Gio trnh: cng ngh c

chng 1

khi nim chung

1.1. Thc cht, c im v cng dng 1.1.1. Thc cht c l phng php ch to sn phm bng cch rt kim loi lng vo khun c hnh dng nht nh, sau khi kim loi ho rn trong khun ta thu c vt c c hnh dng ging nh khun c. Nu vt phm c a ra dng ngay gi l chi tit c, cn nu vt phm c phi qua gia cng p lc hay ct gt nng cao c tnh, chnh xc kch thc v bng b mt gi l phi c. c c nhng phng php sau: c trong khun ct, c trong khun kim loi, c di p lc, c li tm, c trong khun mu chy, c trong khun v mng, c lin tc v.v... nhng ph bin nht l c trong khun ct. 1.1.2. c im - c c th gia cng nhiu loi vt liu khc nhau: Thp, gang, hp kim mu v.v... c khi lng t mt vi gam n hng trm tn. - Ch to c vt c c hnh dng, kt cu phc tp nh thn my cng c, v ng c v.v...m cc phng php kh khn hoc khng ch to c. - chnh xc v hnh dng, kch thc v bng khng cao (c th t cao nu c c bit nh c p lc). - C th c c nhiu lp kim loi khc nhau trong mt vt c. - Gi thnh ch to vt c r v vn u t t, tnh cht sn xut linh hot, nng sut tng i cao. - C kh nng c kh ho v t ng ho. - Tn kim loi cho h thng rt, u ngt, u hi. - D gy ra nhng khuyt tt nh: thiu ht, r kh, chy ct v.v... - Kim tra khuyt tt bn trong vt c kh khn, i hi thit b hin i. 1.1.3.Cng dng Sn xut c c pht trin rt mnh v c s dng rt rng ri trong cc ngnh cng nghip. khi lng vt c trung bnh chim khong 4080% tng khi lng ca my mc. Trong ngnh c kh khi lng vt c chim n 90% m gi thnh ch chim 2025%.

Trng i hc bch khoa - 2006

Gio trnh: cng ngh c

3.1.4. Phn loi K thut c c phn loi theo s sau:

K thut c

c trong khun ct

c c bit

c trong hm khun

c trn nn xng

c bng dng gt

khun kim loi

c p lc

c ly tm

c lin tc

c trong khun v mng

c trong khun mu chy

H.1.1. S phn loi phng php c Chng 2

c trong khun ct
2.1. Khi nim v qu trnh sn xut c Qu trnh sn xut c bao gm cc cng on chnh sau:
B phn k thut Ch to hn hp lm khun Lm khun Sy khun Lp rp khun v rt kim loi B phn mc mu Nu kim loi Ch to hn hp lm li Lm li Sy li

Ph khun ly vt c

Ph li khi vt c

Lm sch vt c

Kim tra cht lng

H.2.1. S cc b phn trong xng c Trng i hc bch khoa - 2006

Gio trnh: cng ngh c

Phng k thut c nhim v lp phiu cng ngh v thit k cc bn v k thut: bn v chi tit, bn v vt c, bn v mu v bn v hp li ri a sang cho b phn mc mu ch to mu v hp li v chuyn cho cc b phn ch to khun v li. Sau khi sy (hoc khng sy) khun v li, tin hnh lp rp khun v rt kim loi. 2.2. cc b phn c bn ca mt khun c Mun c mt chi tit, trc ht phi v bn v vt c da trn bn v chi tit c tnh n ngt ca vt liu v lng d gia cng c kh. Cn c theo bn v vt c, b phn xng mc mu ch to ra mu v hp li. Mu to ra lng khun 6 - c hnh dng bn ngoi ca vt c. Li 7 c ch to t hp li c hnh dng ging hnh dng bn trong ca vt c. Lp li vo khun v lp rp khun ta c mt khun c. dn kim loi lng vo khun ta phi to h thng rt 10. Rt kim loi lng qua h thng rt ny. Sau khi kim loi ho rn, ngui em ph khun ta c vt c. Lng khun 6 ph hp vi hnh dng vt c, kim loi lng c rt vo khun qua h thng rt. B phn 11 dn hi t lng khun ra ngoi gi l u hi ng thi cn lm nhim v b sung kim loi cho vt c khi ho rn cn gi l u ngt. Hm khun trn 1, hm khun di 9 lm na khun trn v di. lp 2 na khun chnh xc ta dng cht nh v 2. Vt liu trong khun 4 gi l hn hp lm khun (ct khun). nng cao bn ca hn hp lm khun trong khun ta dng nhng xng 5. tng tnh thot kh cho khun ta tin hnh xin cc l thot kh 8.
11 10 1234567891011Hm khun trn Cht nh v Mt phn khun Ct khun Xng khun Lng khun Li Rnh thot kh Hm khun di H thng rt u hi (hoc u ngt)

1 2

4 5 6 7 8 9

H.2.2. Cc b phn chnh ca mt khun c ct

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Gio trnh: cng ngh c

2.3. Hn hp lm khun v lm li Hn hp lm khun v lm li gm: ct, t st, cht kt dnh, cht ph, nc v.v... C 2 loi: loi c ( dng) v loi mi ch to 2.3.1. Yu cu i vi hn hp lm khun v lm li Hn hp cn c nhng tnh cht sau: a/ Tnh do Tnh do l kh nng bin dng vnh cu ca hn hp sau khi b tc dng ca ngoi lc. Tnh do tng khi nc trong hn hp tng n 8%, t st v cht dnh tng, ht ct nh. b/ bn bn ca hn hp l kh nng chu tc dng ca ngoi lc m khng b ph hu. bn tng khi ht ct nh, khng ng u v sc cnh, mn cht ca hn hp tng, lng t st tng, lng nc tng n 8 %. - Khun ti c sc bn nn (68) N/ cm2. - Khun kh c sc bn nn (830) N/ cm2. - Khi nhit tng n 9000C th sc bn nn tng 23 ln nh gi bn ta dng gii hn bn nn, c tnh theo cng thc sau: =
P E

(N/ cm2)

vi : P - lc nn; F- din tch tit din ngang mu th c/ Tnh ln Tnh ln l kh nng gim th tch ca hn hp khi chu tc dng ca ngoi lc, cn c tnh ln t cn tr vt c co khi ng c v lm ngui, trnh c nt n, cng vnh. Tnh ln tng khi dng ct sng ht to, lng t st t, cht kt dnh t, cht ph (mn ca, rm vn, bt than) tng. d/ Tnh thng kh Tnh thng kh ca hn hp l kh nng cho php kh lt qua nhng k h nh gia nhng ht ct ca hn hp. Tnh thng kh cn c vt c khng b r kh.Tnh thng kh tng khi ht ct to v u, lng t st v cht kt dnh t, dm cht ca hn hp gim, cht ph nhiu v lng nc < 4 %. nh gi kh nng thot kh ca hn hp lm khun, ngi ta dng thng kh K: vi: K=
Q. L 100. F . P. t

Q : lng thng kh thi qua mu (cm3). L : chiu cao ca mu (cm). F : din tch tit din ngang ca mu ( cm2 )
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Gio trnh: cng ngh c

P : p sut ca kh trc khi qua mu ( N/ cm2 ) t : thi gian khng kh thot qua mu ( pht ) Trong thc nghim, ngi ta ly: Q = 2000 cm3; L = 50 mm; D = 50 mm, do khi th nghim ch cn xc nh thi gian khng kh thot qua mu. g/ Tnh bn nhit Tnh bn nhit ca hn hp l kh nng khng b chy, chy v mm ra nhit cao. Tnh bn nhit tng khi lng ct thch anh Si02 tng, ht ct to v trn, cc tp cht d chy (Na2O, K2O, CaO, Fe2O3) trong hn hp cng t. Tng s nhng cht d chy ny phi 1,520% i vi thp v phi 57% i vi gang, c kim loi mu khng qu 1012%. Hn hp lm khun cho tt c cc loi vt c khng c cha (Na2O + K2O) qu 1%, CaO 12% v Fe2O3 34%. e/ m L lng nc cha trong hn hp , c xc nh bng cng thc sau: X=
g g1 100% . g

vi: g- khi lng hn hp ti; g1- khi lng hn hp kh. m tng khi lng nc trong hn hp tng, nhng m phi 6- 8% v nu nhiu hn s lm cho sc bn, tnh thot kh gim. m i vi khun ti c: gang : 4,55,5%; thp: 4,5%; nhm: 45%. f/ Tnh bn lu L kh nng lm vic c lu v nhiu ln ca hn hp, c xc nh: C=
R 100% . r

vi : R- sc bn sn c ca hn hp, r- sc bn sau mt thi gian s dng. 2.3.2. cc loi vt liu lm khun v lm li Ch yu l ct, t st, cht dnh kt, cht ph v.v... a/ Ct Thnh phn ch yu ca ct l SiO2, ngoi ra cn c Al2O3, CaCO3, Fe2O3... Phn loi ct - Theo ni ly ct: gm ct ni ht sc cnh, ct sng ht trn u. - Theo ht: Ngi ta xc nh ht ca ct theo kch thc l ry. S hiu ry gi theo kch thc l ca n (ht) c phn nhm:

Tn ct

Nhm

S hiu ry

Kch thc ht (mm )

5

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Gio trnh: cng ngh c

ct th rt to to va nh rt nh mn bt

063 04 0315 02 016 01 0063 005

1 - 063 - 04 063 - 04 - 0315 04 - 0315 - 02 0315 - 02 - 016 02 - 016 - 01 016 - 01 - 0063 01 - 0063 - 005 0063 - 005 - nh

0,4 1 0,315 0,63 0,2 0,4 0,16 0,315 0,1 0,2 0,063 0,16 0,05 0,1 < 0,05

- Theo thnh phn thch anh ( SiO2): Loi ct Lng cha SiO2 (%) - Theo thnh phn t st: Tn ct Ct thch anh Ct gy Ct na bo Ct bo Ct rt bo K hiu ct v chn ct K hiu ct: theo thnh phn thch anh v ht. v d: 2K 063A; 2K 016B; vi: 2K : l loi ct thch anh s 2; 063, 016: l ht. A,B : l ct ry trung bnh ca b 3 ry > 50% Chn ct: - Tu thuc khi lng vt c, kim loi vt c m ta chn loi ct, thnh phn v ht nht nh. - lm khun ti c gang xm, m vt c < 200kg, ta dng ct gy (T) ht 01; 016; 02; 04. - Vt c c khi lng m = 2002000 kg, gang trng th dng ct na m tng thch anh ( chu nhit), ht P 16 - 04. Vd : T04A; K02A. - lm khun li c thp m< 500kg, dng ct thch anh (K) ht P 16- 02. V d: K02A; K016B; K016A. - c kim loi mu ta dng ct na m, ht 01; 016; 02, thch anh t. vd : 016A; 01A. b/ t st
Trng i hc bch khoa - 2006

1K 97

2K 96

3K 94

4K 90

K hiu Lin x K T O

S lng t st cha trong ct (%) <2 210 1020 2030 3050

Gio trnh: cng ngh c

Thnh phn ch yu: cao lanh mAl2O3, nSiO2, qH2O, ngoi ra cn c tp cht: CaCO3, Fe2O3, Na2CO3. c im: Do, dnh khi c lng nc thch hp, khi sy th bn tng nhng dn, d v, khng b chy khi rt kim loi vo. Phn loi t st: - Theo thnh phn khong cht : t st thng hay cao lanh c sn trong t nhin. Thnh phn ch yu l Al2O3.2SiO2.2H2O, loi ny lm khun c thng, c mu trng, kh nng ht nc km, tnh do v dnh km, b co t khi sy. Nhit nng chy cao (175017850C). t st bentnit (I ) thnh phn ch yu l: Al2O3.4SiO2.H2O. N l t st trng c tnh do dnh ln, kh nng ht nc v trng n ln, b co nhiu khi sy, ht rt mn, nhit chy thp (125013000C). Do ni la sinh ra lu ngy bin thnh. Loi ny lm khun quan trng cn do, bn cao. - Phn loi t st theo kh nng dnh kt + Loi dnh kt t (M): c bn nn ti 0,5 0,8 kg/cm2; bn nn kh < 3,5 kg/cm2. Loi ny thng dng lm khun c kim loi mu, nh, va. + Loi dnh kt va (C): c bn nn ti 0,791,1 kg/cm2; bn nn kh < 3,55,5 kg/cm2. + Loi dnh kt bn (B): c bn nn ti >1,1 kg/cm2; bn nn kh trn 5,5 kg/cm2. - Phn loi theo kh nng bn nhit + Nhm 1: bn nhit cao, chu c t0 15800C. + Nhm 2: bn nhit va, chu c t0: 135015800C. + Nhm 3: bn nhit thp, chu c t0 13500C. Chn t st: - c thp: thng dng cao lanh (), loi rt bn (B) v c kh nng chu nhit cao. - c gang: dng cao lanh loi dnh kt, chu nhit va, bn v rt bn cho c khun ti v kh. - c hp kim mu: thng dng cao lanh dnh kt va v cao, bn nhit thp. c/ Cht kt dnh: Cht dnh kt l nhng cht a vo hn hp lm khun, li tng tnh do ca hn hp.

Yu cu: - Khi trn vo hn hp, cht dnh kt phi phn b u.

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Gio trnh: cng ngh c

- Khng lm dnh hn hp vo mu v hp li v d ph khun li. - Kh nhanh khi sy v khng sinh nhiu kh khi rt kim loi . - Tng do, bn v tnh bn nhit cho khun v li. - Phi r, d kim, khng nh hng n sc kho cng nhn. Nhng cht dnh kt thng dng: - Du: du lanh, du bng, du tru... em trn vi ct v sy t0=2002500C , du s b oxy ho v to thnh mng oxyt hu c bao quanh cc ht ct lm chng dnh kt chc vi nhau. - Nc ng (mt): dng lm khun, li khi c thp. Loi ny kh sy b mt, khun s bn nhng bn trong rt do nn vn m bo thot kh v tnh ln tt. Khi rt kim loi n b chy, do tng tnh xp, tnh ln, thot kh v d ph khun nhng ht m nn sy xong phi dng ngay. - B h: (nng 2,53%) ht nc nhiu, tnh cht nh nc ng, dng lm khun ti rt tt. - Cc cht dnh kt ho cng: Nha thng, ximng, hc n, nha ng. Khi sy chng chy lng ra v bao quanh cc ht ct. Khi kh chng t ho cng lm tng bn, tnh dnh kt cho khun. Thng thng dng loi ximng pha vo hn hp khong 12%, m ca hn hp 68%, trong khng kh 2427 gi c kh nng t kh, loi ny rt bn. - Nc thu tinh: chnh l cc loi dung dch silicat Na2O.nSiO2.mH2O hoc K2O.nSiO2.mH2O sy 2002500C, n t phn hu thnh nSiO2.(m-p)H2O l loi keo rt dnh. Khi thi CO2 vo khun lm xong, nc thu tinh t phn hu thnh cht keo trn, hn hp s cng li sau 1530 pht. d-Cc cht ph Cht ph l cc cht a vo hn hp khun v li c mt s tnh cht c bit nh nng cao tnh ln, tnh thng kh, lm nhn mt khun, li v tng kh nng chu nhit cho b mt khun li, gm 2 loi: - Cht ph gia: trong hn hp thng cho thm mn ca, rm vn, phn tru b kh, bt than... Khi rt kim loi lng vo khun, nhng cht ny chy li trong khun nhng l rng lm tng tnh xp, thng kh, tnh ln cho khun li. T l khong 3% cho vt c thnh mng v 8% cho vt c thnh dy. - Cht sn khun: mt khun nhn bng v chu nng tt, ngi ta thng qut ln b mt lng khun, li mt lp sn, c th l bt than, bt gratit, bt thch anh hoc dung dch ca chng vi t st. Bt than v gratit qut vo thnh khun, khi rt kim loi vo n s chy to thnh CO, CO2 lm thnh mi trng hon nguyn rt tt, ng thi to ra mt lp kh ngn cch gia kim loi lng vi mt lng khun lm cho mt lng khun khng b chy ct v to cho vic ph khun d dng.
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Gio trnh: cng ngh c

2.3.3. hn hp lm khun, li a/ Hn hp lm khun : c hai loi

Ct o: Dng ph st mu khi ch to khun nn cn c bn, do cao, ng

thi n trc tip tip xc vi kim loi lng nn cn phi c chu nhit cao, ht cn nh hn b mt c nhn bng, thng thng ct o lm bng vt liu mi, n chim khong 1015% tng lng ct khun. Ct m: Dng m cho phn khun cn li, khng trc tip tip xc vi kim loi lng nn tnh chu nhit, bn khng cn cao lm, nhng tnh thng kh tt chim 8590% lng ct. Vt c cng ln yu cu ht ca hn hp lm khun cng ln tng tnh thng kh. - c gang: Nhit va, lng t st nhiu tng do, bn, hn hp c t. Thng thng hn hp lm khun c gang c: ht khong 01 04, lng t st 820%, m 4,55%, thng kh 25100, bn nn 37,5 N/ cm2, hn hp c 4090%. - c thp: Nhit nng chy cao, hn hp cn kht khe hn, thng dng ct thch anh loi 1K, 2K (SiO2 > 95%), ht ct 0160315. t st loi chu nhit cao, lng cha t st khong 815%, bn nn khong 315 N/cm2, thng kh khong (80130), m (3,58%). T l hn hp c 4080%. - c kim loi mu: Nhit nng chy nh, hn hp khng yu cu cao v tnh chu nhit. ht nh tng bng (0,063016), m cn thp (4,56%), thng kh nh hn 20, t l hn hp c (8595%). b/ Hn hp lm li iu kin lm vic ca li kh bt li nn hn hp cn bn, tnh ln, thng kh cao hn khi lm khun nhiu. tng bn cn gim lng t st, tng tnh chu nhit P, lng thch anh t ti 100%, t dng hn hp c, thng kh yu cu cao, dng ht ct c ht 02 v nhiu cht ph. Hu ht cc li u phi sy trc khi lp vo khun. 2.3.4. Ch to hn hp lm khun v lm li a/ iu ch ct c Hn hp lm li sau khi dng nhiu ln th cht lng s km i. Thnh phn nc t i, ht ct thch anh b v vn nn gim tnh thng kh. Mt khc, nhit 7008000C t st mt ht nc ho cng nn ht kh nng dnh kt, nn cn iu ch li: Lm ngui hn hp n 30350C, phn ly cc tp cht (kim loi, x v si ), ry li loi tr cc ht t to v t st bt, bt ct thch anh... Sau pha thm mt lng ct nht nh, t st, cht dnh, cht ph mi m bo tnh cht ca hn hp.
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Gio trnh: cng ngh c

b/ Sy li: Thc hin trong my sy t0 = 1502400C, = 23 gi. t0 v ph thuc vo cc cht hm v kch thc ca li.
chng 3

Ch to b mu v hp li
3.1. Khi nim B mu l cng c chnh dng to hnh khun c. B mu bao gm : Mu chnh, tm mu, mu ca h thng rt, u hi, u ngt. Tm mu kp mu khi lm khun, dng kim tra; mu chnh to nn hnh dng ca lng khun khi lm khun c, ni cch khc mu chnh to nn hnh dng bn ngoi ca vt c. Hp li dng ch to ra li. Li dng to nn hnh dng bn trong ca vt c khi c kim loi. 3.2. Vt liu lm b mu v hp li 3.2.1.Yu cu - Bo m bng, chnh xc khi gia cng ct gt. - Cn bn, cng, nh, khng b co, trng, nt, cng vnh trong khi lm vic. - Chu c tc dng c, ho ca hn hp lm khun, t b mn, khng b r v n mn ho hc. R tin v d kim. 3.2.2-Cc loi vt liu lm mu v hp li Vt liu thng dng: G, kim loi, thch cao, ximng, cht do. Ch yu l g, kim loi. a/ G: u im ca g l r, nh, d gia cng, nhng c nhc im l bn, cng km; d trng, nt, cng vnh nn g ch dng trong sn xut n chic, loi nh, trung bnh v lm mu ln. Da vo tnh cht ca g ta chia thnh 3 loi: - Loi 1: g lim, g, sn: bn, cng, mn, cht thun nht, t b thm nc, khi ct gt b mt nhn bng, nhng kh gia cng bng ct gt, t tin nn dng trong sn xut hng lot, nhng mu quan trng, nhng phn ring ca mu chu mi mn nhiu (gi, phn tho ri ...). - Loi 2: g m, d... c bn, cng trung bnh, chu m, d nhn bng c th lm vic c 25100 ln. Dng trong sn xut nh, n chic, nhng mu phc tp, cn kch thc tng i chnh xc. - Loi 3: g thng, b ... l g tp, r tin, cng, bn thp, g c nhiu lp nn d v, sn si mt nhng t cng vnh v t thm nc. Dng trong sn xut n chic v nhng mu khng cn nhn bng v chnh xc.

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10

Gio trnh: cng ngh c

b/ Kim loi: c bn, cng, nhn bng, chnh xc b mt cao, khng b thm nc, t b cong vnh, thi gian s dng lu hn, nhng kim loi t kh gia cng nn ch s dng trong sn xut hng khi v hng lot. Thng dng: - Hp kim nhm: hp kim nhm silic v hp kim nhm ng gm Al12, Al24, Al26, Al28... Loi ny nh, d gia cng c kh, bng, chnh xc cao, tnh chng n mn ho hc cao, dng c nhiu ln nn c s dng nhiu nht. - Gang xm: thng dng Gx12-28; Gx15-32; Gx18-36... c bn cao hn hp kim nhm, gi thnh h. Dng c ti 10.00015.000 ln, nhng nng, kh gia cng c kh, d b xy ho. - ng thau v ng thanh: bn, d gia cng, b mt nhn bng, chnh xc, khng b xy ho, dng ti 15.000 ln. Nhng nng, co ln. - Thch cao: Bn hn g (lm c 1000 ln) nh, d ch to, d ct gt. Nhng gin, d v, d thm nc. Nn lm nhng mu nh khi lm bng tay, tin li khi lm mu ghp v dng trong c m ngh (v d sa). - Ximng: Bn, cng hn thch cao, chu va chm tt, r, d ch to, nhng nng tuy khng ht nc, kh gt, sa nn ch dng lm nhng mu, li phc tp, mu ln, mu lm khun bng my. 3.3. Nguyn l thit k mu v hp li Mun ch to vt c phi cn c vo bn v chi tit thit k bn v vt c. T bn v vt c v nn bn v mu v hp li. Cn c vo ngi th mc mu s ch to mu, hp li. 3.3.1. Bn v vt c Trn bn v vt c cn biu th c: Mt phn khun, kch thc vt c (tnh n lng d gia cng c v dung sai c), cn phi biu din c li v gi li, dc c v gc c. a/ Mt phn khun Mt phn khun l mt tip xc gia khun trn v khun di. N xc nh v tr chi tit trong khun bng gch xanh. Mi tn T ch khun trn v D ch khun di. Chn mt phn khun, da theo nhng nguyn tc sau: - Mt phn khun bo m d lm khun v rt mu. - Phi n gin nht v s mt phn khun t nht (nn chn mt phng, trnh mt cong, bc). - Nhn c cht lng vt c tt nht (mt quan trng cn c tnh cao nn xung di, trn d r kh, r x, lm co).
100 Trng i hc bch khoa - 2006 60 50 120

11

Gio trnh: cng ngh c

100+2

120+1,5 50-1 120+3,87

70

60

40 R20

150 2 T D

H.3.2. Bn v vt c

b/ co ca kim loi khi c Khi hp kim c ng c v ngui lnh vt c co li do vy kch thc lng khun phi ln hn kch thc vt c: Gang xm: 1%; thp: 2%; gang trng: 1,5%; hp kim ng v nhm: 1,5%. c/ Lng d gia cng c kh L lng kim loi cn ct gt trong qu trnh gia cng c. Trn bn v k hiu bng mu . Chng ph thuc: bng, chnh xc ca chi tit, cht lng ca b mt chi tit c; kch thc vt c, iu kin sn xut (n chic hay hng lot), mc phc tp ca chi tit.v.v... d/ Dung sai c Khi ch to c s sai lch gia kch thc, khi lng danh ngha v thc t. Dung sai c ph thuc vo trnh tay ngh ca cng nhn mc mu, lm khun, li v lp rp.
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Gio trnh: cng ngh c

/ Li v gi li Trn bn v c k hiu bng nhng gch cho mu xanh. Gi li bo m li nm vng trong khun, d lp rp li vo khun. Vi li ng thng dng gi li hnh cn. kch thc, gc s2 s1 nghing gi li vn bo m: h > h1 ; > . trong khi lp rp khng s3 h1 b v khun, li gia gi li v s2 khun cn c khe h. Vi li ngang c th lm gi s1 li hnh tr, hnh vung v cc dng h nh hnh khc. d lp rp v s1 trnh v khun, li, gia li v H.3.3. Li v gi li khun cng c cc khe h: S1, S2, S3 v h > h1; < . e/ Xc nh cn ca mu Mun rt mu ra khi khun c d dng v trnh v khun, nhng mt mu thng gc vi mt phn khun phi lm cn. C 3 dng cn mu c thng hay thit k: - Dng th nht (a): phn cn nm ngoi lng d gia cng c, dng cho nhng phi c c b mt gia cng quan trng nm ng chiu rt mu v cho nhng mt khng gia cng c nhng thnh mng (< 8 mm). - Dng th 2 (b): cn bo m trng lng vt c t thay i, dng cho nhng mt thng ng khng gia cng c c thnh dy t 8 n 12 mm.
h h/2 a b c

H.3.4. nghing thnh c

- Dng th 3 (c): dng cho mt thng ng khng gia cng c chiu dy trn 12 mm v cao ti 100 mm, lm cn ly mu ln vo thnh vt c gim trng lng vt c. Song vi nhng mt thng ng c gia cng c phi chn theo dng 2 m bo cht lng b mt chi tit. Chiu cao thnh vt c ln th dc nh, mu g c dc ln hn mu kim loi, mu lm khun bng tay ln hn mu lm khun bng my.
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Gio trnh: cng ngh c

f. Xc nh gc c Gc c l gc ln chuyn tip gia phn dy v phn mng. Khi thit k vt c cn c bn knh ln nht nh khun khi v khi rt mu v vt c khng b nt khi kim loi lng ng c trong khun v tng kh nng in y ca gang khi c. Tr s ca bn knh ln trong r v bn knh ln ngoi R c th chn theo cng thc thc nghim:
1 1 a + b (mm) . r= 6 8 2
R = b khi
a

a 2. b

r b

R =b+r trong cc trng hp khc

H.3.5. Gc c

3.3.2. Bn v mu T bn v vt c ngi ta v bn v mu. Kch thc mu tng t nh bn v vt c tr phn tai gi v dung sai ch to mu. Kch thc phn tai gi mu phi k thm khong h s1, s2, s3 gia gi li vi khun v gc vt thnh khun , , ch t gi li. Dung sai ch to mu l sai lch cho php khi ch to mu. Sai lch ph thuc vo vt liu ch to mu, dng sn xut, kch thc mu.
102+0,87 120+2,87 70+30 52+0,7

40+0,5 R20+0,5

150+1,15

H.3.6. Bn v mu

lm khun, mu c chia lm 2 na lp ghp vi nhau bng cht nh v. Mt phn mu trng vi mt phn khun. Trng hp c bit mu c th ch to di dng nhiu phn tho ri. Trn bn v mu cn th hin c mt phn mu, cht nh v v cc phn tho ri c ca mu. 3.3.3. bn v hp li
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Gio trnh: cng ngh c

Tu theo phc tp ca li c th lm hp li nguyn, hp li 2 na v hp li tho ri. Kt cu, kch thc, dung sai v cch v hp li tng t nh thit k mu.
chng 4

Cc phng php lm khun v lm li

Trong sn xut c, khun c ng mt vai tr quan trng, l mt trong nhng yu t quyt nh cht lng vt c. Thng c ti 50 n 60% ph phm l do khun c gy ra. V vy phi tun th quy trnh cng nhg lm khun cht ch. Khun c c 3 loi: khun dng mt ln, khun bn vnh cu lm bng vt liu chu nng a sy 6007000C, sau khi ly vt c em sa cha ri dng li c mt s ln (50200 ln). Khun vnh cu lm bng kim loi dng trong sn xut hng lot v hng khi. 4.1.Ch to khun 4.1.1.cc phng php lm khun bng tay Lm khun bng tay c c im: chnh xc ca khun khng cao, nng sut thp, yu cu tay ngh cao, iu kin lm vic nng nhc nhng c th c c nhng vt c phc tp c kch thc v khi lng tu . Do lm khun bng tay thch ng vi sn xut n chic v hng lot nh. a/ Lm khun trong 2 hm khun vi mu nguyn Trnh t nhng thao tc lm khun vi hai hm v mu nguyn nh sau: Lm na khun di: u tin t mu ln tm mu, t hm khun ln tm mu, ct o xung quanh mu, ct m, dm cht ln th nht, tip ct m ri dm cht, l phng, xm kh (a). Lm na khun trn: Quay na khun di 1800, ly tm mu, t hm khun trn ln, bt cht nh v, t mu u hi, mu ng rt, mu rnh lc x, ct o xung quanh mu v tin hnh lm khun nh hm khun di (b, c). Tho lp khun: Tho cht nh v, tho na khun trn ra, rt b mu, khot rnh dn v cc rt, sa cha cc ni b h hng, qut sn ln mt phn khun, lp rp khun li, bt cht c cu kp cht (d).

a/

b/

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Gio trnh: cng ngh c

b/ Lm khun trn nn xng Lm khun trn nn xng l dng ngay nn xng to khun di. Phng php ny thch ng trong sn xut n chic v hng lot nh, vt c trung bnh v ln khng yu cu b mt nhn p, kch thc khng cn chnh xc. Lm khun trn m mm (H.4.2): xi ct khun trn nn xng cho xp u ri gt phng. n nh mu xung m, dng ba g nh ln mu sao cho mt trn ca mu trng vi mt ngang ca m. Dng bay mit nhn lp ct quanh mu, khot l rt, rnh dn v lm mt s rnh trn (nu c h) m bo chiu dy chnh xc cho vt c. Sau khi xin hi quanh mu, rt mu ra khi khun, rc phn ch v mit nhn mt l khun. Rt kim loi lng vo khun, khi y cn ph mt mt lp bt than ci v rc ct kh ln trn gi nhit chng trng cho vt c bng gang.
4 1 2 3 H.4.2. Lm khun trn m mm

1- Mu; 2- Rnh dn 3- Cc rt; 4- Rnh trn

Lm khun trn m cng (H.4.3): trn nn xng o l c chiu su ln hn chiu cao ca mu 300400 mm, dm cht y l ri 1 lp x hoc si dy 150200 mm. tng thot kh, t hai ng nghim 2 dn kh ra ngoi, lp ct m sau ct o 3 v dm cht mt t, n mu xung mt phn khun ca mu trng mt bng ca nn, rc lp bt cch v t hm khun 4 ln, c nh v tr ca hm bng cht 9 st vo thnh hm v tin hnh lm khun trn. Nhc hm khun trn v ct mng dn 8, rt b mu ra v lp khun trn vo, to cc rt 7, t ti trng 6 v rt kim loi.
5 6 7 8 9 12345si (hoc x) ng nghim Ct o Hm khun trn u hi

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Gio trnh: cng ngh c

c/ Lm khun trong 3 hoc nhiu hm khun Phng php ny thch ng khi lm khun vi mu phc tp m khng th lm trong 2 hm khun c.

H.4.4. Lm khun trong 3 hm khun

d/ Lm khun bng dng gt Phng php ny dng ch to cc chi tit trn xoay v i xng, c ng knh ln nh xilanh, ng, bnh xe trn, bnh li, cho, chn vt tu thu v v...Nhc im l tn thi gian v i hi tay ngh cao song khng dng mu, trang b g lp dng gt n gin v r tin. C nhiu kii lm khun bng dng gt: lm khun dng dng gt trc quay thng ng, trc quay nm ngang v dng dng gt ko. Lm khun bng dng gt trc quay thng ng: dng 2 dng gt l 2 tm g c ng lm l ng sinh ra mt trong v mt ngoi ca chi tit c.

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Gio trnh: cng ngh c

/ Lm khun xn Trong thc t, khi mt rp khun l mt mt cong phc tp. Hn na mu l mt mu nguyn song khng th tho mu ra c, ngi ta phi dng thm nguyn cng xn phn ct cn tr vic rt mu gi l lm khun xn. Trnh t lm khun nh sau: t mu ln tm mu ri thc hin lm na khun di. Lt khun di, dng bay xn phn ct 3 lm cn tr vic rt mu. Rc ct chng dnh ri lm na khun trn.
1 2

Lm khun xn tn 1-Hm khun; - Tm sut 3- mt nn ch dng trong sn xut n nhiu cng, nng mu; thp xn chic. Ngoi cc phng php lm khun trn, thch ng vi nhng loi hnh vt c khc nhau ngi ta cn s dng nhiu phng php lm khun khc nh: lm khun bng c ming ri, lm khun dng li ph, lm khun dng ming t ph, lm khun khng hm khun v v... 4.1.2. Cc phng php lm khun bng my
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H.4.6.Lm khun xn

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Gio trnh: cng ngh c

Lm khun bng my tc l c kh ho hon ton qu trnh lm khun hoc mt s nguyn cng c bn nh dm cht v rt mu. Lm khun, rut bng my nhn c cht lng tt, nng sut cao song vn u t cao nn ch dng trong sn xut hng lot hay hng khi. a/ Dm cht khun c Dm cht khun c bng cch p: C nhiu kiu dm cht hn hp lm khun c bng cch p: p trn xung, p di ln v p c 2 pha. My p lm khun c nng sut cao, khng n nhng dm cht thay i mnh theo chiu cao. Khi p trn dm cht mt di khun thp nn chu p lc kim loi lng km. My p ch thch hp vi hm khun thp.
6 5 4 3 2 1 8 7 9 h, mm h, mm

g/cm3

123g/cm3 456789-

bn my mu hm khun chnh hm khun ph chy p x ngang van kh phttng y xilanh

a/

H.4.7. My p lm khun c a/ p trn xung; b/ p di ln

b/

Dm cht khun c trn my dn: Mu 2 v hm khun chnh 3 lp trn bn my 1, hm khun ph 4 bt cht vi hm khun 3. Sau khi hn hp lm khun, ta m cho kh p theo rnh 5 vo xi lanh 6 y pittng 7 cng bn my i ln. n cao khong 3080 mm th l kh vo 5 b ng li v h l kh 8, nn kh p trong xi lanh thot ra ngoi, p sut trong xi lanh gim t ngt, bn my b ri xung v p vo thnh xi lanh. Khi pittng ri xung th l kh vo 5 li h ra v qu trnh dn lp li (H.4.8a).

5 4 3 2 1 8 5 g/cm3 6 9 11 h, mm 4 3 2 1 g/cm3 7 7 8 6 Trng i hc bch khoa 10 - 2006 h, mm

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Gio trnh: cng ngh c

Dm cht khun c trn my va dn va p (H.4.8b) Mu 2, hm khun 3,4 lp cht trn bn my 1. y hn hp lm khun. Kh p theo rnh 8 vo xi lanh 9 v y pittng 7 cng bn my i ln, khi l kh 6 h ra kh p thot ra ngoi, bn my li ri xung thc hin qu trnh dn. Sau khi dn xong quay chy p 5 v v tr trn hm khun, ng ca vo rnh 8, m rnh 10, kh p s nng pittng 11 cng ton b pittng 7 v bn my i ln thc hin qu trnh p. dm cht hn hp lm khun phng php ny tng i u. Trong thc t khi lm khun thp dng my p, lm khun cao dng my dn hoc va dn va p. b/ Cc phng php ly mu bng my Vic ly mu ra khi khun c tin hnh bng cc c cu: y hm khun, bn quay, bn lt v rt mu. Ly mu bng c cu y hm khun

3 2 1 5 4

3 2 1 5

H.4.9. a/ Ly mu nh y hm khun bng cht nng

b/ Ly mu nh y hm khun bng cht nng v tm

Phng php y hm khun bng cht nng (H.4.9a). Khi dm cht xong, tm mu 1 c gi c nh vi bn my 5, cc cht nng 2 t t i ln y vo cnh hm khun 3, mu c ly ra khi khun. Phng php ny n gin, nng sut cao, nhng khun d v ch thch ng vi cc mu n gin chiu cao thp. Phng php y hm khun bng cht nng v tm (H.4.9b). Nh c tm 4 gi hn hp nn khun t b v hn song phi ch to tm cho tng tm mu nn tn km hn.
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Gio trnh: cng ngh c

Ly mu kiu bn quay Sau khi lm xong khun (H.4.10a), bn quay 4 c nng ln v quay mt gc 0 180 , lt khun xung pha di, tip tc nng bn 5 ln ly khun, tho kp hm khun ra khi bn quay v t t h xung, cn tm c bn quay gi li (H.4.10b).

4 5 a b

H.4.10. Ly mu kiu bn quay

Ly mu bng bn quay c cng vng ln, khun v tr lt nn t v khun nhng kt cu phc tp. Phng php ny thch hp khi lm khun di. Ly mu kiu bn lt Sau khi lm khun xong (a), bn lt 1 lt 1800, bn 4 nng ln ly hm khun v tho kp hm khun ri t t h xung, cn tm mu 2 c bn lt gi li (b). Ly mu bng bn lt kt cu phc tp, chim mt bng nhng t v khun, thch hp khi lm khun di.
2 3

1 4

H.4.11. Ly mu kiu bn lt

Ly mu bng cch rt mu khi khun Sau khi lm khun xong, hm khun c khung my 4 gi li cn tm mu 1 c bn my t t h xung v rt khi khun.

2 3 4 1 5 H. 4.12. Ly mu bng cch rt mu khi khun 1- tm mu 2- hm khun 3- tm khun 4- thnh my 5- bn my

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Gio trnh: cng ngh c

4.2. Cng ngh ch to li Li c th ch to bng tay hoc bng my. Trong sn xut n chic v hng lot nh ch yu lm li bng tay, cn trong sn xut hng lot ln v hng khi th lm li bng my. 4.2.1. Ch to li bng tay C th ch to c li phc tp, chi ph ch to hp li thp nhng nng sut khng cao, cht lng li thp v ph thuc vo tay ngh ca cng nhn. Cc phng php lm khun bng tay ph bin l:
1- Hp li

2- Tm sy

H.4.13. Lm li trong hp li nguyn

a/ Lm li trong hp li nguyn (H.4.13)

Phng php ny p dng i vi cc li n gin c th ly ra theo mt phng.

b/ Lm li bng hp li b i (H.4.14)
y l phng php c dng nhiu nht. Hp li gm 2 na (1) v (2) ghp li vi nhau bng cht nh v (3), sau khi kp cht hai na hp li, tin hnh cho hn hp vo v dm cht. Sau t hp rut nm ngang ri ln lt ly cc na hp rut ra.

3 2 1

H.4.14. Lm li bng hp li b i

c/ Lm li bng hp li lp ghp: Hp li gm cc mnh ghp (1), (2) v (3) ghp li vi nhau nh cc mt t hoc cht nh v v c nh nh v hp (4). Sau khi lm li xong dng tm sy hp li v lt 1800, ly v hp ra sau ly cc mnh ghp theo phng thch hp.
1 2

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Gio trnh: cng ngh c

Ngoi cc phng php lm li ni trn, ngi ta cn dng dng lm li khi li c dng trn xoay hoc tit din khng i theo chiu trc v kch thc ln tit kim chi ph ch to li. 4.2.2. Ch to li bng my Lm li bng my c nng sut cao, cht lng n nh nhng chi ph chun b hp li v vn u t thit b cao. Lm li bng my c th tin hnh trn cc my lm khun nh my p, my dn hoc trn cc my chuyn dng nh my nhi, my phun ct, my bn ct.

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