thc nghim v nh hng ca cng phi n hnh thi phoi
c tin hnh vi hai loi thp hp kim 9XC v X12M. Cc phi thp c nhit
luyn t ba cng khc nhau. Phn tch cu trc t vi ca vt liu phi X12M


27
cho thy t chc
mactenxit xen ln cacbit
nhiu loi nm ri rc.
C th thy r khi
cng cng cao, mc
ha tan ca cc ht cacbit
cng thp dn n kch
thc cacbit th trong phi tng: 3 5 m cng 45HRC; 5 10 m v ko
thnh di cng 57HRC; 10 25 m vi mt dy c vi kch thc ln
cng 62HRC (Hnh 2.1).
Vi phi thp 9XC kch thc ca cc ht cacbit nh v ng u, kch thc
di 1m, ch yu l
mactenxit dng hnh kim
bn cnh austenit d mu
sng (Hnh 2.2). Cu trc
t vi khng thay i nhiu
khi cng tng t
45HRC n 62HRC.
Thnh phn ha hc ca hai loi phi thp cho trong Bng 2.1 v Bng 2.2.
Th nghim c tin hnh trn my tin s CNC-HTC2050 (Trung Quc)
(Hnh 2.3a), s dng cc mnh dao PCBN k hiu TPGN160308T200-EB28X ca
a)
b)
c)
Hnh 2.1. Cu trc t vi ca thp X12M (a) cng
45HRC; (b) cng 57HRC; (c) cng 62HRC.


Bng 2.1. Thnh phn ha hc ca thp X12M
Nguyn t C Si P Mn Ni Cr Mo
Hm lng % 0,823 1,2351 0,0241 0,5862 0,0332 1,113 0,0192
Nguyn t Cu/ W Ti Al Fe V

Hm lng % 0,2876 0,1768 0,0299 0,0011 95,447 0,1499


Hnh 2.2. Cu trc t vi ca thp 9XC (a) cng
45HRC; (b) cng 57HRC (c) cng 62HRC.


a) b) c)
Bng 2.2. Thnh phn ha hc ca thp 9XC
Nguyn t
C Si P Mn Ni Cr Mo
Hm lng %
1,4916 0,3589 0,0112 0,2404 0,2125 11,393 0,3803
Nguyn t
Cu Ti Al Fe V
Hm lng %
0,3383 0,0063 0,0249 85,396 0,1799




28
Hnh 2.4. Hnh thi phoi khi tin thp 9XC
cng khc nhau: 43HRC (a,b,c); 52HRC (d,e,f);
57HRC(g,h,i); 62HRC (k,l,m).
a) d)
e)
b)
g)
f) c) i)
h)
l)
k)
m)
hng EHWA - Hn quc
(Hnh 2.3b,c), ch ct:
v=100m/p; s=0,15mm/v;
t=0.2mm. S th nghim
nh trn Hnh 2.3d.
Kt qu cho thy c hai
loi thp, s thay i v hnh
thi phoi u xy ra khi
cng ln hn 50HRC (Hnh
2.4 v Hnh 2.5).
Khi cng nh hn
50HRC, phoi to thnh
dng phoi lin vi cc bin
dng trt ng u, lin tc,
bc bin dng nh c th
quan st thy mt trn ca
phoi (Hnh 2.4 v Hnh
2.5a,b,c). Khi cng ln
hn 50HRC phoi hnh thnh
dng phoi phn on dng
rng ca vi bin dng trt
tr nn ngt qung theo chu
k (Hnh 2.4d-m; Hnh 2.5d-
i). Trong di cng t 57
Hnh 2.5. Hnh thi phoi khi tin thp X12M 9XC
cng khc nhau: 43HRC (a,b,c); 57HRC
(d,e,f); 62HRC (g,h,i).


a) d) g)
e)
h)
b)
c)
f)
i)
Dao
Phi
Hnh 2.3. Thit b v s th nghim kho st mn v c ch mn dng c PCBN.
My tin CNC-HTC2050 (a); Mnh (b) v thn dao (c); S th nghim (d).
b)
d) a)
c)


29
n 62HRC, cc phoi rng ca c bc bin dng vo khong 70m, tng ng vi
tn s ca cc phn on phoi l 160Hz i vi c hai loi thp (Hnh 2.4f,i,m v
Hnh 2.5f,i). S tng tn s ca cc phn on phoi trong di cng 57 n
62HRC khng r nt.
C th thy, khi cng phi tng, vt liu tr nn gin hn. Khi gia cng vt
liu gin, nng lng yu cu cho qu trnh ct t hn do bn lin kt ca cc t
gy yu. Khi bn lin kt gim n gi tr nht nh, cc nt gy tr nn ni tri v
s trt cc b xy ra gin on trong vng trt, phoi phn on c hnh thnh.
2.3. nh hng ca vn tc ct n hnh thi phoi
Hnh thi phoi to thnh khng ch ph thuc vo cng ca vt liu gia cng
m cn ph thuc vo tc ct. Khi tc bin dng ln, thi gian khng
nhit sinh ra t cng bin dng do c truyn i lm nhit tng ng k dn
n lm mm vt liu bin dng. Vng vt liu chu cng bin dng ln tp
trung vng trt th nht b yu i mt cch mnh m v v vy, s bin dng
trong phoi tr nn khng ng nht. Trong mt di hp gia cc phn on (khong
0,002mm), bin dng l rt ln. Tri li, bn trong cc phn on, bin dng tng
i nh. V hnh dng, cc phoi phn on tng t nh phoi ri c ghp li vi
nhau. Dng phoi ny
gi nguyn khi vn
tc tng t nht l n
tc 30,488m/ph
m khng c s thay
i sang dng phoi
khc hoc chuyn v
dng phoi lin [94].
Vn tc m dng
phoi chuyn i t
phoi lin sang phoi
phn on cng thay
i i vi cc vt
liu khc nhau c kim chng trong mt s nghin cu. Nghin cu nh
Hnh 2.6. Hnh thi phoi khi tin thp 9XC cng
57HRC, chiu su ct t=0,02mm; s=0,15mm/v ln lt
ng vi vn tc v=9,42(a); 26,4(b); 64(c); 113(d) v
282,6m/ph(e).


a1)
d1) e1) c1) b1)
a2) d2) e2) c2) b2)
a3) d3) e3) c3) b3)


30
Hnh 2.7. Hnh thi phoi khi tin thp X12M cng
57HRC vi chiu su ct t=0,02mm; s=0,15mm/v vn
tc v=9,42(a); 26,4(b); 64(c); 113(d) v 282,6m/p(e).


a3) d3) e3) c3) b3)
a2) d2) e2) c2) b2)
a1) d1) e1) c1) b1)
hng ca tc ct n hnh thi phoi i vi thp hp kim 9XC v X12M c
ti cng t 57HRC cho thy, tc ct thp, phoi hnh thnh dng phoi ri v
chuyn sang phoi lin tc ct trung bnh v phoi rng ca tc ct cao. Tuy
nhin, th nghim vi thp 9XC cho thy khi tc ct gim xung 9,42m/p phoi
vn hnh thnh dng lin. tc ct trn 100m/p bt u c s chuyn i t
phoi lin sang phoi rng ca, chuyn hon ton sang phoi rng ca tc
113,04m/p (Hnh 2.6).
Vi thp X12M
s thay i v hnh
thi phoi xy ra vi
tc nhanh hn. Khi
vn tc ct di
16,9m/p phoi to
thnh dng phoi ri
v chuyn thnh phoi
lin trong di vn tc
t 1626m/p. tc
ct trn 42,3m/p
bt u c s chuyn
i t phoi lin sang phoi rng ca, chuyn hon ton sang phoi rng ca tc
64m/p v gi nguyn dng phoi n tc 282,6m/p (Hnh 2.7).
Khc vi cc nghin cu trc cho rng phoi rng ca c hnh dng ging phoi
ri c ghp vi nhau, hnh nh SEM cho thy phoi ri c hnh dng khc hn
phoi rng ca khi chiu di cc on phoi ri ln hn nhiu so vi cc phn on
rng ca. Phn tch nh chp SEM c th thy r phoi ri nhn c tc ct
thp thc ra l cc on phoi lin b t. Nguyn nhn gy ra s t on ca phoi
lin khi tc ct thp l do rung ng qu ln khin vic hnh thnh cc vt nt
pht trin mnh m b mt di ca phoi v b mt gia cng mi to thnh. Khi
phoi b cun li vi bn knh cong nh v b chn p trong khng gian hp s d
dng t ri thnh tng on ngn (Hnh 2.7a).
Nghin cu cng chng t hnh thi phoi khng ch ph thuc vo vn tc ct
m cn ph thuc vo chiu su ct v lng chy dao khi tin trc giao thp 9XC


31
vi chiu su ct t=2mm, lng chy dao s=0,08m/vg vn tc ct v=119m/p, gii
hn chuyn i hnh
thi phoi xy ra vn
tc cao hn:
v=188m/p. Tn s
cc phn on ca
phoi rng ca c s
tng r rt theo vn
tc ct, vo khong
157kHz tng ng
vi bc 50m vn
tc ct 471m/p v
44,8kHz tng ng
vi bc rng bng
70m vn tc ct 188m/p (Hnh 2.8).
nh chp SEM cn cho thy, khc vi qu trnh ct trc giao, khi ct nghing
tit din ngang ch nht ca phoi chuyn thnh hnh tam gic. Phn din tch
phoi tip xc vi b mt mi to thnh ca chi tit gia cng b bin dng mnh m
theo phng lc ct
chnh. Th tch kim
loi tng ng vi
chiu rng bng bc
tin dao s trn b mt
chi tit gia cng b
nn p xung gi tr rt
nh gn bng khng v
b ph hy theo chu k
(Hnh 2.9). S to
thnh b mt mi ca
chi tit gia cng khng
phi do tc dng ct
ca dng c tch ra cc lp vt liu m do tc dng cy ln b mt chi tit
Hnh 2.8. Hnh thi phoi khi tin trc giao thp 9XC
cng 50 HRC tng ng vi cc vn tc ct v=75(a);
119(b) ;188(c) ;298(d) ;471m/p (e).


a1)
a2)
a3)
b1)
b2)
b3)
c1)
c2)
c3)
d1)
d2)
d3)
e1)
e2)
e3)
b)
Hnh 2.9. Mt ct ngang ca phoi khi ct trc giao (a) v
khi ct nghing (b-f).

B mt
gia cng
B mt cha
gia cng
B mt to thnh

B dy phoi tip xc vi b mt to
thnh b nn p v ph hy theo chu k
e) g)
f)
a) c)

d)
h)


32
nn cc lp vt liu v cui cng vt liu b ph hy di tc dng ca ng sut nn
ln. c trng ny ca qu trnh to phoi cng gp phn quyt nh cc tnh cht
c trng ca b mt mi to thnh nh nhm b mt, ng sut d, lp bin cng v
lung vt liu bin dng do trn b mt gia cng.
2.4. C ch hnh thnh phoi khi tin thp hp kim qua ti bng dao PCBN
C ch hnh thnh phoi khi tin cng c phn tch da vo hnh nh chp
SEM cc mu gc phoi thu c nh s dng thit b dng dao nhanh. C th thy
r phn b bin dng khc bit trong qu trnh hnh thnh phoi dy n nh v phoi
rng ca.
Trong qu trnh hnh thnh phoi dy n nh, thy r hnh nh bin dng tng
th ng u dc theo thn
phoi v lp chy do bn
mt di ca phoi. iu
ny chng t tn ti lp
chy do ti b mt tip xc
gia phoi v mt trc
dng c (Hnh 2.10a,b).
Khi hnh thnh phoi
rng ca, phn b bin
dng c s thay i vi
bin dng ln ti v tr cc
di hp gia cc rng ca
v bin dng khng ng
k ti trung tm ca cc rng ca. Lp chy do ti b mt di ca phoi ni tip
xc vi mt trc ca dng c chuyn thnh lp trng di tc dng ca bin
dng ln v nhit cao (Hnh 2.10c,d). Nh vy s hnh thnh phoi rng ca i
cng vi bin dng cc b rt ln v nhit cc b tng cao lm thay i cu trc
t vi ca vt liu v hnh thnh cc lp trng. Hnh nh phn tch cu trc t vi ca
phoi thp 9XC cho thy r t chc mactenxit xen ln cc ht cacbit vi kch thc
nh phn thn phoi, cc ht b bin dng ko di phn gia cc phn on rng
ca v lp bin trng nm mt di ca cc phn on (Hnh 2.11).
Hnh 2.10. Cu trc gc phoi thp 9XC cng
55HRC khi ct vn tc v=45,2m/p (a); 113m/p (b);
283m/p (c,d) vi t=0,7mm; s=0,1mm/v.


a)
b)
d)
c)
Di trt
cc b
Vng mt
phng trt
Lp chy
do
Lp trng
Cnh vin li
ct mnh CBN
Lp trng
Vng mt
phng trt


33
Phn tch nh chp cu trc t vi gc phoi thu c nh s dng c cu dng
dao nhanh cho thy r cc di
trt cc b xut hin trong qu
trnh hnh thnh phoi rng ca v
khng thy hnh nh cc vt nt
pha trc li ct trong qu trnh
to phoi (Hnh 2.10).
Nh vy c th khng nh c
ch hnh thnh phoi rng ca trong
nghin cu ny l do trt on
nhit bi trng thi mt n nh
nhit do ca vt liu nh kt lun
ca Zhen[103], [104] m khng
phi do s xut hin v lan truyn ca cc vt nt nh trong nghin cu ca
Poulachon [73].
Trong qu trnh gia cng, vt liu trong vng ct di tc dng ca bin dng
ln v nhit cao s chu tc ng ca hai hin tng c nhit l tng bn do bin
cng v gim bn do mm ha v nhit. Khi phoi dy n nh c hnh thnh, hin
tng bin cng chim u th so vi qu trnh mm ha v nhit. S bin cng
khin cho gii hn bn ca vt liu tng cao v v vy, ng sut yu cu cho bin
dng ph hy tip theo tng ln, qu trnh trt ti mt phng trt s nhanh chng
c chuyn sang mt phng k tip yu hn lm bin dng tng th trong phoi tr
nn ng u. Tri li, khi hnh thnh phoi dy tun hon dng rng ca, hin tng
mm ha v nhit chim u
th khin cho bin dng
trt tp trung ti di trt
cc b, ni vt liu b yu
i do tc dng mm ha v
nhit. Trt mnh trong
mt di hp to thnh
cc phn on phoi lm
cho phn b bin dng
586HV
602HV
536HV
521HV
549HV
474HV
453HV
460HV
475HV
578HV
597HV
598HV
584HV
604HV
464HV
Hnh 2.12. Kim tra cng ti cc v tr bin dng
khc nhau gc phoi lin (a); phoi rng ca (b).



Lp chy do
Hnh 2.11. Phn b bin dng ng u trong
phoi dy n nh (a,b); bin dng khng u
vi lp trng to thnh phoi rng ca (c,d).


Bin dng cc b
b) a)
c)
d)
Bin dng ng u
Lp trng


34
tng th trong phoi tr nn khng u. Kim tra cng ca phoi ti v tr bin
dng khc nhau chng t iu ny khi cng ca phoi thay i so vi cng
vt liu phi ban u (Hnh 2.12). Vi mu phoi thu c khi gia cng thp 9XC
ch ct s=0,07; t=0,115; v= 47m/p471m/p, cc phoi lin c cng trung bnh
ti trung tm phoi l 549 559HV, tng 19%; cc phoi rng ca c cng trung
bnh ti cc rng ca t 406 494HV, gim 3% so vi cng phi ban u l
464HV.
Vi qu trnh hnh thnh
phoi rng ca, bin dng
mnh ti cc di trt cc b
dn n nhit sinh ra ln
lm thay i t chc t vi
ca kim loi v to thnh cc
lp trng vi cng tng
cao: cng trung bnh ti
cc di trt cc b ca cc
rng ca l 523 571HV,
tng17,8% so vi cng
phi ban u (Hnh 2.13).
Nh vy c th thy, khi
cng vt liu gia cng
tng dn n nng lng cn thit cho bin dng trt ca vt liu tng v lm
tng nhit ti vng bin dng v lm mm vt liu gia cng to iu kin cho
phoi dy tun hon dng rng ca c hnh thnh. Vng nhit cao pht trin
trong di trt cc b ca phoi to thnh cc lp trng.
Tng t nh vy, s thay i ca tc ct khi gia cng cc loi vt liu kh
gia cng gy ra s khng n nh ca qu trnh dn n phn ng c nhit
ca vt liu phi di iu kin ct gt. Tc ct cao tng ng vi tc bin
dng cao khin cho nhit sinh ra trong vng bin dng khng kp truyn i lm
nhit tng cao dn n lm mm vt liu. Kt qu l s trt cc b v dng
phoi tun hon c hnh thnh. Nh vy, bn cht ca c ch to phoi y ch
l s cnh tranh ca hai hin tng c nhit l bin cng v mm ha v nhit . C



b)
4
5
7
H
V

5
6
3
H
V
V

5
0
1
H
V

4
6
4
H
V

6
3
1
H
V

5
3
8
H
V

3
8
3
H
V

3
6
7
H
V

4
6
8
H
V

c)
3
8
3
H
V

3
6
7
H
V

4
6
8
H
V

4
5
7
H
V

5
6
3
H
V

4
6
4
H
V

5
0
1
H
V

6
1
3
H
V

5
3
8
H
V

d)
5
5
0
H
V

5
6
7
H
V

5
5
5
H
V

5
6
4
H
V

4
6
1
H
V

5
0
6
H
V

5
0
2
H
V

5
4
8
H
V

4
7
8
H
V

a)
Hnh 2.13. cng phoi thay i theo c ch
hnh thnh phoi: cng tng khi hnh thnh
phoi lin (a,b), cng gim khi hnh thnh phoi
rng ca (c,d).



4
8
4
H
V

5
3
5
H
V

5
2
3
H
V

4
9
8
H
V

5
8
7
H
V

5
4
7
H
V

5
2
9
H
V

5
3
4
H
V



35
th nh gi c trng ny bng t s gia cng ln nht ca phoi vi cng
ban u ca phi gia cng n: n=HV
ph
/HV
bd
. S ph thuc ca hnh thi phoi vo
tc ct v cng ca vt liu phi khi tin cng thp 9XC v X12M c
tng hp nh trn Hnh 2.14.
S hnh thnh phoi dy tun hon do trt cc b lm lc ct thay i tun hon
v gy ra dao ng hoc va p trong qu trnh ct, c bit khi s cng vng ca
h thng thp v nhit trn b mt tip xc gia phoi v dng c ln. Cc kt qu
thc nghim cho thy, dng phoi tun hon lm tng s mi mn ca dao do s hnh
thnh cc phn on phoi i cng vi ti trng dao ng mi tc dng ln li ct
mnh ca dng c. Tuy vt liu b mm ha khi bin dng tc rt cao nhng
lc ct gim khng ng k v mn dng c tng rt nhanh cng vi s tng tc
ct. Mt khi s khng n nh ca kim loi bt u, n gy ra nhng va p trong
vt liu, trong thn dao v my gia cng. V vy, bt k iu g lm gim cng
ca s phn on lun em li li ch cho hiu qu gia cng ni chung.
549HV
n=1,18
559HV
n=1,2
50 75 100 125 150 500
45
50
cng
(HRC)
V
(m/ph)
25
55 157kHz
406HV
n=0,87
Vng trt
ng u
9XC
X12
M
Vng trt
cc b
44,8kHz
494HV
n=1,06
Mm ha
v nhit
M

m

h

a


v

n
h
i

t

Bin cng
B
i

n

c

n
g

Hnh 2.14. Hnh thi phoi thay i theo cng vt liu phi v tc gia
cng ca thp 9XC (nt chm l gii hn chuyn i hnh thi phoi ca thp
X12M).



36
2.5. Kt lun chng 2
- Dng phoi hnh thnh trong qu trnh tin thp hp kim qua ti s dng dao
PCBN bao gm phoi ri, phoi dy n nh v phoi rng ca, trong dng phoi
rng ca l dng phoi ch yu, hnh thnh trong mt di rng iu kin ct v vt
liu gia cng. Phoi ri hnh thnh tc ct thp v l cc on t ri ca phoi
lin m khng phi ca phoi rng ca.
- Hnh thi phoi ph thuc vo cng vt liu v ch gia cng, ch yu l
vn tc ct. Gii hn chuyn i hnh thi phoi t phoi dy n nh sang phoi rng
ca i vi c hai loi thp 9XC v X12M u cng trn 50HRC. Vn tc
tng ng vi s thay i v hnh thi phoi l 113m/p vi thp 9XC v 42,3m/p vi
thp X12M. Gii hn chuyn i hnh thi phoi cng ph thuc vo cc thng s
ct khc nh chiu su ct v lng chy dao.
- Dng phoi hnh thnh ph thuc vo s cnh tranh ca hai qu trnh mm ha
v nhit v bin cng ca vt liu gia cng. Qu trnh hnh thnh phoi lin i cng
vi hin tng bin cng vi cng phoi tng 19,3% so vi cng phi ban
u. Phoi rng ca c hnh thnh khi qu trnh mm ha v nhit chim u th
vi cng trung bnh ca phoi gim 3% so vi cng phi ban u. Bin dng
mnh ti cc di trt cc b lm thay i c tnh vt liu dn n s hnh thnh cc
lp trng vi cng tng 17,3% so vi cng phi ban u.
- C ch hnh thnh phoi rng ca l s trt on nhit do hin tng mt n
nh nhit do ca vt liu, xy ra trong di hp vt liu b mm ha v nhit, khng
phi do s hnh thnh v lan truyn ca cc vt nt t vi. Tn s cc rng ca tng
t 44,8kHz ln 157kHz khi vn tc ct tng t 188m/p ln 471m/p.
- S hnh thnh phoi rng ca lm tng rung ng v gy ti trng thay i tun
hon trong qu trnh ct. Ti trng thay i c th lm li ct b ph hy v mi.


37
Chng 3
NGHIN CU C TRNG V LC CT
KHI TIN THP HP KIM QUA TI BNG DAO PCBN
3.1. Bin thin lc ct theo chiu di ct khi tin thp hp kim qua ti bng dao
PCBN
Nghin cu bin thin lc ct theo chiu di ct khi tin thp hp kim qua ti
bng dao PCBN c tin hnh vi qu trnh tin b mt tr ngoi trn hai loi thp
9XC v X12M ti t cng 5557HRC. Cc thnh phn lc ct c o bng
thit b o lc ct ba chiu Kistler-Thy s cng b khuch i v thit b ngoi v
NI-USB 6009-Hungari. Th nghim c tin hnh trn my tin vn nng HOWA
STRONG 860 (Nht Bn). S v thit b dng trong th nghim nh Hnh 3.1.
Kho st s pht trin ca lc ct theo chiu di ct c thc hin ch ct
c nh v=110m/p; s=0,07mm/v; t=0,115mm. S dng dao gn mnh PCBN k
hiu TPGN160308-EB15
ca hng EHWA (Hn
quc) c bn knh mi
r=0,8mm.
D liu o lc nhn
c cho thy gi tr lc
ct tng i n nh, dao
ng l khng ng k
(Hnh 3.2). th biu
din s thay i ca lc
ct theo chiu di ct ca
a) b) c)
Hnh 3.1. S (a,b) v thit b th nghim o lc ct (c) khi tin thp hp kim qua
ti bng dao PCBN.
Hnh 3.2. D liu o lc ct khi tin cng thp
9XC(a,b,c) v X12M(d,e,f) ch ct v=110m/p;
s=0,07mm/v; t=0,115mm ng vi chiu di ct khc
nhau L=336; 1680; 3360m.
a)
e)
b)
d)
f)
c)


38
hai loi thp 9XC v X12M c biu din nh trn Hnh 3.3.
Phn tch th lc ct trn hnh Hnh 3.2 v Hnh 3.3 cho thy, khi tin cng
thp 9XC, gi tr ca cc thnh phn lc ct kh nh, ch vi chc Niutn. Lc ct
tng khng ng k trn ton b chiu di ct hn 3000m. Thnh phn lc dc trc
F
y
v lc tip tuyn F
z
c gi tr gn bng nhau, xp x 60N. Chnh lch gia hai
thnh phn lc tng nh theo chiu di ct. Lc dc trc F
x
c gi tr nh nht, ch
khong 1517N v hu nh khng thay i (Hnh 3.3a).
Gi tr ca cc thnh phn lc ct khi tin thp X12M ln hn rt nhiu so vi
lc ct khi tin cng thp 9XC. Tc tng lc ct rt ln, t vi chc Niu tn
chiu di ct 300m ln ti gn 1000N chiu di ct trn 3000m. Lc hng knh
F
y
ln hn nhiu so vi lc tip tuyn F
z
. S chnh lch gia hai thnh phn tng
mnh khi chiu di ct tng, gi tr lc F
y
lun ln gp khong 4 ln lc tip tuyn
F
z
(Hnh 3.3b).
C th xc nh c nguyn nhn ca s chnh lch lc ct khi gia cng hai
loi thp 9XC v X12M thng qua phn tch cu trc t chc t vi ca chng cng
cng 57HRC. Thp 9XC c t chc ht nh mn, cc ht cacbit kch thc di
1m phn b ng u xen ln t chc mactenxit hnh kim bn cnh austenit d
mu sng (Hnh 2.2). Cu trc t vi ca thp X12M cho thy cc ht cacbit c kch
thc ln, i khi kt thnh di di nm ri rc vi mt cao bn cnh t chc
mactenxit (Hnh 2.1b). Vi cng rt cao ca cc ht cacbit, c th t ti
658713HV so vi t chc nn c cng 512545HV cn tr qu trnh ct loi
Bien thien cac thanh phan luc cat
khi tien cung thep 9XC
0
10
20
30
40
50
60
70
0 1000 2000 3000 4000
Chieu dai cat L (m)
L
u
c

c
a
t

(
N
)
Fz
Fy
Fx
Bien thien cac thanh phan luc cat
khi tien cung thep X12M
0
100
200
300
400
500
600
700
800
900
0 1000 2000 3000 4000
Chieu dai cat L (m)
L
u
c

c
a
t

(
N
)
Fz
Fy
Fx
Hnh 3.3. th bin thin cc thnh phn lc ct theo chiu di ct khi tin
thp 9XC(a) v X12M(b) cng 57HRC ch ct v=110m/p;
s=0,07mm/v; t=0,115mm.

a) b)


39
vt liu ny v lm gi tr
cc thnh phn lc ct tng
cao (Hnh 3.4). Bn cnh
, cc ht cacbit cng
ng vai tr cc ht mi
mn y nhanh tc mn
do khin cho tc gia
tng ca lc ct ln.
Trong c hai trng hp tin cng thp 9XC v X12M, lc hng tm F
y

lun c gi tr ln nht trong ba thnh phn lc ct. Hin tng ny c th l gii
da trn phn tch hnh hc li ct v c im qu trnh tin cng chnh xc.
Do bn knh mi dao ln (r=0,8mm) v chiu su ct nh (t=0,115mm) nn qu
trnh ct ch din ra ti bn knh mi dao lm gc tip xc ca li ct v b mt
gia cng nh khin cho lc hng
tm F
y
c gi tr ln vt tri (Hnh
3.5). Khi dao b mn, hnh hc li
ct v mi dao thay i lm thay i
tng quan gia cc thnh phn lc
ng thi lm cho qu trnh ct din
ra ch yu l nn v cy ln b mt
gia cng thay cho qu trnh ct nn
gi tr cc thnh phn lc cn thit
to phoi tng [20].
S bin thin ca lc ct theo chiu di ct cn ph thuc vo cng vt liu
gia cng (Hnh 3.6). Khi cng nh hn 50HRC, lc ct gim khi cng tng,
gi tr lc tip tuyn F
z
c gi tr ln nht trong ba thnh phn lc ct. Khi cng
ln hn 50HRC, lc ct tng cng vi s tng cng vt liu gia cng. Lc hng
tm F
y
c gi tr vt tri trong ba thnh phn lc ct. Quy lut ny vn gi nguyn
khi tng chiu di ct.
T kt qu nghin cu qu trnh hnh thnh phoi c th thy mi lin quan gia
quy lut bin thin ca lc ct vi hnh thi phoi c to thnh. cng di
50HRC phoi lin c hnh thnh v s xut hin ca phoi rng ca khi cng vt
a) b)
Fy
Fxy
Fx
Fy
Fxy
Fx
Kr
Kr
Hnh 3.5. nh hng ca bn knh mi
dao v chiu su ct n tng quan gia
cc thnh phn lc ct [20].

715HV
512HV
545HV
651HV
a) b)
Hnh 3.4. T chc t vi ca thp 9XC(a) v kim tra
cng ca cc ht cacbit trong t chc thp
X12M(b).


40
liu phi tng. S hnh thnh phoi rng ca i cng vi s mm ha v nhit do hin
tng trt on nhit vi bin dng do ln v nhit cc b tng dn n lc
ct yu cu cho qu trnh to phoi gim.
3.2. nh hng ca tc ct n cc thnh phn lc ct khi tin cng trc
giao thp 9XC bng dao PCBN.
Nghin cu nh hng ca tc
ct n cc thnh phn lc ct c
tin hnh cho qu trnh tin trc giao
thp 9XC qua ti nh s trn Hnh
3.7. Th nghim c thc hin trn
phi ng ch ct t=2mm;
s=0,06mm; vn tc ct ln lt l
v=18,8; 29,8; 47,1; 75,4; 119,3;
188,4; 298,3; 471m/ph.
Cc d liu thu c nh trn Hnh 3.8 cho thy tc ct c nh hng ln
n cc thnh phn lc ct. Qu trnh tin cng vn tc ct nh cho thy rung
ng ln, c bit vn tc di 50m/ph (Hnh 3.8a,b). Trong khong vn tc
nghin cu t 18,8471 m/ph lc ct gim dn theo thi gian vi tc gim lc
ct khc nhau. Tc gim lc ct ln nht ng vi vn tc nh hn 50m/p, tc
gim lc ct nh hn trong khong vn tc 50m/phsvs200m/ph. Khi lc ct ln
hn 200m/ph, tc gim lc ct gn nh bng hng s. th biu din mi lin
Hnh 3.6. Bin thin ca cc thnh phn lc ct theo cng khi tin thp X12M
ng vi chiu di ct L=255m(a) L=510m(b); v=110m/ph; s=0,12mm/v; t=0,15mm.
Bien thien luc cat theo do cung khi tien thep
X12M ung voi chieu dai cat L=255m
0
20
40
60
80
100
120
43 50 57 62
Do cung (HRC)
L
u
c

c
a
t

(
N
)
Fz
Fy
Fx
Bien thien luc cat theo do cung khi tien thep
X12M ung voi chieu dai cat L=510m
0
20
40
60
80
100
120
140
160
180
43 50 57 62
Do cung (HRC)
L
u
c

c
a
t

(
N
)
Fz
Fy
Fx
a) b)
Hnh 3.7. S th nghim tin cng trc
giao: 1-Mm cp, 2-phi, 3-dao, 4-thit b
o lc, 5-b chuyn i tn hiu, 6-mn
hnh hin th.
1 2
3
4 5
6


41
h gia lc ct v vn tc ct nh trn Hnh 3.9.
Hin tng rung ng ln
khi tin cng vn tc thp cho
thy gi tr lc ct lin quan trc
tip n dng phoi c hnh
thnh. Khi vn tc rt thp, phoi
hnh thnh dng phoi ri i
cng vi cc rung ng mnh.
Mt khc, tc thp lm tng
rung ng do tc ng ca cc
yu t lch tm gy ra trong khi
tc cao lm tng kh nng t nh tm ca chi tit gia cng.
Hin tng lc ct gim khi
vn tc ct tng trong qu trnh
tin cng c ghi nhn
mt s nghin cu [20], [34],
[78]. Nguyn nhn ca hin
tng ny c cho rng khi
tng vn tc ct, tc bin
dng tng khin ma st v nhit
sinh ra ln lm gim cng
ca vt liu gia cng. V th
nng lng yu cu cho qu
trnh ct gim lm lc ct gim.
3.3. Phn tch nh hng ca iu kin ct n cc thnh phn lc ct khi tin
cng trc giao thp 9XC bng dng c PCBN.
Vic nghin cu nh hng ca cc thng s ct v tng tc gia chng n
lc ct khi tin cng thp 9XC qua ti bng dao PCBN c thc hin bng
phng php phn tch thng k. Nghin cu c tin hnh trn s ct trc
giao nh Hnh 3.7. Vi s ny, chiu su ct t khng i v thnh phn lc
hng knh F
y
s c loi b. Cc th nghim c quy hoch theo k hoch
bc mt hai nhn t hai mc yu t nh trong Bng 3.1. Ngoi 4 im th
Bien thien luc cat theo van toc
khi tien cung truc giao thep 9XC
0
100
200
300
400
500
600
700
0 100 200 300 400 500
Van toc cat (m/p)
L
u
c

c
a
t

(
N
)
Fz
Fy
Fx
Hnh 3.9. th bin thin lc ct theo vn
tc ct khi tin cng trc giao thp 9XC vi
s=0,06mm/v; t=2mm ; chiu di ct L=200m.
Hnh 3.8. Bin thin lc ct theo vn tc ct khi
tin trc giao thp 9XC cng 52HRC vi
t=2mm; s=0,06mm/v; v=18,8; 29,8; 47,1; 75,4;
119,3; 188,4; 298,3; 471m/ph.
g)
a) c)
d)
b)
e) e)
h)


42
nghim cn thc hin theo quy
hoch cn c cc th nghim c
thc hin song song ti tm. Mi
th nghim c thc hin tng
ng vi chiu di ct L=25mm
theo phng dc trc chiu su
ct c nh t=3mm. Kt qu th
nghim c tng hp trong hai
ct cui ca Bng 3.1.
Hnh 3.10 l th biu din nh
hng ca cc nhn t vn tc ct v,
lng chy dao s v tng tc gia chng n cc thnh phn lc ct F
z
v F
x
.
T th cho thy cc thnh phn lc ct F
z
v F
x
b nh hng ng k bi vn
tc ct v lng chy dao. Vi chiu su ct ln t = 2mm, gi tr ca cc thnh phn
lc o c tng i cao, trong lc ct chnh F
z
c gi tr ln nht. th cng
cho thy cho thy nh hng ca lng chy dao n cc thnh phn lc ct ln
hn nh hng ca vn tc ct. C th gii thch hin tng ny l do khi tng
lng chy dao, chiu dy phoi khi cha bin dng tng. V lc ct t l trc tip vi
a)
c) e)
f) d)
b)
Hnh 3.10. nh hng ca cc nhn t v v s v tng tc gia chng n cc
thnh phn lc ct trong tin cng trc giao thp 9XC bng dng c PCBN.
Bng 3.1. Kt qu th nghim xc nh cc
thnh phn lc ct.
Th
nghim
Nhn t Lc ct
v
(m/p)
s
(mm/vg)
F
z
(N) F
x
(N)
1 75 0,09 1199.41 297.35
2 245 0,09 894.85 267.09
3 75 0,12 1153.09 337.03
4 245 0,12 1432.56 417.85
5 160 0,105 1362.48 351.48
6 160 0,105 1287.28 376.02
7 160 0,105 1311.52 361.33



43
chiu dy phoi khi cha bin dng nn lng chy dao ng vai tr l nhn t nh
hng chnh n lc ct. Tng tc gia vn tc ct v lng chy dao tc ng
n lc ct nhiu hn vn tc ct.
M hnh hi quy biu din cc gi tr lc ct c dng:
4 3,3903 1,4974ln 6,6020
3, 719.10
v
z
F v s

= (3.1)
2,1426 0,9463ln 3,6504
0, 0837
v
x
F v s

= (3.2)
M hnh c kim tra tha mn cc tiu chun thng k nn hon ton
tng hp vi h thng thc nghim.
Mt hi quy biu din bin thin lc ct theo cc thng s vn tc ct v v
lng chy dao s nh trong
Hnh 3.11.
Phn tch mt hi quy
thy r tc dng tng tc
gia cc bin nh hng n
cc gi tr lc ct. Trn c hai
th, lng chy dao v
tng tc gia lng chy
dao vi vn tc ct c nh hng ln nht n lc ct. Vn tc ct c nh hng t
nht, c bit khi lng chy dao nh, vic tng vn tc ct li cho gi tr lc ct
gim. iu ny c cho l lin quan n s hnh thnh phoi rng ca lm gim
yu cu nng lng tiu th cho qu trnh to phoi dn n gim lc ct [73].
3.4. Kt lun chng 3
- Gi tr lc ct trong qu trnh tin cng thp hp kim qua ti s dng dao
PCBN khng ln hn gi tr lc ct khi tin thng thng. Lc hng tm F
y
lun
c gi tr ln nht trong ba thnh phn lc ct. ln v tng quan gia cc thnh
phn lc ct ph thuc mnh m vo vt liu gia cng.
- Khi cng vt liu gia cng nh hn 50HRC, lc ct c xu hng gim khi
cng vt liu gia cng tng. Khi cng vt liu gia cng ln hn 50HRC, lc ct
tng khi tng cng ca vt liu gia cng. Lc ct c gi tr nh nht khi vt liu
gia cng c cng khong 50HRC, tng ng vi s xut hin dng phoi rng ca.
Hnh 3.11. Mt hi qui v th ng mc ca
cc thnh phn lc ct F
z
(a) v F
x
(b).
a) b)


44
- Trong di tc kho st t 18,8m/p471m/ph, lc ct gim dn khi vn tc ct
tng. Tc gim lc ct cng gim cng vi s tng ca vn tc ct. c bit dao
ng v lc ct sinh ra ln khi tin thp hp kim qua ti tc thp (di 50m/ph).
- nh hng ca lng chy dao v tng tc gia lng chy dao v vn tc
ct ti lc ct ln hn nh hng ca vn tc ct.


45
Chng 4
XC NH TRNG PHN B NHIT TRONG DNG C PCBN
KHI TIN THP HP KIM QUA TI
4.1. Xc nh trng phn b nhit trong dng c PCBN khi tin cng trc
giao bng phng php phn t hu hn (FEM)
4.1.1. M hnh tnh nhit
Bi ton truyn nhit cho h thng dao-phoi-phi khi tin cng bc l bi ton
truyn nhit trong khng gian ba chiu. Tuy nhin, c th quy v bi ton truyn
nhit theo hai chiu vi s hiu chnh thch hp.
Vng m hnh nhit v cc iu kin bin
c m t trn Hnh 4.1 [90]. V chiu rng
dng c v chiu rng phoi (theo hng php
tuyn vi mt phng trong hnh) ln hn 30
ln chiu dy phoi khi cha b bin dng, m
hnh tha mn hon ton vi bi ton truyn
nhit theo hai phng. Kch thc hnh hc
ca m hnh c xc nh trong phm vi
vng chu tc ng ca gradient nhit .
Hu ht cc b mt ngoi l on nhit, ngha
l nhit mt mt do i lu v bc x vo
mi trng l khng ng k. iu ny tng
ng vi vic khng s dng dung dch trn ngui.
Phng trnh truyn nhit n nh trong khng gian hai chiu trong qu trnh ct
kim loi c vit di dng [90] :
( , )
x y x y
T T T T
c u u q x y k k
x y x x y y

| | | | c c c c c c | |
+ + = +
| | |
c c c c c c
\ .
\ . \ .
(4.1)
trong : l khi lng ring ca vt liu; c l nhit dung ring; u
x
,u
y
l thnh
phn vn tc ca vt liu theo hai phng x v y; k
x
, k
y
l h s dn nhit theo hai
phng x v y; q l tc sinh nhit ring.
Gi s k
x
= k
y
= k v coi ngun nhit ch tp trung trn cc mt phng trt v
mt trc ca dng c th phng trnh (4.1) c th vit thnh:
Hnh 4.1. M hnh bi ton tnh
nhit v cc iu kin bin [90].
Phoi
cT
cn
=0
y
x
Vc
cT
cn
=0
Bn g dao
Dao
Mnh
dao CBN
q=h
f
(T-T)
Phi
ux=V
T=T
Bin on nhit


46
2 2
2 2
( , ) 0
x y
T T T T
c u u k q x y
x y
x y

| |
| | c c c c
+ + + = |
|
|
c c
c c \ .
\ .
(4.2)
Phng trnh ny phi c gii trn
min minh ha trn Hnh 4.2, trn biu
din cc iu kin bin m phng trnh
phi tha mn ng vi qu trnh ct trc
giao nh sau [30]:
s
T T = Trn b mt S
T
cn xc nh. (4.3)
0
T
k q
n
c
=
c

Trn b mt S
q0
cn xc nh. (4.4)
1
I II
T T
k k q
n n
c c | | | |
=
| |
c c
\ . \ .
Trn mt phng S
q1
(mt trt AB). (4.5)
2
II IV
T T
k k q
n n
c c | | | |
=
| |
c c
\ . \ .
Trn mt S
q2
(mt trc AC). (4.6)
( )
T
k h T T
n

c
=
c
Trn b mt S
h
cn xc nh. (4.7)
Gii phng trnh (4.2) tha mn cc iu kin (4.3) n (4.7) tng ng vi
vic tm cc tiu ca phim hm I [89].
2
2
2
1
2
1
2
q h
x y x y
A
q h
S S
T T T T
I c u u T k k qT dA
x y x y
qTdS h T TT dS

(
| | | | c c c c | |
(
= + + +
`
| | |
c c c c (
\ .
\ . \ .

)
| |
+ +
|
\ .
}}
} }
(4.8)
vi T
s
l nhit dc theo bin S
T
; ( , ) q x y l tc sinh nhit th tch theo hai
phng x, y; q
0
, q
1
, q
2
l cng dng nhit vung gc vi bin S
q
; h l h s
truyn nhit ring i lu dc theo bin S
h
; T

l nhit mi trng xung quanh; n

l php tuyn ngoi ca bin; ,
T T
x y
c c
c c
l bin thin nhit theo cc phng x v y;
S
T
, S
q
, S
h
l cc bin phn bit to nn ton b bin ca din tch A ca phn t
Hnh 4.2. Cc iu kin bin s
dng trong m hnh nhit [30].



ux=v, u
y
=0
on nhit
ux=v, u
y
=0
on nhit
ux=v, u
y
=0
on nhit
Phi
Dao
Ngun nhit
do ma st q
f
x
y
c
T
c
n
=
0
c
T
=
0
cT
cx
=0
cT
cn
=0
P
h
o
i
c
n
P
h
o
i
u
x
=
v
c
x
,

u
y
=
v
c
y

n

n
h
i

t
Phi
ux=vc, u
y
=0, T
i

n

n
h
i

t
Phi
Ngun nhit vng
bin dng th hai q
2
Ngun nhit vng
bin dng th nht q
1


47
kho st.
C th biu din phim hm (4.8) di dng:
| || | | | | || |
1
2
q h
T
A A A
q h
S S
I c U T TdA T D T dA qTdA
qTdS h T T TdS

= V + V V
| |
+ +
|
\ .
}} }} }}
} }
(4.9)
Vi
| |
x y
U u u
(
=

; | |
0
0
x
y
k
D
k
(
=
(

v
T
x
T
T
y
c

c
V =
`
c

c
)
(4.10)
iu kin cc tiu ca I (4.9) l bin phn 0 I o = (4.11)
| || | | | | || |
1
2
q h
T
A A A
q h
S S
I c U T TdA T D T dA q TdA
q TdS h T T TdS
o o o o
o o

= V + V V
| |
+ +
|
\ .
}} }} }}
} }
(4.12)
S dng phng php phn t hu hn [1], [76] tnh ton v bin i,
phng trnh (4.11) c a v phng trnh tnh ton nhit tng qut cho mt
phn t e nh sau:
4
6
i i i i j i j i k i k i
i
e
i j i j j j j j i j k j j
e
i k i k j k j k k k k k k
x i y i x j y j x k y k
x i y i x j y j x k y k
x i y i x j y j x k y k
b b c c b b c c b b c c
T
k
b b c c b b c c b b c c T
A
b b c c b b c c b b c c T
u b u c u b u c u b u c
c
u b u c u b u c u b u c
u b u c u b u c u b u c

(
+ + +
(

+ + +
( `
(
+ + +
( )

+ + +
+ + + +
+ + +
1 2
2 1 0
1 2 0
6
0 0 0
1 1 1
1 1 1
2 2 2
0 0 0
i i
h
j j
k k
q q
h
e e
T T
hl
T T
T T
l l
hl T
q q

(

(
(

(
+
( ` `
(
(
(

( ) )



= +
` ` `

) ) )
(4.13)
vi A
(e)
l din tch ca phn t (e) v T
i
, T
j
, T
k
nhit nt ca phn t e ; a,b,c l
h s ca cc hm nhit ti cc nt c xc nh theo ta ca cc nt ;
q
l l
chiu di chu s tc ng ca mt dng nhit trn bin
q
S ;
h
l l chiu di chu
s trao i nhit do i lu trn bin
h
S ca phn t e;
1 e
q ,
2 e
q l nhit lng


48
truyn vo cc phn t e
1
v e
2
c chung cnh trn cc bin
q
S .
V t l truyn nhit vo 2 phn t e
1
v e
2
trn cc bin S
q1
v S
q2
cha bit ta
c th ly tng cc phn b nhit c dng nhit tng
1 2 e e e
q q q = + trong
phng trnh chnh tc tng qut (4.13).
Vit phng trnh (4.13) cho tt c E phn t v kt hp s nhn c h
phng trnh tuyn tnh cn tm. Gii h phng trnh ny s nhn c gi tr nhit
T ti cc im nt ca tt c cc phn t. H phng trnh xc nh nhit c
th gii c nh lp trnh trong phn mm nh MATLAB hoc gii t ng nh
cc phn mm khc. y vic gii phng trnh truyn nhit xc nh gi tr nhit
v trng phn b nhit c thc hin bng phn mm ABAQUS. Phn tnh
ton bin i phng trnh (4.11) c trnh by nh trong Ph lc III.
4.1.2. Cc thng s xc nh t thc nghim
Th nghim xc nh cc thng s kho st nhit ct trong qu trnh tin cng
bng dng c PCBN c thc hin vi thp 9XC cho trng hp ct trc giao. S
v thit b th nghim
nh trong Hnh 3.1a,c. Cc
thng s hnh hc ca dng
c ct cho trong Bng 4.1.
Th nghim c tin hnh
ch ct v=119,3 m/p;
t=3mm; s=0,06mm/v.
Cc thng s chiu dy
phoi t
c
, chiu di tip xc
ca phoi vi mt trc dng
c l
c
c xc nh da trn
nh SEM ca gc phoi v
b mt dng c (Hnh 4.3):
t
c
=110m; l
c
=240m.
Cc gi tr lc ct F
z
, F
y
, F
x
c xc nh bng thit b o lc ct ba chiu
Kistler s hiu 9257BA (Thy S). th o gi tr lc ct tng ng vi ch ct
Bng 4.1. Thng s mnh dao PCBN tin cng thp
9XC.
Dao
Gc
trc

Gc
sau
o
Gc
nng

Gc
nghing chnh

Gc
nghing ph

1

PCBN -6 6 0 0 0

Hnh 4.3. nh SEM chp mt ct gc phoi v vt
tip xc trn b mt dng c khi tin trc giao thp
9XC cng 52HRC chiu su ct t=3mm;
s=0,06mm/v; v=119,3m/p.




49
kho st nh trn Hnh 3.8.
phc v cho qu trnh tnh ton nhit, cn xc nh cc thng s v lc ct,
vn tc trt cng nh din tch bin dng ti cc ngun sinh nhit.
Gc trt | c xc nh da vo t s chiu dy phoi v gc trc :
c
os cos
t sin 1 sin
tc r
tg
t r

|

= =

vi l gc trc;
c
t
r
t
= ; t l chiu dy phoi khi
cha bin dng (lng chy dao); t
c
l chiu dy phoi;
Vn tc trt ca vt liu phi ti mt phng trt lng chy dao V
s
v ca
phoi trn mt trc dng c V
c
c xc nh [81]:
Vn tc trt ca vt liu phi trn mt phng trt V
s
:
cos
cos( - )
s
V
V
o
| o
=
Vn tc trt ca phoi trn mt trc dng c V
c
:
sin
cos( - )
c
V
V
|
| o
=
Gi tr lc ct tc dng trn mt phng trt v trn mt trc dng c c xc
nh da vo m hnh tnh lc ca Merchant:
Lc tip tuyn vi mt phng trt F
s
: cos sin
s c t
F F F | | =
Lc tip tuyn vi mt tip xc gia phoi v mt trc dng c:
sin cos
F C T
F F F o o = +
Cc thng s v kch thc, lc v vn tc ct ti cc ngun sinh nhit c
tng hp trong Bng 4.2.
Cc thuc tnh nhit ca vt liu phi v dng c cho m hnh bao gm: H s
dn nhit k, khi lng ring v nhit dung ring c. Khi lng ring c coi
nh khng thay i, cn h s dn nhit v nhit dung ring ph thuc nhit , c
bit i vi vt liu dng c PCBN [79]:
- Khi lng ring ca vt liu PCBN :
3
3120(kg/m ) = .
Bng 4.2. Cc thng s tnh ton trng nhit xc nh t thc nghim.
V
(m/p)
s
(mm/v)
t
(mm)
t
c

(mm)
l
(mm)
r
(t/tc)
|
(rad)
V
s

(m/p)
V
c

(m/p)
F
z

(N)
F
x

(N)
F
s

(N)
F
F

(N)
119,3 0.06 3 0.13 0.24 0,46 0,412 136,5 55,07 410,6 250,4 275,6 206,2



50
Cc thuc tnh nhit ca vt liu dng c PCBN thay i theo nhit :
- H s dn nhit ca mnh PCBN:
0
(20 )
100(W/mK)
C
k = n
0
(900 )
130(W/mK)
C
k =
- Nhit dung ring ca vt liu PCBN:
0
(20 )
1000(J/kgK)
C
c =

n
0
(900 )
1966(J/kgK)
C
c =
Vi thp hp kim, cc thuc tnh nhit c th coi bng hng s v chng thay
i khng ng k trong di nhit tin hnh kho st [79]:
- H s dn nhit ca thp hp kim: 47(W/mK) k =
- Khi lng ring ca thp hp kim:
3
7800(kg/m ) =
- Nhit dung ring ca thp hp kim:
0
(20 )
486(J/kgK)
C
c =
Vi mi trng ct kh, h s truyn nhit i lu: h=525W(m
2
.
0
C) [30].
Nu c dng kh hoc nc p lc: h=10500W(m
2
.
0
C) hoc h=10015000W
(m
2
.
0
C) , h s i lu h=10500W/(m
2
K). Nhit mi trng
0
22 T C

= .
4.1.3. Tnh ton tc sinh nhit ring
+) Tc sinh nhit ring trung bnh trn mt n v din tch ca mt phng
trt (bin S
q1
) [94] :
1 AB s
q k V = (4.14)
vi
AB
k l ng sut ct trn mt phng trt, c xc nh theo lc trt v din
tch mt phng trt.
s
AB
s
F
k
A
= vi F
s
l lc hng dc theo mt phng trt; A
s
l
din tch mt phng phng trt [81].
cos sin
s c t
F F F | | = ;
sin
s
bt
A
|
=
trong : F
c
, F
t
l lc tip tuyn v lc dc trc; b v t l chiu rng v chiu dy
phoi tng ng vi chiu su ct v lng chy dao; l gc trt.

| |
cos sin sin
c t
AB
F F
k
bt
| | |
= (4.15)
Theo Tay [89]: vn tc trt thay i trong vng trt th nht theo cng thc:
sin
sin( )
V V
|
|
| |
=
+
vi l gc lm bi ng xin hypecbol vi phng ct.


51
Gi thit vn tc trt trn mt phng trt l khng i :
( )
cos
cos
s
V
V V const
|
o
| o
= = =

thay vo cng thc (4.14):

| |
( )
1
cos sin cos
cos
c t
AB s
s
F F
q k V V
A
| | o
| o

= =

(4.16)
| |
( )
1
cos sin sin cos
cos
c t
F F
q V
bt
| | | o
| o

(4.17)
Tng ng vi cc thng s ch ct trn, xc nh gi tr ca q
1
.
+) Tc sinh nhit ring trn vng tip xc gia phoi v mt trc dng c
(bin S
q2
):
Tc sinh nhit ring trn vng mt trc dng c gm hai thnh phn q
21
v
q
22
. Thnh phn q
21
sinh ra do ma st gia phoi v mt trc v q
22
sinh ra do bin
dng do ca phoi trong min bin dng th hai.
* Xc nh tc sinh nhit ring q
21
:
Tc sinh nhit ring do ma st trn mt trc dng c c tnh theo cng
thc:
21
( ) ( ) q x V x t =
(4.18)
Trong : t
(x)
l ng sut tip mt trc, V
(x)
l vn tc ca lp phoi di cng.
tnh gi tr tc sinh nhit ring trn mt tip xc ca dao v phoi, c th
da vo m hnh phn b ng sut nh trn Hnh 1.11.
ng sut tip bin thin theo quy lut [81], [106]:
1
(x) s 1
1
( ) 0
= (x)=
s
n
x x l
l x
l x l
l l
t t
t o t
= s s
| |
s s
|

\ .
(4.19)
Vi
s
t l gii hn chy trt trung bnh trn b mt tip xc ; l l chiu di tip
xc; l
1
l chiu di phn dnh, ni ng sut trt c gi tr bng hng s; n l hng
s thc nghim ph thuc vo vt liu v iu kin gia cng: n=1922 cho mt di
rng cc s liu thc nghim [55].


52
Vn tc lp phoi cui cng thay i theo chiu di tip xc (Hnh 4.4):
( )
1
1
1 2
( ) 0
3 3
sin
cos( )
c
c
x
V x V x l
l
V
V x V l x l
|
| o
| |
= + s s
|
\ .
= = s s

(4.20)
Gn ng c th coi ng sut trt
thay i bc nht trn chiu di t
1
l x l s s v c biu din theo quan h
(Hnh 4.4) [55]:
1
(x) s 1
1
( ) 0
=
s
x x l
l x
l x l
l l
t t
t t
= s s
| |
< s
|

\ .

(4.21)
T (4.17) n (4.21) c th v c biu phn b nhit to thnh do ma st
trn mt trc vi gi tr cc i ng vi v tr
1
x l = .
1
1
21
s 1
1
2
1 0
3
s c
c
V x
x l
l
q
l x
V l x l
l l
t
t
| |
+ s s
|
\ .
=

| |

< s
|

\ .
(4.22)
* Xc nh tc sinh nhit ring q
22

Tc sinh nhit trn mt n v th tch vt liu trong vng bin dng do th
hai c tnh theo cng thc [62]:
22 sec sec
q t = (4.23)
vi
sec
t l ng sut chy trt trong vng bin dng th hai;
sec
l tc bin
dng trong vng trt th hai:
sec
w
F
F
l
t = (4.24)
vi F
F
l lc ma st trn b mt tip xc, tnh theo cng thc:
sin cos
F C T
F F F o o = + (4.25)
F
c
, F
T
l lc tip tuyn v lc dc trc; l gc trc; l l chiu di tip xc; w
l chiu rng tip xc (chiu su ct).
Hnh 4.4. Bin thin vn tc trt,
ng sut trt v nhit to thnh
trn mt tip xc gia phoi v dng
c.



l
1
V
phoi
/3
t
s
q
f
l


53
Theo mt s nghin cu [62], [90],
vng bin dng do th hai c gi thit
c dng hnh tam gic vi t
p
l chiu dy
ln nht ca vng. Do kt qu ca hin
tng dnh nn vn tc bin i t gi tr
bng 0 ti v tr tip xc trn b mt dng
c n gi tr V
c
mt ct ngang cch
mt tip xc mt khong bng chiu dy
t
p
(Hnh 4.5). Tc bin dng t l
thun vi vn tc trt v t l nghch vi
khong cch t
p
v

c tnh theo cng thc [62], [86] :
sec
p
V
t
= ;
2 p
t t o = (4.26)
vi t
2
l chiu dy phoi.
2
t o c xc nh t hnh nh bin dng trong nh chp
cu trc t vi ca phoi, gi thit bng hng s 0,05 cho mt di rng tc ct v
thp cc bon thp [90] hoc bng 1/8 cho di rng tc ct xem xt [62].
* Xc nh ng sut tng ng:
n gin, khi tnh ton coi nhit sinh ra trong vng bin dng th hai v ma
st gia phoi v mt trc tng ng vi nhit sinh ra do ma st tng ng
gia phoi v mt trc, xc nh theo nguyn tc bo ton nng lng, ngha l tng
tc tiu th nng lng trong vng bin dng th hai v do ma st gia phoi v
dng c bng tc tiu th nng lng ca lc trt F
F
trn

mt trc [6].
Theo m hnh ny, quy lut bin thin ng sut tip tng ng trn mt trc
phn b nh sau:
(x) s
'( ) ' 0 / 2
' =2 ' 1 / 2
s
x x l
x
l x l
l
t t
t t
= s s
| |
< s
|
\ .
(4.27)
Vi
1
2 l l ; '( ) x t , '
s
t l ng sut tng ng bin thin v khng i c xc
nh t nguyn tc bo ton nng lng nu trn.
Tc sinh nhit ring trn vng tip xc gia phoi v dng c l:
Hnh 4.5. Hnh dng v kch thc
vng bin dng [90].




Phi
v
Dao
Vng bin
dng th nht
V

n
g

b
i

n

d

n
g

t
h

h
a
i
Phoi
C
A
E
M
D
B
F
V
c
H


54
2
s
' 4
1 0 / 2
3
2 ' 1 / 2
s c
c
V x
x l
l
q
x
V l x l
l
t
t
| |
+ s s
|
\ .
=

| |

< s
|

\ .
(W/mm
2
) (4.28)
Vi '
s
t c xc nh da vo gi thit trn nh sau:
Tc sinh nhit do ma st trn ton b vng tip xc gia phoi v dng c l:
/2
2 s
0 /2
' 4
1 2 ' 1
3
l l
s c
c
l
V x x
Q bdx V bdx
l l
t
t
| | | |
= + +
| |
\ . \ .
} }

(4.29)

/2
2 s
0 /2
' 4
1 2 ' 1
3
l l
s c
c
l
V b x x
Q dx V b dx
l l
t
t
| | | |
= + +
| |
\ . \ .
} }

2
1 1
'
3 4
s c F c
Q V bl F V t
| |
= + =
|
\ .

'
1 1
3 4
F
s
F
bl
t =
| |
+
|
\ .
(4.30)
Thay vo (4.28), vi cc gi tr bit ca
F
F
, b bng chiu su ct t; chiu di tip xc l;
vn tc phoi V
c
; xc nh c tc sinh nhit
trn mt trc ca dng c q
2
(x) phn b theo
quan h hm s bc nht dc theo chiu di tip
xc ca phoi v dng c.
+ Tnh nhit sinh ra trn mt tip xc gia dao v
phi:
Nhit sinh ra trn mt tip xc gia dao v
phi c coi nh phn b u (Hnh 4.6). Tc
sinh nhit c tnh theo cng thc [55]:
3
1
1
w
c c
q K VF
t
= (4.31)
Vi K
c
l h s do lc ct khi dng c mn c xc nh bng thc nghim; V
l vn tc ct; F
c
l lc ct tip tuyn; t
1
l chiu dy phoi khi cha bin dng; w l
chiu rng phoi, xc nh nh sau:
Hnh 4.6. Phn b ng sut
trn mt tip xc gia dao v
phi [55].



O
AF
t
V
Dao
o t
f
d
AFc
Vc
Phoi
P
h

i


55
1
tf t
t
t
t t
F F
F d
K
F F t

A
= = (4.32)
1
cf c
c
c
c c
F F
F d
K
F F t

A
= = (4.33)
tf
F ,
cf
F l lc ct dc trc v lc ct tip tuyn khi dng c mn; K
c
; K
t
l h s
xc nh t thc nghim; d l chiu cao vng mn mt sau; w l chiu rng phoi; t
1

l chiu dy phoi khi cha bin dng (lng chy dao);
Thc nghim cho thy:
K
c
=0.0671; K
t
=0.0528 [55];
3
1
1
0.0671
w
c
q VF
t
= (4.34)
Vi cc gi tr bit tng ng ca vn tc ct V, lc tip tuyn F
c
=F
z
, chiu
dy phoi t
1
=t
c
, xc nh c mt dng nhit khng i trn b mt tip xc gia
mt sau dng c b mn vi b mt phi a
3
.
Gi tr tc sinh nhit ti cc ngun nhit c tnh ton v tng hp trong
Bng 4.3.
4.1.4. Trng phn b nhit trong dng c PCBN khi tin cng trc giao thp
9XC bng dao PCBN xc nh bng phng php phn t hu hn
Trng phn b nhit trong
qu trnh tin cng trc giao thp
9XC s dng dao PCBN c xc
nh bng phng php phn t
hu hn vi s h tr ca phn
mm ABAQUS. M hnh tnh
ton c xy dng dng m
hnh 3D nh Hnh 4.7a. Ton b
h thng dao-phoi-phi c xem xt trong mi quan h tng tc v truyn nhit.
Bng 4.3. Cc thng s tnh ton xc nh cc ngun nhit
AB
k
(N/mm
2
)
s
A
(mm
2
)
1
q
(W/mm
2
)
sec

(1/s)
sec
t
(N/mm
2
)
' t
(N/mm
2
)
2max
q
(W/mm
2
)
3
q
(W/mm
2
)
919,32 0,45 1397 1,2 286 490 450 303

Hnh 4.7. M hnh tnh ton trng phn b
nhit trong tin cng trc giao bng FEM (a)
v s chia li cc phn t (b).


a) b)


56
Qu trnh truyn nhit gia phi, phoi v dng c c coi nh thc hin trong
mi trng lin tc.
Th tc chia li cc phn t ca m hnh c thc hin trong phn mm
ABAQUS vi cc thng s iu khin ph hp cc vng sinh nhit c chia
vi cc phn t c kch thc nh mn nhm t chnh xc cao. Tng cng,
ton b m hnh c chia thnh 557.758 phn t dng t din, mi phn t c 4
nt vi tng s 2.231.032 nt nh Hnh 4.7b.
Vi cc thng s
u vo xc nh
bao gm kch thc
hnh hc ca vng
kho st, cc thuc
tnh vt liu ca
dng c v chi tit
gia cng, mt
dng nhit v cc iu kin bin, s tc dng ca cc ngun nhit ca bi ton
c thc hin nh trong Hnh 4.8.
Qu trnh phn tch
trng phn b nhit khi
tin trc giao thp 9XC
bng dao PCBN vi cc
thng s ct nh trn c
tin hnh cho hai trng
hp dng c sc v dng c
mn. Trng phn b nhit
nhn c nh trn Hnh
4.9 v Hnh 4.10.
Gi tr nhit ti cc
nt c xut ra file kt qu
nh trong Ph lc III.
Kt qu phn tch cho
trng phn b nhit cho thy:
500
0
500 1000 1500
1000
Gradient
1500
327
0
C
m
m
991
0
C
1060
0
C
695
0
C
418
0
C
a)
c)
b)
e) d)
Hnh 4.9. Trng phn b nhit khi tin cng trc
giao thp 9XC bng dao PCBN trong trng hp
dng c sc (a-d) v s cc ng ng nhit
phn b trong dng c (e).



Hnh 4.8. S tc dng ca cc ngun nhit trong m hnh
tnh ton trng phn b nhit.




57
Vi c hai trng hp dng c sc v mn, vng sinh nhit ln nht lun l
vng mt phng trt vi gi tr nhit cc i l 1436
0
K (1163
0
C) khi dng
c sc v 1810
0
K (1537
0
C) khi dng c mn (Hnh 4.9a, Hnh 4.10a).
Khi dng c cn sc,
trng phn b nhit
trong dng c c trung
tm nhit ln nht nm
mt trc dng c vi
nhit cc i t
1333
0
K (1060
0
C) ti v
tr cch li ct khong
45m (Hnh 4.9b). Phn
b nhit trn chi tit gia
cng cng tp trung
vng mt phng trt,
phn ln nhit lng
truyn vo phoi, phn
nhit truyn xung chi
tit gia cng lm nhit
chi tit tng n khong 400500
0
C vi vng phn b nhit tng i hp
(Hnh 4.9d).
Khi dng c bt u b mn, phn tip xc gia mt sau dng c v chi tit gia
cng hnh thnh mt trung tm sinh nhit mi khin cho trng phn b nhit
trong dng c dch chuyn v pha li ct vi cc cung ng nhit gn nh i
xng gia mt trc v mt sau ca dng c. Trung tm nhit ln nht s nm ti
vng li ct vi gi tr l 1635
0
K tng ng vi 1362
0
C (Hnh 4.10b). Lng
nhit mt sau truyn vo b mt mi hnh thnh v dng c lm tng nhit
chi tit n 800900
0
C v m rng vng tc ng ca nhit cao trn chi tit gia
cng (Hnh 4.10d).
Nh vy vi vic dng c b mn s hnh thnh mt trung tm sinh nhit mt
sau lm tng ng k nhit ct ng thi lm thay i trng phn b nhit trong
dng c v chi tit gia cng.
a)
c)
b)
500
0
500 1000 1500
1000
Gradient
1500
327
0
C
m
m
960
0
C
1149
0
C
692
0
C
418
0
C
1362
0
C
e) d)
Hnh 4.10. Trng phn b nhit khi tin cng trc
giao thp 9XC bng dao PCBN trong trng hp dng
c b mn mt sau (a-d) v s cc ng ng nhit
phn b trong dng c (e).




58
4.2. Trng phn b nhit trong dng c PCBN khi tin cng trc giao thp
9CX xc nh bng phng php thc nghim
4.2.1. Thit b v ch th nghim
xc nh trng phn b nhit trong dng c ct i hi mt phng php
cho php v nn cc ng ng nhit trong lng dng c v d dng lu gi chng
sau khi gia cng. iu ny c th thc hin c nh s dng cc lp vt liu c
nhit nng chy xc nh ph vo b mt ghp ca dng c ct.
Th nghim xc nh trng phn b nhit ct trong dng c PCBN c tin
hnh cho s tin trc giao trn my tin vn nng HOWA STRONG 860 - Nht
Bn (Hnh 3.1a). Vt liu th nghim l thp 9XC nhit luyn t cng 52HRC
vi kch thc phi dng ng nh Hnh 4.11.

Dng c s dng cho th nghim l mnh dao PCBN dng c k hiu
TPGN160308T200-BAO-EB28X ca hng EHWA (Hn quc), c ch to theo
n t hng
khi ghp li c
dng tam gic
u dng tin
trc giao mt
u (Hnh 4.12).
Mnh dao ghp
sau khi lp vi
thn dao s to
thnh cc thng
s hnh hc c th sau: Gc trc = -6
0
, gc sau o= 6
0
, cnh vin li ct c vt
Hnh 4.11. Phi thp
9XC dng trong th
nghim.



Hnh 4.12. Mnh ghp
PCBN dng c (a) v
thn dao (b) s dng
trong th nghim.


a) b)
B mt ph
Bng 4.4. Kim loi ph v
im nng chy tng ng

TT Vt liu
im nng
chy (
0
C)
1 Thic (Sn) 232
2 Ch (Pb) 327
3 Km (Zn) 419
4 Nhm (Al) 659
5 Bc (Ag) 961
6 Vng (Au) 1064

Hnh 4.13. Knh hin vi in
t qut Jeol-JSM 5410 LV.




59
mp vi gc vt u=20
0
, cnh vt rng a=0,1mm.
B mt ghp l mt trung trc ca tam gic s c ph cc kim loi nguyn
cht c nhit nng chy xc nh nh trong Bng 4.4. Chiu dy lp ph l
150nm m bo lp ph ng u. Thnh phn lp ph v tnh trng mnh dao
trc v sau khi gia cng
c kim tra trn knh hin
vi in t qut Jeol-JSM
5410 LV (Hnh 4.13).
Phn tch EDX cho bit
hm lng ca lp vt liu
ph nh sau: Sn chim
63,5% ; Pb chim 64,5% ;
Zn chim 53,5%; Al chim
45,5%, Ag chim 58,5%; Au
chim 55,8% (Hnh 4.14).
Mi mnh dao sau khi ph lp kim loi nguyn cht s c ghp li vi nhau
v dng gia cng phi ng tng ng vi qu trnh ct trc giao vi chiu su
ct t=3mm, lng chy dao s=0,06mm/v, vn tc ct v=75,3m/p trong thi gian 10
giy m bo trng nhit trong dao t trng thi n nh [60]. Sau mnh
dao c tho ra v b mt ghp c kim tra trn knh hin vi in t qut xc
nh hnh nh cc ng ng nhit. Di tc dng ca nhit ct, cc lp ph kim
loi s b nng chy ti vng c nhit cao hn im nng chy ca kim loi ph.
Bin gii gia phn nng chy v cha nng chy ca lp ph s xc nh cc
ng ng nhit tng ng vi nhit nng chy ca vt liu ph.
4.2.2. Trng phn b nhit trong dng c PCBN
nh chp SEM b mt ghp c ph kim loi nguyn cht ca cc mnh dao
cho thy r cc ng bin gii gia vng nng chy v khng nng chy ca kim
loi ph. Cc bin gii ny xc nh cc ng ng nhit tng ng vi nhit
nng chy ca lp ph (Hnh 4.15).
Kt qu t o c thc nghim cho thy profin vng nhit nh hng ln dao
tng ng vi trng hp dao b mn mt sau trong m hnh l thuyt vi chiu cao
a)
f) e)
d)
b)
c)
Hnh 4.14. Phn tch EDX thnh phn lp ph:
Sn(a), Pb(b); Zn(c); Al(d); Ag(e); Au(f).




60
vng mn khong 200m. Hin tng ny c cho l do b mt ghp khng hon
ton kn kht nn nhit
truyn vo b mt ghp
ngoi tc dng dn nhit cn
c tc dng ca truyn nhit
do i lu.
Vng nhit tng
ng vi im nng chy ca
Au l 1064
0
C cch li ct
khong 200m, ca Al l
659
0
C cch li ct khong
350m, ca Zn l 419
0
C
cch li ct khong
800m, ca Pb l 327
0
C cch li ct khong 1200m v ca Sn l 232
0
C cch li
ct khong 2500m (Hnh 4.16a).
So snh gia m hnh cc ng ng nhit l thuyt v thc nghim cho thy
m hnh l thuyt c s tng hp cao vi cc o c thc nghim. V tr cc
ng ng nhit xc nh theo m hnh l thuyt gn nh trng khp vi cc
ng ng nhit xc nh
theo phng php o c
thc nghim vi sai khc
nh v tr bin nng chy
ca Zn (419
0
C) l 1
0
C
chim 0,2%, ca Al
(659
0
C) l 33
0
C chim
5%, Ag(919
0
C) l 1
0
C
chim 0,1% v ca Au
(1064
0
C) chim 7,9% (Hnh 4.16b). Tuy nhin c s sai khc v phn b nhit trn
mt trc v mt sau dng c hai m hnh khi phn b nhit trong m hnh l
thuyt m rng hn pha mt trc dng c trong khi phn b nhit xc nh bng
thc nghim li m rng hn v pha mt sau. Nguyn nhn ca hin tng ny
c gii thch l do khe h gia hai b mt ghp khin cho ngoi qu trnh
Hnh 4.16. Cc ng ng nhit trong dng c
PCBN xc nh theo o c thc nghim (a), so snh
gia cc ng ng nhit l thuyt v thc nghim
(b).


Gradient
500
0
500 1000 1500
1000
2000
Gradient
1500
2000
232
0
C
327
0
C
419
0
C
659
0
C
1064
0
C
m
m
961
0
C
2500
2500
327
0
C
692
0
C
418
0
C 960
0
C
1149
0
C
Mt sau
M

t

t
r
-

c
Thc nghim
L thuyt
500
0
500 1000 1500
1000
2000
Gradient
1500
2000
232
0
C
327
0
C
419
0
C
659
0
C
1064
0
C
m
m
961
0
C
2500
2500
Mt sau
M

t

t
r
-

c
a) b)
a) c) b)
d) e)
f)
Hnh 4.15. nh SEM b mt ghp mnh PCBN c
ph cc kim loi tng ng Sn(a), Pb(b), ZN(c),
Al(d), Ag(e), Au(f) sau khi gia cng 10s ch
ct t=3mm, s=0,06mm/v, v=75,3m/p.




61
truyn nhit do dn nhit cn c truyn nhit do i lu b mt ghp lm tc
truyn nhit trn b mt ny cao hn so vi truyn nhit trn mt trc dng c.
Kt qu tnh ton v nhit cho thy, nhit ct sinh ra trong qu trnh tin trc
giao thp 9XC rt ln. Mc d phn ln nhit ct c mang i bi phoi v ch mt
phn nh nhit lng truyn vo dng c nhng nhit vng ct ca dng c
PCBN vn rt cao (trn 1000
0
C). C th thy, nguyn nhn lm nhit cc b trn
li ct dng c tng cao l do tnh dn nhit km ca vt liu PCBN khi c ngun
nhit lin tc truyn vo mt v tr c nh ca dng c. Mt khc, trong qu trnh
tin cng, vt liu gia cng c bn cao nn yu cu nng lng ph hy ln lm
lc ct ln dn n tc sinh nhit cao.
Nhit rt cao ti vng li ct dng c PCBN trong qu trnh tin cng s
lm thay i c tnh vt liu cht nn ca dng c dn n hin tng mn v bin
dng do nhanh chng li ct dng c PCBN ch trong thi gian ngn sau khi gia
cng. Nhit rt cao cn l nguyn nhn thc y cc qu trnh ha l din ra
nhanh hn, thc y cc c ch mn v ph hy dng c m s c phn tch t m
chng 5.
4.3. Kt lun chng 4
Trng phn b nhit trong h thng phi, phoi v dng c khi tin trc giao
thp 9XC ti t cng 55HRC bng dao PCBN xc nh bng phng php phn
t hu hn vi cc gi tr tc sinh nhit ti cc ngun nhit c tnh ton da
trn nghin cu ca nhiu tc gi vi cc gi thit nht nh.
ch ct v=119m/p; s=0,06mm/v; t=2mm, kt qu chy m hnh t phn
mm ABAQUS cho hnh nh trung tm nhit ln nht nm vng mt phng
trt vi nhit t ti 1752
0
K (1479
0
C) khi dng c sc v 1873
0
K (1600
0
C) khi
chiu cao mn mt sau t gi tr h
s
=300m. Tng ng, trung tm nhit ln nht
ca dng c nm mt trc vi nhit ln nht t ti 1425
0
K (1142
0
C), cch
li ct 45m khi dng c sc v nm ngay trn li ct vi nhit t ti 1635
0
K
(1352
0
C) khi chiu cao mn mt sau t h
s
=300m.
Trng phn b nhit trong dng c PCBN khi tin trc giao thp 9XC xc nh
bng phng php o c thc nghim ch ct tng ng sau thi gian gia
cng 10s c trung tm nhit ln nht nm trn li ct t nhit 1337
0
K


62
(1064
0
C). Cc ng ng nhit xc nh t phng php thc nghim cho thy
vng nh hng ca nhit cao tng i rng, bn knh ti 150m nhit
1337
0
K (1064
0
C) v 2000m 505
0
K (232
0
C). Trung tm nhit cao nm ngay
trn li ct l nguyn nhn thc y tc mn v ph hy li ct ca dng c
PCBN.
Kt qu o c thc nghim c s tng thch kh cao vi kt qu nhn c t
m hnh l thuyt khi sai lch khng qu 7,8%. iu ny chng t m hnh l
thuyt c xy dng st vi iu kin thc t, m bo tin cy v c th s
dng kho st cho cc ch gia cng khc.



63
Chng 5
MN DNG C PCBN V CHT LNG B MT
KHI TIN THP HP KIM QUA TI
5.1. Mn v c ch mn dng c PCBN khi tin thp hp kim qua ti
5.1.1. nh hng ca cng vt liu gia cng n mn v c ch mn dng
c PCBN
Nghin cu v nh hng ca cng vt liu gia cng n mn v c ch mn
dng c PCBN c tin hnh trn phi thp X12M cc cng khc nhau.
Cc thit b th nghim nghin cu v mn v c ch mn dng c PCBN nh
trn Hnh 2.3 bao gm: My tin k thut s CNC-HTC2050 - Trung Quc (Hnh
2.3a); Mnh dao PCBN ca hng EHWA -Hn quc k hiu TPGN160308T200-
EB15 (Hnh 2.3b) c cc thng s: L=16mm, LC=9,25mm, T=3,18mm, R=0,8mm.
Cht kt dnh TiN, c ht 4m. Thn dao ca hng CANELA) k hiu:
MTENN2020K16-N (Hnh 2.3c). Gc to thnh khi g mnh ln thn dao:
=110, =110. S th nghim tin mt tr ngoi nh Hnh 2.3d.
Quan st trn knh hin vi in t cc mnh dao PCBN dng trong qu trnh th
nghim cho thy chng u b mn c mt trc v mt sau. Cc vt mn th hin
cc vt bin dng do, cc vt co xc, lp kim loi phi dnh bm v hin tng
li ct b ph hy (Hnh 5.1).
Nh vy, mn dng
c PCBN c gy bi
mt c ch kt hp gia
mi mn, bin dng
do, dnh, khuch tn v
ph hy v nhit. Khc
vi nhn nh ca cc
nghin cu trc cho
rng li ct dng c
PCBN khng b bin
dng do, c th quan
st rt r hnh nh ca bin dng do li ct dng c PCBN.
Hnh 5.1. Cc dng hng ca dng c PCBN : (a) mn
mt trc, (b) mn mt sau, (c) ph hy li ct, (d) bin
dng do v dnh, (e) co xc, (f) nt v ph hy.
a)
b)
f)
c)
d)
e)


64
Kch thc vt mn lm trn mt trc dng c thay i theo cng vt liu
gia cng. Trong trng hp tin thp X12M, vt mn lm c chiu rng xp x
150m, chiu di tng theo cng: ~600m khi cng 45 47HRC, ~700m
khi cng 5456HRC, ~800m khi cng 6062HRC (Hnh 5.2).
Hin tng dnh v lng ng ca vt liu phi trn mt trc ca dao cng ph
thuc vo cng ca vt liu phi. cng 45 47HRC, lp kim loi phi dnh
bm trn ton b vng trt v vng chuyn tip. Khi cng > 50HRC, vng
chuyn tip gn nh khng c kim loi phi dnh bm, ch cn lp dnh vng
trt. Lp vt liu phi bm ph ngoi vng tip xc tng mnh khi cng
>60HRC (Hnh 5.2).
Vng mn mt trc dng c PCBN khi tin cng thp X12M qua ti phn bit
thnh ba vng r rt: vng dnh, vng trt v vng chuyn tip (Hnh 5.3a). Cc
vng mn ny cng tng ng vi biu phn b ng sut trn mt trc dng c
(Hnh 5.3b) [81].
T biu phn b ng sut trn Hnh 5.3b c th thy, ti vng mn dnh, di
tc dng ca ng sut php ln v nhit cao, vt liu phi v dao to thnh mi
lin kt kim loi bn cht khin cho phoi c qu trnh dng y v b nn li [67].
Hnh 5.2. Hnh nh mn mt trc v mt sau ca dao PCBN khi ct phi thp
X12M cc cng 4547 (a,b,c,d); 5456 (e,f,g,h) 6062 HRC (i,k,l,m).

g)
a)
b) c)
e) f)
i) k)
l)
h)
m)
d)


65
Hai b mt dao-phoi khng
tip xc ti cc nh nhp
nh m tip xc hon ton
trn ton b din tch, gia
hai b mt khng tn ti cc
vt nt t vi. Qu trnh trt
s xy ra trong lng vt liu
no yu hn. ng sut tip t
c gi tr khng i, khng
ph thuc vo ng sut php
o. Quan h ca lc ma st vi p lc php tuyn khng cn theo quy lut thng
thng [61].
Tuy nhin, khc vi tin thng thng cc vt liu c cng thp cho thy
s trt vng dnh ny xy ra bn trong lp vt liu phoi, gn vi b mt tip
xc gia phoi v dng c. y, qu trnh trt xy ra bn trong lp vt liu dng
c khi khng thy vt liu phoi dnh bm vng ny. C ch trt trong iu kin
tip xc chu ng sut ln nh vy c th gn lin vi c ch lch cnh bi v yu
cu nng lng t hn nhiu so vi trt trn ton b b mt [81]. Vng kt dnh
c b rng nh hn nhiu so vi lng
chy dao cng l mt khc bit ca qu
trnh tin cng so vi tin thng thng
[94]. Nguyn nhn ca hin tng ny
c cho l do ranh gii ca vng kt
dnh v vng trt khng phi bt u t
trung im ca chiu di tip xc nh
cc ti liu cp, m bt u t im
E no , khi gi tr ng sut php o bt
u nh hn ng sut tip t (Hnh 5.3b).
Quan st vng mn dnh c th thy r cc vt bin dng do vi b mt nhn,
ch yu l kim loi nn, khng c kim loi phi dnh bm. Mt ca cc ht CBN
vng ny gim mnh. cng cao, i khi bt gp cc bin dng hnh sng
(Hnh 5.4).

A
C D
B
V
x
D'
Chip
Tool
oc
tc
oc
tc
E
b)
Vng
chuyn tip
Vng trt
Vng dnh
a)
Hnh 5.3. Cc vng mn mt trc dng c PCBN
khi gia cng thp X12M, cng 6062 HRC (a);
Bin thin ng sut trn b mt dng c (b) [83].
Hnh 5.4. Vt mn dng sng do tc
dng ca cc ht cacbit trong vt liu
phi.


66
Cc rnh dng sng l do cc ht cacbit c cng rt cao c trong phi gy ra,
c bit vi thp X12M. Kim tra cu trc t vi cho thy khc vi t chc ca thp
9XC ch yu l mactenxit dng hnh kim xen k vi cc ht cacbit nh mn phn b
ng u (Hnh 2.2), cu trc t vi ca thp X12M cha nhiu ht cacbit vi kch
thc ln nm xen ln t chc mactenxit trong thp (Hnh 2.1). cng ca cc ht
cacbit ny t ti 658713HV tng ng 58,260,6HRC trong khi t chc nn
ch c cng 512545HV tng ng 49,952HRC (Hnh 3.4). iu ny l gii
tnh kh gia cng ca loi vt liu ny ngay c khi c mi v nguyn nhn khin
dng c b mn vi tc rt nhanh khi gia cng thp X12M. Chnh lch cng
gia cc pha trong vt liu phi X12M khin dng c b mn khng u, to nn
cc bin dng sng li ct dng c. L do ny cng c khng nh khi khong
cch cc rnh sng c chiu rng xp x kch thc ca cc ht cacbit trong phi:
~2025m. Nhit cao lm gim c tnh ca cht dnh kt trong vt liu dng c
khin cho lin kt gia chng vi cc ht PCBN gim. Di tc dng ca chuyn
ng va ln va trt ca cc ht cacbit, cc ht PCBN d dng b y bt ra hoc
b ln su vo cht dnh kt to nn vng mn c b mt tng i nhn ca cht
nn (Hnh 5.4).
Nh vy, dng mn vng dnh c nguyn nhn t cc pha cng trong cu trc t
chc t vi ca vt liu phi. T chc ht nh mn s gy ra vng mn bng phng v
u hn. Vng mn dnh s hnh thnh mt b mt trc ph cho dao vi gc trc
mi m ln hn gc trc m ban u. V y l vng dung dch trn ngui khng
th tip cn nn c th ci thin kh nng chng mn cho dao bng cch ch to dao
vi li ct c vt cnh c gc m ln hn tng bn cho dao. Vic la chn
cc ch nhit luyn to thnh cc pha cacbit vi t chc nh mn cng c th
ci thin c dng mn vng kt dnh.
Trong vng trt, kim loi chuyn ng vi vn tc rt cao v ngoi tc ct
cn c hin tng trt n hi ca cc phn t kim loi do b nn trong vng dnh.
H s ma st tun theo cc quy lut ma st thng thng v bng hng s
t

o
= .
Kim loi phi bm nhiu vng trt. V tr lp kim loi dnh bm ph thuc vo
vn tc ct v nht ca pha lng tn ti gia b mt tip xc ca phoi v dng
c. Bng chng v mt pha lng tn ti trn mt tip xc gia phoi v dng c c


67
th thy r qua hnh nh ca vt liu phi nng chy bn ra xung quanh vng tip
xc (Hnh 5.2). C th thy khi cng phi thp, nhit sinh ra khng ln nn pha
lng c nht cao. Do , chng c th bm li trn vng trt thnh mt lp ph
c tc dng bi trn vng trt v bo v b mt dng c. iu ny l gii hnh nh
ca vt mn lm khng r v kim loi phi dnh bm trn ton b vng trt khi
cng phi nh (Hnh 5.2a,b,c). Khi cng phi tng, nht ca pha lng gim,
kim loi lng d dng b p bn ra khi b mt tip xc v ng li vng xung
quanh. V vy vng chuyn tip khng c kim loi phi dnh bm v kim loi bm
nhiu ngoi vng tip xc. cng cng cao v tr ng li trn b mt tip cng
xa v tr tip xc chng t nht ca pha lng cng thp v vn tc ct khng i.
C th thy, vic pha lng tn ti trn b mt tip xc gia phoi v dng c c kh
nng th ci thin kh nng chng mn cho dng c vng ny. Nh vy, vic
nghin cu la chn ch ct thch hp c th iu khin c nht ca pha
lng v ci thin c tui th cho dng c PCBN.
Mn mt sau cng c cng c ch nh mn mt trc. C s tng nh ca chiu
cao vng mn khi tng cng phi. cng 45HRC, chiu cao vt mn ~100
m, tng ln ~ 150 m khi cng 6062HRC (Hnh 5.2).
Thnh phn ca vt liu phi v dao c nh hng ln n dng mn do khuch
tn v tng tc ha hc ca dng c. Cc bng chng v mn do khuch tn v
tng tc ha hc c th
hin qua kt qu phn tch
thnh phn cc cht trn b
mt dao v mt di ca
phoi. S xut hin ca cc
nguyn t c trong c vt
liu phi v dng c nh Fe,
Cr, Mo, Ti chng t c s
khuch tn ca vt liu t
dao vo phoi v ngc li
(Hnh 5.5). Mt khc, xy
c tm thy trn ton b
vng mn chng t cc
b)
a)
Hnh 5.5. Phn tch EDX cc cht trn b mt
dng c(a) vng kt dnh, (b) vng trt.


68
nguyn t kt hp vi xy ngay t vng dnh di tc dng ca nhit v p sut
cao. Tng tc ha hc to ra cc hp cht c nhit nng chy thp hn nhit
nng chy ca kim loi nguyn gc, v d F
2
B c nhit nng chy khong
1450
0
K, B
2
O
3
c nhit nng chy 723
0
K khin cho kim loi vng tip xc d
dng chuyn thnh pha lng nh kt lun trn.
Nhit vng ct cao l nguyn nhn v xc tc ca cc qu trnh mn nh
bin dng do, dnh, khuch tn v tng tc ha hc. Khi nhit qu ln, vt liu
dng c s xut hin cc nt mi do nhit dn n v vn li ct (Hnh 5.2g).
Khi dng c b mn n mt gi tr nht nh lm tng din tch tip xc gia
dao v phi khin ma st sinh ra ln, nhit tng cao dn n hin tng ph hy
li ct di tc dng ca nhit .
5.1.2. nh hng ca ch ct n mn v c ch mn dng c PCBN
Kho st mt sau cc mnh dao PCBN khi gia cng thp 9XC cng 57HRC
ba ch ct khc nhau tng ng vi vn tc ct v=140 m/p; 160m/p v 180
m/p cho thy, mn mt sau lun tn ti t li ct chnh vi chiu cao h
s
tng dn
t pha mi dao n cui chiu di ct trn li ct chnh, chiu cao mn u t
h
smax
~0,1 mm mc d thi gian ct khc nhau nhiu. Cu trc ca b mt mn ny
bao gm lp dnh ca vt liu gia cng trn b mt v cc vt co xc. Cc rnh
mn c chiu su ln khi tng vn tc ct (Hnh 5.6).
(e)
(f)
(c)
(b)
(d)
(a)

(e)
Hnh 5.6. nh vng mn mt sau ca mnh dao PCBN ct vi vn tc ct (a)
v
1
=180 m/p sau 7,69 pht; (b) v
2
=160 m/p sau 12,36 pht; (c) v
3
=140 m/p sau
19,72 pht; nh phng to vng mn mt sau trn li ct chnh (d,e,f).



69
Khi ct vi vn tc ct 180 m/p, sau 7,69 pht, trn mt sau xut hin hai vng
vt liu dng c b phng rp pha di li ct chnh v ph nhng vng phng
rp di li ct ph ln hn v gn mi dao hn (Hnh 5.6a).
Khi gim vn tc ct xung 160 m/p, sau 12,36 pht, trn mt sau ch xut hin
mt vng b phng pha di li ct ph (Hnh 5.6b). Tip tc gim vn tc
ct ti 140 m/p, sau 19,72 pht, mt sau ch tn ti vng dnh vt liu gia cng
(Hnh 5.6c).
Kt qu phn tch vng
phng di li ct ph cho
thy vt liu dng c trong vng
ny b phng ln tng mng v
ln lt bong ra khi mt sau to
thnh nhng hc rng v nng
trn b mt ny (Hnh 5.6e). So
snh hnh nh cu trc b mt
nguyn thy ca mnh dao
PCBN v cu trc b mt ca mnh dao PCBN trn vng phng rp cho thy, mt
cc ht PCBN trn vng phng rp cao hn rt nhiu so vi mt PCBN trn
b mt nguyn thy (Hnh 5.7).
Hnh nh vng li ct ph trn mt trc khi gia cng sau 12,36 pht ct vn
tc ct 160 m/p cho thy vng li ct ph di mi dao b ph hy (Hnh 5.8). C
ch ph hy ca vng ny l s v ra tng mng vt liu dng c di tc dng ca
lc ct trong cc mt phng
gn vung gc vi mt trc
(Hnh 5.8b). Qu trnh ph
hy b phn li ct ph pht
trin dn n mi dao v lm
tng nhm b mt gia cng.
C th thy, c ch mn
mt sau trn li ct chnh l
do tng tc gia lp dnh
(b) (a)
Hnh 5.7. Cu trc t vi t chc vt liu vng
phng rp di li ct ph (a) v vng vt
liu nguyn thy ca dng c PCBN (b).

Hnh 5.8. a) nh vng mn mt trc mnh
PCBN (khi ct vn tc ct 160 m/p sau 12,36
pht); (b) nh phng to th hin c ch ph hy
li ct ph.

(a)
(b)


70
ca vt liu gia cng trn mt sau dng c vi cht dnh kt ca vt liu dng c
lm cc ht CBN b tch ra khi b mt sau ca dao to nn ngun ht mi mn gy
co xc b mt sau (Hnh 5.6d). Cc ht cacbit (FeCr)
3
C vi mt cao v ng
knh xp x 3m trong thp 9XC cng l mt nguyn nhn gy ra mn do co xc
trn mt sau. Mn mt sau t li ct chnh xy ra lin tc vi tc chm. Tc
mn v chiu cao mn h
s
tng khi tng vn tc ct. Khi gim vn tc ct t 180 m/p
xung 140 m/p thi gian mn t ti gi tr h
smax
tng ln 2,5 ln.
Mn mt sau trn vng pha di li ct chnh v ph khi ct vi vn tc 180
m/p v ch di li ct ph khi ct vi vn tc 160 m/p l nguyn nhn ch yu
gy ph hy li ct ph, dn ti ph hy mi dao. Mn vng ny xy ra vi tc
cao do vt liu ca dao trn mt sau b bong ra tng mng lm yu vng di
li ct, c bit l vng di li ct ph. C th thy r c ch mn ny lin quan
n nhit pht trin trn mt sau v khi gim vn tc ct t 180m/p xung
160m/p (tc l gim nhit ct) mn dng ny ch cn tn ti di li ct ph
nhng pht trin chm hn (sau 12,36 pht so vi 7,69 pht) v gy ph hy li
ct ph nh trn Hnh 5.6a,b. Khi gim vn tc ct ti 140 m/p, sau 19,72 pht ct,
c ch mn dnh l ni tri khi hnh nh vng mn mt sau cho thy ch yu l vt
liu gia cng bm thnh lp v sau bong ra tng mng l cc mng vt liu
dng c bn di (Hnh 5.6f). Gim vn tc ct l gim nhit pht trin trn
vng mt sau dn n thay i c ch mn t mn do nh hng ca nhit sang
mn do dnh.
Phn tch hnh nh vng phng rp trn Hnh 5.6e c th gii thch bn cht
hnh thnh vng phng rp v s bong ra cc mnh vt liu dng c do hai
nguyn nhn. Th nht, do kh nng dn nhit km ca vt liu mnh dao (PCBN
v cht dnh kt), vng nhit cao xut hin trn mt sau s gy nn gin n
khng ng u so vi vt liu bn trong to nn vng phng lm yu lin kt
vng vi cc lp bn trong. Th hai, nhit cao thc y qu trnh xy ha
cht dnh kt ca vt liu dng c trn b mt vng phng lm cc ht CBN d b
bt ra khi vng ny v xy ha su vo cc lp bn trong (Hnh 5.7). Sau , tng
mng vt liu dng c b bong ra di tc dng ca lc ma st trn mt sau. y l
kt qu nghin cu mi so vi cc nghin cu trc y v c ch mn dng c khi
tin cng.


71
Hin tng mn mt sau di
li ct ph din ra nhanh hn v
rng hn c th c gii thch
da vo c trng hnh hc ca
dng c PCBN v qu trnh tin
cng chnh xc. Vi mi dng c
c v trn c bn knh r=0,2
1,2mm v chiu su ct thng
thng t t=0,05 0,25mm, lng
chy dao s=0,05 0,2mm/v, ton b qu trnh ct ch din ra ti vng bn knh mi
dng c. Cc c trng hnh hc ny to nn mt gc thot nhit K
2
ti vng li
ct ph nh hn gc thot nhit vng li ct chnh K
1
v lm cho nhit ti
y tng cao, l nguyn nhn khin cho qu trnh mn mt sau bn di li ct
ph din ra khc lit hn vng bn di li ct chnh (Hnh 5.9).
T kt qu nghin cu trn c th thy rng vng mt sau di li ct ph l
vng chu nh hng nng n nht ca mn k c mn do nhit v mn do dnh khi
vn tc ct thay i t 140 m/p n 180 m/p. S pht trin ca mn vng ny l
nguyn nhn lm tng nhanh nhm b mt chi tit gia cng, dn n ph hy li
ct ph v mi dao. V y l vng dung dch trn ngui c th tip cn nn s
dng dung dch trn ngui s lm gim vng mn ny.
5.1.3. Bin thin chiu cao mn dng c PCBN theo chiu di ct khi tin thp
hp kim qua ti
Nghin cu qu
trnh tin trin mn mt
sau mnh dao PCBN
theo chiu di ct c
thc hin trn hai loi
thp 9XC v X12M.
Quan st cc mnh
dao PCBN nhn c
sau khi tin vi chiu
di ct khc nhau trn
K
1
f
a
P
K
2
K
1
K
2
r
c
Hnh 5.9. Gc thot nhit trn mt sau di
li ct chnh v ph.
Hnh 5.10. nh SEM vng mn mt sau mnh PCBN
khi tin cng thp 9XC vi t=0,12mm; s=0,1mm/v;
v=140m/p (a-d); v=180m/p (e-h); chiu di ct tng
ng l
1
=510; 1020; 1530; 2551m (e-h).
a)
e)
b) c)
d)
f) g) h)


72
knh hin vi in t c th
thy r qu trnh tin trin
chiu cao mn mt sau
nh trn Hnh 5.10 v
Hnh 5.11. nh vng mn
mt sau cho thy, chiu
cao mn pht trin nhanh
hn khi vn tc tng. Cng
chiu di ct l=2551m,
chiu cao mn t
h
s
~400m tc ct
v=140m/ph v h
s
~600m
tc v=180m/ph (Hnh
5.10). Tc pht trin chiu cao mn khi tin thp X12M ln hn nhiu so vi khi
tin thp 9XC cng iu kin ct. Vi chiu di ct L=1794m, chiu cao mn
h
s
~75m vi thp 9XC v h
s
~255m vi X12M (Hnh 5.11).
th bin thin chiu cao mn mt sau theo chiu di ct c th hin nh
trn Hnh 5.12. T th cho thy, ng cong mn ca mnh PCBN khi tin thp
hp kim qua ti cng tun theo quy lut mn thng thng gm ba giai on: giai
on chy r, giai on mn n nh v giai on mn khc lit. Trong di vn tc
ct v=110180m/p, tc mn n nh gn nh khng i:
s
dh
dL
~ 0,0220,032m/m
(Hnh 5.12a). Tuy nhin, giai on mn n nh ngn hn vn tc v=140180m/p,
ch ko di trong khong 2000m chiu di ct. Khi vn tc ct gim xung
Hnh 5.11. nh SEM vng mn mt sau mnh PCBN
khi tin thp 9XC (trn) v thp X12M (di) ch
ct v=110m/p; t=0,115; s=0,07mm/v ln lt ng
vi chiu di ct l=448,6; 897,1; 1345,7; 1794,3m.
a)
f)
d)
c) b)
e) h) g)
Bien thien chieu cao mon mat sau theo chieu
dai cat cua manh PCBN khi tien thep hop kim
0
50
100
150
200
250
300
0 500 1000 1500 2000
Chieu dai cat (m)
C
h
i
e
u

c
a
o

m
o
n

m
a
t

s
a
u
(
m
i
c
r
o
m
e
t
)
thep 9XC
thep X12M
Bien thien chieu cao mon mat sau theo chieu dai
cat cua dao PCBN khi tien thep 9XC
0
100
200
300
400
500
600
700
0 1000 2000 3000
Chieu dai cat (m)
C
h
i
e
u

c
a
o

m
o
n

m
a
t

s
a
u

h
s

(
m
i
c
r
o
m
e
t
)
v=180m/p
v=140m/p
v=110m/p
Hnh 5.12. th bin thin chiu cao mn mt sau theo chiu di ct ca mnh
PCBN khi tin thp 9XC(a) ; So snh gia hai loi thp 9XC v X12M (b).



73
v=110m/p, giai on mn n nh tng, n 2551m chiu di ct vn cha xut hin
mn khc lit. Tc mn khc lit vn tc 180m/p din ra d di hn: khong
0,98m/m so vi 0,05m/m vn tc v=140m/ph. Chiu cao mn tng t 100m
n 600m vn tc v=180m/p so vi 400m vn tc v=140m/p trong khong
500m chiu di ct (Hnh 5.12a).
So snh gia bin thin chiu cao mn khi tin thp 9XC v thp X12M th
hin trn th Hnh 5.12b cho thy, tc mn ca thp X12M ln hn nhiu so
vi thp 9XC. Cng chiu di ct l=1794m, chiu cao mn tng ng khi tin thp
9XC l 75m, i vi thp X12M l 250m, ln gp hn ba ln. Tc mn trung
bnh ca thp 9XC
s
dh
dL
~ 0,025m/m; ca thp X12M
s
dh
dL
~ 0,111m/m.
5.2. Cht lng b mt gia cng khi tin thp hp kim qua ti bng dao PCBN
5.2.1. Nhm b mt gia cng
Nghin cu nhm b mt gia cng khi tin thp hp
kim qua ti bng dao PCBN c tin hnh trn phi
thp 9XC v X12M, cng 57HRC ch ct
v=110m; s=0,07mm/vg; t=0,115mm. Nhm b mt gia
cng c o bng thit b o nhm cm tay Mitutoyo
SI-201 - Nht bn (Hnh 5.13).
Bin thin nhm b mt theo
chiu di ct c biu din nh
th trn Hnh 5.14.
th cho thy, nhm b mt gia
cng nhn c khi tin cng
chnh xc thp hp kim bng
dng c PCBN c tr s kh nh:
R
a
=0,571,07m tng ng
nhm cp 78 khi tin thp
9XC v R
a
=0,791,38m tng
ng nhm cp 67 khi tin
thp X12M.
Hnh 5.13. Thit b o
nhm Mitutoyo SI-201.

Hnh 5.14. Bin thin nhm b mt theo chiu
di ct khi tin thp 9XC v X12M cng
57HRC bng dao PCBN vi v=110m/p;
s=0,07mm/v; t=0,115mm.
Bien thien nham be mat theo chieu dai cat khi tien
thep hop kim qua toi bang dao PCBN
0,00
0,20
0,40
0,60
0,80
1,00
1,20
1,40
1,60
0 1000 2000 3000 4000 5000 6000 7000 8000
Chieu dai cat L (met)
N
h
a
m

b
e

m
a
t

R
a

(
m
i
r
c
r
o
m
e
t
)
thep 9XC
thep X12M


74
Trong khong 4000m chiu di ct u tin, nhm b mt gia cng khi tin thp
9XC c xu hng gim dn v sau tng dn trong khong 40006000m chiu
di ct. Nhm b mt gia cng khi tin thp X12M khng c giai on gim, tr s
nhm kh n nh, dao ng v tng nh trong di trn 6000m chiu di ct.
Nghin cu cho thy cng vt liu gia cng cng nh hng n nhm b
mt chi tit khi tin thp hp kim qua ti bng dao PCBN. Quan h ph thuc ca
nhm b mt vo cng ca vt liu gia cng c biu din nh trn Hnh 5.15.
th cho thy, khi cng
thp, nhm b mt hu nh
khng ph thuc vo cng
phi (im A v ng c). Khi
cng phi tng, nhm b mt
tng. Tc tng ca nhm b
mt ngoi ph thuc vo
cng phi cn ph thuc mnh
m vo chiu di gia cng do
nh hng ca mn dao. Chiu
di gia cng cng ln v cng
phi cng cao, tc tng ca
nhm b mt cng nhanh. Khi
cng phi tng t 4547HRC ln 6062HRC, nhm b mt tng 4%, 76%, 166%
tng ng vi chiu di ct L=250; 500;750mm.
5.2.2. Lung vt liu bin dng do v lp bin cng b mt gia cng
Hin tng xut hin cc lung vt liu bin dng do trn b mt gia cng l
mt yu t quan trng nh hng n cht lng b mt trong qu trnh tin cng.
Cc lung vt liu bin dng ny c cho l vt liu phi dch chuyn theo hng
ngc vi hng tin dao v to thnh cc ba via theo vt ca lng chy dao. Lp
vt liu bin dng do l mt nguyn nhn lm gim cht lng b mt, ngay c khi
nhm b mt vn nm trong phm vi cho php. Do c cng v kh nng mi
mn cao nn chng s lm mn mi b mt tip xc [43].
Bien thien nham be mat theo do cung phoi
khi tien thep X12M bang dung cu PCBN
0
0,2
0,4
0,6
0,8
1
1,2
1,4
45-47 55-57 60-62
Do cung phoi (HRC)
N
h
a
m

b
e

m
a
t

(
M
i
c
r
o
m
e
t
)
L=425m
L=850m
L=1270m
Hnh 5.15. th bin thin nhm b mt theo
cng khi tin thp X12M ch ct
v=110m/p; s=0,12mm/v; t=0,15mm.
A
a
b
c


75
Nghin cu nh chp topography b mt gia cng khi tin thp X12M cc
cng khc nhau trn
Hnh 5.16 cho thy: ti
cc khong cch tng
ng vi lng chy dao,
xut hin cc lung kim
loi bin dng do. Mc
d cc lung kim loi
bin dng do gim khi
cng vt liu phi
tng nhng gi tr nhm
b mt vn tng (Hnh
5.15). S d nh vy l
v ng vi gi tr nhm
b mt kho st tng ng cp 78, chiu di chun bng 0,8mm, vt ca lng
chy dao s to thnh cc nhp nh ch yu nn c nh hng quyt nh n nhm
b mt chi tit. Tuy nhin, ngoi cc vng c vt nhp nh do lng chy dao gy
ra, b mt gia cng tng i bng phng vi cc nhp nh nh hn c cho l to
thnh t cc rnh mn ca dng c (Hnh 5.16a,c,e). B rng vng bng phng ln
l nguyn nhn nhm b mt c gi tr nh di cng <50HRC mc d xut hin
cc vt bin dng do rt mnh ca kim loi trn b mt gia cng. Khi cng tng,
cc lung vt liu b bin dng do gim nhng gi tr nhm b mt vn tng do t l
b rng vng nhp nh trong mt bc tin dao tng: chim 20% cng
<50HRC nhng tng ln ~50% khi cng phi >60HRC.
Quan st mu gc phoi t Hnh 2.8 c th thy cc vt bin dng do trn b
mt gia cng ch yu hnh thnh t qu trnh to phoi vng bin dng vt th nht
v qu trnh ma st gia mt sau ca dng c vi b mt gia cng. Nh vy cc
lung vt liu bin dng trn b mt gia cng c lin quan trc tip n c ch hnh
thnh phoi v qu trnh mn mt sau ca dng c. Di tc dng ca nhit v
ng sut cao, vt liu gia cng trong vng ct b chy do hon ton. Mt phn vt
liu chy do b y p dch chuyn theo phng vung gc vi phng chuyn
ng thng thng ca dng phoi, bm vo b mt gia cng to thnh cc ba via g
Hnh 5.16. nh chp topography b mt khi tin thp
X12M ng vi cng phi khc nhau: 45 HRC (a,b);
56 HRC (c,d); 62 HRC (e,f).
d)
f) b)
e
)
c)
Vng vt lng
chy dao
Vng bng
phng
a)


76
gh dc theo vt ca lng chy dao. Cc nhp nh hnh thnh gia cc vt chy
dao l s in dp ca cc rnh mn mt sau dng c ln b mt vt liu chy do.
Chiu cao cc nhp nh tng khi dng c b mn.
nh chp topography b
mt khi tin thp 9XC
cng 52HRC ng vi cc
vn tc khc nhau trn Hnh
5.17 cho thy, vn tc cng
cao, lung vt liu bin dng
do xut hin cng nhiu.
Vn tc ct cao i cng tc
bin dng ln dn n
nhit cao khin vt liu b
chy do nhiu hn. Di
tc dng ca p sut cc b, mt phn vt liu chy do b y p ra khi b mt
tip xc gia dao, phi v dng c theo hng ngc vi hng tin dao v bm
vo b mt gia cng.
Hin tng cc lung vt liu bin dng do gim khi cng phi tng c lin
quan n s thay i v c ch hnh thnh phoi. T phoi lin chuyn thnh phoi
rng ca di cng 5055HRC vi yu cu nng lng ct gim bi lc ct
gim (Hnh 3.6). Chiu
rng vng lung bin dng
do tng khi tng cng
l do s gia tng tc
mn dao khi cng phi
tng lm tng din tch tip
xc ca b mt gia cng
vi mt sau ca dao.
Ngoi vic hnh thnh
cc lung vt liu chy do,
b mt gia cng khi tin
Hnh 5.17. nh chp topgraphy b mt khi tin thp
9XC cng 52HRC ng vi cc vn tc
50m/p(a,b) 100m/p(c,d); 150m/p(e-f).
a)
d)
c)
e)
b)
f)
Hnh 5.18. Kim tra cng t vi lp b mt gia
cng khi tin thp 9XC v X12M cc cng khc
nhau: 45HRC(a,d); 57HRC(b,e); 62HRC(c,f).
a) b) c)
d)
e) f)


77
thp hp kim qua ti bng dao PCBN cng b thay i v c tnh. Kim tra cng
t vi lp b mt gia cng cho thy, lp b mt nhn c sau gia cng c cng
cao hn cng lp vt liu nguyn thy: tng 720% i vi thp X12M v tng
0,615% i vi thp 9XC. Tuy nhin, lp su hn bn di b mt li c s gim
nh cng: gim 0,35% chiu su 70m i vi 9XC v 1,57% i chiu
su 170m vi X12M (Hnh 5.18).
th biu din s thay i cng t vi theo chiu su lp b mt khi tin
thp 9XC v X12M tng ng vi cc cng khc nhau nh trn Hnh 5.19. C
s tng cng lp b mt v gim nh cng lp su hn, st lp b mt so
vi cng ca kim loi nguyn thy. Hin tng ny cng tng t kt qu trong
nghin cu ca Schwach [80] khi pht hin cc lp bn di b mt gia cng nhn
c khi tin cng bao gm lp trng, ni nhit vt qu nhit austenite ha,
t chc t vi bao gm mactenxit xen ln austenit d, c cng tng 30% so vi
vt liu nguyn thy v lp sm mu, ni nhit vt qua nhit ti ca vt liu,
c cng gim khong 60% so vi cng vt liu nguyn thy mc d c s
khc bit v gi tr thay i cng v chiu su cc lp.
Kim tra cu trc t vi lp b mt gia cng ca thp 9XC v X12M, cng
57HRC ng vi chiu di ct khc nhau cho thy, cu trc t vi b mt gia cng hu
nh khng thay i so vi cu trc kim loi nguyn thy (Hnh 5.20). Ring b mt
thp X12M chiu di ct L=2803m, b mt xut hin lp trng nh (Hnh 5.20g).
Bien thien do cung lop be mat
khi tien cng thep 9XC
400
450
500
550
600
650
700
750
0 100 200 300 400 500
Chieu sau lop be mat (micromet)
D
o

c
u
n
g

V
i
c
k
e
r
s

(
H
V
)
60HRC
55HRC
45HRC
Bien thien do cung lop be mat
khi tien cung thep X12M
400
450
500
550
600
650
700
750
0 100 200 300 400 500
Chieu sau lop be mat (micromet)
D
o

c
u
n
g

V
i
c
k
e
r
s

(
H
V
)
60HRC
55HRC
50HRC
Hnh 5.19. Bin thin cng ca lp b mt gia cng nhn c khi tin thp
9XC(a) v X12M(b) cc cng khc nhau.
a) b)


78
Cc mu kim tra tng
ng vi ch ct khc
nhau cng cho kt qu
tng t. T chc kim loi
ca b mt gia cng khng
c thay i ng k,
khng thy xut hin lp
bin trng hoc lp sm
mu. Kt qu ny cng
ph hp vi cc nghin
cu trc khi cho rng
lp bin trng, c trng cho s thay i v cu trc t vi khi vt liu b nng chy
v kt tinh li ch xut hin trong trng hp dng c b mn [80].
5.3. Kt lun chng 5
Nghin cu v mn v c tnh b mt gia cng khi tin thp hp kim qua ti
bng dao PCBN cho cc kt lun sau:
- Mn dng c PCBN c gy ra bi nhiu c ch kt hp nh dnh, mi mn,
khuch tn, tng tc ha hc v ph hy v nhit.
- Vt liu gia cng v ch ct c nh hng ln ti mn v c ch mn dng
c PCBN. Khi cng v vn tc ct nh, c ch mn do dnh chim u th. Khi
cng tng c ch mn do mi mn chim u th. Khi vn tc ct tng, mn do
tc ng ca nhit ct l nguyn nhn ch yu gy mn hng dng c PCBN.
- ng cong mn ca vt liu PCBN cng tun theo quy lut mn thng
thng. Giai on mn n nh gim khi vn tc ct tng. Chiu cao mn ca dng
c PCBN khi ct vt liu X12M ln gp hn 3 ln so vi khi ct thp 9XC cng
iu kin.
- Tng tc ca cc nguyn t c trong vt liu dng c vi xy trong khng
kh vng tip xc to ra cc hp cht mi c c tnh v nhit nng chy
thp to iu kin xut hin pha lng trn b mt tip xc gia dng c vi phoi v
phi. Tnh cht ca pha lng ph thuc vo vt liu gia cng, vt liu dng c, iu
kin ct v c nh hng trc tip n tc mn dng c.
a)
b)
c) d)
e)
h) g)
f)
Hnh 5.20. Cu trc t vi lp b mt gia cng khi
tin thp 9XC(a-d) v X12M(e-h) cng 57HRC
cng ch ct ng vi chiu di ct khc nhau v
b mt cha gia cng (d,h).


79
- C th lm gim dng mn dnh v mi mn bng cc bin php nhit luyn to
ra cu trc t vi nh mn v la chn cc thng s ct thch hp. S dng cc bin
php bi trn v lm ngui s hn ch c dng mn mt sau di li ct ph.
- Nhm b mt gia cng nhn c c tr s kh nh, tng ng nhm
cp 78. Cng iu kin ct nh nhau, nhm b mt nhn c khi gia cng thp
9XC nh hn khi gia cng thp X12M. Nhm b mt tng khi cng vt liu gia
cng tng.
- B mt gia cng nhn c c cc lung vt liu bin dng do dc theo vt
lng chy dao. S xut hin cc lung vt liu bin dng do gim khi cng vt
liu gia cng tng v tng khi tng vn tc ct.
- C s thay i v cng t vi ca b mt gia cng. cng tng lp b
mt v cng gim nh bn di lp b mt, so vi cng vt liu ban u.



80
Chng 6
TI U HA A MC TIU CH CT
KHI TIN THP HP KIM QUA TI BNG DAO PCBN
6.1. Xy dng m hnh ton
Vic m hnh ha mi quan h ca cc thng s u vo v u ra l mt bc
c bn ca qu trnh ti u. M hnh quan h ca cc thng s u vo v u ra
c xem nh l s c trng tm lc v mi quan h nguyn nhn v kt qu
hoc s chuyn i qu trnh t u vo n u ra. K thut ti u cung cp cc
gii php ti u hoc gn ti u cho cc bi ton ti u tng qut, c cng thc
ha v sau c thc hin trong qu trnh gia cng [40]. Vic ti u ha cc
thng s ct trong gia cng i hi cc kin thc v nhiu kha cnh nh: qu trnh
gia cng, cc phng trnh thc nghim lin quan n ch tiu gia cng: tui th
dng c, lc ct, cng tiu th, nhm b mt... xy dng cc rng buc, cc c
trng k thut ca my gia cng, cch pht trin mt tiu chun ti u c hiu qu
ng thi cng cn cc kin thc v ton hc v k thut s ti u [85].
Trong cc th tc ti u, yu t u ra quan trng chnh c gi l mc tiu ti
u hoc tiu chun ti u. Tiu chun ti u c s dng nhiu nht trong gia
cng l chi ph gia cng. Ngoi ra, thi gian gia cng, tc bc vt liu, tui th
dng c, cht lng b mt... cng c s dng. Trong gia cng tinh nh tin
cng, ch tiu v cht lng b mt ng vai tr quan trng. Ngoi ra, tui th dng
c cng c trng cho chi ph gia cng khi gi thnh dng c CBN cao v nh
hng trc tip ti cht lng b mt. Tuy nhin, vic ti u n mc tiu ch c
gi tr gii hn bi v bn cht phc tp ca qu trnh gia cng i hi cc mc tiu
khc nhau v i khng phi c ti u ha ng thi [75]
Cc m hnh ca qu trnh ct c th c xy dng bng phng php phn tch,
phng php s v phng php thc nghim. Trong phng php phn tch, m
hnh c xy dng da trn cc nh lut vt l c bn nh m hnh lc ct ca
Merchant, m hnh tnh gc mt phng trt ca Oxley Phng php thc nghim
xy dng m hnh da trn cc o c thc nghim, in hnh l m hnh xc nh
tui th dng c ca Taylor. Phng php phn tch s xy dng m hnh da trn
ton hc ng dng kt hp vi my tnh thng qua cc thut ton v chng trnh


81
nh phng php phn t hu hn, phng php sai phn hu hn, cc phng php
m hnh tr tu nhn to nh: mng nron nhn to, l thuyt logic m
Cc m hnh thc nghim c xy dng da trn cc d liu th nghim thu
c trong mt iu kin c th nn mc d i khi khng ng khi p dng cho
cc iu kin tng t khc nhng chng cho php nghin cu mt di rng cc vn
phc tp mt cch nhanh chng v cc k hu dng khi cho php s dng kt
qu d dng v thun tin. C th coi cc kt qu nhn c t m hnh thc
nghim l im khi pht ca qu trnh iu khin ngi s dng c th chc
chn khng c sai hng nghim trng no xy ra v l c s vng chc kim
chng hoc ci tin cho m hnh phn tch l thuyt [94]. Mc chnh xc ca m
hnh cn ph thuc vo nhiu yu t khi la chn cc thng s u vo cho m hnh
cng nh cch x l cc d liu. Ngay c vic xy dng mt m hnh phn tch c
xt n y cc nhn t nh hng cng rt phc tp, t tnh ng dng v thng
l iu khng th thc hin c. Cn phi sng lc la chn cc nhn t quyt
nh xy dng mt m hnh c chnh xc cn thit.
Cc nghin cu c cho thy trong gia cng, cc yu s nh hng ln nht
ti cht lng b mt v tui th dng c l cc thng s ch ct bao gm vn
tc ct v, chiu su ct t v lng chy dao s. Quan h ph thuc ca hm mc tiu
vo cc thng s ny l quan h hm s m [2], [4], [5], [69]:
r p q
F Cv s t = (6.1)
M hnh d on nhm b mt chi tit gia cng v mn dng c trong tin cng
chnh xc thp hp kim qua ti bng dao PCBN c xy dng bng phng php
hi quy thc nghim [3], [8], [9], da trn cc quy tc thng k v ti u ha thng
k v c trnh by trong phn Ph lc V.
6.1.1. Thit b v ch thc nghim
Thit b th nghim xc nh nhm b mt v din tch gia cng theo quy hoch
thc nghim c m t trong mc 2.2 bao gm: My tin k thut s CNC-
HTC2050 (Hnh 2.3a), mnh v thn dao PCBN (Hnh 2.3b,c); thit b o nhm b
mt MitutoyoSJ 201- Nht Bn (Hnh 5.13); Phi thp 9XC s dng trong th
nghim c chiu di: L=300mm, ng knh: C62, ti th tch t cng
5658HRC. Thnh phn ho hc ca phi nh trong Bng 2.2.


82
+ S th nghim c m t nh trn Hnh 2.3d.
+) Ch thc nghim:
Cht lng b mt gia cng v tui th dng c ph thuc vo ba nhn t chnh
ca ch ct vi min gi tr nh sau:
1) Vn tc ct: v=100170m/s
2) Chiu su ct: t= 0,090,15 mm
3) Lng chy dao: s= 0,070,15mm/vng
Mi mnh dao PCBN c dng tin lin tc b mt tr ngoi ca phi thp
9XC cho n khi chiu cao vng mn mt sau t gi tr xc nh l 120m. Sau ,
mnh dao c tho ra kim tra v tui th dng cng c nh gi thng qua
din tch b mt gia cng t c S
c
(cm
2
) . Nhm b mt c o bng thit b
phn tch b mt Mitutoyo SJ hin th s sau khi thc hin thi gian ct t=4,5 pht
ng vi mi ch thc nghim c quy hoch nh trong bng V.1 ca Ph lc V.
6.1.2. Xy dng m hnh hi quy m t nhm b mt
Kt qu o nhm b mt sau thi gian ct xc nh t=4,5 pht ti cc im th
nghim theo quy hoch nh trong Bng 6.1.
Da trn cc s liu o c t cc th nghim theo quy hoch, ln lt tin
hnh theo cc bc theo cng thc t V.12 n V.23 trong Ph lc V:
1. Tnh cc h s ca m hnh hi quy b
j
, b
ju
:
b
0
=-0,7846; b
1
= 0,0541; b
2
=-0,0080; b
3
= 0,0799;
b
12
=0,0948; b
13
=0,0486; b
23
=-0,0135; b
123
=0,0178
2. Tnh phng sai lp:
0
0
1
1
m
a
a
y y
m
=
=

= -0.9256
3
0
2 0 2
11
1
1
( )
3 1
a
a
S y y
=
=

= 0,0027
Bng 6.1. Gi tr nhm b mt ti cc im th nghim theo qui hoch
S TT 1 2 3 4 5 6 7 8 9 10 11
R
a
(m) 0,45 0.39 0,39 0.46 0,51 0.50 0,39 0.60 0,38 0.42 0,39
lnR
a
-0,798 -0,941 -0,941 -0,776 -0,673 -0,693 -0,941 -0,510 -0,967 -0,867 -0,942



83
3. Tnh sai lch trung bnh ca phn b b
j
:
0,5
2
11
b
S
S
N
| |
= |
|
\ .
= 0,0184
4. Kim tra tnh c ngha ca cc h s hi quy:
Cc h s c ngha khi tha mn iu kin:
2
, j b p f
b S t >
Tra ph lc 7 [9] nhn c t
p,f2
=4,3
2
, b p f
S t =0,0790
Vy cc h s b
1
, b
2
,b
13
,

b
23
,

b
123
l khng c ngha.
5. Xc nh m hnh ton hc: Sau khi loi b cc h s khng c ngha,
phng trnh hi quy c dng:
3 1 2
0, 7846 0, 0799 0, 0948 y x x x = + +
Tnh gi tr hm hi quy
i
y ti cc im th nghim:
1
y = -0.7697;
2
y = -0.9594;
3
y = -0.9594;
4
y = -0.7697;
5
y = -0.6099;
6
y = -0.7996;
7
y = -0.7996;
8
y = -0.6099;
6. Tnh phng sai d S
d
vi l=3:
2 2
1
1
( )
N
d i i
S y y
N l
=

=0,0094
7. Kim tra tng hp ca m hnh:
2 1
2
, ,
2
11
d
p f f
S
F F
S
= s
Vi mc c ngha p=0,05, bc t do lp f
2
=m-1=3-1=2, bc t do d f
1
=N-l vi
l l s h s c ngha trong phng trnh hi quy: f
1
=8-3=5 chun s Fisher tra
bng ph lc 7 [9] F
p,f2,f1
=19,2
2
2
11
d
S
F
S
= =3,439 < F
p,f1,f2
=19,3 m hnh thng k tng hp vi h thng thc.
Chuyn phng trnh hi quy vi cc bin m ha x
j
v phng trnh vi cc
bin thc lnz
j
nhn c:
ln 14, 9819 3, 013ln 6,8176ln 0, 2097ln 1, 3998ln ln
a
R v t s v t = + + + (6.2)

7 3,0130 0,2097 1,3998ln 6,8176
3,115.10
v
a
R v s t

= (6.3)


84
So snh gi tr nhm b mt xc
nh theo phng trnh hi quy v
thc nghim ti cc im th
nghim nh Hnh 6.1. th cho
thy mc tng hp ca m
hnh hi quy vi h thng thc
nghim kh cao khi cc gi tr
nhm b mt t thc nghim v
phng trnh hi quy cc im th
nghim tng i gn nhau.
th quan h ca nhm ph thuc vo cc thng s ch ct c v
bng MATLAB nh Hnh 6.2.
T phng trnh hi quy v th cho thy:
Trong vng kho st:
- Nhm b mt tng khi tng vn tc ct v, lng chy dao s v chiu su ct t.
- Vn tc ct v c nh hng r nht ti nhm b mt chi tit.
- Vic tng chiu su ct t hu nh khng c nh hng ti nhm b mt. Do
trong vng kho st c th chn chiu su ct ln m vn m bo nhm cn
thit.
Tuy nhin nh gi hiu qu qu trnh gia cng cn phi xem xt ng thi
cc nhn t va t c nhm cn thit, va m bo tui th dng c ln
nht cng nh nng sut gia cng cao.
Hnh 6.1. Gi tr nhm b mt xc nh t
thc nghim v m hnh hi qui.


Gia tri nham be mat tu thuc nghiem
va mo hinh hoi qui tuong ung
0
0.15
0.3
0.45
0.6
0.75
0 2 4 6 8 10 12
Diem thi nghiem
R
a
(
M
i
c
r
o
m
e
t
e
r
)
Thuc nghiem
Mo hinh
a) c) b)
Hnh 6.2. Mt hi qui v th ng mc ca nhm R
a
theo cc thng s
ch ct: vn tc v chiu su ct (a); vn tc ct v lng chy dao (b), chiu
su ct v lng chy dao (c).



85
6.1.3. Xy dng m hnh hi quy m t mn dng c
Tiu chun nh gi tui th dng c ct rt a dng: Dng c cn phi mi
li hoc thay th khi hng v khng cn kh nng ct gt, khi nhit ct tng cao v
to thnh hoa la, khi qu trnh ct gy n ln hoc rung ng mnh, khi kch thc
hay hon thin ca b mt gia cng thay i hoc khi hnh dng dng c thay i
mt lng c th [94]. Thng thng, c th kho st tui th dng c thng qua
thi gian gia cng ng vi mt ch ct xc nh. Tuy nhin, nu ch ct thay
i, vic nh gi bng ch tiu thi gian gia cng tr nn thiu chnh xc v khng
phn nh ng thc cht hiu qu lm vic ca dao. Trong trng hp ny, tui th
dng c cn c nh gi qua cc ch tiu khc nh khi lng vt liu ct c
hoc mn dng c tng ng vi yu cu m bo cht lng b mt gia cng.
Vi qu trnh gia cng tinh c lng d nh nh tin cng chnh xc bng dng c
PCBN, khi lng vt liu ct i khng ngha bng din tch b mt c gia
cng. V vy, trong nghin cu ny tui th dng c c kho st thng qua ch
tiu din tch b mt gia cng m bo t nhm b mt theo yu cu.
Kt qu o din tch b mt c gia cng S
c
khi chiu cao vng mn mt sau
t gi tr h=160m tng ng vi cc ch ct ti cc im th nghim theo quy
hoch nh Bng 6.2.
Da trn cc s liu o c t cc th nghim theo quy hoch, ln lt tin
hnh theo cc bc theo cc cng thc t V.12 n V.23 trong Ph lc V :
1. Tnh cc h s ca m hnh hi quy b
j
, b
ju
:
b
0
=8.4728; b
1
= -0.5407;
b
2
= -0.2699; b
3
= -0.1724
b
12
=0.0009; b
13
= -0.2082;
b
23
= -0.0209; b
123
=0.1461
2. Tnh phng sai lp:
Bng 6.2. Gi tr din tch b mt gia cng ti cc im th nghim theo qui hoch
S TT 1 2 3 4 5 6 7 8 9 10 11
S
C

(cm
2
)
8792 6044,5 7143,5 2747,5 13188 2198 5495 1648,5 3297 2747,5 3077,2
lnS
c
9.08 8,71 8,87 7,92 9,48 7,69 8,61 7,41 8,10 7,92 8,03



86

0
0
1
1
m
a
a
y y
m
=
=

=8.0170
3
0
2 0 2
11
1
1
( )
3 1
a
a
S y y
=
=

= 0.0085
3. Tnh sai lch trung bnh ca phn b b
j
:
0,5
2
11
b
S
S
N
| |
= |
|
\ .
=0.0325
4. Kim tra tnh c ngha ca cc h s hi quy:
2
, j b p f
b S t >
Tra ph lc 7 [9] nhn c:
2
, p f
t =4,3
2
, b p f
S t = 0,0325.4,3=0,1400
Vy, cc h s b
12
, b
23
khng c ngha.
5. Xc nh m hnh ton hc:
Sau khi loi b cc h s khng c ngha, phng trnh hi quy c dng:
1 2 3 1 3 1 2 3
8, 4728 0, 5407 0, 2699 0,1724 0, 2082 0,1461 y x x x x x x x x = +
Tnh gi tr hm hi quy
i
y ti cc im th nghim:
1
y = 9.1016;
2
y = 8.7287;
3
y = 8.8539;
4
y = 7.8967;
5
y = 9.4653;
6
y = 7.6753;
7
y = 8.6333;
8
y = 7.4276;
6. Tnh phng sai d S
d
vi l = 6:
2 2
1
1
( )
N
d i i
S y y
N l
=

= 0.0017
7. Kim tra tng hp ca m hnh :
2 1
2
, ,
2
11
d
p f f
S
F F
S
= s = 3,024<
1 2
, , p f f
F =19,3
Vi
1 2
, , p f f
F l chun s Fisher tra bng mc ngha p=0,05, bc t do lp f
1
=m-1, m l s th nghim lp li tm, f
2
l bc t do d: f
2
=N-l=8-6=2, l l s h
s c ngha trong phng trnh hi quy. Tra bng [9]:
1 2
, , p f f
F =19,3.

2
2
11
d
S
F
S
= = 0.2062 <
1 2
, , p f f
F =19,3
m hnh thng k tng hp vi h thng thc.
Chuyn phng trnh hi quy vi cc bin m ha x
j
v phng trnh vi cc


87
bin thc ln
j
nhn c:
ln 97,1678 21, 0112 n 63, 8259ln 49, 7292ln 12, 8876ln ln
10,1174ln ln 27, 5521ln ln 5, 6569ln ln
c
S l v t s v t
v s s t t s
= + +
+ +
(6.4)
43 21,0112 10,1174ln 49,7292
ln (12,8876 5,6569ln ) 63,8259 27,5521ln
6, 3178.10

v
c
v s s
S v s
t

+
=
(6.5)
So snh gi tr din tch gia cng
xc nh t phng trnh hi quy v
thc nghim ti cc im th nghim
nh Hnh 6.3. th cho thy mc
tng hp ca m hnh hi quy vi h
thng thc nghim l rt cao khi cc
gi tr din tch gia cng ti cc im
th nghim l gn nh trng kht nhau.
th biu din quan h gia din
tch gia cng S
c
v cc thng s ch ct c v bng MATLAB nh Hnh 6.4.
T phng trnh hi quy v th cho thy:
Trong vng kho st:
- Tui th dng c gim khi tng vn tc ct, chiu su ct v lng chy dao.
- Vn tc ct v c nh hng ln nht ti tui th dng c.
- Vic tng lng chy dao t c nh hng ti tui th dng c. Thm ch ng
vi chiu su ct t khng thay i (t=0,12), vic tng lng chy dao lm tng tui
th dng c. V vy trong phm vi lng chy dao s = 0,070,15, c th chn lng
chy dao ln tng hiu qu qu trnh gia cng.
Hnh 6.3. Gi tr din tch gia cng xc
nh t thc nghim v m hnh hi qui.

Dien tich gia cong tu thuc nghiem
v m hnh hoi qui tuong ung
0
3000
6000
9000
12000
15000
0 2 4 6 8 10 12
Diem thi nghiem
S
c

(
m
m
2
)
Thuc nghiem
Mo hinh
a)
c)
b)
Hnh 6.4. Mt hi qui v th ng mc ca din tch gia cng Sc theo cc
thng s ch ct: vn tc v chiu su ct (a); vn tc ct v lng chy dao (b),
chiu su ct v lng chy dao (c).



88
6.2. Ti u ha a mc tiu ch ct khi tin thp 9XC qua ti bng gii
thut di truyn (GAs)
6.2.1. Xc nh bi ton
Cc bin thit k
Trong qu trnh tin cng bng dng c PCBN, vic ti u ha cc thng s ct
ng vai tr c bit quan trng. Trong khi cc thng s ch ct c th c iu
khin d dng ph hp vi tng qu trnh gia cng th rt kh thay i cc thng s
khc v my, dao hay vt liu. m bo hiu qu, qu trnh tin cng thng ch
c thc hin trn cc my gia cng t ng c cng vng v chnh xc cao
vi dng c ct c ch to sn, c gi thnh cao v khng mi li.
V vy, cc bin c xem xt trong qu trnh ti u ha ch ct l ba thng
s: vn tc ct v (m/p), lng chy dao s(mm/v) v chiu su ct t (mm).
Hm mc tiu
Mc tiu quan trng nht ca qu trnh gia cng tinh l cht lng b mt gia
cng c c trng bng nhm b mt. Bn cnh , mn dng c c c trng
bi din tch gia cng cng l ch tiu c quan tm v n nh hng trc tip n
cht lng b mt v ng thi l nhn t quyt nh chi ph gia cng bi PCBN l
vt liu dng c c gi thnh rt cao. V vy mc tiu ca bi ton ti u ha a
mc tiu ch ct trong qu trnh tin cng l ti u hai mc tiu i lp: cc i
ha din tch gia cng v cc tiu ha nhm b mt. Sau khi xc nh c tp hp
cc gii php ti u, nng sut gia cng cng c xem xt trong qu trnh la chn
phng n gia cng ti u ph hp.
S dng cc hm hi quy m t nhm b mt v din tch gia cng c xy
dng, cc hm mc tiu c dng:
7 3,0130 0,2097 1,3998ln 6,8176
3,115.10
v
a
R v s t

=
43 21,0112 10,1174ln 49,7292
ln (12,8876 5,6569ln ) 27,5521ln 63,8259
6, 3178.10

v
c
v s s
S v s
t

+
=

Cc rng buc
Cc thng s rng buc nh hng n vic xc nh ch ct ti u l cc
gii hn ca cc thng s ct. Cc gi tr gii hn trn v di ca cc thng s ct


89
c xc nh da trn xut ca cc nh sn xut dng c v kt qu t cc th
nghim sng lc [28], [75]: 100 170 v s s ; 0, 09 0,15 s s s ; 0, 07 0,15 t s s ;
Ngoi ra, trong mt s nghin cu cn k n mt s thng s lin quan n c
trng ca my gia cng nh lc ct (gii hn bi cng sut my), cng vng ca
dao Tuy nhin v tin cng l qu trnh gia cng tinh nn cc thng s ny thng
khng vt qu gii hn cho php nn khng cn a vo rng buc.
Bi ton ti u c dng:
Cc tiu ha:
1
1
1 2 2
1,3998ln 6,8176 7 3,0130 0,2097
1 1 2 3
10,1174ln 49,7292 43 21,0112
2 1 2
ln (12,8876 5,6569ln ) 27,5521ln 63,8259
3
3,115.10
6, 3178.10

x
x
x x x
f x x x
f x x
x


+
=
= (6.6)
Chu cc rng buc:
1min 1 1max
2min 2 2max
3min 3 3max
x x x
x x x
x x x
s s
s s
s s
(6.7)
Mc tiu gii bi ton ti u ha ch ct trong tin cng thp 9XC bng dng
c PCBN l tm kim cc gii php ti u tha mn iu kin v cht lng b mt
v tui th dng c gia cng thng qua thng qua nhm b mt v din tch gia
cng, ng thi cng chn ra mt gii php ti u tt nht s dng trong trng
hp ch yu cu thc hin mt ch gia cng.
Cc gii php ti u khi khng c gii php no tt hn trong khng gian tm
kim khi tt c cc mc tiu c ti u ha ng thi chnh l cc ti u Pareto
[10] . Gii php ti u gn vi im l tng nht c gi l gii php tha hip
[41]. Cc khi nim v ti u Pareto v gii php ti u tha hip c trnh by
trong Ph lc IV.
Cc phng php ti u truyn thng nh phng php tng trng s, quy
hoch ch, phng php cc tiu cc i, phng php th t t in hc [41],
[52], [63] thng khng hiu qu v chng khng th tm ra nhiu gii php ti u
trong mt ln chy chng trnh. Do , s ln chy yu cu phi bng s gii
php ti u Pareto mong mun tm c. Phng php gii thut di truyn thc


90
hin qu trnh vi mt qun th cc c th v v vy, thch hp vi vic tm kim
nhiu gii php song song [7], [36], [65], [95]. Vic so snh, la chn phng
php ti u a mc tiu v cc thut ton ti u ca gii thut di truyn c trnh
by trong phn Ph lc IV.
S dng gii thut di truyn trong c hai trng hp ti u ha a mc tiu
tm kim cc gii php ti u Pareto v ti u ha n mc tiu khi xc nh im
l tng m ti tt c cc hm mc tiu u t gi tr ti u lm cn c khi
xc nh gii php ti u tha hip. Gii php tha hip c xc nh bng vic
cc tiu ha khong cch t cc im ti u Pareto n im l tng [41]. Cc tnh
ton c thc hin trn phn mm MATLAB.
6.2.2. Kt qu thc hin gii thut di truyn cho bi ton ti u n mc tiu
Hm n mc tiu nhm b mt f
1
:
- Gi tr hm mc tiu tt nht: R
amin
= 0,382982 m
- im ti u: v=100m/p; s=0,07mm/v; t=0,15mm
- S th h : 49
- S ln lng gi hm thch nghi: 50980
- iu kin dng thut ton: Thay i trung bnh ca gi tr hm mc tiu v s
vi phm cc rng buc trn th h xc nh nh hn 10
-50
.
Hm n mc tiu din tch gia cng f
2
:
- Gi tr hm mc tiu tt nht: S
cmax
= 12896,7 cm
2
.
- im ti u: v=100m/p; s=0,15mm/v; t=0,09mm
- S th h: 39
- S ln lng gi hm thch nghi: 43440
- iu kin dng thut ton: thay i trung bnh ca gi tr thch nghi v s vi
phm cc rng buc trn s th h xc nh nh hn dung sai cho trc: 10
-40
.
6.2.3. Kt qu thc hin gii thut di truyn cho bi ton ti u a mc tiu
- Gi tr cc im ti u Pareto tm c nh Bng 6.3. th biu din mt
bin Pareto v gii php ti u tha hip nh trn Hnh 6.5.


91
- S lng cc im trn mt bin Pareto l 24.
- S th h l 152.
- iu kin dng thut ton: Thay i trung bnh di rng ca cc gii php ti
u Pareto nh hn 10
-3
.
Bng 6.3.Cc gi tr ti u Pareto v ch ct tng ng tm c t qu trnh ti
u ha
STT
Nhm b
mt R
a

(m)
Din tch
gia cng S
c
(cm
2
)
Vn tc
ct
v (m/p)
Lng
chy dao
s (mm/v)
Chiu
su ct
t (mm)
Nng sut
gia cng
Q (mm
3
/p)
im
ti u
tha hip
1 0.3830 6996.36 100.0000 0.0700 0.1500 1050.00
2 0.5365 12346.00 100.1960 0.1456 0.0913 1331.93 X
3 0.3966 7145.92 100.3060 0.0729 0.1399 1022.99
4 0.3830 6996.36 100.0000 0.0700 0.1500 1050.00
5 0.4952 10231.10 100.2800 0.1073 0.0954 1026.51
6 0.5365 12346.00 100.1960 0.1456 0.0913 1331.93
7 0.5169 11118.80 100.4130 0.1295 0.0944 1227.53
8 0.4852 9771.07 100.4000 0.1010 0.0973 986.66
9 0.5317 11936.10 100.2570 0.1436 0.0928 1336.03
10 0.4461 8478.10 100.1180 0.0789 0.1064 840.49
11 0.5080 10906.20 100.2690 0.1150 0.0925 1066.61
12 0.5170 11292.10 100.1620 0.1259 0.0930 1172.77
13 0.5345 12114.30 100.6050 0.1440 0.0914 1324.12
14 0.5069 10678.60 100.6470 0.1178 0.0942 1116.86
15 0.4763 9537.91 100.3200 0.0884 0.0949 841.60
16 0.4221 7873.92 100.2920 0.0718 0.1171 843.23
17 0.4696 9198.67 100.3070 0.0905 0.1000 907.78
18 0.4068 7511.99 100.3550 0.0704 0.1281 905.03
19 0.5021 10533.6 100.2760 0.1132 0.0947 1074.96
20 0.4745 9333.27 100.2830 0.0955 0.1002 959.62
21 0.4023 7337.98 100.5210 0.0713 0.1331 953.95
22 0.4886 10078.10 100.0420 0.0969 0.0935 906.40
23 0.4100 7581.60 100.0440 0.0710 0.1268 900.68
24 0.4632 8915.07 100.7710 0.0877 0.1017 898.79



92
Phn tch th mt bin ti u Pareto c th thy cc im ti u Pareto phn
b tng i u. Mt bin Pareto khng c tim cn. Gi tr nhm b mt R
a
gim
khi din tch gia cng S
c
gim. Tc gim ca nhm b mt l 6.25% v din tch
gia cng l 6.44% gn nh t l thun.
Gii php ti u gn vi gii php l tng nht l ti im th 2, tng ng vi
vn tc ct v=100,26m/p; lng chy dao s=0,15mm/v; chiu su ct t=0,09mm.
Din tch gia cng ti y t c l S
c
=12.731,41 cm2, nhm b mt t c l
R
a
=0,5421 m. Tuy nhin cng c th cn c vo tnh hnh thc t chn ch
gia cng ph hp. V d nu u tin tui th ca dng c th nn chn cc ch
gia cng ng vi cc im c din tch gia cng ln nh im 2,4,5,6... Khi yu cu
t nhm b mt nh nn chn cc im 1,3,10,11,18
Nng sut gia cng
Nng sut gia cng c tnh bng biu thc [70]:
3
1000 ( / ) Q vts mm ph = (6.8)
Nh vy, c th nhn thy mt cch trc quan l phng n ti u nht v
phng din nng sut l phng n tng ng vi cc gi tr gii hn trn ca cc
thng s ct trong vng kho st. Kho st tp hp cc gii php ti u Pareto nhn
c trn cho thy, cc gii php ti u tng ng vi lng chy dao ln s t
c nng sut gia cng cao nht. T c chn la d dng cc ch gia cng
ti u tha mn ch tiu v nng sut, cht lng b mt v tui th dng c.
Hnh 6.5. th mt bin ti u Pareto (a) v gii php ti u tha hip (b).

a)
b)


93
6.3. Kt lun chng 6
- Qu trnh ti u ha a mc tiu ch ct khi tin thp 9XC qua ti bng
dng c PCBN xc nh c b ti u Pareto v gii php ti u tha hip gn
vi gii php l tng nht, cung cp c mt khi lng ln thng tin cho vic ra
quyt nh khi chn la cc thng s gia cng.
- Cc gii php ti u tm c p ng c s cn bng gia cc ch tiu i
lp v cht lng b mt gia cng v tui th dng c.
- Cc hm mc tiu s dng trong qu trnh ti u c xy dng bng phng
php phn tch hi quy thc nghim tha mn cc tiu chun thng k. Sau khi xc
nh c tp hp cc gii php ti u, nng sut gia cng cng c xem xt trong
qu trnh la chn phng n gia cng ti u ph hp.
- Cc kt qu nhn c cho thy vn tc ct c nh hng quyt nh n trng
thi ti u ca cc phng n gia cng trong min kho st. Gi tr vn tc ct ti
u tp trung gn tc 100m/ph. Cc gi tr ti u ca chiu su ct v lng
chy dao phn b tng i u trong min kho st. Nh vy, vic thay i chiu
su ct v lng chy dao khng nh hng nhiu n trng thi ti u ca cc
phng n gia cng.
- Cc gii php ti u Pareto tm c trong vng kho st cho thy gi tr nhm
b mt R
a
gim khi din tch gia cng S
c
gim. Tc gim ca nhm v mt
(6.25%) v din tch gia cng (6.44%) gn nh t l thun. Gii php ti u tha
hip gn vi gii php l tng nht tng ng vi vn tc ct v=100,26m/ph,
lng chy dao s=0,15mm/v, chiu su ct t=0,09mm. Din tch gia cng ti y t
c l S
c
=12.731,41cm
2
, nhm b mt t c l R
a
= 0,5421m.
- Vic gii bi ton ti u a mc tiu bng gii thut di truyn cung cp mt
cng c gii cc bi ton ti u n gin v thun tin vi m bo cao, trnh
c cc nhc im nh hi t sm, i hi cc hm mc tiu phi c tnh kh
vi vi chi ph tnh ton tng i thp, thi gian tnh ton nhanh, c bit hu
hiu vi cc bi ton c kch thc ln.



94
KT LUN V PHNG HNG NGHIN CU TIP THEO
I. KT LUN
T nhng nghin cu ca lun n c th rt ra nhng kt lun sau:
- Cc dng phoi hnh thnh trong qu trnh tin cng thp hp kim qua ti s
dng dao PCBN bao gm dng phoi ri, phoi dy n nh khng c lo dao v phoi
rng ca, trong dng phoi rng ca l dng phoi ch yu hnh thnh trong mt
di rng iu kin ct v vt liu gia cng. Gii hn chuyn i hnh thi phoi ph
thuc vo cng vt liu v ch gia cng, ch yu l vn tc ct i vi c hai
loi thp 9XC v X12M. C ch hnh thnh phoi ph thuc vo s cnh tranh ca
hai qu trnh mm ha v nhit v bin cng ca vt liu gia cng. C ch hnh
thnh phoi rng ca l s trt on nhit do hin tng mt n nh nhit do ca
vt liu.
- Lc ct khi tin thp hp kim qua ti s dng dao PCBN khng ln hn gi tr
lc ct khi tin thng thng. Lc hng tm F
y
lun c gi tr ln nht trong ba
thnh phn lc ct. ln v tng quan gia cc thnh phn lc ct ph thuc
mnh m vo vt liu gia cng v ch ct. Lc ct c gi tr nh nht khi vt liu
gia cng c cng khong 50HRC, tng ng vi s xut hin dng phoi rng
ca. Trong phm vi nghin cu, lc ct gim khi tng vn tc ct. Gi tr lc ct khi
tin thp X12M ln hn nhiu so vi khi tin thp 9XC cng iu kin.
- Trung tm nhit ln nht ca dng c PCBN khi tin thp hp kim qua ti
nm mt trc khi dng c sc v nm ngay trn li ct khi dng c mn. Nhit
cao ti li ct l nguyn nhn thc y cc c ch mn v ph hy li ct
dng c PCBN. Kt qu xc nh trng phn b nhit trong dng c nhn c t
m hnh l thuyt sai lch khng qu 7,8% so vi m hnh thc nghim.
- Mn dng c PCBN c gy ra bi nhiu c ch kt hp nh dnh, mi mn,
khuch tn, tng tc ha hc v ph hy v nhit. Vt liu gia cng v ch ct c
nh hng ln ti mn v c ch mn dng c PCBN. Tn ti pha lng trn b mt
tip xc gia phoi v mt trc dng c. Tnh cht pha lng ph thuc vo iu kin
ct, vt liu phi v dng c. Pha lng c nh hng ln ti tc mn dng c.
- ng cong mn ca vt liu PCBN cng tun theo quy lut mn thng
thng. Giai on mn n nh gim khi vn tc ct tng. Chiu cao v tc mn


95
mt sau dng c PCBN khi ct thp X12M ln gp hn 3 ln so vi khi ct thp
9XC cng iu kin.
- Nhm b mt gia cng khi tin thp hp kim qua ti bng dao PCBN c tr s
kh nh, tng ng nhm cp 78. Cng iu kin ct nh nhau, nhm b mt
nhn c khi gia cng thp 9XC nh hn khi gia cng thp X12M. Nhm b mt
tng khi cng vt liu gia cng tng.
- B mt gia cng nhn c khi tin thp hp kim qua ti bng dao PCBN xut
hin cc lung vt liu bin dng do do kim loi chy do dch chuyn theo
phng vung gc vi phng chuyn ng thng thng ca dng phoi, to thnh
ba via dc theo vt lng chy dao v lm gim cht lng lp b mt. Lp b mt
khng c s thay i v cu trc t vi. Tuy nhin c s bin i v c tnh khi
cng t vi tng lp b mt v gim nh bn di lp b mt, so vi cng vt
liu ban u.
- Cc kt qu nhn c t qu trnh ti u ha a mc tiu ch ct khi tin
cng chnh xc thp 9XC bng dng c PCBN cho thy vn tc ct c nh hng
quyt nh n trng thi ti u ca cc phng n. Gi tr vn tc ct ti u tp
trung gn tc 100m/p. Chiu su ct v lng chy dao trong min kho st
khng nh hng nhiu n trng thi ti u ca cc phng n gia cng.
II. PHNG HNG NGHIN CU TIP THEO
pht trin v hon thin nghin cu v l thuyt cho cng ngh tin cng
Vit nam, phng hng nghin cu tip theo cn tp trung vo cc ni dung:
- Nghin cu nh hng ca thnh phn vt liu dng c PCBN n tnh nng
ct gt, tui th dng c v cht lng b mt khi tin cng chnh xc thp hp kim
qua ti.
- Nghin cu nh hng ca cc thng s hnh hc dng c ct n qu trnh
hnh thnh phoi, lc ct v nhit ct khi tin cng.
- Nghin cu m rng i vi cc loi vt liu gia cng khc c s dng ph
bin Vit Nam nh thp hp kim thp 40X, cc loi thp khng g...
- Nghin cu ti u ha trit hn, xem xt ng thi cc ch tiu v chi ph
gia cng, nng lng tiu th, rung ng... c th t c mt gii php ti u
tng th.



96
DANH MC CC CNG TRNH CNG B
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