Gii thiu chung v qu trnh n p nhm

T thanh Billet nhm (thnh phn6063) di c gia nhit ln n 430

0
C - 450
0
C,
qua my ct nng ct thnh on kYch thc nht nh, Container gia nhit v khun
(vt liu: SKD 6l) cng c gia nhit n 430
0
C - 450
0
C . Khi nhit m bo
billet nhm c a vo trong container, khun c t vo trong DlE RlNG v trong
DlE HOUSE. Chy p i vo, lc ny nhit khong 580
0
C nhm trng thi gn
nh lng c chy qua khun to ra hnh dng hnh hc ca profile, khi n ra th thit
ca thanh nhm cn khong 530
0
C. Thanh nhm c n ra v lm mt trn gin
bng ti, sau qua h thng ko cng, qua h thng ct to ra kYch thc sn phm
theo yu cu. a ton b sn phm qua l ho gi lm thay i t chc to
cng cho thanh nhm, sau qua quy trnh ant, sn tnh in, ph phim to ra
sn phm hon chnh.
nhm c th n p ra th phi m bo 3 yu t nhit sau:
- Nhit ca Billet
- Nhit ca Container 430
0
C 450
0
C
- Nhit ca khun
- Lng co ngt ca nhm khi ng c l l/l00.
Qu trnh n p:
l. Xylanh my p
2. Thn chy p
3. u chy p
4. Nhm billet
5. Bc
7. L.l.P (BG)
8. DlE
9. BK
l0. DlE Ring
ll. BOLSTER
6. Container l2. DlE HOUSE
Kt cu c bn ca hun
Khun n p nhm c phn ra lm 2 loi chYnh l:
- Khun SOLlD
- Khun HOLLOW
l. Kt cu ca khun SOLlD gm c 3 thnh phn c bn l:
+ L.l.P
+ DlE
+ BACKER (BK)
Chc nng v nguyn l lm vic:
- L.l.P: Phn chia dng nhm v dn hng cho dng nhm vo khun, c lp
ghp phYa trc DlE thng qua cht nh v, chu p lc p v n hi
nhit cho khun, tng cng vng v tui th ca khun trong qu trnh lm
vic.
- DlE: To ra hnh dng hnh hc ca profile v cht lng b mt ca sn phm,
cho php dng nhm chy qua cc khe h c to trn b mt DlE.
- BACKER: Tng cng vng cho DlE, c lp ghp phYa sau DlE thng qua
cht nh v, lm tng n nh v tui th ca khun.
2. Kt cu khun HOLLOW gm c 3 thnh phn c bn:
+ BRlDGE (BG)
+ DlE
+ BACKER (BK)
Chc nng v nguyn l lm vic:
- BG: Phn chia dng nhm v dn hng cho dng nhm vo khun, to ra hnh
dng hnh hc cc l rng khp kYn bn trong ca profile. c lp ghp cht vi
DlE thng qua cht nh v
- DlE: To ra hnh dng hnh hc bao qut phYa bn ngoi ca profile, khi c lp
ghp vi BG sl to ra hnh dng hnh hc ca sn phm hon chnh.
- BK: Tng cng vng cho khun, c lp ghp phYa sau ca DlE m bo
tYnh n nh cho khun.
Sau khi lp ghp c mt b khun hon chnh ta lp ghp vo vi DlE RlNG (l
chi tit bao bn ngoi ton b khun), tip tc lp ghp vi BOLSTER v t vo
trong DlE HOUSE sau a vo n p. (theo nh hnh vl)
! "h# $% Trc khi a vo n p th ton b khun phi c gia nhit ln ti 430
0
C
450
0
C.
&u' trnh (n )ut hun h*+n ch,nh%
l. N/c thit k: Tu thuc vo tng loi my n p, cng nh yu cu ca khch
hng m ngi thit k khun sl a ra phng n thit k cng nh cch b trY
dng nhm vo khc nhau.
2. N/c chn phi: Chn theo ng kYnh v chiu dy (theo bn vl thit k)
3. N/c tin trc khi nhit luyn: Tin th phi cho tt c cc chi tit m bo
nhm 3 (theo bn vl thit k)
4. N/c ly du: Ly du cho tt c cc chi tit (theo bn vl thit k)
5. N/c khoan: Khoan l cht cho tt c cc chi tit, khoan dn hng cho L.l.P, BG,
BK, khoan gim bt lng d gia cng cho DlE (theo bn vl thit k), khoan l mi
cho N/c ct dy i vi DlE.
6. N/c phay:
- My phay ng:
Phay th: ng dn nhm vo cho L.l.P v BG, chn bearing v bearing cho
BG ( li lng d l l mm cho nguyn cng phay CNC) nhm 3 , ng
dn nhm ra cho BK, gim bt lng d gia cng cho nguyn cng EDM. (theo
bn vl thit k)
- My phay CNC: Phay th b mt li vo nhm ca DlE nhm 3
7. N/c nhit luyn: Ti v ram tt c cc chi tit m bo cng 49 - 50 HRC.
8. N/c tin sau khi nhit luyn: Tin tinh ng kYnh m bo nhm 5 v
kYch thc theo bn vl thit k cho tt c cc chi tit, tin tinh b mt vo nhm
ca DlE v b mt ra nhm ca BG, ng kYnh lp ghp ca DlE v ca BG
t nhm 6. (theo bn vl thit k)
ch : i vi DlE v BG cho khun HOLLOW tin ng kYnh lp ghp
lm chun cho n/c phay CNC v n/c ct dy r chun.
9. N/c phay sau khi nhit luyn: Phay tinh b mt vo nhm ca DlE, phay ht l -
ng d b mt ra nhm ca BG m nguyn cng tin li, nhm 6.
l0. N/c mi:
- My mi phng: Mi phng ton b 2 mt cho L.l.P, BK, DlE t nhm 4.
- My mi cm tay chy bng in: Mi th bng tr: lm phng v nhn lp
nhp nh t vi do n/c phay li (ch : khng lm nh hng n hnh dng
hnh hc ca chi tit gia cng) cho BG, L.l.P,
Mi tinh bng giy rp: i vi L.l.P t nhm 5(ch bo gc tt c cc cnh
sc)
ll. N/c phay CNC: Phay tinh b mt bearing ca BG t nhm 6 li lng d
+0.05 cho nguyn cng ngui, khoan chYnh xc v trY 2 l cht nh v trn
BG. (theo bn vl thit k)
l2. N/c ct dy: Ct theo hnh dng ca profile, li l ng d cho nguyn cng
ngui - 0.05, ct chYnh xc 2 l cht nh v trn DlE. (theo bn vl thit k)
Ch : y l khu quyt nh n hnh dng hnh hc ca sn phm, do
khi gia cng phi ch n sai s ca my m ngi gia cng c th iu
chnh ch ct cng nh lng d gia cng hp l m bo ng kYch thc
theo bn vl thit k.
l3. N/c EDM (my xung): gia cng cc chi tit bearing ca DlE v BG.
C 2 loi in cc l : in cc ng v in cc ch
- in cc ng: Dng xung nhng v trY v hnh dng trn bearing
ca BG m my phay CNC khng gia cng c,
- in cc ch: xung nhng v trY v hnh dng m my phay khng
gia cng c i vi chn bearing ca BG (ng dn nhm vo),
xung gia cng di ngn ca bearing theo bn vl thit k:
Ch : i vi DlE cho khun SOLlD th dng in cc ch xung bearing
ngay sau khi ct dy xong. (theo bn vl thit k)
i vi khun HOLLOW th xung sau khi lp ghp gia BG vi DlE, di
ngn ca bearing theo bn vl thit k.
l4. N/c ngui : Hon thin v lp ghp cc chi tit:
i vi DlE cho khun SOLlD v khun HOLLOW:
- Sa cha nhng khuyt tt do n/c trc li,
- Kim tra khng thng, khng phng ca b mt bearing,
khng vung gc ca b mt bearing vi mt chu p lc nhm. (cc
kYch thc phi tun theo bn vl thit k)
- Gia cng b mt bearing vi lng d gia cng < 0.05, mi t bng 6
i vi BG ca khun HOLLOW:
- Kim tra cc l dn nhm vo khun, sa li cc mp m t vi (khng lm
nh hng cng nh sai lch n hnh dng hnh hc) mi bng giy rp
cc l t bng 4.
- To cong cc v trY cnh sc m bo cho dng nhm chy d
dng v thun li.
- Kim tra khng phng, khng thng , song song gia cc cnh
(tu thuc vo tng kt cu khun).
- Mi b mt bearing m bo vung gc vi b mt chu p lc
nhm v t bng 6
Lp ghp hon thin khun :
- i vi khun SOLlD:
Cc chi tit c lp ghp theo th t: L.l.P + DlE + BK, ch lp lng
thng qua cht,
- i vi khun HOLLOW:
Cc chi tit c lp ghp theo th t: BG + DlE + BK, ch lp cht
thng qua cht.
Sau khi lp ghp gia BG vi DlE, phi kim tra li kYch thc, khe h ca
profile bng dng kim, tun theo bn vl thit k. Tu thuc vo yu cu
ca khch hng m khi lp ghp sl chnh lch gia bearing ca BG
v bearing ca DlE l bao nhiu.
Sau mi phng 2 mt ca sn phm t bng 4.
Thng qua quy trnh sn xut khun ta thy v trY ca khu gia cng ngui l
khu hon tt v lp ghp cc chi tit, kim tra kYch thc, dy ca sn phm, nh
hng trc tip n cht lng b mt sn phm khi n p.
Sau khi lp ghp hon chnh b khun, mang i n th khun v kim tra
cht lng b mt cng nh v kYch thc v hnh dng hnh hc ca sn phm. Nu
t th mang i ho nhit luyn, thm Nit cho b mt bearing, tu thuc vo tng
loi khun m thi gian thm Nit l bao lu v thm bao nhiu ln.
Ch : khi mt b khun m bo v tt c cc thng s v kt cu cng nh v
cht lng sn phm, mang i n p, trong qu trnh n p ta phi kim tra xem vi
b mt bearing nh th c th n p c khi lng l bao nhiu, khi ta mi a ra -
c phng n ho nhit luyn cho b mt bearing m bo cht l ng ca khun
cng nh nng sut ca sn phm. Khi kim tra nu thy b mt c du hiu r th
phi i ho nhit luyn ngay m bo cho b mt ca bearing.
-.ng c. ch* qu trnh /+m ngu0i%
l. My mi cm tay bng in trn v a
2. My da cm tay dng khY nn
3. Da cc loi
4. Giy rp th v giy rp tinh
5. Ba
6. t v chy
7. Dng kim tra
8. Thc kp
9. Ke gc
l0. Cc loi dng c ct v mi cho qu trnh sa ngui. (nh tr cc kYch c,
a cc loi, li doa u vung, li doa u trn, li da)
ll. n
l2. t
"c 'u t1 nh h2ng n cht /3ng (n ph4m%
Trong qu trnh n p nhm c rt nhiu yu t nh hng n cht lng sn
phm, theo thng k trn thc t th 30 do khun, 30 do Billet, 30 do my n p
v l0 do ngi sn xut. Do khi mt sn phm n ra m khng m bo cht lng
cng nh v hnh dng th phi xem xt nh gi nguyn nhn dn n t u v do
khu no gy ra nhng li .
50t (1 67ng h h8ng ha' g9p tr*ng qu trnh n p nhm:
a) Li khun b nt:
- Hin tng: b nt chn rt nhng v trY cnh gc
- Nguyn nhn: do kt cu yu, bn kYnh gc qu b, hoc p lc p qu ln.
- Phng php khc phc: mi sang phanh ri hn li bng que hn BKS 6l, xem
xt li p lc v tc n p ca my p.
b) Gy mt v trY no trn DlE:
- Hin tng: Khi n p do khng chu c p lc ca my p m mt s v trY
no trn DlE b gy, thng thng hay gy nhng ch kp cng vng.
- Nguyn nhn: Do kt cu yu, do lc p ln qu
- Phng php khc phc: Phi tng cng vng nhng v trY ln, bng
cch ct mt ming thp khc cng vt liu v cng, kYch thc v hnh dng
tng t ghp vo v trY b gy.Trong nhiu trng hp do cu trc cng nh v
trY ca hnh dng hnh hc qu yu, th khi gia cng trn n/c ct dy phi ch
tng cng vng nhng v trY ln bng cch ct TAPER.
c) Sn phm b trc vy
- Hin tng: trn b mt sn phm xut hin nhiu v trY b trc vy, b mt
xu khng t.
- Nguyn nhn: Do trong qa trnh c billet b hin tng r khY do trong khi
ko cng sn phm lc ko ln qu do trong khi nung nng billet v khi n
p nhit lm vic cao qu mc quy nh sl dn n hin tng ny.
- Phng php khc phc: Kim tra Billet trc khi a vo n p, hn ch ti a
hin tng r khi khi c billet, Gim lc ko cng xung cho hp l, gim nhit
lm vic ca my xung mc hp l.
d) B mt cnh ca sn phm b nt:
- Hin tng: rng nt v trY cnh ca sn phm, khng t yu cu
- Nguyn nhn: do bn kYn gc qu b
- Phng php khc phc: tng bn kYnh gc ln.
e) Sn phm b cong:
- Hin tng: B mt ca sn phm b cong ln
- Nguyn nhn: Do ng dn nhm vo cha cn bng (lng nhm b trY khng
ng u), do chiu di bearing ln qu
- Phng php khc phc: Kim tra li kYch thc ca ng dn nhm vo, phi
m bo tYnh ng u ca nhm khi i vo khun, nu kYch thc ng dn
hp l th khi ta x l chiu di bearing cho ngn li hoc tng tc dng
chy ca dng nhm v trY ln lng nhm c ng u trn ton b
khun.
f) Nhn b mt sn phm:
- Hin tng: B mt sn phm khi n ra b nhn
- Nguyn nhn: Do ti v trY ny dng nhm chy nhanh qu, lng nhm vo
nhiu qu.
- Phng php khc phc: Hn ch dng chy ti v trY ny bng cch iu
chnh b mt bearing.
g) im trng trn b mt sn phm:
- Hin tng: Xut hin nhiu vt trng di, hay nhng im trng trn b mt
ca sn phm.
- Nguyn nhn: do billet khng ng u v thnh phn, cng c th do nhit
n p qu cao.
- Phng php khc phc: Kim tra li thnh phn ca billet, iu chnh li nhit
ca my n p khi lm vic.
h) B rch sn phm:
- Hin tng: Khi n ra c mt s v trY ca sn phm b rch, khng m bo
hnh dng hnh hc ca sn phm.
- Nguyn nhn: Do lng nhm vo v trY ny khng
- Phng php khc phc: iu chnh li dng nhm vo khun, tng lng nhm ti
v trY ny ln,
i) Mp, vnh, xon sn phm:
- Hin tng: Khi n ra sn phm b cong vnh, mp li, xon, khng m bo
hnh dng hnh hc ca sn phm.
- Nguyn nhn: Do lng nhm vo khun khng ng u, ch nhanh ch chm,
do p lc p qu ln.
- Phng php khc phc: iu chnh li dng nhm, iu chnh li p lc v tc
n p.
;hng php (<a ch=a hun thng th>ng
Trong qu trnh n p th c rt nhiu nhng phng n sa khun, tu thuc vo
tng loi khun v kt cu khun, cng vi s cm nhn ca ngi sa khun m c th
a ra c nhng phng thc sa khc nhau. Tuy nhin vn theo trnh t u tin cho sa
bearing u tin v y l phng php n gin nht. Khi n p th nhm nhit
khong 580
0
C 6l0
0
C, lc ny nhm trng thi gn nh th lng nn tun th theo
ng quy lut ca dng chy l cng chu lc masat ln cng chy chm.
Ch : Khi lm thay i dng chy ca nhm ta c th iu chnh gc nghing
ca bearing ra ngoi hay vao trong, lm tng tc chy ca bearing ta lm nh tr-
ng hp a) v ngc li mun lm chm dng chy ta lm theo trng hp b) vi gc vt
khong l l.5
a) b)
Nu nh sa bearing m sn phm vn ra khng nh mong mun th ta c th sa
li l dn nhm vo, tu thuc vo tng kt cu khun m c th a ra c phng n
sa hp l nht.
?* qun hun:
Khi khun n p xong th lng nhm vn cn bm li trong khun, khi ta phi
ly lng nhm ny ra bng cch un trong dung dch NaOH 20 nhit l00
0
C, tu
thuc vo tng loi kt cu khun m ta un trong thi gian l bao lu, thng thng t
8 l2 h. Sau khi ly nhm ra ta chuyn vo phng sa khun v dng giy rp mn
nh bng li ton b b mt bearing sau xt vo b mt bearing dung dch bo
qun (NABAKEM). Thng thng i vi mi loi khun sau khi n p c mt lng
nhm nht nh no ta phi b ra i ho nhit luyn sau mi bng giy
rp, tip theo xt dung dch bo qun ri a vo phng bo qun khun.
Khun c thng k theo h thng v bo qun ni kh ro trn cc gi khun.
Ch : Tui th ca mi b khun ph thuc vo mc lm vic v my n p,
cng nh phc thuc vo qu trnh ho nhit luyn cho b mt bearing.