ANH HNG CUA IU KIN UC

N CHT LNG SAN PHM

1

DIECASTING LA GI ?

1. inh nghia Diecasting

La phng phap nguyn liu long vao trong khun uc cac san phm co chinh xac cao vi s lng ln. Ngoai ra
Diecasting con c dung chi nhng san phm uc o.

2. Hoat ng cua 1 chu ky t ng (May uc nhm)

Phun cht tach khun Kep khun nguyn liu long vao Phun nhm Lam mat M khun y san phm
Gp san phm Bi trn Plunger

3. Phng phap Diecasting la 1 trong nhng phng phap uc

La phng phap dung tc cao y hp kim long vao thay th cho khng khi trong
khun, dung ap lc cao nen trc khi hp kim ng cng lai.

D liu khun :
ng kinh Tip 70 mm
Chiu day san phm 2.0 mm

Phng phap
Diecasting

Trong lng san phm 430 g

Tit din ln nht

Khun

May uc

Hinh dang san phm

Nguyn liu

Nguyn liu

iu kin uc

Phng an uc

ADC12

Nhit nhm long

c tinh cua hp kim

X ly nhm long

4. San phm Diecasting

San phm tt cua Diecasting se khng co l rng, ngoai quan ep, kich thc chinh xac

iu kin uc

Circle time 28 giy

Tc thp
(m/s)

Tc cao
(m/s)

Khoang
cach tc
cao (mm)

Tng tc tc
cao (ms)

Giam tc
(m/s)

Thi gian
tng ap (ms)

Ap lc uc
(Mpa)

0.20

3.2

67

1.5

30

65

430 cm2
680

(hardware desk drive )

CNG OAN PHUN NHM CUA DIECASTING 3

TC THP :
- Nhm long t gau muc vao
Sleeve va c a n cng
Gate.
- Luc nay, gi cho b mt nhm
long khng bi gn song, y khi
bn trong Sleeve ra ngoai qua
cng thoat khi cua khun. Vy se
phong nga c vic khi ln
vao trong nhm long.
- Tuy nhin nu chm qua thi
nhm se bi ng cng lai mt.
(Tc thp).

TC CAO :
- Tao hinh dang san phm.
- Tai vi tri Sleeve va Runner c in
y bi nhm long, bt u chuyn qua
tc cao.
( trang thai khng khi trong Sleeve va
Runner a thoat ra ngoai ht).
(Vi tri chuyn i tc cao, khu vc tc
cao).
- Nhm long c phun nh sng vao
cac chi tit manh cua san phm tao
lp da ep (Tc cao).
- Khng khi trong san phm khng thoat
ra ngoai kip se ong lai trong san phm.

TNG AP :
- Nen san phm.
- Nen ap lc trc khi nhm
long ng cng lai.
(Thi gian tng ap).
Cac l rng bn trong san
phm se nho lai, tng s kt
dinh vi khun.
(Ap lc uc).

LY LUN UC C BAN
(1). Ty sut rot cua Sleeve
La ty l chim ch cua nhm long bn trong Sleeve.
Trong lng uc
Ty sut rot cua Sleeve =

Tit din Tip x Hanh trinh x Mt nhm

(2). Thi gian rot

- a nhm long vao trong Cavity trc khi ng cng lai
Thi gian rot = 0.01 x chiu day san phm x chiu day san phm
(cng thc n gian)
(3). Khoang cach tc cao
(Trong lng rot)
San phm + Lng Over-flow

Khoang cach tc cao

Tit din Tip Mt nhm long
(4). Tc cao
San phm + Over-flow
Tc cao

Tit din Tip Thi gian rot Mt nhm long

(5). Xac nhn tc tai cng Gate

Tit din Tip
Tc Gate

Tit din cng

Tc cao

Khoang 4060 m/s la va

ANH HNG CUA KHOANG CACH TC CAO

San phm bi thiu nhm : thc t sau khi rot nhm vao Sleeve, bn nhm dng vi tri chuyn i tc cao.

Trc cng - Tc cao

Ngay cng Tc cao

Sau cng Tc cao

ANH HNG CUA PHUN TC CAO 6

(Cht lng bn trong)

Tc phun
m/s
m/s

Kich thc ti a cua l rng

(Ngoai quan)

Tc phun
(m/s)

Pham vi cai t
may trc y

Pham vi cai t
siu cao tc

4 m/s

AZ91 0.7100300
Co hiu qua vi trng hp dong chay keo dai va lam giam kich
thc cac l rng.

CHUYN NG CUA NHM LONG TRONG KHI

PHUN TC CAO

Dung Camera tc cao chup anh t mt trc may & t trn xung
Anh Camera

MEMRECAM GX-8

Anh Camera tc cao

T phia trn

T mt trc may

Tc chup : 40000[fps]
sang :8 - 900000[lux]

Chiu day cng 3.5 mm

Tit din 2.8 cm2

Chiu day cng 2.0mm

Tit din 1.6cm2

CHUYN NG CUA NHM LONG TRONG KHI

PHUN TC CAO

Tc phun 1.0m/s
(Tc cng 24m/s)

Tc phun 2.0m/s
(Tc cng 48m/s)

Tc phun 1.0m/s
(Tc cng 13.7m/s)

Tc phun 2.0m/s
(Tc cng 27.5m/s)

Theo inh nghia J.Wallace, trang thai nhm long

phun ra tai cng Gate :

1064

vg
t
g

0.59

Tc cng
Chiu day cng

Tc phun 3.0m/s
(Tc cng 72m/s)

Tc phun 3.5m/s
(Tc cng 84m/s)

Tc phun 3.0m/s
Tc phun 3.5m/s
(Tc cng 41.25m/s) (Tc cng 48.13m/s)
Kt qua tinh toan : (trong lng ring ly la 2.4)
Chiu day cng 3.5, tc hn 17.4m/s
Chiu day cng 2.0, tc hn 24.2m/s
La con s phu hp vi quan sat bng mt thng

Trong lng ring nhm long

ANH HNG CUA TNG TC TC CAO

Thi gian
tng tc
10[msec]

Chuyn ng cua nhm long t cng

Chuyn ng tc thp cua nhm long
Gia inh rng sau khi qua cng chuyn
thanh tc cao, thi nu gia tc cua phun
chm, se khng thng c bc tng
nhm long tc thp, dn n tinh lu
ng se kem i.
Trng hp mun co tc cao sau khi
qua cng, phai cai t tng tc tht
nhanh am bao dong chay.

Thi gian
tng tc
15[msec]

ANH HNG CUA AP LC UC

10

60
[MPa]

Van Check cua Toshiba

Kiu 2 xi lanh

50
40
30
20

Giam c Time-lag (lch gi)

10

100ms
50ms
200
400
600
800

[ms]

Anh CT

52msec

97msec

Phng thc 2 xi lanh c lp se giup tng ap trong thi gian ngn

CHIU DAY SAN PHM VA THI GIAN NG KT

Tai thi im s ng kt kt thuc, 2 lp ng kt t 2 phia
se cham nhau vung gia nn co cng thc sau y :

2tx tm
tx : Chiu day lp ng kt
tm : Chiu day san phm

Ts K tm

2
Thi gian
ng kt Ts
Chuyn i
tc cao
(Gate)

Vit lai la :

Ts
K

tm

K la h s

tm

Chiu day
lp ng kt

Ngoai ra, chiu day san phm va thi gian ng kt

con co cng thc kinh nghim sau :

11

Ap lc phun
Tc

San phm co chiu day tw, thi bn

phai hin thi thi gian ng kt va iu
kin uc sao cho hoan tt phun va gia ap
trong thi gian o.

(Tc cao)
(Tc thp)

ng cong
tng ap

San
phm
ng kt

Thi gian T

Ts
K

MT S CNG THC TINH THI GIAN PHUN12

Cng thc tinh thi gian phun do NADCA xng :

t = k [ Ti T + FZ / T T d ]T
Cng thc thi gian phun F.C.Bennett :

t = 0.7

qT

S T i T
q = { qa + c T m T s } S T

Thi gian phun theo cach tinh c

Chiu day
mm

Thi gian phun

sec

1.5

0.010.03

1.8

0.020.04

2.0

0.020.06

2.3

0.030.07

(thi gian ng kt) :

2.5

0.040.09

t A = t Zn =0.033e2

3.0

0.050.10

3.8

0.050.12

5.0

0.060.20

6.4

0.080.30

Cng thc thi gian phun G.Ulmer

Cng thc thi gian phun G.Lievy :

t =0.005e2

Cng thc thi gian phun cua Toshiba Machine :

t =0.01e2

 THI NG P-Q2 LA GI ?

13

Trn thi, ke ng Die-line va ng Machine-line tim giao im. T o tim

ra tc phun gii han cua khun va may.
Cng thc c ban Die-line :

Pg
Vg

Theo cng thc Bernoulli, quan h cua ap lc & tc

cua nhm long se la : Pg Vg 2
P V2
g

2g

Zg

2g

Ag

Z p C (const )

y, ZgZp0, VVg, Pg0, cho nn nu

gian lc Zg, Zp, V, Pgthi ta c :

Vg

Ap
2

y c goi la cng thc c ban cua Die-line.

Cng thc c ban Machine-line :

Theo cng thc Bernuolli thi tng nng lng cua ap lc, tc , vi tri cua may tac ng ln nhm
long la khng i. Vy nn nu mun tng tc thi ap lc se giam. Ngc lai mun tng ap lc
thi tc se giam. Vi du khi chay khng tai khoang cach tc cao thi co tc nhng khng
co ap lc. Ngc lai khi phun xong thi tc giam nhng lai co ap lc.
Theo cng thc Bernoulli trn, nu gian lc Zthi se c cng thc sau :

PC

Tip theo, tim hng s C, ta gia inh khi Q=0V=0 khi phun xong), luc nay P=Pt
(ap lc uc theo ap lc n), nhp gia tri vao ta se co C=P.
2

y c goi la cng thc c ban cua Machine-line.

P Pt

V
2

V 2
2

 THI NG P-Q2 LA GI ?

14

Tai y, cng thc lin tuc gia Sleeve va cng Gate se la :

Q C g Ag Vg Ap V
Q
Vg
C g Ag

- Tai vung phu cn cng, tit din giam t ngt nn chung ta

phai xem xet h s chay Cg.

Q
V
Ap

Thay cac gia tri V,Vp vao cac cng thc c ban Dieline & Machine-line ta se c cac cng thc sau :
Ve 2 cng thc nay ln thi :
Die-line
Q2
2 C g Ag
2

Q2

2 C g Ag
2

P Pt

Q2
2 Ap

thi PQ2

P
P

Machine-line

Machine-line

Die-line

Q2

P
P Pt

Q2

2 Ap

Q02

Q2

Q02

Q2

T thi P-Q2 , oc gia tri truc lu ng cua giao im 2 cng thc, t o se bit c :
(1). Tc phun gii han.
(2). Chon c ng kinh Tip hiu qua.

THAM KHAO THI NG P-Q215

P
P

Q2

Giam ap lc ACC
Ap lc n giam P
giam Tc phun
giam Q02 giam

Tng ng kinh Tip

Xit van phun lai

Tng tit din cng

Ap lc n giam
P giam

Tc phun giam
Q02 giam

Giam lc can tai cng

nghing Die-line giam

P
P

P
O

Q02

Tc phun
gii han giam

Q2

Q02

Q2

Tc phun gii han giam

Machine-line P Pt

Q2
2 Ap

Q02

Tc
phun gii
han giam
Die-line

2
Q02 Q

Q2

Tc phun
gii han tng

Q2
2 C g Ag
2

TINH TOAN P-Q2 TRONG TOSCAST16

Machine-line

P Pt

Q2
2 Ap

Hin thi kt
qua tinh toan

Khng cn tinh toan phc tap, man hinh TOSCAST se hin thi kt qua.

ANH HNG CUA CAI T GIAM TC 17

3
2
1
0 10 20 30 40 50
Thi gian [ms]

50
40
30
20
10

Tc [m/s]

60

60

Ht bi Surge 50
40
30
20
10

3
2
1

0 10 20 30 40 50
Thi gian [ms]

<Lin quan gia giam tc va bavia (ap

lc uc c inh)>

Nhanh

Tc cui cung

Ap lc [MPa]

Surge phun

60

Ap lc[MPa]

Tc [m/s]

60

Chm

K ca khu vc siu cao tc, nu giam tc nhay thi se giam c Bavia.

AP LC SURGE
Pm Pd Ps Pl

18

( Cng thc ly lun cua Surge )

2
m Vc A h Ph A h Pr A h A r
A og A c 2 Vc 2
A c
2

Pm
Vc

2
2
A c t A c
Ah
A o A og 2
2A g

Ap lc ng cua Ap lc tinh cua nhm long

Tn tht t khun
Theo hi nghi Diecasting cua Toshiba Machine 2006 : Anh hng cua iu kin
nhm long
khun & iu kin uc n cht lng san phm va xut phng phap anh gia
mi

Ao

Vog

Nhm long

Aog
Pm

Du thuy lc

Vg

Vc

Ag
Pc

Ac

Ar

A h Ph

Mt nhm long
A p lc phia Head xi lanh phun
A p lc phia Rod cua xi lanh phun
A p lc cua Tip ln nhm long
A p lc nhm long
Tc Plunger (tc cao)
Tc cng
Tc OF Gate
Tit din Head cua xi lanh phun
Tit din Rod cua xi lanh phun
Tit din cng
Tit din OF Gate
Tit din OF
Tit din Tip

I SACH CHO AP LC SURGE

19

Pm Pd Ps Pl
2
m Vc A h Ph A h Pr A h A r
A og A c 2 Vc 2
A c
2

Pm
Vc

2
2
A c t A c
Ah
A o A og 2
2A g

Ap lc ng cua Ap lc tinh cua nhm long

Tn tht t khun
Theo hi nghi Diecasting cua Toshiba Machine 2006 : Anh hng cua iu kin
nhm long
khun & iu kin uc n cht lng san phm va xut phng phap anh gia
mi

(Phng phap giam ap lc khi hoan tt phun)

(1). Giam P

Giam ap lc ACC

Giam ap lc uc

(2). Giam V

Giam tc Plunger

Giam tc cao

(3). Giam A/A

Thay i Gate hoc Tip

Thay i iu kin khun

(4). Tng Pl

Tng tn tht t khun

Thay i iu kin khun

(5). Tng Pr

Giam tc nhay ben

Dung may uc bm Servo

 THI PHUN KHI S DUNG GIAM TC20

VI DU SO SANH THI GIAN ROT KHI S DUNG HOC KHNG S
DUNG PHANH HAM

Dung phanh ham thi

ap lc Surge thp

Nhn thy c tac

dung cua phanh ham

Dung phanh ham

Khng dung phanh
ham

Khoang 30msec
Hu nh khng co khac bit v thi gian phun.
Khng co anh hng n cht lng san phm. Nu co Bavia se gy anh
hng xu n cht lng san phm.

(Nen nhm khng u, kich thc thay i)

H S LU XUT TAI CNG

21

H s lin quan n ap lc rot va lu lng i qua cng

thi P-Q2 Die-line

P : ap lc phun (Mpa)
: Trong lng ring nhm
long (g/cm3)
Q : Lu lng cng (cm3/s)
Ag : Tit din cng (cm2)
Cg : H s lu xut cng
Vg : Tc cng (m/s)
Vi du o thc t h s lu xut cng

V c ban, nu chiu day cng cang ln, hoc khun cang phc
tap, thi h s lu xut cng se cang nho.

MACH THUY LC CUA VAN SERVO

thi cua ap lc uc cua Meter-out
la thi kt hp cua phia Rod va phia
Head cua xi lanh phun
P

Ph A Pr Ah A
Ah

[MPa]

Dung phanh ham co nghia la

giam ap lc phia Rod, nn
thi se i xung.

22

thi cua ap lc uc cua

Meter-in se hin thi nh phia
Head cua xi lanh phun.