TI U HO CH CT KHI PHAY VT LIU SKD61

BNG MNH DAO PH PVD - TIALN

KS. DNG XUN TRNG
TS. NGUYN VN HNG
Trng i hc K thut Cng nghip
i hc Thi Nguyn
Tm tt: Hin nay, mc d trn th gii c nhiu ti v cng trnh nghin cu v
ch gia cng ct gt v ti u ho ch ct trn cc my CNC. Tuy nhin, a s cc cng
trnh nghin cu lin quan n vn ny, thng c thc hin trn mt h thng cng
ngh c th vi cc vt liu v dng c ct xc nh. Bi bo ny trnh by kt qu nghin cu
ti u ho ch ct khi phay vt liu SKD61 bng mnh dao ph PVD - TIALN, gii bi
ton ti u ho bng phng php thc nghim theo mc tiu ti u ho v nng sut gia
cng, mn dng c ct v nhm b mt, kt hp vi nghin cu c ch mn ca dng c ct
phn tch v nh gi khch quan kt qu nghin cu.

CT 2

Summary: Nowadays, although there have been many researchs on the cutting
mechanism and optimization of the cutting on CNC machines. However, most of these studies
are often carried out in a specific technological system with defined materials and cutting
tools. This paper presents research results on optimizing of cutting parameters in end milling
SKD61 steel using PVD - TIALN coated carbide insert, resolving the optimization problems
with the experimental method in the direction of optimizing the efficiency of processing,
cutting tool wear and surface roughness in combination with studies on investigation of wear
mechanisms of cutting tool in detail using scanning electron microscope (SEM) for objective
analysis and evaluation of such results.

I. GII THIU
Ti u ho qu trnh gia cng ct gt l phng php xc nh ch ct ti u thng qua
vic xy dng mi quan h ton hc gia hm mc tiu v kinh t hoc k thut ca qu trnh
gia cng vi cc thng s ca ch ct tng ng trn mt h thng cng ngh xc nh [1],
nhm t c cc mc tiu v kinh t hoc k thut ca qu trnh gia cng. Nh vy, thc cht
ca vic xc nh ch ct ti u l gii bi ton ti u ho bng phng php thc nghim
[2] tm cc tr v min ti u ho theo cc ch tiu ra.
II. M HNH HO QU TRNH NGHIN CU
nghin cu ti u ho ch ct mt cch c h thng v logic, da vo kt qu nghin
cu [1, 3, 6, 7, 9] ta xy dng m hnh ho qu trnh ct khi phay nh hnh 1. T m hnh ny ta
thy, c rt nhiu yu t nh hng n qu trnh phay nh: cng vng ca h thng cng

ngh, chnh xc ca my, vt liu v cht lng ca phi gia cng, cht lng v thng s
hnh hc ca dng c ct, ch gia cng s, v, t..., chng c nh hng ln n cc thng s
u ra l cc ch tiu v kinh t v k thut nh: nng sut, cht lng v chnh xc ca b
mt, mn v tui bn ca dng c ct ...

Hnh 1. M hnh ho qu trnh ct khi phay

Theo kt qu ca mt s nghin cu mi y v ch gia cng ct gt th lc ct trong

qu trnh gia cng v mn dng c ct l cc i lng c nh hng rt ln ti qu trnh gia
cng, khi ct vn tc cao th nh hng ca lc ct c xu hng gim dn [9] v nh hng
ca mn dng c ct li tng nhanh v tng nhm b mt gia cng [6]. Trn c s , nh
hng nghin cu ti u ho trn m hnh phay vt liu SKD61 c th vi cc hm mc tiu ti
u nh sau:
- Nng sut ct

: Q = f(s,v,t) QMax

- Mn dng c ct : hs = f(s,v,t) hs Min

- nhm b mt : Rz = f(s,v,t) Rz Min
III. M T TH NGHIM
3.1. Thit b th nghim
- My: Th nghim c tin hnh trn Trung tm gia cng VMC - 85S/CNC.
- Dao: Mnh dao hp kim ph PVD - TIALN c thng s hnh hc nh hnh 2.

Hnh 2. Thng s hnh hc mnh ct TIALN

CT 2

- Vt liu: Vt liu SKD 61 theo tiu chun JGS ca Nht Bn c thnh phn ho hc phn
tch quang ph nh bng 1 v th nghim gia cng cng 32 - 40 HRC.
Bng 1. Thnh phn ho hc ca SKD61

N.T

Mn

Si

Cr

Ni

0.371

0.339

0.93

0.021

0.0083

5.22

0.103

N.T

Mo

Cu

Nb

Al

Co

Ti

1.169

0.835

0.106

0.0079

0.019

0.025

0.008

N.T

Pb

Sn

Mg

Fe

0.044

0.013

0.0085

0.01

0.0023

90.75

3.2. Thit b o
1. My o to 3 chiu CMM - C544 hng Mistutoyo, Nht Bn, c phn gii 0.0001
mm.
2. My o nhm b mt: SJ 201 ca hng Mitutoyo c phn gii 0.03m/300m,
0.08m/75m, 0.04m/9.4m.
3. Knh hin vi in t: My TM - 1000 ca hng Hitachi, c phng i 10.000 ln.
4. ng h so: S dng ng h so ca hng Mistutoyo, c phn gii 0.01 mm.
3.3. Ma trn th nghim
CT 2

Khong ch ct nghin cu c xc nh thng qua cc th nghim s b v tham kho

[4], [5], ng thi xy dng m hnh quy hoch thc nghim theo [2, 3] ta c ma trn th
nghim nh bng 2.
Bng 2. Bng ma trn th nghim

G.hn di Mc di Mc TB
(-1)
(0)
(- )

Thng s

Mc trn
(+1)

G.hn trn
(+)

Cc bin
x1

ae

0.246

0,3

0,55

0,8

0.854

ap

S(mm/vg)

0.178

0.2

0.3

0.4

0.421

x2

V (m/ph)

261.4

270

310

350

358.6

x3

t(mm)

3.4. Qu trnh th nghim

T min gii hn ch ct, ma trn th nghim c thit lp theo quy hoch hp Box Willson [2], mi th nghim c thc hin bng 2 mnh ct TiAlN. S dng my o 3 chiu
CMM, ng h so xc nh gi tr mn mt sau ca dng c ct v o nhm b mt Ra, Rz.
ng thi, phn tch c ch mn ca dng c ct TiAlN trn nh SEM. Sau khi th nghim, kt

qu c thng k nh bng 3.
Bng 3. Kt qu th nghim gia cng SKD61

TT
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

t
mm
0.3
0.8
0.3
0.8
0.8
0.8
0.3
0.8
0.854
0.246
0.55
0.55
0.55
0.55
0.55

S
mm/vg
0.2
0.2
0.4
0.4
0.2
0.2
0.4
0.4
0.3
0.3
0,421
0,178
0.3
0.3
0.3

V
m/ph
270
270
270
270
350
350
350
350
310
310
310
310
358.6
261.4
310

hs
mm
0.0025
0.0037
0.0039
0.018
0.016
0.0315
0.015
0.0547
0.039
0.0029
0.015
0.0091
0.0357
0.0014
0.0102

Rz
m
2.283
3.14
2.065
3.533
2.013
2.033
2.553
2.97
2.25
2.675
3.033
2.215
2.545
3.26
2.845

Q
g/ph
17.9
44.6
38.3
91.8
23
60
51.4
129.4
76.0
20.8
71.8
26.6
110.3
41.3
90.6

IV. KT QU NGHIN CU
4.1. Xc nh hm hi quy ti u ho
S dng phn mm Matlab quy hoch thc nghim v gii bi ton ti u ho, ta c
cc hm hi quy v nng sut gia cng, mn dng c ct v nhm b mt nh sau:
- LnQ = (157.057599 - 2.650311.lnt - 4.934117.lnS - 56.147729.lnV - 0.046275.lnt.lnS +
0.448740.lnt.lnV + 0.512351.lnS.lnV - 0.672684.lnt2 - 1.211865.lnS2 + 5.130406.lnV2).
- ln(hs) = (-170.914172 - 0.142169.lnt + 29.140555.lnS + 57.368954.lnV + 1.410713.lnt.lnS
+ 0.796190.lnt.lnV - 3.766014.lnS.lnV + 0.936300.lnt2 + 2.272186.lnS2 - 4.733311.lnV2).
- ln(Rz) = (28.977480 + 8.491366.lnt - 9.752964.lnS - 10.234771.lnV + 0.217090.lnt.lnS 1.449336.lnt.lnV + 1.647837.lnS.lnV - 0.160584.lnt2 - 0.284649.lnS2 + 0.936091.lnV2).
Da vo cc hm hi quy ny kho st qu trnh gia cng vt liu SKD61, ta c gi
tr cc hm mc tiu nh sau:
- Nng sut Qmax = 153.224292 (g/ph)
ti: t = 0.854(mm), S = 0.4210(mm/vg), V = 358.6 (m/ph)
- Lng mn hsmin = 0.004788 (mm)
ti: t = 0.246(mm), S = 0.2944(mm/vg), V = 309.996 (m/ph)
- Nhm b mt Rzmin = 1.966820 (m)
ti: t = 0.246(mm), S = 0.1780(mm/vg), V = 358.6(m/ph)

CT 2

4.2. Phn tch kt qu nghin cu

m rng phm vi la chn hp l ch ct, ta s dng phng php kho st th ti
cc gi tr ti u nh hnh 3, 5, 7, 9, 10, 11 v nh gi y hn na kt qu nghin cu ti
u ho ti cc im cc tr v min ti u khi phay vt liu SKD61, ta kho st mn v c ch
mn ca mnh dao TiAlN. T , nh gi nh hng ca cc thng s cng ngh n nng
sut v cht lng b mt gia cng.
4.2.1. nh hng ca cc thng s cng ngh n mn dng c ct
- nh hng ca vn tc ct v lng chy dao c m t nh hnh 3.
Trn th ta thy, vn tc ct cng cao th mn dng c cng ln. Khi gia cng vn tc
V = 260 310 (m/ph) th nh hng ca lng chy dao ti mn dng c ct l khng ng k
v lng mn xut hin u trn li ct chnh (hnh 4a). Tuy nhin, khi tng vn tc ct t 320
350 (m/ph) th lng mn tng vi lng chy dao nh nh hnh 3 v mn pht trin v pha
mi dao (hnh 4b) do lm tng nhm b mt gia cng.

CT 2

Hnh 3. nh hng ca vn tc ct v lng chy dao n mn dng c

Hnh 4. nh SEM mn trn li ct chnh

V = 350m/ph, S = 0.4 (mm/vg)

V vy gia cng vt liu SKD61 c lng mn nh nht ta nn chn vn tc ct v

lng chy dao theo ng mc ti u hs = 0.0053716 nh th hnh 4.1 vi vn tc ct V nh

hn 320(m/ph) v chiu su ct ti u t = 0.2460(mm).
- nh hng ca vn tc ct v chiu su ct nh th hnh 5 ta thy, c vn tc v chiu
su ct u c nh hng n mn dng c ct, khi chiu su ct nh th nh hng ca vn tc
ct n mn vn cha r.

Hnh 5. nh hng ca vn tc v chiu su ct n mn dng c

CT 2

Hnh 6. Hin tng nt tch v ph hu li dao (V = 350m/ph, t = 0.8mm)

Tuy nhin khi tng chiu su ct t = 0.4 - 0.8 (mm) th mn tng rt nhanh theo vn tc
(hnh 5). Nguyn nhn l do khi tng vn tc v chiu su ct, di tc dng ca lc ct lm
nt tch v rn v li dao nh hnh 6. y l hin tng nt tch ri v ra tng mng ca li
ct di tc dng ca lc ct ln khi gia cng tc cao.
Nh vy, kt qu min ti u ho trn ng mc v mn hs = 0.010954 hon ton ph
hp vi nghin cu ny, vi lng chy dao ti u S = 0.2944(mm/vg), ta nn la chn vn tc
ct V v chiu su ct t theo th hnh 5 t ch tiu v lng mn dng c nh nht.
- nh hng ca chiu su ct v lng chy dao c m t nh hnh 7.

Theo quan h ny th khi chiu su ct nh 0.1 - 0.43(mm) th lng chy dao khng c
nh hng nhiu n mn dng c ct. Tuy nhin, khi tng chiu su ct t 0.5 - 0.8(mm) th
lng mn tng nhanh theo lng chy dao v chiu su ct v nh hng ca lng chy dao
khi tng nhanh hn.

Hnh 7. nh hng ca lng chy dao v chiu su ct n mn dng c

CT 2

Nguyn nhn chnh ca hin tng ny l do khi gia cng tc cao vi lng chy dao
v chiu su ct ln, lc ct v nhit ct xut hin ngy cng tng. Do , hin tng nt tch,
rn v li ct v dnh bm vt liu gia cng do nhit ct kt hp vi xi ho lp b mt lm
mt phn vt liu b khuch tn ln nhau, gy mn nhiu v tin ti ph hu li dao (hnh 6 v
8). Tc ng ny lm gim tui bn ca dng c ct v tng nhm b mt gia cng.

Hnh 8. Hin tng khuch tn vt liu

Trn ng mc hs = 0.012877 hnh 4.5 ta nn chn chiu su ct (t = 0.5 - 0.7)mm ng

vi vn tc ct ti u V = 309.996(m/ph).
4.2.2. C ch mn ca dng c ct TiAlN
Phn tch ti mt s im cc tr v nghin cu c ch mn ca dng c ct TiAlN khi
phay vt liu SKD61 cho thy, cc mnh dao u b mn c mt trc v mt sau. Khi gia cng

 tc ct cao, qu trnh mn dng c ct c pht trin u trn li chnh (hnh 4a).

Nguyn nhn l do cc ht cng ca vt liu gia cng co xc vo b mt tip xc ca dng
c. Khi tng vn tc ct V ln hn (V = 320 - 350m/ph) ta thy bt u c hin tng dnh bm,
nt tch vt liu gia cng v gy mn nhiu mt sau ri pht trin mnh v pha mi dao (hnh
4b). Hin tng nt tch, rn v li ct v dnh bm vt liu gia cng do nhit ct kt hp vi
xi ho lp b mt lm mt phn vt liu b khuch tn ln nhau (hnh 8), gy mn nhiu v
tin ti ph hu li dao. Do , tc ng ny lm gim tui bn ca dng c ct v tng
nhm b mt gia cng.
4.2.3. nh hng ca cc thng s cng ngh n nhm b mt gia cng
- nh hng ca vn tc ct v lng chy dao n nhm bn mt nh th hnh 9 ta
thy, vn tc ct v lng chy dao c nh hng trc tip n nhm b mt gia cng, lng
chy dao nh dn n chiu cao nhp nh t vi b mt thp.

CT 2

Hnh 9. nh hng ca vn tc ct v lng chy dao n nhm b mt

Tuy nhin nu gia cng vn tc V < 290 (m/ph) th nh hng n mc bin dng do
v bin dng n hi b mt gia cng cao hn nn nhm b mt tng. Tip tc tng vn tc ct
th chiu cao nhp nh b mt li gim lng chy dao thp v tng u theo lng chy dao
nh hnh 9.
Trn ng mc ti u ho Rz = 2.0573 khi gia cng vn tc cao V > 290 (m/ph) ta nn
chn S = < 0.2(mm/vg), v khi gia cng vn tc V = < 280(m/ph) ta nn chn S = 0.35 0.42(mm/vg) ng vi chiu su ct ti u l t = 0.2460(mm).
- nh hng ca vn tc v chiu su ct n nhm bn mt th hin nh hnh 10.
Khi gia cng chiu su ct nh, do li ct ca dng c trt v co xc ln b mt gia
cng v lm tng nhm b mt. Tuy nhin, khi tng chiu su ct th nhm b mt li gim
vi trng hp gia cng tc cao.

Hnh 10. nh hng ca vn tc ct v chiu su ct n nhm b mt

Do t c nhm b mt ti u theo ng mc Rz = 1.8872 nh hnh 10 ng

vi lng chy dao ti u S = 0.1780(mm/vg) ta nn chn chiu su ct trong khong t = 0.45 0.85(mm), vn tc V > 320(m/ph). Nghin cu ny cng ph hp vi kt qu khi phay vt liu
(Ti-6Al4V) [5].
- nh hng ca lng chy dao v chiu su ct n nhm bn mt th hin nh hnh 11.

CT 2

Hnh 11. nh hng ca lng chy dao v chiu su ct n nhm b mt

Kt qu trn th cho thy, nh hng ca lng chy dao ti nhm b mt l rt r v

ph hp vi c ch mn ca nghin cu ny. Khi tng lng chy dao S th nhm b mt tng
nhanh v t b nh hng ca chiu su ct. Tuy nhin, trn ng mc ti u v nhm b mt
Rz = 1.8384 th cn chn chiu su ct t ln hn 0.55(mm) v lng chy dao nh hn
0.22(mm/vg) vi vn tc ct ti u V = 358.6(m/ph) th qu trnh gia cng s t ch tiu v
nhm nh nht.

4.3. Cc sn phm ng dng

ng dng kt qu nghin cu gia cng b mt khun c p lc nh hnh 12.

Hnh 12. Gia cng khun c v khun ci

Kt qu ng dng gia cng khun mu cho thy, ch gia cng ny cho nng sut v cht
lng cao hn so vi cc ch ct trc y, c th l: Vn tc ct t 120 - 160(m/ph) theo [3,
10] tng ln t 260 - 358(m/ph), nng sut gia cng tng 3 ln v nhm b mt gim 1.8
ln theo kt qu nghin cu ny.

CT 2

Hnh 13. Sn phm ng dng

V. KT LUN
Gii bi ton ti u ho bng phng php thc nghim v nghin cu c ch mn ca
dng c ct phn nh c bn cht L - Ho xy ra trong qu trnh phay vt liu khun mu
SKD61 bng mnh dao TiAlN, v mi quan h nh hng gia chng n nng sut v cht
lng ca sn phm. Kt qu nghin cu ny tm c cc tr v min ti u ho theo cc
ch tiu v nng sut, mn dng c ct v nhm b mt gia cng. y l c s khoa hc quan
trng tin hnh cc nghin cu tip theo v ch gia cng vt liu SKD61 v lm c s
nghin cu ti u ho ch gia cng ct gt cc loi vt liu v dng c ct khc. ng thi
trin khai ng dng kt qu nghin cu ny vo thc t sn xut cho nng sut v cht lng
cao hn. y l nhng ng gp chnh v khoa hc v thc tin ca nghin cu ny.

Ti liu tham kho

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[3]. Nguyn Vn Hng; Nghin cu ti u ho cc thng s cng ngh ca qu trnh mi in ho; Lun
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[4]. Mitsubishi materials carbide; General catalogues 2007 - 2008
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prediction model in end milling titanium alloy (Ti-6Al4V); (1) Department of Manufacturing and
Industrial Engineering, University Technology Malaysia, 81310 Johor, Malaysia; (2) Department of
Mechanical Engineering, Sriwijaya University, Inrdralaya, 30662, Indonesia; (3) Faculty of Engineering
and Technology, Multimedia University, 75450, Melaka, Malaysia.
[7]. D. Baji, B. Lela, D. Zivkovi; Modeling of machined surface roughness and Optimization of cutting
parameters in face milling; Faculty of Electrical Engineering, Mechanical Engineering and Naval
Architecture, University of Split, Croatia.
[8]. A.G. Jaharah, C.H.Che-Hassan, M.Z.Omar and M.J. Ghazali; Wear mechanism and failure mode of
P10 TiN coated carbide tools; Department of Mechanical and Material Engineering, Faculty of
Engineering; National University of Malaysia, 43600 Bangi, Selangor, Malaysia.
[9]. Ivett Viktria BANA; Manufacturing of high precision bores; okleveles gpszmrnk, Universiteit
Miskolc, Hongarije - geboren te Miskolc, Hongarije.
[10]. Habeeb H.H; Performance of different cutting tools when machining die and mould material;
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University Malaysia Sabah, Locked Bag 2073, Kota Kinabalu, Sabah, Malaysia 88999 (2) Singapore
Institute of Manufacturing Technology 71 Nanyang Drive, Singapore 638075
CT 2