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CNG NGH CH TO PH
TNG
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LI NI U
Cng ngh ch to ph tng l mn hc dng cho cc ngnh C gii ho xy
dng giao thng, C kh t, C kh Giao thng cng chnh, My ng lc, nhm
trang b cho cc k s C kh chuyn ngnh Giao thng cc kin thc c bn trong
gia cng ch to phc v cho vic ch to thay th cc chi tit ca cc phng tin
GTVT.
Khi bin son gio trnh ny, chng ti tham kho cc ti liu ca nc
ngoi, ti liu ca Trng i hc Bch khoa H Ni, ti liu ca cc c s sn xut
trong nc c ni dung va m bo tnh hin i va m bo thc t sn xut
ca Vit Nam.
Trong qu trnh bin son, khng th trnh khi nhng thiu st, chng ti
mong c s gp ca ngi c cc ln ti bn c hon chnh hn. kin
ng gp xin gi v B mn Cng ngh Giao thng Khoa C kh Trng i hc
GTVT H Ni. Xin trn trng cm n.
Nhm tc gi
CNCTPT..3
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4.CNCTPT
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Chng I
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0,01
6.CNCTPT
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ng
d
lm
chu
n.
Hnh 1.1. Hai l chun nh v
c cc mt b mt k trn lm chun
tinh th nguyn cng u tin ngi ta phi gia cng cc mt chun . Vic chn
chun th cc nguyn cng ny rt quan trng. C th dng cc phng n chn
chun th nh sau:
a) Mt th ca cc l chnh (4 bc t do).
b) Mt th khng gia cng ca hp pha trong (3 bc t do) (Xem hnh v
1.2).
to iu kin d dng gia cng l chnh xc sau ny. Khi chn chun th, nu khng
ch n mt trong khng gia cng s c th lm cho khe h lp ghp gia n vi
cc b phn lp bn trong (bnh rng, tay gt) khng m bo.
Trong sn xut hng lot nh v n chic phi c ch to c chnh xc
thp v khi gia cng khng dng cc g chuyn dng nn c th thc hin nguyn
tc chn chun nh trn bng phng php ly du.
Khi ly du, phi kt hp vic chn chun th ny vi cc chun th khc
phn phi lng d gia cng cho tho mn cc yu cu khc nhau. Phng php ly
du c nhc im l nng sut thp nn gi thnh cao.
1.5.2- Th t gia cng cc b mt ch yu ca hp
Quy trnh cng ngh gia cng cc chi tit hp bao gm cc giai on chnh sau
y:
a) Gia cng mt phng chun v 2 l chun tinh.
b) Gia cng cc b mt cn li.
S dng mt phng v 2 l lm chun gia cng cc b mt khc:
- Gia cng cc mt phng cn li.
- Gia cng th v bn tinh cc l lp ghp
- Gia cng cc l dng kp cht.
- Gia cng tinh cc l lp ghp
- Tng kim tra.
1.6- CC BIN PHP THC HIN CC NGUYN CNG CHNH
1.6.1- Gia cng cc mt chun
a) Gia cng mt phng chun
- i vi hp gia cng c sn lng nh c th tin hnh trn my phay hoc
my bo gia cng mt chun phng.
Nu hp c kch thc ln, b mt lm chun c dng hnh vung hoc trn th
c th gia cng trn my tin ng, cn nu c kch thc nh c th gia cng trn
my tin bng cch g trn mm cp 4 chu hoc g chuyn dng.
- Trong sn xut hng lot ln v hng khi i vi hp c kch thc va v
ln th tin hnh gia cng trn my c nhiu trc hoc my c bn quay nhiu v tr.
Vi cc hp nh c th gia cng trn cc my t hp hoc chuyn dng.
b) Gia cng 2 l chun.
- Trong sn xut hng lot ln hoc hng khi thng s dng my khoan
nhiu trc gia cng 2 l chun.
Khi gia cng ngi ta thc hin tun t cc bc khoan, khot, doa trong mt
ln g v s dng bc dn hng m bo chnh xc v ng knh l v
khong cch tm 2 l nh v.
Cnctpt..9
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- Trong sn xut hng lot nh v n chic vic gia cng 2 l c thc hin
bng cch ly du 2 l v khoan trn my khoan cn, i vi cc hp nh c th
dng my khoan ng.
1.6.2- Gia cng cc mt ngoi ca hp
Gia cng cc mt phng ngoi hp c th p dng nhiu phng php: phay,
bo, tin, mi, chut tu theo sn lng v kch thc, kt cu ca hp.
a) Trong sn xut hng lot nh v n chic
Thng dng phng php bo v n gin v r. C th nng cao nng sut
bo bng cch g nhiu phi mt lc.
b) Trong sn xut hng lot va v ln
Dng phng php phay gia cng cc mt ngoi.
Hp c kch thc nh c th g nhiu phi mt lc gia cng.
Hp c kch thc ln c th gia cng trn my phay ging hay my bo
ging.
Gia cng trn cc my ny c th t c nng sut v chnh xc cao.
song song ca cc mt 0,02mm/1000mm.
khng phng 0,02 0,03mm/1000mm.
khng vung gc 0,03 0,06mm/500mm.
c) Trong sn xut hng khi
Dng phng php phay lin tc trn my phay c nhiu v tr (my phay c
bn quay, my phay c tang trng) gia cng 2 mt phng song song cng mt lc
bng 2 dao.
Hnh 1.3 gii thiu s gia cng trn my phay c bn quay.
I
2
1
II 3
3
I
II
a)
b)
1. u lc;
II
doa
3. Bn my;
4. u thay i trc dao doa.
Cnctpt..11
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a)
c)
12.CNCTPT
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b)
Hnh 1.7. Th t gia cng cc l chnh.
Bc 1: Gia cng l 4 t 4 (Hnh 1.7a)
Bc 2: Gia cng l 3 t 3 (Hnh 1.7b)
Bc 3: Quay bn my 180o tip tc gia cng l 1 t 1
(Hnh
1.7c).
Bc 4: Gia cng l 2 t 2 (Hnh 1.7d)
c) Gia cng tinh cc l
Gia cng tinh cc l trn mt hng c th thc hin theo 2
phng
n:
- Phng n 1: Gia cng lin tc cc l bng cch s dng cc l gia cng
trc
lm dn
hng
gia
cng
cc l
tip sau
(Hnh
1.8).
Cnctpt..13
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H
nh 1.9. Phng n gia cng 2 l
pha ngoi cng.
+ Gia cng hon chnh
tng l hoc tng hng l ring
bit (nh nu trn).
14.CNCTPT
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Cnctpt..15
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Hnh 11.2b.
My khoan
cn.
16.CNCTPT
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Cnctpt..17
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Kch thc v hnh dng l c kim tra bng cc dng c kim tra: thc
cp, ca-lp, ng h so hoc dng c o l c trang b ng h so. Hnh v 1.14 trnh
by s kim tra kch thc l.
Trn s ny hnh dng hnh hc ca l theo tit din ngang nh -van,
e-lp, a cnh c xc nh bng cch o kch thc nhiu v tr khc nhau ri
so snh kt qu rt ra kt lun.
Sai s hnh dng hnh hc theo chiu trc ca l nh cn, tang trng
c xc nh bng cch kim tra ng knh l theo chiu trc.
Kch thc theo chiu di l c kim tra bng thc cp hoc bng Ca-lp.
- ng tm ca cc l chnh c kim tra bng cc loi trc kim (trc
trn hoc trc bc). Cc l c ng knh qu ln c th g trc trong bc (hnh
1.15a). xc nh c th gi tr ng tm ca 2 l c th dng trc kim tra c gn
ng h so (hnh 1.15b)
Ngoi ra, kim tra ng tm c th dng g chuyn dng. Trn hnh
1.16 trnh by phng php kim tra ng tm ca 3 l trn 3 vch ngn ca hp.
a)
b)
a. Kim tra ng tm nh trc g
b. Kim tra ng tm nh trc kim tra c ng h so.
Hnh 15. Kim tra
ng tm nh trc
g.
18.CNCTPT
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Cnctpt..19
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tm l
n mt phng ca hp v song song ca chng.
- Kim tra vung gc gia tm cc l.
Ngi ta tin hnh kim tra vung gc gia ng tm cc l i vi nhng
hp c cc l cng nm trn mt mt phng v c ng tm vung gc vi nhau
bng ng h so hoc bng ca-lp. Hnh 1.20a kim tra bng ng h so; hnh 1.20b
kim tra bng ca-lp.
a)
b)
Hnh 1.20. a,b.
a. Kim tra vung gc bng ng h.
b. Kim tra vung gc bng ca-lp.
Tin hnh kim tra bng ng h so (hnh 1.21a) hoc bng calip chuyn dng
(hnh 1.21b).
a)
b)
Hnh 1.21. a,b.
a. Kim tra vung gc gia ng tm l v mt u bng ng h so.
b. Kim tra bng calp.
1.7- QUY TRNH CNG NGH CH TO MT S CHI TIT IN HNH DNG
HP
1.7.1- Quy trnh cng ngh ch to thn hp gim tc
1- c im kt cu v vt liu ch to thn hp gim tc
Hnh
1.22.
Kt cu ca v hp gim tc.
Hp gim tc l mt chi tit dng hp, kt cu ca hp gm 2 na lp ghp vi
nhau bng 1 mt phng lp v 2 cht nh v. Hp gim tc l mt tng thnh my
c dng rt ph bin trong cc thit b nng chuyn v cc thit b dng trong
Cnctpt..21
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22.CNCTPT
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Hnh 1.23
Hnh
1.23.
Kt cu ca thn ng c t trong.
1,2,3,4 cc chi tit lp trn chi tit c s
l thn ng c t trong ca mt thn ng c hon chnh.
Cnctpt..23
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24.CNCTPT
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Chng II
qu 0,1mm.
+ Khong cch t nh piston n rnh sec mng khng sai qu 0,3mm, ring
i vi rnh u khng qu 0,15mm.
+ Chiu dy cc vnh ai ngn cch gia cc sec mng sai lch khng qu
0,2mm.
2.1.2- Thn piston
26.CNCTPT
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Cnctpt.27
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.
Hnh 2.1. Kt cu ca piston ng c t trong.
28.CNCTPT
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0,01
qu
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1- Gang
Thng dng gang xm, gang do, gang cu ch to piston.
- Gang xm c bn c hc cao, bn nhit cao, h s gin n nhit thp,
tnh cng ngh c v ct gt tng i tt, r tin.
- Tuy nhin gang xm c mt s nhc im: Trng lng ring ln, nhit
cao (725oC) d b nt n. Do nhc im trn nn t s dng gang xm
ch to piston ca cc ng c cao tc v ti trng ln.
- Gang do Peclit c t chc Peclit nh gang xm nhng c bn cao hn v
grafit dng tp trung. Gang do c dng trong cc ng c 2 k c ti
trng ln.
- Gang cu c bn cao, chu nhit cao, chu mi mn cao.
2- Thp
Thp c t trng ln nhng c bn cao nn c th ch to cc piston thnh
mng. Tuy nhin vt liu thp t dng v gi thnh cao.
3- Hp kim nhm
Hp kim nhm c c s dng nhiu trong ch to piston. Piston nhm c
cc u im:
- Trng lng ring nh.
- Truyn nhit tt.
- H s ma st nh.
- D gia cng ct gt.
Tuy vy piston nhm c nhc im: h s gin n nhit ln, kh nng chu
mi mn km hn gang.
Hp kim nhm thng dng l Al-Cu v Al-Si. Vt liu c dng ph bin l
loi A-10B c cc thnh phn chnh sau: Mg: 0,2 0,5% ; Cu 4 8%; Si: 4 6%;
cn li Al.
Hin nay nhiu ni s dng hp kim nhm c c h s gin n nhit thp,
trng lng ring nh v c kh nng chu nhit v chu mi mn tt hn A-10B.
Thnh phn hp kim ny nh sau:
Si: 11 13% ;
Zn: 0,5%;
Fe: 0,8% ;
Sn: 0,02%;
30.CNCTPT
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Pb: 0,7% ;
Al : % cn li;
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Hnh 2.2.
B mt kp cht l l cht piston. Mt trc rt c mt u lng qua cht ngang
lp vo l cht, mt u c ren c xit cht bng ai c qua u trc chnh ca
my tin s gi cht chi tit trn i g c lp trn my tin. Phng n g lp ny
c u im chc chn, c th gia cng c ton b cc b mt bn ngoi piston, tuy
nhin phng n c th gy bin dng ln hoc nt thn piston nu lc kp qu ln
v im t ca lc trn b l cht khng ng yu cu; ngoi ra phng n ny cn
c nhc im v chnh xc khi nh tm khng cao do c sai s mt nh v phn
l tr trong ca thn piston gy nn.
b) nh v bng mt cn y thn v l tm nh piston
2.3)
32.CNCTPT
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(Hnh
5 gi.
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34.CNCTPT
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Hnh 2.4
1. u dao; 2. Phi; 3. Mm quay; 4. Trc khoan;
5. Dao xn gc; 6. Dao khot; 7. Dao vt gc.
i vi cc piston cn thm chun ph l l tm nh, phi m bo ng
tm gia l tm v g tr pha trong thn piston. Trong sn xut hng lot ln gia
cng trn my tin lin hp tc dng 2 pha ng thi gia cng 2 b mt (hnh 2.4)
i vi phi c chnh xc.
Theo hnh 2.4, piston c kp trn mm cp (3) khng quay, u dao (1) v
u khoan (4) va quay va chuyn ng chy dao tin vo piston, n chiu su
nht nh th u dao t ng dng li v li ra khi chi tit.
i vi phi c c chnh xc khng cao, chun ph c gia cng trn
my tin bn t ng (hnh 2.5). Phi c g trn trc chnh ca my tin. C 2 bn
dao gia cng mt y v mt tr trong, ng thi pha nh piston c mi khoan
khoan l tm.
Cnctpt.35
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Hnh
2.5.
Gia cng chun ph trn my tin bn t ng.
Gia
cng mt ngoi
Mt
ngoi
gm cc b mt tr
phn
thn
dn
piston v cc rnh
cc mt ny ngi
ph nh v v kp
qua l cht.
Trong
sn
hng lot nh vic
xut n chic v
gia cng mt ngoi
36.CNCTPT
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c tin hnh trn my tin vn nng v chia lm cc bc tin th, tin tinh. Trong
sn xut hng lot ln, nguyn cng ny c thc hin trn my tin nhiu dao
(Hnh 2.6). Bn dao dc ca my g dao gia cng phn u v thn piston. Bn dao
ngang ca my gia cng mt nh v ct cc rnh sec mng.
Trong
lot
ln,
ny thc hin
tin chp hnh
Cnctpt.37
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38.CNCTPT
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Dng dao tin nh hnh gia cng. Qu trnh tin nh hnh phi qua nhiu
bc: gia cng th, gia cng tinh. m bo bng b mt ca bung chy c th
Hnh 2.9. Cn ln
- Gia cng
phng php chp
Gia
cng
chp hnh l to ra
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a)
b)
40.CNCTPT
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Gia cng s
Hnh 2.11.
b l cht trn my khoan tang trng,
tc dng 2 pha.
Cnctpt.41
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my tin.
42.CNCTPT
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- bng cao.
- n gin ho quy trnh cng ngh.
- Lm tng cng b mt vt liu sn phm.
2.4.6- Gia cng rnh hm cht piston
Nguyn cng tin rnh hm cht piston cn c thc hin trc nguyn cng
tin tinh l cht. Gia cng rnh hm cht c thc hin sau 2 ln g. Phng php
ny khng cho php t ng tm ca 2 rnh cao nhng cng cho php m bo
sai s t 0,1 0,2 mi bn.
7- Gia cng rnh phng n v l du trn rnh vng gng du
Trong sn xut hng lot ln, ngi ta dng loi my phay, khoan lin hp
cng sut nh gia cng cc l v phay rnh cc v tr khc nhau.
Hnh 2.13 l s gia cng trn my phay khoan lin hp nhiu v tr c bn
my quay trn. My khoan c cc u khoan, phay b tr theo kt cu c th ca
piston gia cng cc l v 2 rnh phng n nghing v nm ngang. Qu trnh gia
cng c 5 v tr.
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44.CNCTPT
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Cnctpt.45
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Hnh 2.15. g kim tra v phn loi kch thc thn piston.
Hnh 2.16 gii thiu dng c g lp kim tra v
46.CNCTPT
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Cnctpt.47
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Chng III
bn sau:
48.CNCTPT
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0,03
0,05 0,25
Rz:
50
Cnctpt.49
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50.CNCTPT
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cnh ng).
Cnctpt.51
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Cnctpt.53
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54.CNCTPT
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0,01
Cnctpt.55
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0,07 0,1.
1%
56.CNCTPT
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a)
b)
Hnh 3.4
a. Trc cn to hnh; b. Phi thanh truyn qua cc giai on cn.
i vi cc ng c xng c nh, phi cn c ch to bng phng php
c t gang do Pclit. Phi c c u im t chnh xc cao do gim c
chi ph sn xut, hiu qu s dng kim loi cao i vi cc thanh truyn c kt cu
phc tp.
3.7.4- Quy trnh cng ngh ch to thanh truyn
Thanh truyn l mt chi tit thuc dng cng, do qu trnh s dng chun
nh v, cc phng php gia cng cc b mt c bn ca thanh truyn u thc hin
nh cc chi tit dng cng khc. i vi cc l lp bu lng thanh truyn l cc l lp
bu lng tinh, do cn phi gia cng chnh xc qua cc gia on: th, bn tinh, tinh.
Cc nguyn cng ch yu gia cng thanh truyn bao gm:
- Gia cng cc mt u v l.
- Gia cng cc mt chun nh v ph.
- Gia cng th cc l chnh.
- Gia cng cc mt phng lp ghp gia np, thn v cc mt
phng khc.
- Rp thn v np thanh truyn.
- Gia cng tinh cc l chnh.
- iu chnh trng lng.
- Tng kim tra.
Quy trnh cng ngh ch to thanh truyn ph thuc vo nhiu iu kin c th
khc nhau. Sau y xin gii thiu mt quy trnh c tnh cht lm mu (loi phi dp
np v thn ring bit).
Cnctpt.57
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thanh truyn.
(Cc cng vic gia cng trn c thc hin trn thn v np tu theo cc kt
cu c th ca thn v np u ln).
+ Rp np, thn v gia cng ng thi 2 l lp bu lng ca thn v np (khot,
doa).
+ Gia cng bn tinh l u ln.
+ Tho np v thn thanh truyn.
+ Phay rnh hm bc u to trn np v thn.
+ Lp np vo thn.
+ Gia cng tinh mt u l u ln.
+ Gia cng tinh l u ln.
+ p bc ng vo l u nh.
+ Doa v vt mp bc ng l u nh.
+ iu chnh trng lng thanh truyn.
+ Tng kim tra.
3.7.5- Phng php gia cng cc b mt c bn ca thanh truyn
Quy trnh cng ngh ch to thanh truyn trnh by phn trn ch c tnh cht
lm mu vi cc nguyn cng gia cng cc b mt ca thanh truyn m khng ch
nh cc phng php gia cng c th. Ph thuc vo kt cu ca tng loi thanh
truyn, ph thuc vo sn lng, ph thuc vo cc iu kin sn xut c th m
c cc phng php gia cng khc nhau.
1- Gia cng cc mt u l u nh v u ln
Qu trnh gia cng thanh truyn bt u thc hin t nguyn cng gia cng cc
mt u ca thanh truyn. Ph thuc vo sn lng m c nhiu phng n gia cng
khc nhau: bo, phay, chut khi gia cng cc b mt ny, cn m bo s phn b
i xng ca chng vi ng trc ca thn thanh truyn, do cn phi tun theo
cc nguyn tc s dng chun th nh trnh by phn u ca gia cng chi tit
dng cng.
58.CNCTPT
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b)
Hnh 3.5.
Cnctpt.59
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60.CNCTPT
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i vi loi thanh
truyn phi dp lin vi np,
m bo chnh v tr
tng quan gia 2 l nn gia
cng ng thi 2 l u to v
nh 1 ln g. Thanh truyn
c nh v bng mt u
ca l v chun ph u
thanh truyn. Qu trnh gia
cng c thc hin qua cc
bc khoan, khot, doa trn
my khot ng nhiu trc,
nhiu v tr. Trong sn xut
hng lot nh v n chic
c th thc hin gia cng
trn my khot ng (doa
ng) mt trc, nhng trong
trng hp ny phi tin
hnh gia cng ln lt tng
l, u tin gia cng l u
nh sau tin hnh gia
Hnh 3.7. g gia cng
cng l u to. Khi gia cng
l th 2 (l u to) chun
l u nh thanh truyn.
nh v l l u nh, mt
u ca l u to v 2 chun
ph mt cnh ca u to. Trong sn xut n chic c th dng phng php r g
thc hin qu trnh nh v. Gia cng theo phng php gia cng tng l ring
bit s khng m bo c chnh xc v tr tng quan cao gia 2 l ca thanh
truyn.
* Gia cng ln cui l u to v u nh.
L u nh thanh truyn c doa, chut chnh xc trc khi p bc ng
Bc ng sau khi c p vo u nh li phi doa chnh xc. Nu thc hin c
vic gia cng l bc ng v l u to ng thi s m bo c chnh xc cao
ca 2 l.
Gia cng ln cui cng l u to thanh truyn c thc hin sau khi lp rp
gia np v thn thanh truyn bng bu lng thanh truyn.
Gia cng ln cui l u to qua 2 bc: khot v doa tinh. Hnh 3.9 l s gia
cng ng thi 2 l trn my khot tinh nm ngang 2 trc.
Do l u nh ng bc ng c yu cu cao v bng nn trc dao c gn 2
dao khot: khot th v khot tinh. L u to thanh truyn ch cn gn mt dao khot
tinh v khot th c thc hin nguyn cng trc. Thanh truyn c nh v
bng mt u ca l u ln v nh (l u ln v u nh c chiu dy bng nhau),
ng thi cn c nh v bng mt ngoi ca mp u ln thanh truyn. tng
cng vng g lp cn dng thm cc im t ph c iu chnh.
Cnctpt.61
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Gia cng ln cui l u ln thng dng phng php mi khn (hnh 3.10)
trn my ny c th g ng thi 2 chi tit gia cng.
bc gia cng l
Hnh 3.8. Cc
u nh thanh truyn.
62.CNCTPT
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.
Hnh 3.11. g chut.
Cnctpt.63
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3.12.
Hnh
g mi.
Mt phng tip xc gia np v thn thanh truyn ca loi phi dp ring thn
v np c th dng nhiu phng php: phay, chut, mi. i vi cc loi phi dp
lin np v thn th b mt ny s c chut hoc mi sau khi ct i thn v
np.
Hnh 50 v hnh 51 gii thiu g chut v g mi mt tip xc ca thn
v np thanh truyn.
4- Gia cng cc l lp bu lng thanh truyn
L lp bu lng thanh truyn thng l cc l xuyn thu, ring i vi cc
thanh truyn c mt tip xc nghing mi lm cc l khng xuyn thn. L lp bu
lng xuyn thu gia thn v np cn phi t chnh xc 2 3 TCVN (7 8
ISO).
Gia cng cc l lp bu lng c thc hin sau khi gia cng cc mt u v l,
mt phng tip xc gia np v thn, mt phng cnh lm chun ph.
i vi loi thanh truyn phi np v thn khng lin nhau thng tin hnh
gia cng 2 l ny ng thi trn my khoan c 2 trc hoc trn my khoan ng 1
trc c gn thm u khoan 2 trc. m bo trng tm cao gia cc l ca np
v thn cn phi gia cng chng trn cng mt my.
i vi loi thanh truyn phi c thn v np dp lin th tin hnh gia cng
khoan 2 l ny trc khi ct ri np v thn. L lp bu lng thanh truyn phi thc
hin qua nhiu bc: khoan, khot, doa.
Mun nh tm np v thn thanh truyn chnh xc cn phi m bo khe h
lp rp phi phn b u gia np v thn. Mun m bo yu cu ny, cn phi tin
64.CNCTPT
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3.14.
Hnh
Cn iu chnh trng lng thanh truyn.
6- Kim tra ln cui thanh truyn
Ni dung kim tra ln cui gm cc cng vic chnh sau:
L1 .b
L2
Trong :
L1 Khong cch gia hai mi d ca cn kim tra;
L2 Khong cch t tm cht n tm mi d ca ng h;
66.CNCTPT
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b Gi tr o trn ng h.
Hnh 3.15. S dng c kim ra song song ca 2 ng tm l u nh v
u to thanh truyn.
Hnh 3.15
1. Trc kim; 2. n kim tra; 3. ng h o; 4. L xo; 5. Cht.
Hnh 55 l g kim tra v tr ca 2 ng tm l u to v u nh. Khi tin
hnh kim tra, dng mt mu o chun iu chnh cc ng h kim tra:
ng h 1: kim tra khong cch 2 tm l.
ng h 9: kim tra song song 2 ng tm l nh cng kim
tra 10.
Cnctpt.67
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Hnh 3.16.
g kim tra v tr ca 2 ng tm l thanh truyn.
68.CNCTPT
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Chng 4
L
4
d
L
4 10
d
L
10
d
b) Trc bc:
Trn sut chiu di ca trc c mt s kch thc ng knh khc nhau.
Trn trc bc cn c rnh then, then hoa hoc c ren.
c) Trc rng:
L trc rng c tc dng gim trng lng v cn c th lm cc mt lp rp.
d) Trc rng:
L loi trc m trn c bnh rng lin trc.
e) Trc lch tm:
L loi trc c cc c trc khng cng nm trn mt ng tm (trc khuu).
4.2. IU KIN K THUT CHUNG CA TRC
Khi ch to trc cn phi m bo cc iu kin k thut sau:
(theo: TCVN)
1. Kch thc ng knh cc c lp ghp yu cu t cp chnh xc 2 5,
trong mt s trng hp cn t cp 1.
2. chnh xc hnh dng hnh hc:
Cnctpt.69
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a)
b)
Hnh 4.1
a: nh v trn 2 mi tm. b: nh v trn 2 mi tm ct.
C th dng mi tm thng i vi cc trc c, cn i vi cc trc rng
dng mi tm ct, hoc mi tm kha nhm.
Khi dng l tm lm chun gia cng cc mt ngoi s khng c sai s
chun theo kch thc ng knh nhng s c sai s chun theo kch thc chiu
Cnctpt.71
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500 vng
i vi cc trc c cng vng km phi dng luynt (khi tin, mi) hoc
cc cht t ph (khi phay) chng bin dng khi gia cng.
Ngoi vic s dng 2 l tm, cn c th dng chun nh v l mt tr ngoi
ca trc gia cng cc bc trc khc, gia cng cc rnh then, then hoa trn trc.
Khi dng mt chun ny c th dng mm cp, ng kp, khi V tu theo tng trng
hp c th.
i vi cc trc rng, m bo v ng tm cao gia mt ngoi v mt
trong ca trc, khi gia cng tinh mt ngoi ngi ta dng mt tr trong gia cng
lm chun nh v.
Nhiu khi gia cng trc, ngi ta cn dng phi hp gia mt mt tr v
mt l tm lm chun nh v.
Trn c s vic chn chun nh v cho cc chi tit trc, cn c cc bin php
cng ngh v th t gia cng cc b mt thch hp vi kt cu ca tng loa trc
4.5.2. Th t cc nguyn cng v bin php cng ngh ch to trc
1. Th t gia cng cc b mt
Th t gia cng cc b mt trc trn v trc bc c th c trng cho cc chi
tit dng trc.
Vic lp trnh t gia cng cc b mt v chn thit b cho cc chi tit dng trc
ph thuc vo cc yu t c bn nh hnh dng, kch thc, cng vng, chnh
xc yu cu v sn lng ca sn phm. Khi ch to trc c th chia ra cc giai on
chnh sau y:
a) Giai on gia cng chun b.
- Ct t phi theo chiu di hoc bi s chiu di ca trc.
- Xn 2 mt u khoan l tm.
b) Gia cng trc nhit luyn.
72.CNCTPT
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I
4
3 II
4
1
3
4
B1
B2
B1
6
B2
A2
74.CNCTPT
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Khi s dng phng php tin nhiu dao s c mt lot nhn t nh hng n
chnh xc gia cng:
+ Sai s do v tr dao iu chnh khng chnh xc.
Cnctpt.75
Su tm bi: www.daihoc.com.vn
+
s
H ng n dao
l max
.
m
Trong :
Lmax: Chiu di bc trc ln nht;
m: S dao b tr trong on .
S b tr dao c th hin hnh v 62.
Lp
76.CNCTPT
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.
Hnh 4.7. Tin nhiu dao theo phng php chia nh on trc.
Phng php ny c nng sut cao hn phng php trn khi gia cng cc trc
bc c chiu di ca cc bc khc nhau nhiu, nhng sau khi tin c cc vt dao ti
cc v tr dng xe dao; do sau tin phi c mi xo cc bc do vt dao li.
+ Chia theo lng d.
Theo phng php ny, tt c cc dao c g theo ng knh xc nh v
cch nhau nhng on bng chiu di cc bc. S g dao c trnh by trn hnh
4.8.
L1
L2
L3
Hnh 4.8. Tin nhiu dao theo phng php chia theo lng d.
Theo phng php ny, hnh trnh chy dao dc ca xe dao ln v b hn ch
bi sau. Phng php ny thng dng tin cc trc c bc nh dn v mt
pha, chiu di tng bc ngn, lng d nh. S lng dao s dng b hn ch do
cng vng ca phi, do cng sut my v cu to ca gi dao.
Trong sn sut hng lot ln v hng khi, gia cng mt tr ca trc ngi
ta cn dng my bn t ng chp hnh thy lc. Dng my ny c nhiu u im so
vi tin nhiu dao:
+ Thi gian iu chnh v iu chnh li gim 2 3 ln.
+ Nng sut gia cng cao v c th ct tc cao nu cng sut my cho
php.
- S dng thun li i vi cc trc km cng vng.
c) Mi th v tinh cc c trc. Mi cc c trc thng c hon thnh qua 2
nguyn cng: mi th v mi tinh.
Khi mi c th thc hin trn my mi trn ngoi vi tin dao dc hoc tin
dao ngang. Vi cc trc bc ngn v trc trn c th mi trn my mi v tm.
Mi trn my mi trn ngoi, chun nh v thng l 2 l tm. m bo
chnh xc cao, trc khi mi tinh cn sa cc l tm loi tr sai hng ca b mt
l tm do b xy ho hoc b chy trong qu trnh nhit luyn. Mi chy dao dc
c p dng khi chiu di gia cng l 80mm cn khi chiu di l < 80mm c th
dng chy dao ngang. Mi chy dao ngang cn c p dng khi mi cc b mt
nh hnh trn xoay bng cch dng mi nh hnh.
d) Gia cng cc b mt nh hnh cc mt nh hnh trn trc bao gm cc mt
c ren, bnh rng lin trc, then hoa, rnh then, cc mt lch tm.
Cnctpt.77
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a)
c)
Hnh 4.9
a) Ct ren bng dao tin ren; b) Ct ren bng 2 dao;
c) Ct ren bng ba dao.
78.CNCTPT
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bn ngui.
a)
b)
a) Cn ren bng mt
con ln cn: 1: phi;
2: con ln cn; 3: gi
.
b) Cn ren bng hai
con ln cn n dao
hng tm. 1: phi; 2:
gi ; 3: con ln cn
c)
Cnctpt.79
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phng php cn ngui, vi phng php ny trc then hoa c bn xon cao hn
phng php phay then.
Vi cc then hoa chnh xc, sau khi ct then hoa cn phi gia cng tinh bng
phng php mi.
a)
b)
Hnh 4.13
a) Phay then bng dao phay a; b) Phay then bng dao phay ngn.
Hnh 4.14a.
80.CNCTPT
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Cnctpt.81
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4
5
7
82.CNCTPT
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84.CNCTPT
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.
Hnh 4.19.
a) Cc giai on to hnh khi dp phi trc khuu.
b) S phn b ca cc th kim loi trong phi dp trc khuu.
Cnctpt.85
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4.20a. Phi
Hnh
86.CNCTPT
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- Khi gia cng th cn phi c cc bin php thch hp tng cng cng
vng cho h thng cng ngh, gim kh nng bin dng i vi phi: dng b truyn
dn trung tm truyn dn hai pha, dng luy nt gim bin dng un, xon.
- Thc hin gia cng cc c trc chnh, cc c u trc, mt bch trc trc khi
gia cng cc c bin.
- Cc c bin v cc m c bin khi gia cng nn dng c trc chnh lm chun
nh v m bo chnh xc cao kch thc bn knh khuu, song song ca
cc c bin vi c trc chnh, ng thi m bo g lp vng chc hn so vi dng
chun nh v ph.
- Khi gia cng cc c bin phi dng cc mt chun ph m khuu nh v
hng gc cho cc c bin. Mt chun ph ny c phay cng vi nguyn cng
phay mt bin ca m khu gia (mt ny dng g b truyn moment trung tm).
- Cc c trc v c bin c ti cao tn m bo cng b mt chng
mi mn. Khi ti cao tn, trc khuu d b bin dng nhit, do cn phi b tr cc
vng cm ng ph hp hn ch s cong vnh khi t nng cc c trc v c bin.
2. Cc nguyn cng c bn khi gia cng trc khuu dng phi dp
- Nn sa, kim tra phi.
- Gia cng cc mt chun ph:
+ Phay hai mt u trc.
+ Khoan hai l tm.
+ Phay cc mt phng m khuu lm chun nh v hng gc v g b
truyn dn trung tm.
- Sa, nn li trc theo hai l tm.
- Tin c trc chnh gia.
- Tin cc c trc chnh cn li, cc mt bn ca m khuu, cc u trc.
- Mi s b c trc chnh.
- Tin cc c bin, cc mt bn ca m c bin.
- Gia cng cc l trn mt bch trc.
- Gia cng cc l dn du.
- Gia cng ren u trc.
- Phay rnh then.
- Ti v ram cc c trc (ti b mt).
- Nn sa, kim tra trc.
- Mi tinh cc c trc chnh.
- Mi tinh cc c bin.
- Nn sa, kim tra trc.
- Cn bng trc khuu.
- nh bng cc c trc chnh v cc c trc bin.
- Tng kim tra ln cui.
4.6.4. Phng php gia cng cc b mt c bn ca trc khuu
Cnctpt.87
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4.21a. S
Hnh
gia cng phay hai mt u trc.
1. ta nh v dc trc; 2. Khi V; 3. dao phay mt u.
88.CNCTPT
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Gia cng mi cc c trc chnh c thc hin trn my mi trn ngoi hai
hoc nhiu mi v gia cng theo phng php chy dao ngang. S mi c
trnh ny hnh 4.24.
Cnctpt.89
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Hnh
4.25.
S g lch tm.
90.CNCTPT
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4
L ng n dao
ng tm c7
gia cng 1
Qu o ca
dao ct
Hnh 4.27. S
gia cng c bin trc khuu
theo phng php gia cng ng thi cc c.
1. Phi; 2. Trc khuu mu; 3. Dao tin.
Cnctpt.91
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a) Tin xn mt bn m;
b) Tin c trc.
Hnh 4.28. S my tin trc khuu 2 trc
gia cng ng thi cc c bin.
1. Chun nh v gc; 2. Luy nt.
Khi cc trc khuu mu quay, li ct ca dao c chuyn ng song phng
vch nn qu o II, Cn tm c bin gia cng c qu o I. Nh vy khi phi quay
ht mt vng th dao ct ht chu vi c bin. Bng phng php ny tt c cc c bin
c gia cng cng mt lc bng phng php n dao ngang (dng dao bn rng).
Ni chung khi gia cng theo phng php ny, chi tit gia cng d b bin dng
un do tc dng ca lc ct v lc kp cht theo chiu trc. Do cn c bin php
chng un cho phi nh dng ai kp, dng bu lng kiu kch (hnh 4.29).
Ngoi ra ngi ta c th gia cng c bin bng phng php phay trn my
chuyn dng vi dao phay kiu a c ng knh ln:
= 450
1100mm xem hnh 4.30.
a)
b)
c)
Hnh 4.30.
a) S phn b mp dao phay; b) S phay;
phay a c ng knh ln.
92.CNCTPT
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Phay c bin.
c) Dao
Cnctpt.93
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94.CNCTPT
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Cnctpt.97
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Hnh
4.35. Kt cu trc cam ng c t trong.
98.CNCTPT
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Cnctpt.99
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Sau khi dp cn thng ho: Nung nng phi n 850 870oC, gi nhit 1 gi
sau lm ngui ngoi khng kh. Sau thng ho, phi t cng 230 300HB.
Trong sn xut lot nh, phi trc cam c th l thp cn trn.
b) Trc cam phi c.
Phi c c thc hin i vi trc cam bng gang. i vi sn lng nh c
th c trong khun ct, i vi sn lng ln c th p dng cc phng php c
c bit, dng cc phng php c c bit c th nhn c cng khc nhau
trn b mt ca cc vu cam. C 2 phng php c c th nhn c cng cao
phn mt nng ca vu cam.
* Khun tng hp.
c trong khun tng hp l loi khun ct, phn mt nng ca vu cam (cn
cng cao) c b tr cc mnh khun kim loi. Ti y kim loi lng s ngui
nhanh hn so vi cc phn khc do cng s cao hn (hnh 4.37).
Hnh 4.37. Khun c tng hp.
100.CNCTPT
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rng xon.
- Mi tinh cc c trc.
- Mi tinh cc vu cam v bnh lch tm.
- nh bng cc c trc, vu cam, bnh lch tm.
- Tng kim tra.
4.7.4. Phng php gia cng cc b mt chnh ca trc cam
1/ Gia cng chun nh v ph
Cng nh cc chi tit dng trc khc, khi gia cng trc cam hu ht cc nguyn
cng gia cng u s dng chun nh v ph: 2 l chng tm.
Gia cng 2 l chng tm c nhiu phng n khc nhau tu thuc vo sn
lng v thit b.
Trong sn xut hng lot ln c th gia cng trn my phay khoan lin hp tc
dng 2 pha (nh trnh by phn u ca chng) hoc c th thc hin 2 nguyn
cng: phay 2 mt u trn my phay, khoan ng thi 2 l tm trn my khoan nm
ngang.
Trong sn xut n chic dng phi thp cn trn, nguyn cng ny c th gia
cng trn my tin vn nng.
2/ Gia cng cc c trc
Cc c trc cam c gia cng qua 2 giai on: gia cng th (tin), gia cng
tinh (mi). V trc cam c chiu di ln nn khi gia cng d b bin dng un v bin
dng xon do khi gia cng phi c bin php tng cng vng cho trc, dng
luy nt c trc gia, dng truyn dn hai u trc gim bin dng xon.
a) Tin cc c trc
Gia cng tin cc c trc cam c thc hin trn loi my tin nhiu dao bn
t ng. Loi trc cam phi dp do c lng d gia cng ln nn phi qua hai
nguyn cng: tin s b v tin tinh. S gia cng c th hin hnh 95.
b) Mi cc c trc.
Cc c trc ca trc cam c mi trn my mi trn ngoi hoc my mi trn
ngoi bn t ng. Trong cc nh my ch to t tin tin nguyn cng mi cc c
trc c thc hin trn my mi trn ngoi bn t ng, nhiu mi gia cng
ng thi theo phng php chy dao ngang v t ng o nhn c kch thc
c trc yu cu. Khi mi, trc cam c chng trn 2 mi tm v dng luy nt
c trc gia.
a)
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Cnctpt.103
b)
Hnh 4.40. S gai cng cc c trc
a) gia cng cc c hai u trc; b) gia cng cc c gia trc.
i vi trc cam dng phi dp thng c mi qua ba ln.
- Mi ln 1: Trc khi mi vu cam.
- Mi ln 2: Sau khi nhit luyn (ti v ram).
- Mi ln 3: Mi tinh ng kch thc yu cu.
Trc cam c c trc u tin lp bnh rng cam, yu cu khi mi phi t
vung gc gia tm trc v vai trc, do b mt ny c gia cng ring, dng
mi nh hnh c trc quay nghing 45o so vi tm trc cam khi mi.
3/ Gia cng cc vu cam
Vu cam v bnh lch tm l cc b mt c bit, c gia cng theo phng
php chp hnh. Ging nh c trc cc b mt ny c gia cng theo hai giai on:
gia cng th (tin) gia cng tinh (mi).
a) Tin cc vu cam.
104.CNCTPT
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l
o
c
t
n
y
u
l
i
a
H
Hnh
4.41.
S b tr dao trn my tin chp hnh
bn t ng gia cng cc vu cam.
1. ng kp n hi; 2. Then nh v gc vu cam.
Tin cc vu cam v bnh lch tm c thc hin trn my tin chp hnh
chuyn dng bn t ng. Hnh 4.41 gii thiu s b tr dao trn my tin chp
hnh nhiu dao bn t ng.
Khi tin vu cam, do bin dng ca cam c nng ln do trong qu trnh
ct cc gc ct ca dao thay i rt ln (gc trc v gc sau ) do nh hng
n iu kin ct gt, nh hng n cht lng gia cng. V vy trong qu trnh tin
Cnctpt.105
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106.CNCTPT
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1.
tin;
Bn
trt;
Cam
4.
dao;
xo; 6.
ln
hnh.
Dao
2.
dao
3.
mu;
Cam
5. L
Cn
chp
Trong sn xut lot nh, khng c my tin chp hnh chuyn dng c th p
dng nguyn l tin chp hnh thng thng, nhng m bo dao tin c cng
vng cao, cn chn dao c gc m ln m bo dao khng b gy khi gc thay
i. Hnh 4.45 gii thiu u dao tin c m.
Cnctpt.107
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b) Mi cc vu cam.
Mi cc vu cam v
bnh lch tm c thc hin
trn my mi cam chp hnh
bn t ng. Dng 1 mi
ln lt mi cc vu cam. Khi
mi thc hin phng php
chy dao ngang. S mi
gii thiu hnh 102.
Trn bn my (1) l p
gi lc l (2) cng vi cam
mu chp hnh (4). Trn gi
lc l trc cam gia cng (3)
c g ng trc vi cam
mu. L xo (5) m bo cho
con ln (7) lun tip xc vi
mt cam mu. Khi trc cam
v cam mu quay s to ra
chuyn ng lc, chuyn ng
ny s to ra b mt cam gia
cng nh
mi (6). Trc
cam gia cng c nh v
trn 2 mi tm hoc trn hai
c trc chnh (G trn hai c
trc chnh t c chnh
xc ng tm cao hn). Ngoi
ra phi nh v theo hng
gc m bo s phn b
ng ca cc vu cam theo
gc thit k.
Hnh
4.47. S mi chp hnh vu
cam.
nng cao chnh xc ca chi tit gia cng tc quay ca chi tit nn p
dng nh sau:
- Mi th: Vct = 5 8m/ph
- Mi tinh Vct = 2 3m/ph
Trong iu kin sn xut nh, c th thit k g mi vu cam theo nguyn l
nu trn dng trn my mi trn ngoi.
3/ nh bng cc c trc v vu cam
108.CNCTPT
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Trong sn xut hng lot nguyn cng nh bng c thc hin trn my
nh bng chuyn dng bn t ng (hnh 4.48).
1. Cam mu;
2. L xo;
3. Phin t;
4. Dy ai c ht mi;
5. Con ln dn ai;
6. Cam gia cng.
Cc
cam v
lch
i vi
vu
ngoi
kim
kch
vu
bnh
tm.
cc
cam,
vic
tra
Cnctpt.109
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.
Hnh 4.50. S kim tra bin dng cam.
1. Cam kim tra; 2. Cam mu; 3. ng h kim tra.
110.CNCTPT
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Chng V
b)
c)
d)
)
e)
25 32mm
ng knh t
32 40mm
112.CNCTPT
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ng knh t
40 50mm
ng knh t
50 65mm
ng knh t 65 100mm
c trng quan trng ca kch thc bc l t s gia chiu di v ng knh
ngoi ln nht ca chi tit. T s ny thng nm trong khong t 0,5 n 3,5.
5.1.2. Tnh cng ngh trong kt cu ca bc
Cng nh cc chi tit khc, tnh cng ngh ca bc c ngha quan trng i
vi vic gia cng t cc yu cu k thut cn thit. l t l c trng ca kt
cu bc, ng knh trong ca bc v chiu dy ca bc. Chiu dy bc qu mng s
d b bin dng khi gia cng c kh v nhit luyn.
5.2- IU KIN K THUT
Yu cu k thut quan trng nht ca chi tit dng bc l ng tm gia mt
tr ngoi v trong cng nh vung gc gia mt u v ng tm.
iu kin c th nh sau:
-
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m bo 2 yu cu k thut ny c th
thc hin cc phng php sau:
Hnh
2)
114.CNCTPT
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1)
2)
1)
2)
3)
4)
(hnh 5.5).
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5
+
7
4
+
3
2
Bin php gia cng ging nh phi thanh, nhng do c l sn nn thay nguyn
cng khoan bng khot l sau doa l.
3. CC BC CH TO T PHI C HOC RN TNG CHIC
cng tinh.
m bo ng tm ca cc b mt, cn ly mt ny lm chun nh v
gia cng mt kia.
Cc b mt gia cng tinh thng c thc hin trn my mi. i vi cc chi
tit ln kh gia cng trn my mi th c th gia cng trn my tin ct, my tin
ng dng dao tin hp kim cng hoc dao tin kim cng ct gt.
Nu b mt yu cu bng cao, phi dng phng php mi khn hoc mi
nghin gia cng tinh ln cui.
5.6.
Cnctpt.117
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Ct thp v g un.
Hn kn mp thnh ng.
Chnh hnh ng trong khun.
kh ni lc.
nh sau:
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3. Tin ph l, vt mp 2 u;
8. Ct t v xn phng mt u;
9. Mi trn ngoi;
13. Dp g nh v bc;
120.CNCTPT
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Chng VI
Cnctpt.121
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ng
Hnh 6.1.
lt xy lanh t.
Hnh 6.3. ng
lt xy lanh t,
c ng lt ph bng thp.
122.CNCTPT
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Cnctpt.123
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Cnctpt.125
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cng cc mt vt
Cnctpt.127
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a)
b)
128.CNCTPT
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.
Hnh 6.9. Tin mt ngoi trn my tin
chp hnh bn t ng (Tin th).
Su tm bi: www.daihoc.com.vn
130.CNCTPT
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L lo
1 th chn chiu di ca thanh l L= (1 1,2)Ll. Chiu
d lo
di phn nh ln ca : Lth = (0,25 0,5) L iu chnh phn nh ln ca c th
hiu chnh c sai s hnh dng l khi mi khn. Thng chn Lth = 1/3 L.
+ Khi t s
Llo
1 ; chiu di l 100 500mm th chiu di thanh chn theo
d lo
1 3
chiu di l: L = Ll.
3 4
+ Khi t s
Cnctpt.131
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l2
l4
l1
l2
gii hn ca mi.
bng b
mt
cng ca vt
mi (HB)
7 8
7 8
9 10
9 10
200 250
> 300
200 250
> 300
c tnh mi
Sx(150 220) MV1MV2G
Sx(150 280) M3 MV1G
Sx(320 M14) MV1MV2G
Sx(320 M14) M3 MV1G
3. Kim tra ng lt
Mi ng lt u qua b phn kim tra ca ni sn xut m bo cc tiu
chun k thut quy nh. Vic kim tra ng lt bao gm cc ni dung sau:
- Xem xt cc b mt bn ngoi (r, nt, rn).
- Kim tra cc kch thc: ng knh ngoi, ng knh trong v cc kch
thc khc.
- Kim tra chnh xc cc v tr tng quan: ng tm mt trong, mt
ngoi; vung gc gia vai lp ghp v tm trc
ng lt.
132.CNCTPT
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Cnctpt.133
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Chng VII
7.1.
Hnh
Vng gng ng c t.
a) Vng gng hi; b) Vng gng du.
Vng gng trng thi t do (cha lp vo xy lanh) c hnh dng phc tp,
kch thc mt ngoi ca vng gng ln hn kch thc ng knh xy lanh. Nh
134.CNCTPT
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180o
P
150o
120 o
120o
90o
90o
60 o
60 o
30 o
Gc
P/P0
0o
1,05
30o
1,05
0o
60o
1,14
30 o
90o
0,90
120o
0,45
150o
0,67
180o
2,86
Cnctpt.135
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136.CNCTPT
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Cnctpt.137
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138.CNCTPT
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.931
T
P
C
N
Si
Mn
Cr
Ni
W
hoc Ti
Mo
3 3,3
1,62,0
0,81,0
0,30,5
0,1
0,6
0,4
0,2Ti
C 28 48
3,53,7
1,51,9
0,50,8
0,30,5
0,1
0,6
0,51,0
0,30,6
2,853,1
1,752,25
0,60,9
0,250,45
0,1
0,50,85
0,30,5
0,080,15
Cng ho Sec
3,53,9
2,13,7
0,40,8
0,12
Php
3,43,6
2,83,0
0,90,8
0,4
2,02,5
3,23,4
2,22,4
0,60,8
0,20,6
<0,1
0,20,5
Cnctpt.135
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c vng gng
140.CNCTPT
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Phi c c tng chic theo hnh dng vng gng trng thi t do (dng
van, khe h ming c c kn) c lng d gia cng.
Sau khi gia cng 2 mt bn, s ct ming (theo yu cu ca tng loi vng
gng trng thi t do).
Vng gng sau khi ct b phn khe h ming s dng g bp trn li gia
cng trn mt ngoi v trong.
Hnh dng vng gng trng thi t do khng c sai lch nu nh khng c
cc sai s khc gy nn (sai s ca phi c).
7.4.2. Phng php chp hnh
Phi c theo tng chic dng vng gng trong trng thi t do, c lng
d gia cng.
Sau khi gia cng 2 mt bn, vng gng s c gia cng chp hnh to dng
van mt ngoi. Sau mi ct khe h ming (theo tng loi vng gng) v tin mt
trong.
Phng php ny c u im to ng hnh dng vng gng trng thi t do
chnh xc, do m bo chnh xc th p lc hng knh ca vng gng.
7.4.3. Phng php nhit nh hnh
Phi c ng ly tm c tin s b, bn tinh mt trong, mt ngoi v tin ct
t phi thnh tng vng trn, c lng d gia cng 2
mt bn.
Cc vng gng c phay ming (khong 1mm) v thc hin nhit luyn nh
hnh.
Vng gng c tch rng ming bng mt g, khe h tch ming ph
thuc vo tng loi vng gng. Cng thc thc nghim xc nh khe h ming nh
sau:
14,14P D
1
E.b h
cm
Trong :
D : ng knh ngoi ca vng gng (cm);
h : Chiu cao vng gng (cm);
b : Chiu dy vng gng (cm);
E: Moun n hi ca vt liu (E = 1,2 . 106KG/cm2;
P : Lc hng knh ca vng gng.
Ch ram nh hnh nh sau:
- Nhit vo l: 350 400oC
- Tc nung Vn = 100 120oC/h
- Thi gian gi nhit 1h nhit nung 560 580oC. Sau lm ngui
ngoi khng kh.
Sau khi nhit nh hnh thc hin tip cc bc gia cng c kh
tip theo.
Cnctpt.141
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142.CNCTPT
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Trong sn xut lot nh hin nay, c th thay th nguyn cng nhit nh hnh
bng cch gia cng chp hnh dng vng gng trng thi t do bng cch tin chp
hnh phi ng trn my tin vn nng c thit k b g chp hnh c kh. Bng cng
ngh ny c th m bo c cht lng v n nh v cht lng ca vng
gng ch to theo dng phi ng c ly tm.
7.6. CC BIN PHP THC HIN CC NGUYN CNG
7.6.1. kh ni lc
Phi c ly tm cn phi tin hnh v qu trnh b lm ngui nhanh mt ngoi
d b bin trng, ni lc trong phi ln do phi kh ng sut v ci to lp bin
trng, n nh kt cu ca vt liu.
Quy trnh thc hin nh sau: (xem hnh 7.4).
Toc
930
850
650700
ngoi
khng kh
1h
30pht
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82084
ngoi khng kh
65070
2h
t
Hnh 7.5. Ch ti ng phi.
580600
350400
ngoi
khng kh
O
1h
144.CNCTPT
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Gia cng mt ngoi vng gng bng phng php chp hnh l to mt
ngoi ca vng gng c hnh dng tng ng vi l thuyt trng thi t
do, bng cch chp li hnh mu ca vng gng trng thi t do l hnh
van - vng gng c nh v trn mt trc g, tin hnh gia cng trn
my tin c b g chp hnh, s hnh 7.8.
1.Cam mu;
2. Con ln chp hnh;
3. Dao tin;
4. Trc g;
5. Phi.
Hnh 7.8. g tin chp hnh mt ngoi
vng gng.
Gia cng mt ngoi ca vng gng bng phng php tin trn mt ngoi.
Trng hp ny p dng cho quy trnh cng ngh ch to vng gng dng phi
chic theo phng php khng chp hnh hoc phng php nhit nh hnh.
tin hnh tin trn mt ngoi ca vng gng, ngi ta a vng gng vo
g bp ming li sau s a vo trc g v xit cht li bng c cu ren vt.
Hnh 7.9 gii thiu g bp vng gng trn trc g v trc g g vng gng
a ln my tin gia cng mt ngoi.
Cnctpt.145
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a)
Hnh 7.9a. g bp ming vng gng;
b)
Vng gng sau khi c gia cng mt ngoi s tin hnh gia cng mt trong.
m bo chiu dy ng u ca vng gng, khi gia cng mt trong, ngi ta
dng mt tr ngoi ca vng gng lm chun nh v. Vng gng c g trn mt ng
g v dng dao tin gia cng mt tr
trong, hnh 7.10.
1. Mm g;
146.CNCTPT
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2. ng g;
gng du.
Phng php chp hnh: phay ct ming sau khi tin chp hnh mt ngoi.
Phng php khng chp hnh: phay ct ming trc khi tin mt ngoi v
trong.
Cnctpt.147
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nh hnh.
148.CNCTPT
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mi bn.
Cnctpt.149
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trn.
mi th.
150.CNCTPT
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Cnctpt.151
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a)
b)
Hnh 7.16. g kim tra chiu dy
ca vng gng.
a) Kim tra bng tay; b) Kim tra
bng truyn ng c kh.
.
a)
b)
Hnh 7.19. S kim tra lt sng ca vng gng.
152.CNCTPT
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CNCTPT.139
Cnctpt.153
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Chng VIII
Cnctpt.155
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Cc bnh rng lin trc c thc hin hon ton ging nh mt chi tit trc,
nguyn cng ct rng s c thc hin sau khi tin b mt tr cn ct rng.
8.5.CC PHNG PHP GIA CNG RNG CA BNH RNG
RNG TR
Bnh rng cn c bn v tui th cao trong qu trnh lm vic khng gy
ting n v c hiu sut cao; do cn phi c cc phng php ct rng thch hp
m bo yu cu lm vic ca bnh rng.
V nguyn l ct rng c 2 phng php:
8.5.1. Phng php nh hnh
1. PHAY RNG NH HNH
8.2.
Hnh
S phay rng v
cc dng c phay rng bng dao phay mun.
Thc hin bng dao phay nh hnh c profil ph hp vi prfil ca rnh rng.
C th s dng dao phay ngn hoc dao phay a mun
(hnh 141).
Sau khi phay xong mt rnh rng, phi c quay i mt gc
360 o
(Z l
Z
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158.CNCTPT
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L phng php ph bin nht, c nng sut cao v chnh xc cao. Dng c
l dao phay ln, c dng trc vt thn khai m profil mt php tuyn l dng thanh
rng. Vi loi dao ny c th gia cng c rng ca bnh rng v bnh vt.
Phay ln rng c thc hin trn my phay rng chuyn dng, trn dao v
bnh rng gia cng thc hin s n khp ca b truyn trc vt vi t s:
d
n
Z
d ct
ct n ct Z d
Trong :
d ; nd ; Zd : l tc gc, s vng quay v s u mi ca dao.
ct ; nct ; Zct : l tc gc, s vng quay v s rng ca bnh rng
gia cng.
S ct c th hin trn hnh 143.
b)
)
s
Hnh 8.3. S
Khi phay bnh rng rng thng, trc ca dao phay phi t nghing so vi tr
ca vt gia cng ng bng gc nng ca ng xon vt trn trc chia ca dao. Dao
phay c g theo hng nghing phi hoc tri tu theo hng nghing ca rng.
Khi phay rng nghing, phi g trc dao hp vi mt u ca phi mt gc sao
cho tho mn (hnh 8.4):
= o d
Trong :
: gc g ca trc dao so vi mt u phi.
o : Gc nghing trn vng chia ca bnh rng gia cng.
d : Gc
nng vng chia
ca dao.
Cnctpt.159
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Xc rng bao hnh c th thc hin bng dao xc dng bnh rng hoc dao xc
dng thanh rng trn my xc dng thanh rng trn my xc bao hnh. S xc
rng bng dao xc dng bnh rng c th hin hnh 8.5.
n ct Z d
n d Z ct
160.CNCTPT
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a) Phay rng:
Bnh rng cn rng thng v rng nghing c phay bng dao phay nh hnh
vi phng php phn trn my phay vn nng. Xem hnh 8.6.
146. S
Hnh
ct rng cn rng thng bng phay nh hnh.
Cnctpt.161
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b1 b 2
2L
Trong :
b1 : Chiu rng rnh rng pha u to, c o trn ct tuyn ca
cn chia (mm).
b2 : Chiu rng rnh rng pha u nh, c o trn ct tuyn
ca cn chia (mm).
L : Chiu di rng (mm).
Phng php ny c s dng ch to cc bnh rng c mun ln v
khng yu cu chnh xc cao.
b) Bo rng theo dng
Rng ca bnh rng cn rng thng c c knh v mun ln c ch to
bng phng php bo theo dng. Trn bnh rng cn rng thng, kch thc ca
rng tng dn theo hng t nh, nn rng ca cc c bnh rng cn c s rng nh
nhau. Do dng tng ng mt thn khai ca mt bn rng s dng chung cho
cc bnh rng cn c tng s rng ging nhau.
Thc hin bo rng theo dng trn my bo rng cn chuyn dng.
Vt gia cng c g vo trc chnh ca thit b chia v khng di chuyn
trong qu trnh ct. Dao c g vo bn dao v chuyn ng tnh tin vi tc ct
V, qu o chuyn ng ca dao c dn hng
theo dng.
2. PHNG PHP BAO HNH
Phng php bao hnh bnh rng cn ging nh nguyn l gia cng bao hnh
bnh rng tr, rng c to nn do s ln ca cn chia bnh rng theo mt phng
chia ca bnh dt sinh, bnh dt sinh l bnh cn tng tng vi gc nh ca cn
chia l 180o. Profil rng c to nn bng s ln tng i ca dng c v bnh
rng gia cng. Dng c l mt hoc 2 dao c li ct dng hnh thang. Dng c ct
dch chuyn tnh tin theo hng n nh cn chia ca bnh rng gia cng nh g
trn u dao. u dao c chuyn ng nh 1 bnh rng dt sinh tng tng n khp
vi bnh rng gia cng. Hin nay c mt s phng php gia cng theo nguyn l
ny.
a) Phay bnh rng cn rng thng:
Phng php phay bao hnh ny t nng
sut cao. Dao phay c ng knh ln, dng
rng chp, mt bn ca chng l cnh ca hnh
thang ging dng thanh rng. S gia cng
xem
hnh 8.7.
Trc chnh ca dao phay a g trn mt
u ca mt bn trt m s vng quay nd ca
n c lin h vi s vng quay nc ca phi, to
162.CNCTPT
Loi ny c gia cng trn my Gleason bng phng php bao hnh vi u
dao quay. Nguyn tc lm vic ca my xut pht t s n khp gia bnh dt sinh
tng tng vi phi, trong bnh dt sinh c thay th bng gi lc l.
S gia cng c th hin hnh 149. Bnh dt sinh tng tng Zd c
th hin bng kt cu ca gi lc l (2), trn gi ny lp u dao phay c tm quay
nm lch tm vi a g pha trn ca a. u dao phay (3) lp cc li ct dng
hnh thang. Khi iu chnh my gia cng phi sao cho nh nn chia ca bnh
rng gia cng trng vi nh ca bnh dt sinh, mt phng u rng ca dao tip xc
vi mt nn chn rng. u dao quay chuyn ng quay quanh trc to ra tc ct
V, ng thi quay cng vi a g thc hin chuyn ng n khp ca bnh dt
Cnctpt.163
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id1-2 = 12 d
d
Z12
Trong :
d : Tc gc ca a g;
1-2 : Tc gc ca phi;
Zd : S rng ca bnh dt sinh;
Z1-2 : S rng ca bnh gia cng.
Gia cng bnh rng epixicloid c tin hnh trn my Oerlikon Spiromatic.
Nguyn l gia cng c th hin hnh 8.10.
u dao l mt a phng c gn nhiu li b tr theo ng Acximet. Khi gia
cng, dng c v phi thc hin s n khp ca bnh rng cn vi bnh dt sinh
tng tng. Trong bnh dt sinh c thay th bng a g quay vi tc nd
m trn c g u dao phay quay vi tc V v c tm quay lch vi tm ca
a g.
Trong qu trnh gia cng, ngoi chuyn ng n khp u dao khng quay c
lp nh khi ct rng dng cung trn m c mi lin h vi chuyn ng quay nc ca
phi qua xch phn .
164.CNCTPT
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det Z dao
dao Z det
Trong :
dt : Tc gc ca bnh dt (a g);
dao : Tc gc ca u dao;
Zdao : S dy dao ca u dao;
Zdt : S rng ca bnh dt sinh.
3. GIA CNG BNH RNG CN RNG CONG THN KHAI
Gia cng bnh rng cn rng cong thn khai c th hin trn my
Klingelnberg bng mt dao phay ln c bit dng hnh cn.
Nguyn l gia cng da trn s n khp ca dao phay vi phi. Dao phay c
g trn a g m trc quay ca n trng vi trc ca bnh rng dt sinh c s rng
Zdt ; bnh rng dt sinh tng tng c to bi a g lc l ca my. Dao phay
ln trn bnh dt sinh v thc hin thm chuyn ng quay cng vi a g quanh
trc ca n. Chuyn ng ny bt u t v tr I m v tr ny vng trn trn ng
knh ln nht ca dao phay cn u tip xc vi bnh rng gia cng v kt thc v
tr II m vng trn b nht ca dao phay cn ra khi tip xc vi vt gia cng.
S nguyn l hot ng, xem hnh 8.11.
Cnctpt.165
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Hnh 8.11.
S gia cng
166.CNCTPT
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Dn
nK
nc
Hnh 8.14. S
gia cng
bnh vt bng
dao quay.
Phng php chy r bnh rng c thc hin bng cch cho bnh rng gia
cng n khp vi cc bnh rng mu c ti cng nng cao chnh xc v
cng ca bnh rng gia cng.
Cnctpt.167
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3
2
Hnh 8.15. S
C rng l mt phng php gia cng tinh bnh rng bng cch cho n khp
vi dng c c rng. Dng c c rng l bnh rng tr hoc thanh rng khi c bnh
rng tr; l bnh rng cn khi c bnh rng cn; l trc vt khi c bnh vt.
Khi c rng, dng c c v chi tit c c n khp khng c khe h vi nhau.
Trn mt rng ca dng c c x cc rnh to ra li ct. Qu trnh ct gt xy ra
khi bnh c trt trn mt rng gia cng. Lp phoi c ct i rt mng t 0,001
0,005mm (xem hnh 8.16).
Bnh rng trc khi c phi c ch to chnh xc hn so vi em mi.
Lng d cho c ln nht l 0,15mm cho mt rng. C rng s sa i nhng sai s v
hnh dng v nng cao nhn bng b mt rng. nhm c th t Ra : 0,63
0,16 (8 10). C rng c th gia cng c cc loi bnh rng thng, nghing, n
khp trong, ngoi, c ng knh t 6 1200mm, c mun 0,1 12mm.
b)
a)
Hnh
8.16.
S c rng.
168.CNCTPT
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mt
rng).
1. MI RNG BNH RNG
L phng php gia cng tinh cc bnh rng trc v sau khi nhit luyn, c
kh nng t chnh xc cao: cp 46; nhn bng b mt rng Ra: 1,250,32
(79).
Mi rng c dng gia cng dng c ct rng, bnh rng mu, bnh rng
c yu cu k thut cao.
Mi rng c 2 nguyn l: nh hnh v bao hnh.
a) Mi rng theo phng php nh hnh:
8.17.
Hnh
Cc s mi rng nh hnh.
mi c bin dng ca rnh rng cn gia cng. Trong qu trnh gia cng
mi quay trn v c chuyn ng dc trc ca bnh rng. Qu trnh mi thc hin
tng rng v c thc hin nh s phn chi tit gia cng.
S mi c trnh by hnh 157.
Khi mi nh hnh thng dng tc quay ca V = 3035m/sec; tc
tin ca Vt= 816m/pht; lng d mi l 0,20,3mm chia lm 3, 4 bc.
u im ca phng php mi nh hnh l c th gia cng c bnh rng n
khp trong, ngoi nhng chnh xc v nng sut
khng cao.
b) Mi rng theo phng php bao hnh:
Mi rng theo phng php bao hnh t chnh xc cao v ng dng rng
ri hn so vi mi nh hnh. Gia cng theo phng php ny da theo nguyn l n
khp ca thanh rng vi bnh rng m thanh rng c thay th bng dng c mi.
S mi rng bao hnh trnh by hnh 8.18.
Cnctpt.169
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Mi nghin bnh rng cng l mt phng php gia cng tinh sau nhit luyn
nng cao bng b mt rng. Sau khi nghin rng, nhn bng c th t c
Ra : 0,63 0,32 (8 9); hiu chnh c sai s chung v dng rng, bc rng,
nhng bin dng sau khi nhit luyn, lm sch cc xyt, cc vt li lm. Tuy vy,
mi nghin khng th sa c cc sai s ln v nng sut thp. Mi nghin c s
dng trong cc trng hp bnh rng c yu cu chnh xc cao nh bnh rng
trong t.
Bn cht ca phng php mi nghin rng l cho bnh rng gia cng n khp
vi cc bnh rng l dng c nghin v trn mt rng c bi bt nghin, khi nghin
c p lc n khp 57 kG/cm2.
Bnh rng lm dng c nghin c ch to t gang Peclit, c cng
180220HB nh cc mc gang GX 2140; GX 1532. Chiu rng bnh nghin ln
hn bnh rng gia cng t 4 10mm. Lng d mi nghin mt pha khng ln hn
0,020,05mm.
C 2 phng php mi nghin:
a) Trc bnh rng gia cng song song vi trc ca dng c nghin.
Phng php ny dng c nghin l bnh rng b ng. nghin c c 2
mt rng phi i chiu chuyn ng, ngoi ra cn c chuyn ng chiu trc mi
ht chiu dy rng.
b) Cc trc ca dng c v chi tit cho nhau:
phng php ny, bnh rng gia cng 1 n khp vi 3 bnh nghin, trong
c 2 bnh nghin s 2 c rng nghin do 2 trc ca n cho so vi trc bnh rng
gia cng; ngoi ra bnh rng gia cng cn c chuyn ng tnh tin dc trc mi
ht chiu dy rng.
170.CNCTPT
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8.19. S
Hnh
mi nghin.
Mi khn rng l mt phng php gia cng tinh bnh rng nng cao
chnh xc v bng mt rng, hiu chnh phn no sai s v dng rng v nhng
khuyt tt do nhit luyn gy nn. Bnh rng sau khi mi khn gim c ting n,
tng din tch tip xc, nng cao tui bn. Mi khn t c nhm Ra: 1,250,32
(79).
Qu trnh mi khn l s n khp gia 2 bnh rng: mt l vt gia cng v mt
l dng c mi khn. Dng c mi khn l mt bnh rng lm t vt liu nhm nh
Cacbuasilic, hoc lm bng cht do nhng mt ngoi rng lm t cc vt liu c
tnh nng ct gt tt nh ccbit Bo, kim cng nhn to.
Khi thc hin mi khn, dng c nghin truyn chuyn ng cho bnh rng gia
cng. Trc bnh rng gia cng v dng c t cho nhau mt gc, do to ra s
trt v c st vo mt rng ging nh c rng lm cho b mt rng gia cng c
co i 1 lp phoi rt mng. gia cng 2 mt ca rng, sau mt thi gian n khp s
i chiu quay. ct ht chiu dy rng, c chuyn ng tnh tin dc trc.
Tu theo yu cu k thut m c cc bin php khc nhau.
a) Mi khn c khe h:
S n khp gia dng c v bnh rng gia cng c khe h t
0,10,2mm, c ngha l ch tip xc mt pha rng. thc hin ct gt c, phi
c mt p lc theo chiu tip tuyn hm bnh rng gia cng (P: 5050N). Bin
php ny sa cha cc vt li lm v lm nhn mt rng, sai s hnh dng rng
sa c rt t.
b) Mi khn khng c khe h:
S n khp gia dng c v bnh rng gia cng khng c khe h; hai pha ca
rng c gia cng ng thi. Mi khn theo phng php ny phi c p lc hng
Cnctpt.171
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knh. Phng php ny hiu chnh c sai s hnh dng v sai s n khp khi lm
vic ca bnh rng.
Lng d ca mi khn rng thng trong phm vi 0,0250,05mm. Nu lng
d ln s gim nng sut. Tc ct mi khn 45m/sec. Lng chy dao ngang ca
bn my t 25150mm/pht. Lng chy dao dc 0,0250,5mm/ vng bnh rng.
Dung dch bi trn: du ho hoc du cng nghip. Phng php mi khn c th p
dng cho cc bnh rng c mun t 26mm.
8.9. KIM TRA BNH RNG
Tu theo iu kin s dng v nhim v chnh ca bnh rng khi lm vic m
kim tra theo cc yu cu sau:
8.9.1. chnh xc ng hc
chnh xc ng hc c kim tra khi bnh rng c yu cu truyn ng
chnh xc nh cc bnh rng trong my o, my gia cng chnh xc, u phn .
Cc ch tiu chnh xc ng hc bao gm:
- Sai s ng hc
- Sai s tch lu bc vng
- o vng chia
- Sai lch chiu di khong php tuyn chung
- Sai lch khong cch tm khi bnh rng quay mt vng
8.9.2. n nh khi lm vic
n nh khi lm vic c kim tra khi bnh rng lm vic tc cao. N
bao gm cc ch tiu sau:
- Sai s chu k
- Sai lch bc c s
- Sai s bc vng
- Sai s profil
- Sai lch khong cch tm khi quay mt rng.
8.9.3. chnh xc tip xc
chnh xc tip xc c kim tra khi bnh rng lm vic vi ti trng ln.
N bao gm cc ch tiu:
- Din tch tip xc
- Sai lch phng ca rng
8.9.4. Khe h mt bn
Khe h mt bn c kim tra khi bnh rng lm vic c 2 chiu.
172.CNCTPT
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[1] TRN NH QU
Cng ngh ch to ph tng Trng i hc GTVT H Ni, 1999.
[2] NGUYN C LC
Cng ngh ch to my Trng i hc Bch khoa H Ni, 1993.
[3] H THANH GING
Cng ngh ch to ph tng t - my ko Nxb GTVT, 2001.
[4] TRN NH QU TRNG NGUYN TRUNG
K thut ch to my Trng i hc GTVT H Ni, 1993.
[5] . P. MASLOV
Cng ngh ch to t (Bn ting Nga) Nxb Masinostroenia, 1964.
[6] M.E. GROV
Cng ngh ch to my (Bn ting Nga) Nxb Vsaia Skola, 1976.
[7] HONG THNH
Gia cng piston Nxb Khoa hc k thut, 1969.
Cnctpt.173
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MC LC
Trang
Li ni u
Chng I
1.1.
1.2.
1.3.
1.4.
1.5.
1.6.
1.7.
6
7
8
10
22
Chng II
2.1.
2.2.
2.3.
2.4.
26
29
31
34
174.CNCTPT
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Chng III
3.1.
3.2.
3.3.
3.4.
3.5.
3.6.
3.7.
48
49
50
51
53
Chng IV
4.1.
4.2.
4.3.
4.4.
4.5.
4.6.
4.7.
69
70
84
98
Chng V
5.1.
5.2.
5.3.
5.4.
5.5.
5.6.
112
113
114
116
118
Chng VI
CNG NGH CH TO NG LT XYLANH
NG C T TRONG
121
c im kt cu ca ng lt xylanh
iu kin k thut ch to ng lt xylanh
Vt liu v phi ca ng lt xylanh
Quy trnh cng ngh ch to ng lt
124
126
128
6.1.
6.2.
6.3.
6.4.
Cnctpt.175
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Chng VII
CNG NGH CH TO VNG GNG NG C T TRONG
134
7.1.
7.2.
7.3.
7.4.
7.5.
7.6.
c im kt cu ca vng gng
iu kin k thut ch to vng gng
136
Vt liu v phi
Phng php ch to vng gng bng gang
Quy trnh ch to vng gng
Cc bin php thc hin cc nguyn cng
Chng VIII
CNG NGH CH TO BNH RNG 154
8.1
8.2.
8.3.
8.4.
8.5.
8.6.
8.7.
8.8.
8.9.
c im cu to ca bnh rng
Vt liu v phi ca bnh rng
iu kin k thut ch to bnh rng
156
Quy trnh cng ngh ch to bnh rng Cc phng php gia cng bnh rng tr 157
Ct rng bnh rng nn (rng cn)
Gia cng bnh vt
Gia cng tinh bnh rng
Kim tra bnh rng
155
175
176.CNCTPT
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137
140
142
143
162
167
169
173