LI NI U

Ngy nay, vi s bng n v khoa hc k thut v ang thay i nhiu nhn

thc v cuc sng ca chng ta. chnh l cng ngh s ha. Bng vic to ra mt th
gii o m con ngi c th m t gn nh th gii tht. iu c ngha nhiu
hot ng ca con ngi c th c phng on, m phng trong th gii o ging nh
th gii tht. V t nhiu hot ng c s ha con ngi c th thy trc c
kt qu m cha cn phi lm tht. y chnh l hng pht trin ph hp cho khoa hc
k thut ca Vit Nam trong iu kin nc ta cha ngun lc lm mi th.
Bng vic tm kim u ra cho sn phm ca lun vn tt nghip. Nhm chng em
tm n nhng yu cu ca doanh nghip hin ang cn trong qu trnh sn xut. V
khi ng trc nhng yu cu , cng ngh s ha l cng c t lc cho chng em
p ng yu cu v hon thnh lun vn. l vic s ha qu trnh dp kim loi tm.
y l mt lnh vc hon ton mi vi chng em, nhng vi s gip tn tnh
ca thy chng em hon thnh mn hc tt nht. Tuy nhin vic thit st l khng th
trnh khi, chng em mong mun c tip thu nhng kin n gp hon thin
ti nghin cu v tip thu kin thc.

PHN I : TNG QUAN V CNG NGH DP NGUI V CHI TIT

1. Tng quan v tnh hnh nghin cu cng ngh dp tm trn th gii v ti Vit
Nam:
1.1.

Trn th gii.

Hin nay trong ngy cng nghip dp tm ni chung v cng ngh ch to my pht
in ni ring th th gii ang trong giai on pht trin nht t trc ti nay. Bng
chng l s pht trin n r ca ngnh cng nghip t vi cc sn phm hng hiu t
cht lng v c a chung trn khp th gii. Sn phm chnh ca ngnh dp trong
cng nghip t l sn xut khung gm, v xe v cc chi tit my khc. Bng vic pht
trin cc cng ngh s trong tnh ton, thit k gip to ra nhiu mu xe c chnh
xc, tnh an ton cao. Ring ti khu vc ng Nam mi ch c Thi Lan sn xut c
v xe t du lch v vn ti hng nh. Ngnh cng nghip dp tm ca th gii cn to ra
cc sn phm cho ngnh hng khng v tr nh cnh my bay, v my bay, Lnh vc
xy dng v hng hi cng pht trin gn lin vi s pht trin ca cng ngh dp.
1.2.

Ti Vit Nam.

Ngnh dp Vit Nam ch c bit n vi cc sn phm gia dng nh ni, cho,

mun, cc loi tn. V vic ch to khun dp ln i hi phi c nhng my mc ln c
chnh xc cao nn gy ra nhiu kh khn cho cng nghip nc nh. Nhng n nay
c nhiu doanh nghip i u trong vic pht trin cng ngh dp nhng chi tit ln
hn nh v xe du lch, cc loi sn phm t tm khc. Theo d kin, nm 2013 Vinaxuki
s xut xng chic xe du lch u tin mang thng hiu Vit, m trong v xe s
c dp trong nc thay v nhp khu t cc cng ty nc ngoi. Trc mt s chi
tit ca thn tu thy c sn xut trong nc.
Ring lnh t trong nc cng xut hin nhiu doanh nghip ln nh: Cng Ty
TNHH Auto Trng Hi, Cng Ty TNHH Toyota Hi Dng, Cng Ty TNHH Ford Vit
Nam Trong qu trnh sn xut b phn t c nhiu chi tit phi dng cng ngh dp
chng hng v, cm ng, pat, bn l Nhng nm trc vic t hng nc ngoi xem
nh l ph hp nhng hin nay v tnh cnh tranh v pht trin buc cc doanh nghip
phi tip thu cng ngh v t sn xut.

2.

Gii Thiu Chi Tit Cm ng 27

Cm ng 27 l mt chi tit rt quan trong trong cng nghip t bn ti , t

ng lnh, cm ng dng c nh ng trn cc cnh ca xe tng thm cng vng
cho ca xe. Ngoi vic dng trong nghnh t, n cn c dng trong xy dng c
nh cc ng ng dn nc.

3. c im ca dp ngui
Dp ngui l mt cng ngh mi so vi lch s pht trin ca cng nghip th
gii. Cng ngh dp ngui l bc pht trin ca cng ngh g. l qu trnh gia
cng kim loi bng p lc, bin kim loi tm hay khi thnh sn phm c hnh dng
mong mun.
Khun dp ngui l dng c to hnh sn phm bng phng php bin dng vt liu
trng thi ngui. C nhiu loi khun dp ngui: t dp, dp vut, dp su, khun ko,
chut siSn phm ca khun dp ngui rt a dng v phong ph bao gm nhng vt
dng trong cuc sng nh chu ra mt, ni, cho, dng y t, cc sn phm trong cng
nghip nh cc chi tit trong xe my nh bnh xng, ng b xe my
Khun dp ngui c cu to t hai phn: phn khun trn (hay cn gi l chy) v
phn khun di (hay cn gi l ci). Khun trn c gn vi ba, chuyn ng nh p
lc ca ba, khun di c nh.
Khun dp c s dng rt a dng vi nhiu chng loi khc nhau. Tuy nhin da vo
tnh nng lm vic c th chia ra lm hai loi khun chnh l khun dp vut (dp to
hnh), dp su v khun t dp.
i vi khun dp vut, dp su do lm vic trong iu kin chu ma st cao, mi mn
cao nn loi khun ny yu cu cng b mt cao (58-60HRC), dai va p va phi
v c dng dp su xoong, ni lm bng nhm hoc inox, dng c y t t tm thp
khng g. dp ra cc chi tit c su mong mun, ty theo su ca sn phm, c
th dp mt bc, hai hay ba bc.

Cng ngh dp ngui c nhng c im ch yu v cng l nhng u im c bit

nh sau:
C th hon thnh cng vic phc tp bng mt ng tc n gin ca my dp.
Ch to c nhng chi tit c hnh dng phc tp, c bit l nhng chi tit c
thnh mng m i khi cc phng php gia cng ct gt khng thc hin c,
hoc thc hin rt kh khn.
Sn phm dp ra c th s dng c ngay, khng cn phi gia cng ct gt li, c
bn vng cao.
Tit kim c nhiu nguyn vt liu.
Nng sut cao, thun li cho qu trnh c kh ha v t ng ha.
Cng nhn khng cn trnh tay ngh cao.
Sn lng ln, gi thnh thp.
Do nhng c im trn ca cng ngh dp ngui, m cc nc cng nghip tin
tin, dp ngui chim mt t l cao trong nhiu ngnh cng nghip.
Dp ngui c nng sut cao, nn rt thch hp vi sn xut hng lot v hng khi.
3.1

u im ca phng php dp tm
a.

V mt k thut

Thc hin nhng nguyn cng phc tp bng nhng hnh trnh n gin ca my
p v ch to nhng chi tit hnh dng rt phc tp m bng nhng phng php
gia cng khc khng th hoc ch to rt kh khn.
Ch to nhng chi tit lp vi chnh xc tng i cao, phn ln khng cn gia
cng c tip theo .
Ch to cc chi tit c kt cu bn, cng, nh vi lng tiu hao vt liu khng
ln.
b.

V mt kinh t

 Tit kim c nguyn vt liu, ph liu tng i t.

Nng sut ca thit b rt cao nh s dng c kh ha v t ng ha qu trnh sn
xut.
Thao tc trn my p n gin, khng cn cng nhn c trnh chuyn mn
cao.Sn xut hang khi v gi thnh ca sn phm ch to thp.
3.2

Phn loi v cc nguyn cng ca dp ngui

a Phn loi
Dp tm

Tn

gia

nguyn

cng

cng
Ct phi
Ct hnh

Hnh v chi tit

C. Dp lin hi

IV. To hnh

tc. 3.Dp phi hp lin

Dng

III. Dp vut

tit. 4.Lp ghp cc chi

2.Dp lin tc.

II. Un

3. t l.
4. Ct trch.
5. Ct chia.
6. Ct mp.
7. Ct tinh.
1. Dp vut.
8. Ct phi 2.
kim
loi.
Cun mp.
mng. 2. Dp vut c bin

2. Ct hnh .

1.Ct phi.

I. Ct

B Thay i hnh dng phi

2.Dp
3. Vn
xon.ni.
3.Ln vnh.
4.To hnh.
5.Tp.
2.Dp
du.
6.Dp gin.
3.p chy.

A Ct vt liu

V. Dp p

Cc nguyn cng ca dp ngui

nh ngha v c im ca nguyn
cng

Ct vt liu thnh cc phn theo ng

bao khng khp kn
Ct cc b mt phn vt liu ra khi

Ct

phi
Tch mt phn kim loi theo mt

vt

ng bao khp kn, phn kim loi tch

liu

ra l chi tit
Ct vt liu theo ng bao khp kn

t l

to thnh l sut trn chi tit hoc trn

Ct trch

tm. Phn vt liu ct ra l ph phm

Tch mt phn vt liu theo ng bao
khng khp kn. Phn vt liu tch ra

Ct chia

khng ri khi chi tit

Ct phi thng, phi cong hoc phi
rng thnh mt hoc vi chi tit ring
bit. p dng cho nhng chi tit khng
i xng, ban u ch to thnh phi

Ct mp

i xng sau ct chia

Ct b phn kim loi tha theo ng
bao ngoi hoc phn mp khng iu
ca chi tit cong hoc chi tit dp

Ct tinh

vut
Ct b phn lng d cng ngh rt
nh theo ng bao ca phi hoc l
nhm mc ch t c hnh dng v
kch thc chnh xc, b mt ct sch

Un

v vung gc vi b mt chi tit

Bin phi thng thnh cc chi tit cong

Cun

Cun cc mp ca phi to thnh chi

Vn

tit c dn vng neo hoc hnh tr

Quay mt phn phi xung quanh trc

Dp

Dp vut

dc ca n
L phng php nhn c chi tit

vut

khng

rng t phi phng hoc phi rng.

bin

Chiu dy vt liu hu nh khng i

mng
Dp vut

L phng php nhn c chi tit

c bin

rng t phi phng hoc phi rng, c

mng

ch nh bin mng chiu dy vt liu

Un

Nn

Khc phc hin tng khng bng

Dp ni

phng cc b ca phi hoc chi tit

Thay i hnh dng ca sn phm
nhng khng thay i chiu dy vt
liu, c thc hin nh cc phn li v

Ln vnh

lm tng ng ca cc b phn khun

To thnh g theo ng bao ngoi

To

Cun

hoc ng bao trong ca chi tit

To g mp c dng trn

hnh

mp
To hnh

Thay i hnh dng ca phi c

dp vut s b nhn c chi tit c
hnh dng cui cng hoc kch thc

Tp

chnh xc hn
Lm gim tit din ngang mt phn ca
chi tit rng hoc ng c dp vut
s b

Gin

Tng tit din ngang mt phn ca

rng

chi tit rng hoc ng

( nong )
Ty

To cho chi tit c hnh dng v kch

chnh

thc chnh xc

Dp ni

To nhng hnh ni li lm trn b mt

mt

chi tit, c s thay i chiu dy vt

liu

Dp

p chy

Bin i phi dy thnh chi tit hoc

ngui

phi rng mng`mng bng cch chy

do kim loi qua khe h gia chy v
ci

Dp du

To vt lm trn chi tit sau

khoan l

Dp

Dp phi

ng thi thc hin hai hoc mt vi

hp

nguyn cng khc nhau trong cng mt

lin

b khun sau mt hnh trnh ca my

hp
Dp lin

vi mt ln t phi
Lin tc thc hin hai hoc mt vi

tc

nguyn cng khc nhau trn mt b

khun sau mt vi hnh trnh ca my
vi s dch chuyn phi lin tc theo
bc ca chy. Sau mi hnh trnh ca

Tn

nhn c mt chi tit

To mi ghp cc chi tit bng inh tn

To ra mi ghp bng cch lp c

Gp mp

di
Ghp hai chi tit bng cch to ta cc
kha vng

Lp

Un tai

Ghp hai chi tit bng cch un cc tai

Un mp

Ghp hai hai hoc vi chi tit bng cch

ghp

un mp

Tp

Ghp chi tit bng cch tp mt trong

cc chi tit ghp

Gin

Ghp hai chi tit bng cch gin rng

mt chi tit bn trong

4. Cc Loi My Dp
4.1 My ct vt liu tm
ct phi tm thnh di hoc thnh tng phi mt, ngi ta s dng my ct vt liu
tm (cn gi l my ct tn).
c im ca my ny l c li dao nghing, c th ct ngui kim loi tm c chiu
dy t 0,5 mm n 30 mm trn chiu di khng qu 3 m.
4.2 My dp trc khy
My dp trc khuu l my c chuyn ng nh lin kt cng. C cu chp hnh ca
my dp trc khuu c khu cui cng l u trt, khu u l khu trc khuu hoc
bnh rng.
Thn my c th l kn (c) hoc thn h (hn) .
My dp trc khuu c rt nhiu loi nh my dp trc khuu dp nng, my dp trc
khuu dp ngui, my dp trc khuu
4.3 My dp lin hp
My dp lin hp l loi my c th ct vt liu tm bng ko li nghing. Trn my
c th lp cc khun ct t n gin v nh thc hin cc nguyn cng ct t,
ng thi my c th ct c mt s dng trn, dng gc, dng ch I
My c u im l c th ct c cc chiu dy chnh lch nhau kh nhiu so vi
my ct vt liu tm.
Nhng c nhc im l ct vi tc thp, di vt liu sau khi ct thng b cong,
vnh
4.5 My dp tc ng kp
Trong cc loi my trc khuu in hnh th my dp tc ng kp (my dp vut )
l thit b chuyn dng thc hin qu trnh cng ngh dp vut v to hnh vt
liu tm trong cc ngnh t, quc phng m cc my khc thc hin kh khn
hoc khng th thc hin.

My dp tc ng kp l my dp c hai u trt: u trt ngoi dng chn

phi, u trt trong mang dung c to hnh thc hin nguyn cng dp vut.
4.6 My dp hai tc ng S4
Mt lm vic chnh ca chi tit l mt trn c nhm l Ra1.6 v t phng 0.2
mm. Mt ny trong qu trnh lm vic lun chu ma st vi vi. Ngoi ra yu cu v
song song gia ba rnh so vi tm hai l vt v khong cch gia hai tm l vt
cng rt quan trng.
Trong qu trnh lm vic, mt nguyt lun chu ma st v mi mn. Tuy nhin iu
kin lm vic cng khng qu khc nghit.
4.7 Yu cu k thut
Vi nhng c im v chc nng v iu kin lm vic ca mt nguyt nh trn th
yu cu k thut ch yu ca mt nguyt l ta phi m bo:
phng ca mt trn l 0,2 mm.
song song gia 3 rnh so vi tm hai l vt l 0,3 mm trn chiu di 100mm.
nhm mt trn t Ra1,6
V cc kch thc t dung sai nh Bng 4.1
Thp kt cu l loi thp c s dng nhiu nht trong vic ch to cc chi tit my
v kt cu chu ti. Chng p ng c cc yu cu khc nhau v c tnh, chnh xc
v hnh dng, kch thc v t bng theo yu cu lp rp. Ph hp vi vic s
dng phng php cn. Thp kt cu c cc thnh phn ha hc ch yu l:
Ccbon: L nguyn t c bn nht quyt nh c tnh v tnh cng ngh ca thp
kt cu. Lng ccbon trong thp SCM415 l 0,130,18% nn thp thin v do
v dai.
Cc nguyn t hp kim: c a vo thp kt cu nhm mc ch nng cao
bn. Tuy nhin gi thnh thp s cao hn. Cc nguyn t hp kim c trong thp
SCM415 ch yu l Cr nng cao bn v Mo nng cao do dai.
5. Cng Ngh Dp Kim Loi Tm
2.1.

Ct kim loi tm bng my.

Dp ct dng ct tch phn vt liu ny vi phn vt liu khc. Trong phm vi

ti ny ch cp dp ct hon ton tc l phn vt liu ny c tch ri hon ton

vi phn vt liu kia. Nguyn cng ny thng dng to phi, ct hnh chi tit. Phi
cho nguyn cng ny thng l dng di mng hoc l sn phm ca nhng nguyn cng
trc.
-

Giai on n hi: khi s bin dng nm trong vng bin dng n hi, ng
sut khng vt qu gii hn n hi.

Giai on bin dng do: bin dng l bin dng d, ng sut trong kim loi
vt qu ng sut chy. Giai on ny dao ln su vo vt liu tm t 0.2 0.5
chiu dy phi, ty theo cng v do ca vt liu.

Giai on nt: khi to thnh nhng vt rn nt t vi, vt nt ln dn theo

hng b mt trt v lm tch vt liu ny vi phn vt liu khc.

Trong qu trnh ct phn vt liu gi li s b quay (b bt do lc n by) nn phi

dng tm chn chng li lc ct ca dao.

Bng 1: Cc nhiu phng php ct kim loi tm v

kiu dng c khc nhau. [1, 34-37]
Phng php ct

Ct kiu tay n
v my ct dao
thng.

Hnh minh ha

Cng dng chnh

Thng dng ct thnh di,
tm phi.
Chiu dy thng ct
40mm (cn ph thuc vo
my v vt liu)

Ct kiu a loi
hai trc song
song.

Ct kiu a loi
trc dao t di
nghing.

Ct kiu a loi
dao
hai
mt
nghing.

Ct kiu nhiu a
c trc t song
song.

Ct kiu rung
ng (kiu ct
ko)

Ct tm thnh di, tm phi

trn.
Chiu dy thng ct
30mm (cn ph thuc vo
my v vt liu)
Ct tm thnh di, tm phi
trn.
Chiu dy thng ct
30mm (cn ph thuc vo
my v vt liu)
Ct tm thnh di, tm phi
trn bn knh nh.
Chiu dy thng ct
20mm (cn ph thuc vo
my v vt liu)
Ct ng thi nhiu di,
nhiu chiu rng khc
nhau.
Chiu dy thng ct
20mm (cn ph thuc vo
my v vt liu)

Ct theo bin dng.

Chiu dy thng ct
10mm (cn ph thuc vo
my v vt liu)

Khun ct

ng bin ct theo hnh

dng khun ct. Tc ct
cao, chnh xc.
Chiu di bin ct t l
nghch vi b dy vt liu.

2.2.

Ct kim loi tm bng khun.

Trong phm vi ti ny ch ch cp n phng php ct bng khun.

Bn cht ca vic s dng khun ct hnh, t l v mt s nguyn cng khc

cng nh nhau. y ci v chy ng vai tr nh nhng li dao hnh dng khp kn,
c mp ct khp nhau.
Qu trnh ct bng khun cng bao gm 3 giai on (hnh 3.1):

Hnh 3.1: Tnh lin tc ca qu trnh ct hnh t l. [5, 11]

1. Giai on bin dng n hi.

2. Giai on bin dng do.
3. Giai on nt.
Trong giai on th nht v th hai do lc cn ca vt liu nn tc ca chy
gim xung, sang giai on th ba th tc tng t ngt do vt liu mt s lin kt.
Nu tip tc chuyn ng th chy gip y phn vt liu b ct ra khi ci.
Cht lng mp ct ph thuc vo cc yu t nh tr s khe h chy v ci, tc
ct, b dy vt liu, thnh phn v tnh cht vt liu. Trong cc yu tr s khe h v tc
ta c th iu chnh trong qu trnh sn xut, cc yu t khc do yu cu ca sn phm
thit k. Trong qu trnh ct th ti vng ct vt liu b bin cng. (hnh 3.2)

Hnh 3.2: Hnh dng mt ct v chiu su b bin cng khi ct vi s hnh trnh khc
nhau. [1, 44]
a. 60 hnh trnh/pht

c. 330 hnh trnh/pht

b. 120 hnh trnh/pht

d. 450 hnh trnh/pht

Khi dp vi tc 450 hnh trnh/pht th thi gian ginh cho giai on bin do
v su ca chy gim 14% so vi 60 hnh trnh/pht, giai on ba ca qu trnh cng
c pht trin nhanh, kt qu l vt ct u n, chiu su lp bin cng nh.

2.3.

Lc ct kim loi tm bng my.

Bng 2: Cng thc xc nh lc ct. [1, 40]
Phng php ct

My ct thng dao song

song.

Hnh minh ha

Cng thc tnh lc ct

P (Kg)

P = L.S.c

P 0.5

Mt ct thng dao nghing.

S2
c
tg

Hoc
Pk

S2
u
tg

( = 2o 5o)

P 0.5

My ct a.

h nS
c
tg

K hiu:
L

chiu di ct (mm)

Sh

b dy vt liu (mm)

gc nghing ca dao ()

tr lc ct (sc bn ct) (kg/mm2 ) tra bng 1

hn

chiu su ln dao ti thi im nt (mm)

gc n ca a ()

Cng sut ct (kg.mm/mm3)

Thp dy 1020mm : u 10; ng : u 6 ; ura : u 1.5

H s bng 1.2 i vi vt liu dy, bng 1.8 i vi vt liu mng

Do cc yu t nh hin tng un khi ct, b dy vt liu khng u, mn dao

nn lc ct c tng ln 30%:
Pn= 1.3 P
T vic nghin cu qu trnh dp thy rng lc ct khng phi l hng s m thay
i sut trong qu trnh ct.
Ngoi ra mt s sn phm khi ct c s dng b phn g ph liu, chn phi, y
sn phm th phi cng thm phn lc ny.
Bng 3: Cng thc xc nh lc ct hnh bng khun c
mp ct song song. [1,50]
Hnh dng chi tit

Lc tnh ton khi ct hnh

Lc yu cu ca my p

Bt k

P = L.S.c

P = L.S.c + Qd

Hnh trn

P = .d..S.c

P = .ds.c + Qd

K hiu:
L

chiu di ct (mm)

b dy vt liu (mm)

ng knh l t (mm)

sc bn ct (kg/mm2 ) tra bng 4

Qd

lc cn ca c cu ph (chn phi, y sn phm)

Khi gim t s d/S <30 th lc ct gim 20%.

Kh h mi bn nm trong phm v 10% n 1%S thc t khng nh hng ti
lc ct. Tr lc ch tng khi he h vo khong 1%S
Trong cng ngh tnh ton tr lc ct c tnh:
c = (0.8 0.86) b
b : gii hn bn kg/mm2
Bng 4: Tr lc ct (sc bn ct) (kg/mm2 ). [1, 51]
Tr lc ct c (kg/mm2)
Vt liu

Vt liu

Thp tm:

Tr lc ct c (kg/mm2)

Bin cng
ng

Bin cng

20

28

0.1%C

25

32

ura

22

38

0.2%C

32

40

Nhm

10

15

0.3%C

36

48

Km

12

20

0.4%C

45

56

Ch

23

23

0.6%C

56

72

Thic

34

34

0.7%C

72

90

1.0%C

80

105

Thp Silic

45

56

Thp khng g

52

56

Khi thc hin ti ny chng ti ch a vo cc gi tr thp c kh nng dng

lm bnh xng, ngoi ra cn nhiu loi thp theo tiu chun. bit c c tnh ca
mt s loi thp tm s dng trong dp ngui, ngi c c th tham kho trong cc
cun s tay dp ngui (S tay dp ngui- dch Nguyn Ging, L Nhng -NXB Khoa
hc v k thut, cun s tay thit k khun dp tm dch V Trn Khc Nh NXB Hi
Phng)
gim lc ct khi ct hnh cc nguyn vt liu dy hoc c kch thc ln, ngi
ta thng dng khun vi chy hoc ci c mp ct nghing (Hnh 3.3).
Khi ct hnh chi tit th chy cn phng cn mp ci s lm nghing.
Khi t l th ci cn phng v chy c mp ct nghing.

Hnh 3.3: Cc kiu mp nghing ct hnh v t l. [1, 66]

Bng 5: Cc tr s nghing mp dao thng dng. [1, 67]

Chiu dy
S (mm)

Chiu cao nghing

H (mm)

Gc nghing
()

T l % lc ct so
vi Pmax

n 3

2S

n 5

30 40

3 10

n 8

60 65

Bng 6: Cng thc gn ng xc nh lc khi ct hnh trn khun c mp ct

nghing. [1, 68]
Kiu ct

Trng hp chung

Ct hnh ch nht, khun c

mp nghing hai bn

Kiu
theo
hnh

Cng thc tnh lc ct

P = L.S.c.k

k : h s i vi L 200 mm

Khi H = S

k = 0.4 0.6

Khi H = 2S

k = 0.2 0.4

a
b

Khi H > S
Khi H = S

Ct hnh vung khun c

mp nghin bn bn

0.5S

P 2 c a b
S
H

P = 2S.c (a+ 0.5b)

4S2 c
tg

a
Ct hnh trn khun c mp
nghing hai bn

Khi H = S

c
K hiu:
H

chiu cao nghing mp (mm)

gc nghing ()

a, b

chiu rng v chiu di ca hnh ch nht ct (mm)

P = 0.66.d.S.c

ng knh hnh trn ct (mm)

2.4.

Khe h gia chy v ci.

Nh phn tch trn kh h gia chy v ci quyt nh rt nhiu n cht

lng sn phm dp, nh hng ti cng vng ca khun v nng lng tiu hao.
Bng 7: T s ca khe h mt pha i vi nhng trng hp dp khc nhau. (ch
xt b dy vt liu t 3mm tr xung) [1, 76]

Phm vi s dng

Ct hnh v t l thng
thng vt liu thp.
Ct hnh v t thp
khng g 1X18H9 v
1X18H9T.

Chiu dy vt liu
S (mm)

Tr s khe h mt pha
tnh % S

n 0.2

Khng c khe h

0.3 3.0

36

n 3

0.02 0.03 mm

Ct hnh v ct t thp
k thut in.

36

Dp trn my tc cao

n 3

6 10

Ct hnh chi tit rt ln t

vt liu mng

n 2

8 10

Ct tinh c tm chn

n 3

0.01 mm

Bng 8: Tr s khe h ban u khi ch to khun ct hnh v t l (khe h hng

knh hoc hai bn) (mm). [1, 77]
Khe h ban u

Chiu dy
vt liu
(mm)

Nh nht

0.3

Khe h ban u

Ln nht

Chiu dy
vt liu
(mm)

Nh nht

Ln nht

0.02

0.04

2.5

0.20

0.28

0.5

0.03

0.06

2.8

0.22

0.32

0.8

0.04

0.08

3.0

0.24

0.36

1.0

0.06

0.10

3.5

0.32

0.46

1.2

0.08

0.12

4.0

0.40

0.56

1.5

0.10

0.16

4.5

0.50

0.68

1.8

0.12

0.20

0.6

0.8

2.0

0.17

0.25

Ch thch:
1. Khe h ban u nh nht l tr s khe h danh ngha. Khe h ban u
ln nht c tnh n s tng ln do dung sai ch to chy v ci.
2. Nu vt liu dy hn 2mm th ly theo bng 23 [1,77]

Nhng nguyn tc c bn khi chn khe h:

Khi ct hnh, khe h ly bng cch gim kch thc ca chy. Kch thc ca
ci ly bng gii hn kch thc nh nht ca chi tit.

Khi t l, khe h ly bng cch tng kch thc ca ci, kch thc ca chy
ly bng kch thc gii hn ln nht ca l.

6. Cng Ngh Dp Vut

5. Cng ngh dp vut:
5.1.

C ch dp vut kim loi tm:

Phn ny trnh by c ch dp vut chi tit c dng cc hnh tr trn nu ln nhng

khi nim, hin tng c bn nht v qu trnh dp vut kim loi tm.

Hnh 5.1: S tun t dch chuyn kim loi trong qu trnh dp vut [1, 194]
Hnh 5.1 trnh by c ch dp vut mt chi tit hnh tr t phi kim loi tm. S tun t
dch chuyn ca cc phn t phi 1, 2, 3, 4, 5 trong qu trnh dp vut lm gim ng
knh ngoi ca vnh phi theo mc chiu su dp vut.
Phn vnh khn ca phi (D-d) chuyn thnh thnh ca hnh tr chi tit c ng knh d
chiu cao h. Do c hin tng bin dng do kim loi, nn khi dp vut hon ton hnh

tr, chiu cao h ln hn chiu rng ca phn vnh khn b. Th tch phi dch chuyn biu
th bng cng thc:
V dc =S

( Dd )2
4

Trong :
V dc th tch dch chuyn

S b dy ca chi tit
D,d c biu th trn hnh 5.1

Hnh 5.2: S bin dng mt phn t ca phi v s d to thnh vt nhn khi dp vut
[1, 197]
Khi mc bin dng nh, chiu dy kim loi ln s t xy ra hin tng nhn. Khi dp
vut su, mc bin dng ln, chiu dy kim loi nh, thng to thnh cc vt nhn

trn sn phm. Sau y chng ta s phn tch k hn cc c ch hnh thnh vt nhn trong
qu trnh dp vut (hnh 5. 2).
u tin, ti phn t I ca phi nm vin ngoi ca vnh, bin dng nn theo hng tip
tuyn c tr s ln nht, bin dng ko hng tm c tr s trung bnh v lng ha dy
ca kim loi c tr s nh nht.
Di tc dng ng sut nn tip tuyn

, vnh phi s b mt n nh, b nn, lm cc

ng trn vnh phi trng nhau (hnh 5.3) v to ra np nhn hnh sng (thi k 1-hnh
5.2). Np nhn y lm bin dng n hi tm chn phi v cc chi tit gi n, lm tng
khe h gia tm chn v ci.
ng sut nn s tng ln do ng knh ngoi ca phi khi dp vut gim khng ngng.
iu dn n vic nn p lp sng nhn (thi k 2), ri lm mt n nh phn
phng ca np nhn, lm phn b un ngc chiu li (thi k 3). Cui cng s to
thnh cc np nhn nh hn, t mt np nhn sinh thnh ba np nhn (thi k 4).
Hnh 5.3: S dch chuyn v thay th kim loi [10, 368]

Qu trnh hnh thnh cc np nhn xy ra mt cch nhy vt v tip tc cho n khi to ra

c np nhn nh hon ton n nh. Lc ban u np nhn sinh ra vnh phi khc

nhau ty thuc vo mc n nh ca vnh phi c trng bi t s

vut K =

d
D

S
D

, v mc dp

Khi phn t I dch chuyn n mp vut ca ci, bin dng ko hng tm s ln nht,
nn tip tuyn dn dn gim i. Khi phn t i qua mp vut bin dng s phc tp
hn do s xut hin ca qu trnh un. Sau phn t chuyn t cong thnh thng ng
v chu ko di chiu trc dc theo ng sinh vi bin mng ca vt liu khng ln
lm. y thnh phm chu lng ko di phng khng ln (1-2%) v bin mng (2-3%),
cho nn thc t c th b qua. Thng thng tit din nguy him nm gc ln di
y v y tr s ng sut ko ln lm bin mng vt liu ln.
Khi mc bin dng ln hoc trong trng hp hnh thnh np nhn phi, ng sut
tit din nguy him s vt c gii hn bn ca n v lm rch y. iu kin bn ca tit
din nguy him xc nh mc bin dng c th khi dp vut v c biu th bng
phng trnh:
P ( 1.11.2) b

Thit k hp l v hon ho mt qu trnh dp vut l to nhng iu kin thun li nht

cho vic bin dng kim loi nh:
-

Vic lm gim sc chng bin dng ca vnh phng;

Vic gim ng sut ko tit din nguy him loi b cc vt rch v vic tng
bn ca kim loi tit din y;
Vic gim ng sut nn tip tuyn vnh bin dng hoc tng tnh n nh ca n
vi mc ch ngn nga hin tng nhn.

Nu thc hin tt vic k trn ta c th tng chiu su ca dp vut trong mt nguyn

cng, gim s lng nguyn cng, lm cho qu trnh dp vut cc chi tit c hnh dng
phc tp c tt hn.
Trong trng hp dp vut cc chi tit hnh tr khng c vnh, tr s bin mng ln nht
khong 10-18%, cn s ha dy mp bng 20-30% chiu dy vt liu.
Chiu dy vt liu ch chuyn tip t y n thnh cng gim nu tng mc bin
dng, tng chiu dy tng i ca phi S/D, tng do ca kim loi, tng s nguyn
cng dp vut v nu gim bn knh ln ca chy v ci.

Chiu dy gn ng cnh trong trng hp dp vut chi tit hnh tr c xc nh

theo cc h thc sau y:
i vi cc chi tit hnh tr khng c vnh:
S ' =S

D
d

i vi cc chi tit hnh tr c vnh:

'

S =S

D
Db

Trong :
S'

chiu dy thnh chi tit, mm

chiu dy ca phi, mm

D ng knh phi, mm
Db ng knh vnh, mm
d ng knh chi tit, mm
Bin dng thc t xy ra trong qu trnh dp vut l bin dng khi (theo c ba phng)
nhng n gin cho vic phn tch, nh gi qu trnh bin dng, chng c xem l
bin dng phng. Bng cc phng php dp vut ngi ta ch to rt nhiu chi tit
rng khc nhau v hnh dng mt y cng nh thnh bn.
5.2.

Dp vut c chn phi:

Ty theo cch phn loi m ta c nhiu phng php dp vut khc nhau. Trong n
ny, ch tp trung vo phng php dp vut c chn phi, cc phng php khc c th
tham kho cc ti liu lin quan.
Dp vut c chn phi c chia ra lm hai giai on: giai on u khi phi c ko
vo trong ci cho n khi gc m ca phi xung quanh mp lm vic ca chy v ci vi

gc < 2

(hnh 5.4a). Giai on sau khi gc m 2

(hnh 5.4b). Ti thi im

ny c ba phn ca phi vi trng thi ng sut khc nhau: phn vnh khn 1, phn hnh
tr 2 v phn y 3 (hnh 5.4c).

Hnh 5.4: S dp vut c chn phi [4, 127]

Chiu dy ln nht ti phn vnh

Sk

sut gn vi trng thi ng sut n (

S k =S

l mp ngoi cng ca n. y trng thi ng

p 0 ; n=0

Ro
R

Khi ko ton b phi vo trong ci th phn vnh s khng c, tng ng R=r .

Do :

(5.1)

S k =S

Ro
r

Hoc tnh n tnh d hng ca kim loi th:

S k =S

Ro
r

( )

1+ R

i vi kim loi ng hng, h s d hng R =1 . Khi cng thc 5.1 c th s

dng tnh gn ng khe h z gia chy v ci ca khun dp vut nu ta coi

z=Sk

Chiu dy ca thnh chi tit sau khi dp vut khng ng u dc theo chiu cao: ti
mp trn cng, chiu dy ca chi tit l ln nht; ti phn bn knh ln ca y, chiu
dy l nh nht; ti y chi tit chiu dy ca n hu nh khng thay i so vi chiu dy
phi ban u.

Hnh 5.5: Chi tit b rch, nhn khi dp vut

Mt ct ngang ca chi tit ti vng c chiu dy nh nht c gi l mt ct ngang nguy
him, ti chi tit thng b ph hy nh b t y hoc rch (hnh 5.5). Mt tit din
nguy him na l cc lp kim loi phn vnh, ti kim loi b ha bn t hn so vi
cc lp kim loi cc lp tit din ngang khc.
Nu mc bin dng khng vt qu mc cho php th chiu dy thnh ti tit din
nguy him c th xc nh mt cch gn ng nh sau:
S min =

S
Ro
r

( )

S
2 rc

Nh phng php s dng ng cong ha bn ngi ta nhn c cng thc xc

nh ng sut ko hng knh ln nht ti bin dng thi im bt k khi dp vut
kim loi ng hng:

( ) (

1
x
pmax = b
.
1

. ln

Ro
.Q
S
x +
+
( 1+1.6 )
x
. Ro . S . b 2 r c + S

Trong :
x=

R oR
Ro

co tht t i khi ko

chiu dy phi

s dch chuyn tng i ca mp vnh trong qu trnh dp vut

gii hn bn ca vt liu phi

rc

bn knh ln ca ci

h s ma st tip xc
Q

lc chn phi

Tn ti mt gc nghing ti u ca ci dp dp vut sao cho khi

pmax

nh nht.

Gi tr gn ng ca gc ti u c th c xc nh nh sau:

( )

sin ti u= 1

r
R ph

2 R ph
S

Ty theo iu kin bin dng, gc ti u ca ci dp vut thay i t 10-35o. Khi dp

vut cc nguyn cng trung gian c th thc hin trong cc ci hnh cn. Khi , trong
phn hnh tr ca phi cha b ko vo trong ci s c ng sut ko tip tuyn

th s gy ra nhng vt nt dc trong iu kin nht nh. S ha bn do bin dng ca

phi sau khi dp vut ln u lm cho tnh do ca n b gim i cng gp phn to nn

nhng vt nt dc . hn ch xy ra nhng vt nt ny ngi ta dng vng chn

phi.
Phng php dp vut nghin cu trn c ng dng rt rng ri hu nh trong tt c
cc ngnh cng nghip. Ngoi ra c th nhanh chng s dng nhng kiu sn phm
mi cn phi thit k cc qu trnh gm nhng thit b vn nng hoc vn nng mt phn,
r tin.

Hnh 5.6: Dp vut c vng chn phi [10, 404]

5.3.

Tnh ton cng ngh:

5.3.1 Mc bin dng v h s dp vut:

C th thc hin dp vut qua mt hoc vi nguyn cng ty thuc vo t s chiu cao v
ng knh ca chi tit dp vut, chiu dy tng i ca phi.
Cn phi tnh ton th no vic dp vut thc hin vi mt s nguyn cng t
nht, cc nguyn cng hon thnh vi mc bin dng ln nht (s gim tng
i ng knh v tng chiu su dp vut), khng cn trung gian.
Mc bin dng khi dp vut cc chi tit hnh tr c th o bng mt trong cc ch s
sau y:
Dd Dd
D
;
; ln ;
d
D
d

K=

D 1
d 1
= ; m= =
d m
D K

Trong :
D ng knh phi, mm
d ng knh chi tit, mm
m h s dp vut
K mc dp vut, tr s nghch o ca h s dp vut

Cc tr s bng s ca nhng ch s y c nu trn hnh 5.7 ph thuc vo t s

D
d

. Ch

D
d

s mc bin dng ng hn c l ch s di dng lgart ln , song dng n khng

thun tin trong iu kin nh my. Ch s mc bin dng t c trng nht l h s
d
D

dp vut m = , bi v tr s ca n nghch o vi mc bin dng (m cng nh, mc

bin dng cng ln). Nhng n li n gin v thun tin nht cho cc tnh ton nhanh
chng v c dng rng ri trong thc t.

Hnh 5.7: So snh cc ch s khc nhau ca mc bin dng [1, 261]

Nh kinh nghim v cc s liu th nghim ch r: ch s c xc nh i vi kim
loi do l tng khng ha bn, trong mt vi trng hp s khng phi l tr s gii
hn.
Tr s lng bin dng gii hn khi dp vut b hn ch bi 3 l do ch yu:
1. Tnh do ca kim loi khng cao, to iu kin cho tr lc bin dng ln
vnh phi phng, dn n s tng ng sut ko tit din nguy him v rch
y.
2. Do mt n nh vnh phi, vic to thnh np nhn lm tng t ngt tr lc
bin dng v nhanh chng lm phi b rch. Phi c chiu dy tng i nh t
n nh v d b cc np nhn hn.
3. Cng vi cc nguyn nhn khc, nu tr s bn knh ln ca ci dp vut nh
s lm tng tr lc ko phi phng vo l ci rt nhiu, s tng ng sut ko
tit din nguy him v sm lm rch y.
iu kin bn ca tit din nguy him c xc nh bng h thc:
K (1.1 1.2) b
K

- ng sut ko tit din nguy him

Phng php xc nh mc bin dng cho php ng n v chnh xc hn c l da

trn vic xc nh ng sut thc sinh ra khi dp vut v dng cc nh lut c bn ca l
thuyt do. Nhng v phc tp v khng tin li nn cch tnh k trn c thc hin nh
cc h s dp vut, do thc nghim xc lp nn, cc h s ny c trng cho mc bin
dng cho php.
Tr s cc h s dp vut c dng trong thc t phn ln l tr s gn ng, bi v
khng tnh nh hng chiu dy tng i ca phi, bn knh ln ca ci, tc dp
vut, n cc h s dp vut. Do cc quan h k trn cc h s dp vut ra cho thc
t s dng cn phi phn nh theo chiu dy tng i ca vt liu.
nh hng ca chiu dy tng i ca phi n tr s dp vut ln hn nhiu ln nh
hng ca tnh do vt liu ny hay vt liu khc, bi v i vi dp vut ngi ta ch
yu dng cc kim loi c do cao vi dao ng tnh cht do khng ln (tr mt
vi hp kim c bit).
5.3.2 Xc nh kch thc v hnh dng phi khi dp vut:
Do trong qu trnh bin dng do, th tch ca kim loi lun gi khng i nn cho nn
nguyn tc c bn xc nh kch thc phi khi dp vut l s cn bng th tch ca
phi v chi tit thnh phm.
Khi dp vut khng bin mng thnh, ngi ta thng b qua s thay i chiu dy ca
vt liu (sai s c th n 20-25%), vic xc nh kch thc phi tin hnh theo cn
bng din tch b mt ca phi v ca chi tit thnh phm, k c lng d ct mp.
Khi dp vut c bin mng thnh, vic xc nh kch thc phi c tnh theo s cn
bng th tch phi v thnh phm. Trong thc t thng gp trng hp dp vut cc chi
tit c hnh dng khc nhau, chng i hi cc phng php tnh ton kch thc phi
khc nhau nh sau. y ch xt dp vut khng bin mng thnh.
5.3.2.1.
gin:

Kch thc v hnh dng phi phi dp vut cc chi tit trn xoay n

Trng hp ny l dp vut khng bin mng vt liu, do vic xc nh kch thc

phi c tin hnh theo s cn bng din tch b mt phi v chi tit thnh phm (k c
lng d ct mp tra theo cc bng 13 v 14). iu kin c chn phi hay khng c
xc nh theo bng 15.
Bng 13: Lng di h xn theo chiu cao cc chi tit tr trn [2, 245]

Lng di

khi

h
dn

Di 0.8

Trn 0.8
n 1.6

Trn 1.6
n 2.5

Trn 2.5

Di 10

1.5

1.8

2.3

3.0

Trn 10 n 20

2.2

3.0

3.7

4.5

Trn 20 n 50

3.5

4.5

6.0

7.0

Trn 50 n 100

5.0

6.5

8.5

10.0

Trn 100 n 150

6.5

8.0

10.5

12.0

Trn 150 n 200

7.5

9.0

12.0

15.0

Trn 200 n 250

9.0

11.0

13.5

16.0

Trn 250 n 300

10.0

13.0

15.0

18.0

Bng 14: Lng di D xn vnh cc chi tit tr trn [2, 245]

Lng di D khi D/d
D
Di 1.5

Trn 1.5
n 2

Trn 2
n 2.5

Trn 2.5

Di 25

2.5

2.2

2.0

1.5

Trn 25 n 50

4.0

3.0

2.5

2.5

Trn 50 n 100

5.0

4.5

3.7

3.0

Trn 100 n 150

6.0

5.0

4.0

3.5

Trn 150 n 200

7.0

6.0

5.0

4.0

Trn 200 n 250

8.0

7.0

5.5

4.2

Trn 250 n 300

9.0

7.5

6.0

4.5

Bng 15: Xc nh c chn phi hay khng [2, 255]

Thao tc vut

C chn phi

C chn phi hoc khng

Khng kp

Th nht

D-d>22S

D-d=22S

D-d<22S

K tip

100S/dn-1<1.25

100S/dn-1=1.25-1.5

100S/dn-1>1.5

i vi trng hp dp vut ny, phi c dng hnh trn, ng knh ca n c tnh

theo cng thc :
D=1.13 F=1.13 f

(mm)

Trong :
F din tch b mt chi tit thnh phm, mm2

tng din tch cc phn t ring ca b mt chi tit , mm2

Trong hnh sau a ra cc cng thc xc nh din tch ca b mt cc hnh n gin.

Hnh 5.8: Din tch b mt cc hnh n gin [10, 399]

Thay th cho vic tnh ton ng knh phi bng cch chia b mt chi tit thnh cc
phn t ring bit, ngi ta xc nh ng knh phi ca cc chi tit dp vut c hnh
dng ph bin theo cc cng thc nu trong hnh sau:

Hnh 5.9: ng knh phi ca cc chi tit dp vut [10, 397-398]

5.3.2.2.

Kch thc v hnh dng phi dp vut chi tit trn xoay phc tp:
Hnh 5.10: Phng php th tm kch thc phi [4, 142]

Trong trng hp ny vic xc nh din tch b mt thnh phm tin hnh trn c s ca
nguyn tc Gunden Paput, theo : din tch b mt vt th trn xoay to bi
ng cong bt k khi quay chung quanh trc nm cng trn mt phng , bng
tch s chiu di ng sinh nhn vi qung ng ca trng tm ng cong y
(chiu di vng trn, v nn bi trng tm ca ng sinh)
F=2 Rs L

Trong :
F din tch b mt vt th trn xoay, mm2

L chiu di ng sinh, bng l1+l2+l3++ln , mm

Rs khong cch t trc n trng tm ca ng sinh, mm

ng knh phi tm theo cng thc :
D= 8 L R s= 8 lr

Trong :
r

khong cch t trng tm cc phn t ca ng sinh

Ngi ta dng hai phng php xc nh chiu di ng sinh v v tr trng tm ca

n: phng php th v phng php gii tch- th.
Phng php th tm trng tm ng sinh c biu th trn hnh 5.10: ng sinh
c chia lm nhiu on ring bit (thng hoc cung ln), tm trng tm tng on, ri
v cc ng song song vi trc.
Bn cnh hnh v ngi ta xy dng mt hnh a gic lc, t chiu di cc on (hnh
5.10, bn phi) v t tm O ly ty k cc tia. Sau , k cc ng thng song song
vi cc tia k trn (6//6; 7//7; v.v) lp nn hnh gii qut. Giao im ca 2 tia ngoi
cng 6 v 11 cho v tr trng tm S v i lng Rs.
Tm ng knh phi theo cng thc nu trn hoc bng th u xut pht t h thc
:
2

R =2 Rs L

Trong :
R Bn knh phi, tm theo chiu di on thng gc im B (hnh 5.10) cho n giao
im vi ng vng trn c ng knh bng L+2Rs.
Ta dng phng php th - gii tch xc nh kch thc phi i vi chi tit c
hnh dng phc tp:
1. Chia ng vin chi tit (theo ng trung bnh) ra cc on ring bit, ch
yu l on thng v mt phn ng trn. Cc on cong th chia ra cc on
nh gn vi ng thng.
2. Trng tm ca mi on s nh du bng mt im.
3. Xc nh chiu di cc on ng sinh.
4. Nhn chiu di cc on l vi bn knh trng tm r, tng cng chng v tm :

 lr=l1 r 1+l2 r 2 ++ln r n

5. Theo tr s ca tng y, tm ng knh phi theo cng thc :
D= 8 lr

5.3.2.3.
Kch thc v hnh dng phi dp vut cc chi tit c dng khng
gian phc tp v khng i xng:
i vi cc chi tit c dng khng gian phc tp (loi chi tit v, mui t) phn ln
trng hp khng i hi s chnh xc c bit v kch thc ca phi. V vy khng c
phng php tnh ton chnh xc cc phi .
u tin, ngi ta xc nh kch thc bao quanh gn ng ca phi, k c cc ng
cong v tr s lng d cng ngh cn thit ( chn phi). Kch thc phi s c iu
chnh khi th khun dp vut. Phi iu chnh s dng lm mu ch to khun ct
hnh. Trn hnh 5.11 ch tm ngoi ca cnh ca t v phi dp ra n, nhn c
bng phng php trn. Lng d cng ngh chim n 66mm mi pha.
Trong mt vi trng hp, ngi ta xc nh kch thc v hnh dng phi dp vut
cc chi tit c hnh dng phc tp v khng i xng bng cch:
1. Chia ng vin ra tng yu t ring bit.
2. Xc nh phi v xy dng cc hnh khai trin ca cc yu t ring bit.
3. Xy dng ng vin u n bng cch b cc phn di ra v phn b ct i
vi nhau.

Hnh 5.11: Phi dp tm ngoi cnh ca t [1, 254]

Trong cng nghip t, khi thit k khun cho cc chi tit mui, v c hnh dng khng
gian qu phc tp, ngi ta dng phng php m hnh. Dng m hnh g hoc thch cao
khng ln (t l 1:10) c hnh dng ca v t, ngi thit k c th xc nh chnh xc
hn phn phi b bin dng, hng chy c th ca kim loi, v tr khng gian tt nht khi
dp vut, b mt chn thch hp nht, s cn thit phi dng cc gn dp vut, hnh dng,
kch thc phi phng.
Trn hnh 5.12 biu th phng php c o thit k cc hnh chuyn tip dp vut
cc chi tit c hnh dng qu phc tp.
Thc cht ca phng php ny l da theo mu chi tit hoc theo ci c hnh dng cui
cng ca chi tit ngi ta ch to khun bng vi bng th trt sp (hnh 5.12a) chiu dy
khun khong 2-3mm.

Hnh 5.12: Xy dng cc hnh chuyn tip khi dp vut phc tp bng cch dng khun
bng sp [1, 255]
Sau khi sp ngui, ly khun ra v da theo c tnh bin dng, nn phng dn cho hnh
dng li v su dng cho nguyn cng dp vut trung gian (hnh 5.12b).
Da theo dng vut ca khun sp ngi ta ch to m hnh bng thch cao ca ci
trung gian. Tip tc nn phng khun sp s c hnh dng cho nguyn cng dp vut
u tin (hnh 5.12c) v da vo ngi ta ch to m hnh thch cao cho ci dp vut
u tin.
5.3.2.4.

Kch thc v hnh dng phi dp vut cc chi tit hnh hp:

Xt dp vut chi tit hnh hp ch nht. y l mt qu trnh dp ngui phc tp,

v trong trng hp ny s bin dng thay i dc theo chu vi ca chi tit hnh ch nht.
Trn hnh 5.13, ch s bin dng ca li ta ch nht vch ln phi. T hnh
v thy r rng cc thnh bn khng ch n gin b un, m cn chu s bin dng phc
tp, gm co nn dc theo chu vi, ko di v pha thng ng v tng mt phn chiu dy
ca thnh hp phn trn ca chi tit.
Trong bng 5.4 nu cc tr s gn ng ca lng bin dng nn tng i dc theo chu
vi, o 2 im: im gia mp ca thnh hp, v im cnh gc ln. Trong nu c
lng bin dng tng i khi dp vut chi tit hnh tr cng mt chiu cao so snh.

Tr s bin dng c cho trong gii hn bit, bi v tr s ph thuc vo t s

r
B

Bng 16: Tr s gn ng ca lng bin dng nn tng i (%) [1, 235]

Lng bin dng tng i
khi dp vut hnh ch nht

Lng bin dng

tng i khi dp
vut chi tit hnh
tr

Chiu cao tng i ca

hp

gia mp
phn thnh
thng (hnh
5.13a)

mp phn
cung ln
gc
(hnh 5.13b)

H=B

26-30

45-50

55

H=0.5B

15-20

33-38

42

H=0.3B

5-8

25-30

32

V vy, nu i vi cc hp ch nht thp (H=0.3B) c th b qua lng bin dng

phn thnh thng ca hp v coi mt cch gn ng rng n ch b un, th i vi cc
hp cao hn (H>=0.5B) khng th b qua lng bin dng c.

Hnh 5.13: Bin dng ca li ta khi dp vut hnh ch nht [10, 416]
Bng 17: Chiu cao tng i ca hp ch nht c dp vut sau mt nguyn cng
(thp 08-10) [1, 236]
Bn knh
gc ln

Chiu cao tng i ca phi

H
B

vi chiu dy tng i

tng i

r
B

ca phi

S
100
D

2-1.5

1.5-1

1.0-0.5

0.5-0.2

0.3

1.2-1.0

1.1-0.95

1.0-0.9

0.9-0.85

0.2

1.0-0.9

0.9-0.82

0.85-0.7

0.8-0.7

0.15

0.9-0.75

0.8-0.7

0.75-0.65

0.7-0.6

0.1

0.8-0.6

0.7-0.55

0.65-0.5

0.6-0.45

0.05

0.7-0.5

0.6-0.45

0.55-0.4

0.5-0.35

0.025

0.5-0.4

0.45-0.35

0.4-0.3

0.35-0.25

Ch thch:

r
B

S
D

1. Ngoi cc i lng tng i v

, chiu cao c th khi dp vut ph thuc
vo kch thc tuyt i ca hp ch nht. V vy tr s ln trong bng dnh cho cc
hp kch thc nh (B<100mm), cn tr s nh cho cc hp ln.
2. i vi cc vt liu khc cn iu chnh v pha ny hay pha khc ph thuc vo
do ln hay nh ca kim loi.
V phng din cng ngh cn phi phn bit r gia dp vut cc hp ch nht thp tin
hnh trn mt nguyn cng vi cc hp cao c dp t nhiu nguyn cng lin tc.
Chiu cao tng i ln nht ca hp ch nht sau mt nguyn cng dp vut ph thuc

vo chiu rng ca hp B, bn knh ln gc v y

phi

S
D

r
B

v vo chiu dy tng i ca

Trong tr s chiu cao H ca hp cn c lng d ct mp, tr s ca chng c nu

bng 5.6. Khi chiu cao tng cng ca hp ch nht, theo tnh ton cng ngh bng:
H=H0+H0=(1+)H0
Trong H0 l chiu cao hp theo hnh v.

Bng 18: Tr s lng d ct mp ca cc hp ch nht [1, 237]

S nguyn cng dp
vut

Lng d ct mp

(0.003-0.05)Ho

(0.04-0.06)Ho

(0.05-0.08)Ho

(0.06-0.10)Ho

Kch thc v hnh dng phi dp vut hnh hp qua mt nguyn cng:

H
B

r
B

Ph thuc chiu cao tng i

ca hp, bn knh gc ln tng i
v
vo mc chn y kim loi khc nhau ra thnh bn ngi ta xc nh c cc
vng ring bit (hnh 5.14), m tng ng vi cc vng c cc phng php thit k
hnh dng phi khc nhau.
ng cong 1 v 2 ch chiu cao cc i ca hp c dp su sau mt nguyn
cng khi chiu dy tng i ca phi:

S
100 2
D

S
100 0.6
D

Hnh 5.14: Cc vng ca cc trng hp khc nhau khi dp vut cc hp ch nht [1,
238]
Cao hn ng cong gii hn y l vng dp vut nhiu nguyn cng (Ia, Ib, Ic)
cn thp hn l vung dp vut mt nguyn cng. Ngi ta chia vng di ra 3 vng ring
bit IIa, IIb, IIc theo mc chn y kim loi t gc ln ra thnh bn ca hp.

Vng IIa l vng dp vut cc hp thp vi bn knh gc ln tng i nh, biu

r
0.17
BH

th bng h thc
. c trng ca trng hp dp vut ny l s chn y
kim loi t gc ln ra thnh bn ca hp khng ln lm, khng thay i chiu cao ca
chng. Vic thit k phi trong trng hp ny tin hnh bng cch khai trin hnh hc
cc phn t ca hp ra mt phng.
Vng IIb bao gm dp vut cc hp khng cao, nhng c bn knh gc ln tng

0.17

r
0.4
BH

i ln, xc nh bi h thc
. Dp vut cc hp nh vy c t
trng bi s chn y kim loi tng i t nhiu t gc ln ra thnh bn v bi tng
chiu cao cui cng ca chng. Vic thit k phi c tin hnh bng cch khai trin
hnh hc vi s iu chnh ng vin.
Vng IIc bao gm dp vut mt nguyn cng cc hp tng i cao c bn knh

r
0.4
BH

gc ln ln, biu th bng quan h

v c trng bi s dch chuyn kim
loi rt ln t gc ln ra thnh bn v bi s tng nhanh chiu cao cui cng ca chng.
a s cc trng hp trong vng ny khi dp vut cc hp vung thc t c th dng
phi hnh trn, cn khi dp vut hp ch nht dng phi hnh van vi hai gc ln v
hai cnh thng. Cc phn gch cho trn hnh 5.14 l cc vng chuyn tip t vng ny
sang vng khc, m bin gii gia cc vng ny nm trong gii hn ca cc phn y.
Khi thit k hnh dng phi cho cc hp thp c bn knh gc ln tng i nh (vng
IIa) chng ta qui c rng, dp vut ch xy ra cc gc hp, cn phn thnh thng ca
hp b un. Hnh dng phi nhn c bng cch khai trin hnh hc cc phn t ca hp
ch nht ra mt phng y v thm on ng vin iu n cc gc ca hnh khai
trin (hnh 5.15).
Tnh ton v thit k theo th t sau y:
1. Theo kch thc ca hp cho, xc nh chiu di ca phn thnh hp b un
l, k c gc ln y:
l=H +0.57 r d

2. Xc nh bn knh phi gc R nh l dp vut mt phn t cc hnh tr

ng knh l v chiu cao H. Khi ly bn knh gc ln gc v y bng
nhau rg=rd=r
R= 2rH = dH
Trng hp bn knh ln gc rg v y rd khc nhau:
R=

2
g

+2 r g H0.86 r d (r g +0.16 r d )

3. V phi c bc on chuyn tip t gc ln sang thnh thng.

4. Chia on ab ra lm hai v v tip tuyn vi vng trn bn knh R.
5. Ni ng tip tuyn y vi thnh thng bng cung bn knh R.

Hnh 5.15: Thit k ng vin phi cho cc hp ch nht thp, dp mt nguyn cng
(vng IIa, hnh 5.14) [1, 241]
Khi thit k ng vin ca phi theo cch trn y, cc hp ch nht thp c dp vi
bn knh gc ln nh thng khng i hi phi ct mp, bi v kim loi tha so vi
tnh ton gc ln (+f) s b y ra thnh bn v b vo phn phi b ct i (-f).

Trong trng hp dp vut cc hp cn ct mp vnh, kch thc khai trin l c tnh

thm lng d ct mp. Khi vic thit k ng vin ca phi khng i hi
chnh xc cao. C th dng phi hnh ch nht vi cc gc b ct.
Khi thit k phi cho cc hp c bn knh gc ln tng i ln (vng IIb). Trong
trng hp ny vic tnh ton v thit k phi s tin hnh theo th t sau y:
1. Xc nh chiu di khai trin l ca cc thnh thng v bn knh phi R cc
gc theo cng thc nu trn.
2. V phi vi phn chuyn tip c bc t gc ln n thnh thng.
3. Xc nh bn knh tng thm cc gc khai trin R1=xR b phn kim loi
b chn y ra thnh bn. H s x tm theo cng thc:
2

x=0.074

R
+ 0.982
d

( )

Hoc ly bng 19 theo cc kch thc tng i ca hp

Bng 19: H s x [1, 243]
H s x khi chiu cao

Bn knh
gc ln

tng i

r
B

tng i ca hp

H
B

0.30

0.40

0.50

0.60

0.10

1.09

1.12

1.16

0.15

1.05

1.07

1.10

1.12

0.20

1.04

1.00

1.08

1.10

0.25

1.035

1.05

1.06

1.08

0.30

1.03

1.04

1.05

4. Xc nh chiu rng hb v ha ca di b ct ra khi hnh khai trin ca cc cnh

thng b phn kim loi dch chuyn t cc gc ln ra (hnh 5.16).
Kch thc hb v ha xc nh t ng thc gia b mt thm ca phn t vng vi b mt
bt ca di c chiu rng hb v chiu di B-2r (hoc ha v A-2r) v xc nh theo cng
thc:

hb = y

R
B2 r

ha = y

R2
A2 r

H s y tm trong bng 20 theo cc kch thc tng i ca hp.

Bng 20: H s y [1, 244]
H s y khi chiu cao

Bn knh
gc ln

tng i

r
B

tng i ca hp

H
B

0.30

0.40

0.50

0.60

0.10

0.15

0.20

0.27

0.15

0.08

0.11

0.17

0.20

0.20

0.06

0.10

0.12

0.17

0.25

0.050

0.08

0.10

0.12

0.30

0.04

0.06

0.08

5. Tin hnh vic iu chnh hnh khai trin bng cch tng bn knh ti R1 v
gim chiu cao i mt lng ha v hb.
6. Da theo cc kch thc nhn c ca chiu rng, chiu di v bn knh
gc ln ca hnh khai trin, v ng vin iu ha bng cc cung ni tip
ca cc vng trn bn knh Ra v Rb.

Hnh 5.16: Thit k hnh dng ca phi dp vut cc hp khng cao vi bn knh gc
ln tng i ln (vng IIb hnh 5.14)
a.i vi hp vung b.i vi hp ch nht [1, 243]

A
1.5 2
B

Cch thit k ny dng cho cc hp ch nht c h thc gia cc cnh

.
Trong trng hp dp vut cc hp cn ct mp th ng vin phi c th n gin ha,
cho php tng kch thc phi ln mt cht.
i vi cc hp tng i cao, c dp vut qua mt nguyn cng v nm trong vng
IIc th hnh dng phi gn vi hnh trn hoc hnh bu dc, do c th khng thit k
bn v phi m nhn cc kch thc bng cch tnh ton, s dng iu kin cn bng cc
b mt ca hp v phi. i vi cc hp vung chiu rng B v chiu cao H trong trng
hp bn knh ln gc v y bng nhau (hnh 5.17), ng knh phi c xc nh
theo cng thc :
D p=

4
F=1.13 B2 +4 B ( H0.43 r ) 1.72r ( H + 0.33 r)

Trong :
H chiu cao k c lng d ct mp
F din tch b mt ton phn ca hp vung
R bn knh ln gc v y ly bng nhau

Trong trng hp tr s bn knh ln gc v y hp khc nhau th ng knh phi

c xc nh theo cng thc chnh xc:

D p=1.13 B 2+ 4 B ( H0.43 r d )1.72 r g ( H +0.5 r g )4 r d (0.11 r d 0.18 r g)

C th coi cc hp ch nht c kch thc AxB nh hai na hp vung rng B ghp vi

nhau bi phn trung gian kch thc A-B. Trong trng hp ny ng vin phi c dng
hnh bu dc do 2 na vng trn bn knh R v 2 cnh song song to thnh (hnh 5.18).
Dng ng vin chnh xc v n gin hn c cho vic ch to khun ct hnh.
i khi vic dng phi dng elip lm cho vic ch to khun ct hnh phc tp i nhiu,
t tin v khi dp vut khng c g li hn.
Ph hp vi nguyn tc thit k phi nu, tm vng trn bn knh Rb nm cch cnh
hp ca hp mt on B/2. Chiu di ca phi hnh bu dc s bng L=Dp+(A-B).
Trong :
Dp=2Rb ng knh phi ca hp vung qui c vi kch thc BxB, xc nh theo
cng thc nu trn
A-B khong cch gia cc tm
Chiu rng ca phi hnh bu dc c xc nh t iu kin tng u n chiu cao
mi cnh ca hp theo cng thc:
K=

D p ( B2 r d ) + [ B+ 2 ( H +0.43 r d ) ] ( AB)
A2 r d

Hnh 5.17. Hnh dng phi i

Hnh 5.18. Kch thc v hnh

vi hp vung cao c bn
knh gc ln tng i
ln (vng IIc, hnh 5.14) [1, 246]

dng phi i vi hp ch nht

c bn knh gc ln ln
(vng IIc, hnh 5.14) [1, 246]

Trong phn ln cc trng hp th K<L v phi c dng bu dc. Bn knh gc ln ca

phi cnh hp ca bu dc c xc nh theo cng thc R=0.5K. Vic thit k phi
c nu trn hnh 5.18.
Nu cc trc ca phi hn km nhau khng qu 3% i vi cc hp nh v 5% i vi
hp ln th c th chn phi trn ng knh D=L.
Trong trng hp kch thc A v B khc nhau t A<1.3B v khi H<0.8B th chiu rng
K ca phi bu dc c th ly bng 2Rb.
Kch thc v hnh dng phi dp vut hnh hp cao qua nhiu nguyn
cng:
Nghin cu qu trnh cng ngh dp vut qua nhiu nguyn cng nhng chi tit hnh hp
cao ni chung bao gm nhng giai on sau:
1. Xc nh hnh dng v kch thc ca phi phng.
2. Tnh s b s nguyn cng dp vut cn thit v chn h s dp vut.
3. Chn phng php tnh ton cng ngh tng ng cho cc thng s hnh hc
ca hp.
4. Tnh hnh dng v kch thc ca cc nguyn cng dp vut t u n cui.

5. Vch ra nhng nguyn cng khc ca quy trnh cng ngh: ct mp, t l,
nhit luyn
6. Xc nh lc, tnh ton cc nguyn cng.
i vi nhng trng hp ch yu ca dp vut chi tit hnh hp qua nhiu nguyn cng
th tr s bin dng tng cng c biu th bng cc h s sau:
a. Khi dp vut hnh hp vung (BxB) t phi trn ng knh D:
mtng=

4B
B
=1.27
D
D

b. Khi dp vut chi tit hnh hp ch nht (AxB) t phi trn:

mtng=

2( A+ B)
A+B
=1.27
D
2D

c. Khi dp vut hnh hp ch nht (AxB) t phi hnh van (L v K):

mtng=

2 ( A+ B )
A +B
=1.27
L+ K
0.5 ( L+ K )

Ch c nguyn cng cui cng ca dp vut hnh hp vung t phi hnh tr, cng nh
hnh hp ch nht t bn thnh phm dng van c tin hnh vi tr s ln ca h s
dp vut trung bnh
mtb =0.90 0.95

Bng 21: S lng nguyn cng dp vut chi tit hnh hp ch nht ph thuc vo tr s
h s dp vut tng cng [1, 334]

H s dp vut
S lng
nguyn cng

tng i

mtng

S
100
D

vi chiu dy

hoc

S
100
LK

2-1.5

1.5-1.0

1.0-0.5

0.5-0.2

0.40-0.45

0.43-0.48

0.45-0.50

0.47-0.53

0.32-0.39

0.31-0.42

0.36-0.44

0.38-0.46

0.25-0.30

0.27-0.32

0.28-0.34

0.30-0.36

0.20-0.24

0.22-0.26

0.24-0.27

0.25-0.29

S lng nguyn cng cn thit dp vut chi tit hnh hp qua nhiu nguyn
cng c th xc nh theo bng 21 ph thuc vo tr s h s dp vut
mtng

v chiu dy tng i ca phi

S
100
D

hoc

S
100
LK

Sau khi xc nh s lng nguyn cng ngi ta tin hnh tnh ton kch thc
ca mi nguyn cng v bt u tnh t nguyn cng trc nguyn cng cui cng l
nguyn cng quan trng nht.
Khi dp vut t hnh tr thnh hnh vung hoc t hnh van thnh hnh ch nht
th mc bin dng theo chu vi sn phm khng ng u. Tr s bin dng nh nht l
cc gc hnh hp cn ln nht l gia cc cnh ca hnh hp.
Phng php tnh ton cng ngh dp vut nhiu nguyn cng nhng chi tit hnh hp
vung v ch nht khc nhau c kho st ring bit.
Dp vut nhiu nguyn cng hnh hp vung cao:
Khi dp vut nhiu nguyn cng hnh hp vung th hnh dng ca chi tit nhng
nguyn cng trung gian trong a s trng hp l hnh tr.
nguyn cng cui cng v trc nguyn cng cui cng hnh tr ny bin thnh hnh
hp vung hoc hp hnh trng.
Khi dp vut nhiu nguyn cng nhng chi tit hnh hp ch nht th c th c hai
trng hp thay i tun t hnh dng cc nguyn cng:

1. Phi hnh van: nguyn cng u v cc nguyn cng tip theo l hnh van,
cn nguyn cng cui cng l hnh ch nht, dng cho dp hnh hp ch nht
c t s cc cnh A :B> 1.2
2. Phi hnh trn: nguyn cng u l hnh tr, nguyn cng tip theo hnh van,
nguyn cng cui cng l hnh ch nht, vi t s cc cnh

A :B< 1.15 , v

c khi chiu cao tng i rt ln m n i hi nhiu hn ba nguyn cng

dp vut.
5.3.3 Lc dp vut, lc chn:
Nhng cng thc k thut xc nh lc dp vut thng xut pht t nguyn tc sau:
ng sut cho php ti tit din nguy him cn phi nh hn ng sut ph hy, v do
lc ln nht gii hn kh nng dp vut cn phi nh hn lc cn thit ph hy thnh
bn ca sn phm gn y (trong tit din nguy him) mt t.
P LS ph

Trong :
L chiu di chu vi sn phm (theo ng knh trung bnh)
S chiu dy ca vt liu
ph

ng sut ph hy tit din nguy him bng (1.11.2) b

Gi tr thc t ca ng sut tit din nguy him, tr s lc dp vut ph thuc vo: tr

lc bin dng ca kim loi, mc bin dng, chiu dy tng i ca phi, bn knh
ln tng i ca ci v chy, bi trn.
Ly ng sut cho php ln nht ti tit din nguy him

ph=1.1 b

v s dng nhng

s liu ca sn xut v thc nghim i vi chi tit c hnh dng hp ch nht thp dp
vut qua mt nguyn cng th lc dp vut c tnh ton nh sau:
P=( 2 A +2 B1.72 r ) . S . b . k t

Trong :
P lc dp vut, kG
S chiu dy vt liu, mm

A, B chiu di v chiu rng ca hp ch nht, mm

r bn knh gc ln ca hp, mm
b

gii hn bn ca vt liu
Bng 22: Tra h s

H
B

kt

[1, 400]

Gi tr ca h s

Chiu cao tng i ca hp

khi
chiu dy tng i ca phi

kt

khi bn knh gc ln

tng i

r
B

2-1.5

1.5-1.0

1.0-0.5

0.5-0.2

0.3

0.2

0.15

0.1

0.05

1.20

1.10

1.00

0.90

0.80

1.00

0.95

0.90

0.85

0.70

0.80

0.90

0.85

0.76

0.70

0.60

0.70

0.80

0.75

0.70

0.65

0.60

0.50

0.60

0.70

0.80

0.60

0.55

0.50

0.45

0.40

0.50

0.60

0.70

0.80

0.40

0.35

0.30

0.25

0.30

0.40

0.50

0.60

0.70

Ghi ch: Theo chiu cao ca hp cho

r
B

H
B

v theo chiu dy tng i ca phi, da

kt

vo bn knh ln tng i
ngi ta c h s
phn bn phi ca bng.
Chiu cao tng i vi nhng vt liu khc phi hiu chnh v pha ny hay pha kia
cho ph hp vi tnh do ln hay nh cu kim loi.
Bng 23: Cng thc tnh lc chn phi [1, 402]
Trng hp dp vut

Nhng cng thc

Lc chn dp vut nhng chi tit c

hnh dng bt k (trong dng tng
qut)

Q=Fq

Lc chn i vi dp vut ln th
nht nhng chi tit hnh tr
Lc chn i vi dp vut tip tc
nhng chi tit hnh tr (t phi
rng)

Q=

Q=

2
2
D ( d 1+2r c ) ] q
4[

2
d ( d n +2 r c ) 2 ] q
4 [ n1

Trong :
F

din tch ca phi di tm chn

q p lc chn, kG/mm2
d 1 d n ng knh dp vut (ci) nguyn cng th nht v th n, mm
r c

bn knh gc ln ca ci, mm
Bng 24: p lc chn phi trung bnh [1, 403]
Vt liu

2
p lc, kG/mm

Thp mm (S<0.5mm)

0.25-0.30

Thp mm (S>0.5mm)

0.20-0.25

ng thanh

0.15-0.20

ng

0.10-0.15

Nhm

0.08-0.12

y l nhng s liu gn ng, bi v ngi ta khng tnh n mc dp vut v chiu

dy tng i ca phi. H thc chnh xc hn, tnh n tt c nhng nhn t k trn i
vi thp mm c xc nh theo cng thc:
q=0.2

D
, kG/mm
( Dd 1.2) S .100

Do , lc dp vut ton phn i vi nhng my p n ng bng:

Ptp =P+Q

Trong :
P

lc dp vut tnh ton

lc chn phi

nhng my p song ng ln, lc chn thng ly bng 0.50.6 lc danh ngha ca

my. Khi s dng c cu y kh nn hoc thy lc khi nn trn my p n ng th
lc chn phi thng khng ly qu 25% lc danh ngha ca my.
5.3.4 Bn knh ln v khe h chy-ci khi dp vut:
Bn knh gc ln mp ci:
Bn knh ln mp ci dp vut nh hng rt nhiu n qu trnh dp vut. N ph
thuc vo:
-

Tnh cht ca vt liu kim loi tm.

Lc dp vut.
Gi tr ca h s dp vut cho php.

Gim bn knh ln dn n vic tng lc dp vut. Khi tng bn knh ln qu trnh dp

vut tin hnh d dng hn, v ng sut tit din nguy him gim i, do chiu su
dp vut sau mt nguyn cng cho php s tng ln. Tuy nhin tng bn knh ln ca
ci thng dn n vic gim din tch di tm chn v d to ra nhng np nhn v
np gp ch phi i ra khi tm chn. khc phc nhng nhc im k trn ngi ta
cng dng vng chn ph hnh cu.
Bng 25: Bn knh ln gn ng mp ci dp vut c tnh n chiu dy tng i
ca phi [1, 412]

iu kin dp vut

Bn knh ln khi chiu dy tng i ca phi

S
100
D

2.0-1.0

1.0-0.2

0.2-0.06

Khng c vnh

(6-8)S

(8-10)S

(10-15)S

C vnh

(10-15)S

(15-20)S

(20-30)S

C g chn phi

(4-6)S

(6-8)S

(8-10)S

Khi ch to khun nn lm bn knh ln nh nht thun tin cho vic sa khun sau
ny.
Bn knh gc ln ca chy nh hng rt nhiu n qu trnh dp vut, cho php gim
tr s gii hn ca h s dp vut. Bn knh ca chy nh lm kim loi b bin mng rt
nhiu tit din nguy him.
Khi dp vut mt s loi chi tit ngi ta dng n gn vut tng ng sut ko, gim
ng sut nn, ngn nga to ra nhng np nhn. Khi bn knh ln ca ci ly tr s
nh hn. S lng v s b tr cc gn vut ph thuc vo hnh dng ca ng bao, c
tnh ca b mt v chiu su dp vut. Gn vut t v tr phi d b bin dng nht,
v tr y cn hm s dch chuyn ca vt liu v tng ng sut ko.
Nhng v d v s b tr cc gn vut:

Hnh 5.19: Nhng v d v s b tr cc gn vut trn phi khi dp vut

Ta thy, ngi ta khng t cc gn vut hoc ch c mt dy gn v tr gc ln ca
ming ci, cn nhng thnh thng chy di th b tr hai hoc ba dy gn hm phi.

Nhng khun c gn vut ch to rt phc tp v t tin, c bit khi b mt nhng tm

chn l mt cong. i vi sn xut hng lot, nhng khun nh vy khng kinh t v
khng c ng dng.
Khe h chy-ci:
Khe h gia chy v ci dp vut dng gim ma st gia ci v vt liu. Khi xc nh
tr s khe h cn phi xt n s ha dy mp phi khi dp vut v khng ng u
chiu dy ca vt liu (dung sai theo chiu dy) khng th xc nh mt tr s khe h
thng nht trong mi trng hp ca dp vut, v nhng chi tit dp vut rt khc nhau
v khun kh, mc chnh xc v iu kin k thut, cng nh v phng php dp
vut (khng c tm chn, c tm chn,).
Khe h theo cc nguyn cng s gim dn, nu tr s khe h nh lm tng tr lc dp
vut, tng ng sut ko tit din nguy him v gim mc bin dng. iu khng
c lin quan n dp vut c bin mng thnhv trong trng hp ny mc bin dng
tng cng tng ln do s bin mng vt liu.
Khi dp vut chi tit hnh hp ch nht khe h gia chy v ci cc gc cn phi ln
hn khe h nhng on thng vi mt lng 0.1S, bi v ti cc gc ny s ha dy rt
mnh lit.
Nguyn tc chn hng ly khe h khi dp vut:
-

i vi tt c cc nguyn cng, tr nguyn cng cui cng, hng ca khe h

ly ty .
- i vi nguyn cng cui cng:
+ Khi dp vut chi tit c kch thc bn ngoi cho trc, ngi ta ly
khe h theo chy:
d c =D sph.ng ; d ch =d o2 z

+ Khi dp vut nhng chi tit c kch thc bn trong cho trc, ta ly
khe h theo ci:
d ch =d sph. trg ; d c =d ch +2 z

Trong :
d c ,d ch

ng knh ca ci v chy, mm

z tr s khe h v mt pha
D sph .ng

ng knh ngoi ca sn phm

d sph .trg ng knh trong ca sn phm

5.3.5 Bi trn khi dp vut:

Tc dng ca bi trn khi dp vut l gim ma st gia vt liu v dng c (bng 5.14
so snh h s ma st khi c bi trn v khng bi trn, bng 5.15 l h s ma st gia cc
loi vt liu), gim ng sut trong kim loi, ngn nga khun v sn phm khi b dnh,
c nhng vt lm mn, vt xc.
Bi trn cn phi c nhng tnh cht sau y:
-

To ra mt mng vng bn khng b kh i, c kh nng chu p lc ln (tr

dp vut nhng thp khng g v hp kim titan).
C dnh tt v phn b ng u lp bi trn trn b mt.
D dng loi tr ra khi b mt ca chi tit.
Khng lm mt tnh cht c hc ca v ha hc trn b mt ca dng c v chi
tit.
C bn ha hc v khng c.

Trong sn xut ngi ta dng nhiu cht bi trn c thnh phn khc nhau, nhng cht
ny c th phn thnh hai nhm bi trn khng c cht n v bi trn c cht n.
Mt s thnh phn ca cht bi trn nh sau: du cng nghip, m c, graphc, axt oleic,
lu hunh,
Bng 26: Gi tr ca h s ma st khi dp vut c bi trn v khng c bi trn [1, 425]
iu kin dp vut
(c bi trn v
khng c bi trn)

H s ma st cn c vo vt liu mang dp
vut
Thp 08

Nhm

ura

Khng bi trn

0.18-0.20

0.25

0.22

Bi trn bng du khong cht (du

my)

0.14-0.16

0.15

0.16

Bi trn c cht n (phn graphit)

0.06-0.10

0.1

0.08-0.10

Bi trn nhng phi n chic ln thng tin hnh bng cch ngm hoc qut bng chi
lng. Khi t ng ha qu trnh dp, bi trn tin hnh bng cch phun cht bi trn ln
phi nh thit b phun c vi phun c bit.

Khi dp vut thng thng nhng chi tit hnh tr t nhng phi n chic, nn p dng
nhng nguyn tc bi trn sau y:
-

Khng cn bi trn ton b phi bng cch ngm.

Bi trn ch cn pha vnh tip xc vi ci, hoc l bi trn b mt ca ci
v tm chn theo chu k.
Khng c bi trn chy hoc phi pha tip cn i vi chy, v n d lm
vt liu trt dc theo chy v lm bin mng n.
T mt u v t ch ln ca chy cn phi loi tr bt k mt vt bi trn
no tng ma st gia chy v phi (theo quan im ny b mt ca chy
dp vut khng cn lm nhn).
Bng 27: H s ma st gia cc loi vt liu [12, 128]

Vt liu
iu kin lm vic
H s ma st
- Gang vi gang, thp vi
C du bi trn
0.05
thp
- Thp vi thp
Kh
0.10-0.15
- Tectolit vi thp hoc
-nt0.20-0.25
gang
- Php vi thp hoc gang
-nt0.15-0.20
- Da vi gang
-nt0.25-0.35
- G vi gang
-nt0.40-0.50
Vt liu hoc phi c bi trn cn phi gi khng c lm bn, nu khng s lm
hng chi tit hoc khun. Lm sch cht bi trn khi nhng chi tit c dp tin
hnh bng nhiu phng php khc nhau.
5.3.6 Cc dng h hng chnh trong dp vut v nguyn nhn:

Bng 28: Cc dng h hng khi dp vut v nguyn nhn

TT
1

Cc dng hng
Nhn thnh
vt dp
-

Nguyn nhn
Nhn phn b u:
Lc p chn chng nhn khng
Khe h gia chy v ci qu ln
Bn knh ln ming ci qu ln
Nhn phn b ch mt phn:

Ghi ch

- Lc p chng nhn khng u

- Chy ci lp lch (khe h khng ng u)
- Chy, ci b mn
2

Rch tit din - H s dp vut ly nh hn kh nng cho php

nguy him
- Tnh do ca vt liu km hay kim loi bin bin
cng
- Lc p chn qu ln hoc khng u
- Khe h chy, ci qu nh hay lp lch
- Cht bi trn khng t yu cu hay nhn
ca khun thp
- Bn knh ln ming ci qu nh
Chiu cao khng - Khe h gia chy, ci khng u
u v thnh
- Lc p chn khng phn b u
dy mng khng - nh v phi liu khng chnh xc
- Chiu dy vt liu khng u
u
To thnh bn - Do tnh ng hng ca vt liu gy nn,
mui cao
thng khc phc bng phng php kt
tinh vt liu
Nt dc theo
- Bin dng khng u, tp thnh bn mui cao
thnh
- C vt co xc su t trc
- C np nhn gp li khi dp vut
- C vt nt ngm trong vt liu phi
- Vt liu b bin cng
Nt ngang thn - H s dp vut ly qu nh
vt dp
- Lc p chn ln v khng u
- Bn knh ln ming ci qu nh
C vn sng hay - Khuyt tt do tm cn li, kim loi c ln tp
cn gi l xp
cht hay lp oxt b mt
vy vnh
- Kim loi b bin cng

Thnh b co
xc

- Bn, ct, bi ln vo trong cht bi trn, bm

vo vt dp hay b mt lm vic ca chy, ci

Va nhn va
rch gn
ming

- Bao gm cc nguyn nhn gy nhn

- B dy vt liu ln khng i qua c khe h
gia chy v ci nn li rch

10

Vt dp kh ly - Chy khng c l thot hi b tt

ra chy
- Chy khng c cn khi dp vut su
- Cht bi trn km

- Ci b ngc (ng knh ming thu nh)

Trong cc dng h hng trn nu khng xt n nguyn nhn do li ch to, do vt liu
th phn ln cc dng h hng ri vo cc dng: nhn, rch. Nhn xy ra vng c ng
sut nn ln, rch xy ra vng c ng sut ko ln.

PHN 2 : TNH TON THIT B KHUN DP

1. Khun Ct Hnh - t L
1.1 Tnh ton thng s cng ngh
Vt liu thp CT3
i lng
bn ko
Gii hn chy
gin di

Gi tr
370 - 480
245
26

Chu vi hnh bao cn ct

C = 352.538 mm (bin dng ngoi )

C = 25.12 mm ( l )
B dy vt liu : S = 2mm

n v
MPa
MPa
%

Theo ph lc c tnh vt liu lm phi: c = 33 kg/mm2

Lc chn phi : Qd = 100 kg
Lc cn thit khi ct hnh : P = L.S.c + Qd = 352.538 2 33 + 235 = 23503 kg
Lc cn thit kh t l : P = L.S.c + Qd = 3,14 8 33 +10 = 838 kg
V cng nm trn mt b khun nn ta chn lc ct hnh trong qu trnh dp
Do cc yu nh b dy phi khng u (s khc nhau v thi im
ct), mn dao nn lc ct c tng thm 30%:
P = P . 1.3 = 23503 1.3 = 30554 kg
Khe h : 3%S = 0.06mm
1.2 Kt cu khun ct hnh ( bn v )
2. Khun vut
2.1 ng dng CAE :
a. Qu trnh hnh thnh sn phm

Nhn xt : lc dp thay i lin tc v t cc i ( khong 1,5 tn ).

Lc chn phi : 300 kg
Phi c ly t nguyn cng ct hinh t l
2.2 Kt cu khun ( bn v )
PHN 3:
KT LUN V HNG PHT TRIN CA N
Sau thi gian nghin cu ng dng phn mm Deform 3D vo vic m phng qu trnh
ct hnh t l, dp vut kim loi tm v thc nghim trn sn phm thc t, lun vn
t c mt s kt qu sau:
-

Tm hiu c s l thuyt dp ct hnh t l, dp vut cm ng 27.

Trnh by c s thit k cm ng 27

M phng qu trnh dp cm ng trn phn mm DEFORM 3D

nh gi v so snh kt qu thc nghim vi kt qu m phng bng phn mm,

t chn c thng s cng ngh ph hp cho qu trnh dp vut v dp ct t

Thit k hon chnh b khun dp: dp ct, dp vut.

Trnh by quy trnh cng ngh sn xut cm ng 27.

Bi bo co kt qu mn hc l tin cho bi lun vn n mn hc.