C.04 Cac Phuong Phap Cong Nghe Co Ban Trong San Xuat Co Khi

General Mechanical Engineering
4.01
C.4 CC PHNG PHP CNG NGH C B N TRONG S N XU T C KH
HCM City Univ. of Technology, Mechanical Engineering Department
Nguyen Tan Tien - Phan Hoang Long
4.02
1. Khi qut v qu trnh s n xu t c kh Kh qu qu tr kh - My mc l ph n khng th tch r i c a b t k d ng s n xu t no - My mc m b o s pht tri n c a t t c cc ngnh trong n n kinh t ph ng qu c dn - Quy trnh ch t o my bao g m tr
+ Thi t k + S n xu t Chu n b v ki m tra v t li u Ch t o phi (trong m t s tr ng h p phi l s n ph m) Gia cng c o l ng, ki m tra trong qu trnh s n xu t v nh n s n ph m ng, qu tr Bo qun, ng gi, xut xng qu xu x - Nhng cng vic m bo k thut cho qu trnh sn xut Nh vi thu qu tr xu + Bo qun, sa cha my qu ch + Ch to, sa cha dng c ct, o lng Ch ch l + m bo k thut nng lng trong ni b doanh nghip thu l nghi
HCM City Univ. of Technology, Mechanical Engineering Department Nguyen Tan Tien - Phan Hoang Long
4.03
2. K thu t c - Vt c c ch to bng cch rt kim lai lng vo khun c hnh dng ch kch thc xc nh. Sau khi kim lai kt tinh ta thu c chi tit c hnh th nh. ti dng kch thc theo yu cu th - Hin nay ngnh c pht trin rt mnh v c ng dng rng ri trong Hi ng ph tri cc ngnh cng nghip ng nghi - Khi lng vt c chim trung bnh khong 40~80% khi lng my mc Kh l chi kho kh l - Mc du khi lng vt c trong my kh cao nhng gi thnh ch chim kh l kh gi th ch chi 20~25% gi thnh tng th gi th th - u i m m bo k thut nng lng trong ni b doanh nghip + C th c c cc lo i kim lo i v hp kim c thnh phn khc nhau th th ph kh + C th c c cc chi tit c hnh dng, kt cu phc tp m cc th ti ng, ph phng php khc kh hoc khng hoc hoc khng cht to c ph kh kh ho ho ho ch + Ty theo mc u t cng ngh m chi tit c c th t chnh ngh ti th ch xc cao hay thp th - Nh c i m + Tn kim loi cho h thng rt, ngt (gn 25%) lo th ng + C nhiu khuyt tt lm cho t l ph phm cao nhi khuy ph ph + Kim tra khuyt tt bn trong vt c i hi thit b hin i Ki khuy thi hi
4.04
- Cc lo i c + c khun ct (sand casting) khun casting) + c trong khun kim lo i (permanent mold casting ) n khu + c p l c (die casting) casting) + c ly tm (centrifugal casting) casting) + c lin t c (continuous casting) casting) + c theo mu chy (lost foam) ch foam) + c theo mu chy (investment casting / lost wax casting ) ch + c p (squeeze casting / squeeze forming) forming) + c chn khng (vacuum casting) ) casting +
4.05
I. c khun ct (sand casting) khun casting) - L phng php c thng dng nht trong cng ngh c ph nh ngh - Chi tit c c nh rt kim loi nng chy vo khun c lm bng ti nh lo ch ct (t nhin hay tng hp), ngui v ph ct ra ly sn phm c ngu ph ph
1 4 7
4.06
- Cc bc trong phng php c ct b ph
4.07
1. Ch mu (patern making) Ch making) - To khng gian rt kim loi to vt phm lo ph - V t li u m u: g , kim lo i, th ch cao, cao, - Cn c vo vt phm m to mu, vi cc ch ph ch + s co rt kim loi: gang, thp lo th + lng d gia cng tip cc b mt cn thit l ti thi + m t phn khun ly mu, vt phm khi khun ph kh + dc thnh khun rt mu th + gc ln trnh v khun v vt c khng nt l tr 2. Ch li (core making) making) - Nhiu trng hp, vt c c li mi to c khng Nhi tr gian rt kim loi lo - Li phi lm bng vt liu ph c v kim loi bc ly ph li ph lo n khi rt v ng c
4.08
3. Lm khun (mold assembling) assembling) - To hnh cng vi li cho vt c - Khun lm trong hm hoc trn nn ct Khun ho - Dng tay hoc my dm, rung, ln cht khun ho ch - Cht trng mt khun, li: nc bt graphic, nc Ch tr khun, li: n n thy tinh, cht bm dnh b mt, th tinh, ch - Khi lm khun ch cc vn sau ch + rt + ngt ng + thng kh kh + phn khun l y m u, li, l p chnh xc li, ch 4. Rt kim lo i vo khun (pouring into mold) mold) Ch nhit kim loi khi rt khun lun l n hn Ch nhi lo lun nhi t nng ch y c a kim lo i c t 500C n 1000C kim lo i c th i n y ton b khun to
4.09
5. D khun v lm sch vt c (removing, cleaning, and finishing) removing, finishing) - D h p khun - Ph li n u c (n c, rung, c, ) Ph - Ct cc u rt, ngt ng - Lm s ch b m t (phun ct, mi, phun bi, ) 6. Ki m tra (testing: defects, pressure tightness, dimensions) dimensions) - Hnh dng, kch th c ng, - Thi u h t, r n t - L n t p ch t - T ch c kim lo i (bi n tr ng, thin tch) ng, ch) - Thnh ph n ho h c v c tnh Th ho
4.10
- u nh c i m c a phng php c ct ph + u i m c c nhi u lo i kim lo i khc nhau kh Kh i l ng v t c c th t vi ch c gram
n vi ch c t n
c c cc chi ti t ph c t p Tnh ch t s n xu t linh ho t, thch h p v i cc d ng s n xu t th u t ban u th p D c kh ha v t kh + Nh c i m Nh chnh xc v t c khng cao d n n l ng d gia cng l n ch Ch t l ng v t c th p, th ng c r kh, r x kh Ch t l ng b m t v t c th p ng ha
4.11
II. c trong khun kim lo i (permanent mold casting) khun casting) - S dng nhiu trong sn xut quy m ln hay hng lot ln nhi xu lo - Vt c c hnh dng khng phc tp vi thnh dy 3~100mm v khi ph th kh lng vt c c th t n 5 tn l th - Vt lu c l thp, gang v hp kim mu th - to cc cu trc rng bn trong, thng dng li ct (sand core) v tr trong, th core) li kim loi (metal core) lo core)
4.12
- Quy trnh c gang trong khun kim loi tr lo + Ph lp bo v (vt liu chu la hay b hng) ln b mt khun Ph li ch ng) + Rp khun + Rt kim lo i + Lm ngu i ho r n kim lo i ho + Tho khun l y s n ph m Th - u im i + m bo c tnh ca vt c: khun kim loi c dn nhit cao hn lo nhi khun ct nn m bo cho vt c c cu trc mn hn, dn n c tr hn, tnh cao hn + Cht lng vt c tt: bng b mt, chnh xc lng khun cao Ch l ch + Tu i b n c a khun kim lo i cao + Nng su t cao, gi thnh h cao, gi th - Nh c im Nh i + Truyn nhit nhanh nn d xy ra hin tng khng in y kim loi Truy nhi hi t i lo trong khun, d b nt khun, + Khng c c vt qu phc tp, thnh mng v khi lng qu ln qu ph th kh l qu + Khun kim loi khng c tnh ln v thot kh nn cng ngh c kh lo tho kh ngh kh + Gi thnh ch t o khun cao Gi th
4.13
III. c p lc (die casting) casting) - c p lc dng trong sn xut hng lot ln xu lo - y l phng php c tin tin v rt ph bin, c thc hin trn ph ti ph bi th hi cc my chuyn dng m kim loi lng c a vo khun bng lo thp nh p lc ca piston hay kh nn, lm cho khun c in y th nh kh i nhanh chng ch - Vt liu c: hp kim nhm, ng km v cc hp kim mu khc li nhm, kh - u im i + c c vt phc tp, a dng v thnh rt mng (dn 1 mm), l ph th mm), c ng knh nh n 1 mm. c vt c khi lng n 50 kg nh mm. kh l + Vt c c chnh xc cao v bng cao ch + C tnh vt c cao nh mt vt c ln nh + Nng sut cao nh in y nhanh v kh nng c kh ho thun li su nh i kh kh ho thu - Nh c im Nh i + Khng dng c li c bng ct do dng chy c p lc ch + Khun mau mn do dng chy c p lc ca hp kim nhit cao ch nhi - C hai dng c p lc: c p lc thp v c p lc cao th
4.14
1. c p l c th p (low pressure die casting) casting) - p lc c khong 0,7 bar kho - c p lc thp thng dng cho cc sn phm c dng i xng th th ph
- V d : Qu trnh c chi ti t nhm b ng phng php c p lc thp Qu tr ph th

1 2 3 4 5 6
4.15
2. c p l c cao (high pressure die casting) casting) - Kim loi nng chy c bm vi vn tc v p sut cao vo khun lo ch su kim loi lo - Thit b c gm 2 na khun c th tch ra theo phng thng ng Thi th th - Kim loi nng chy c a vo lng khun nh mt piston. Sau khi lo ch nh kim loi ngui rn li, khun c m ra ly sn phm lo ngu ph - Thit b c v khun c p lc cao rt mc tin nn ch dng cho Thi ti ch nhng sn phm c th tch kim loi ln nh ph th lo - Ty theo cch a kim loi nng chy vo lng khun, ta c hai lo ch khun, phng php c p lc cao ph + c p lc cao khun nng + c p lc cao khun ngu i
4.16
a. c p lc cao khun ngu i (cold chamber high pressure die casting) casting) - Kim loi nng chy c a vo xylanh trung gian, sau piston lo ch gian, s y kim loi nng chy vo lng khun lo ch - p sut y kim loi khong 10.000 psi hay 70.000 KPa su lo kho
Li (core) Lng khun (cavity) Kim lo i c (molten metal) C n tho s n ph m (ejector pin) V khun (ejector die)
V khun (cover die)
ng phn khun (parting line)
4.17
- Qu trnh c p lc cao khun ngui nh sau Qu tr ngu + Kim lo i nng ch y c a vo lng xylanh + Piston y kim lo i nng ch y vo lng khun v gi cho kim lo i ng r n l i + M khun, ch cc li cng c rt ra khun, ch + Cc c n
1 2
n khi
y s n ph m
y chi ti t c ra kh i khun
3 4
4.18
b. c p lc cao khun nng (hot chamber high pressure die casting) casting) - Kim loi nng chy c a trc tip t l nu chy vo lng lo ch tr ti ch khun nh bm nh - Cc qu trnh tng t nh i vi c p lc cao khun ngui qu tr ngu
4.19
c. So snh hai phng php c khun ngu i v khun nng ph - u im ca c p lc cao khun ngui so vi khun nng i ngu + Cc loi hp kim nh hp kim nhm hay hp kim nhm-km v lo nhmmt s hp kim magi ch c th c p lc cao khn ngui ch th ngu + p sut v vn tc y kim loi vo lng khun c c th nng su lo th cao nhm nng cao mt kim loi c nh lo + Chi ph bo dng thit b thp ph d thi th - Nh c im ca c p lc cao khun ngui so vi khun nng Nh i ngu + Chu k c thp th + Kh iu khin c nhit kim loi nng chy lm gim kh Kh i khi nhi lo ch gi kh nng in y khun i + Kim loi c th b ngui trc khi piston y vo lng khun lo th ngu tr + Kim loi nng chy b oxy ho bi oxy trong mi trng c khi lo ch ho tr c cp vo xylanh
4.20
IV. c ly tm (centrifugal casting) casting) - Kim loi lng c rt vo khun kim loi quay ( ng hoc nm lo lo ho ngang) vi vn tc c th n 3000 vng/pht ngang) th vng/ph - Di tc dng ca lc ly tm, kim loi lng in y lng khun v to D tm, lo i thnh vt c khi kt tinh th - Ch yu dng c cc chi tit c dng trn xoay: ng nc, nng Ch ti xoay: n sng, ng lt, cc dng tang trng, ng, tr ng,
10
4.21
- u im i + T chc kim loi mn cht do s kt tinh ca kim loi lng di tc ch lo ch lo d dng ca lc ly tm m bo cho vt c c ng cht cao, loi ch cao, lo b cc r kh v tp cht cha x kh ch ch + To c cc khoang rng bn trong m khng c n dng li + Khng dng h thng rt phc tp nn tit kim c kim loi th ph ti ki lo + c c vt c vi lp kim loi ring bit trong cng mt vt c lo bi - Nh c im Nh i + Thin tch vng theo thit din ngang do lc ly tm thi di + ng knh l km chnh xc v cht lng b mt l xu ch ch l
4.22
V. c lin t c (continuous casting) lin casting) - Rt kim loi lin tc v ng c nhanh, ko di lin tc vi chiu di lo nhanh, chi khng hn ch ch
- u im: nng sut rt cao, t bt r i su cao, - Nhc im: tc ngui nhanh lm ng sut d bn trong vt c ln, Nh i ngu su gy bin dng, d nt bi ng,
11
4.23
4.24
VI. c theo m u chy (lost foam casting) ch casting)
ng c L61 ca General Motor v mu c ca n
12
4.25
- Mu c lm t polystyrene xp, nh hn g 50~100 ln, d ct bng nh dy thp nng th - Cc mu phc tp c th d dng thc hin t cc mu polystyrene ri ph th th hi sau lin kt li vi nhau - Khun c c to thnh theo phng php bnh thng th ph th - Vt c c to thnh bng cch in y kim loi lng vo cc th i lo khoang khun c to ra t kt qu kim loi lng t chy mu qu lo ch polystyrene xp, mu khng cn ly ra
4.26
- u im i + t chnh xc cao ch + Gi m l ng d v cng lao thm sau c ng gia cng cc m t c gia cng
13
4.27
VII. c theo m u ch y (investment casting/lost wax casting) casting)
Cc sn phm ca c theo mu chy ph ch - Dng c cc vt c hnh dng rt phc tp, i hi nhiu cng on gia ph nhi o cng c kh, t bt k hp kim no kh - C th c chnh xc vi khi lng t 0,02 n 100 kg, b dy thnh th ch kh l kg, th n 0,5 mm v cc l c ng knh n 2 mm - Sau khi lm khun, khun c nung t chy mu, to lng khun khun, ch rt kim loi khi c lo
4.28
- Qu trnh c theo khun mu chy Qu tr ch 1. To mu (pattern making) making) Ch to mu vt c bng sp (wax) t c p Ch wax) 2. T o c m m u (pattern assembling) assembling) Mu c lin kt vi trc sp lm rnh rt cho khun tr 3. T o khun nguyn ch u l a (shell building) building) + Ph cm mu bng lp trt vt liu chu la bng cch Ph tr li ch nhng cc cm mu vo dung dch gm chu la nh ch + Rc ct thch anh kh mn ln, phi kh v nhng li th ln, nh + C th to n tm lp ph nh th ny th ph th 4. t chy m u (dewax) ch dewax) Nung nng khun, sp chy ht to nn b khun cui khun, ch cu cng c
14
4.29
5. c (conventional casting) casting) Chun b kim loi lng v rt vo khun nh c ct Chu lo thng thng th
6. D khun (knockout) knockout) Khi kim loi ho rn, vt c ngui, tho b khun lo ho ngu th 7. Tch chi ti t c (cut off) off) Ct cc chi tit c ra khi cm chi tit va c c ti kh ti 8. Lm sch (finished castings) castings)
4.30
- u i m + D thit k (design flexibility) thi flexibility) + c c nhi u lo i h p kim (wide choice of alloys) alloys) + Gi m chi ph gia cng t o khun (eliminate tooling set-up) ph set- up) + Gi m gi thnh (reduce production costs) gi th costs) + c c nhi u chi ti t m t l n (cut assemble operations) operations) + chnh xc cao (reproduce fine details) ch details)
15
4.31
VIII. c p (squeeze casting / squeeze forming) forming)

1 2 3
- Kim loi nng chy c a vo ci khun (lng khun di) lo ch d - Chy khun (khun trn) c p xung, kim loi s c in y Ch trn) xu ng, lo i trong lng khun - Kim loi ngui v c tho ra khi khun lo ngu th kh
4.32
IX. c chn khng (vacuum casting) casting)

1 2 3
16

C.04 Cac Phuong Phap Cong Nghe Co Ban Trong San Xuat Co Khi

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C.04 Cac Phuong Phap Cong Nghe Co Ban Trong San Xuat Co Khi

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General Mechanical Engineering

C.4 CC PHNG PHP CNG NGH C B N TRONG S N XU T C KH

HCM City Univ. of Technology, Mechanical Engineering Department

Nguyen Tan Tien - Phan Hoang Long

General Mechanical Engineering

General Mechanical Engineering

General Mechanical Engineering

HCM City Univ. of Technology, Mechanical Engineering Department

Nguyen Tan Tien - Phan Hoang Long

General Mechanical Engineering

HCM City Univ. of Technology, Mechanical Engineering Department

Nguyen Tan Tien - Phan Hoang Long

General Mechanical Engineering

- Cc bc trong phng php c ct b ph

HCM City Univ. of Technology, Mechanical Engineering Department

Nguyen Tan Tien - Phan Hoang Long

General Mechanical Engineering

HCM City Univ. of Technology, Mechanical Engineering Department

Nguyen Tan Tien - Phan Hoang Long

General Mechanical Engineering

HCM City Univ. of Technology, Mechanical Engineering Department

Nguyen Tan Tien - Phan Hoang Long

General Mechanical Engineering

HCM City Univ. of Technology, Mechanical Engineering Department

Nguyen Tan Tien - Phan Hoang Long

General Mechanical Engineering

- u nh c i m c a phng php c ct ph + u i m c c nhi u lo i kim lo i khc nhau kh Kh i l ng v t c c th t vi ch c gram

HCM City Univ. of Technology, Mechanical Engineering Department

Nguyen Tan Tien - Phan Hoang Long

General Mechanical Engineering

HCM City Univ. of Technology, Mechanical Engineering Department

Nguyen Tan Tien - Phan Hoang Long

General Mechanical Engineering

General Mechanical Engineering

General Mechanical Engineering

- V d : Qu trnh c chi ti t nhm b ng phng php c p lc thp Qu tr ph th

HCM City Univ. of Technology, Mechanical Engineering Department

Nguyen Tan Tien - Phan Hoang Long

General Mechanical Engineering

HCM City Univ. of Technology, Mechanical Engineering Department

Nguyen Tan Tien - Phan Hoang Long

General Mechanical Engineering

V khun (cover die)

ng phn khun (parting line)

HCM City Univ. of Technology, Mechanical Engineering Department

Nguyen Tan Tien - Phan Hoang Long

General Mechanical Engineering

HCM City Univ. of Technology, Mechanical Engineering Department

Nguyen Tan Tien - Phan Hoang Long

General Mechanical Engineering

HCM City Univ. of Technology, Mechanical Engineering Department

Nguyen Tan Tien - Phan Hoang Long

General Mechanical Engineering

HCM City Univ. of Technology, Mechanical Engineering Department

Nguyen Tan Tien - Phan Hoang Long

General Mechanical Engineering

HCM City Univ. of Technology, Mechanical Engineering Department

Nguyen Tan Tien - Phan Hoang Long

General Mechanical Engineering

HCM City Univ. of Technology, Mechanical Engineering Department

Nguyen Tan Tien - Phan Hoang Long

General Mechanical Engineering

General Mechanical Engineering