THÔNG TIN TÀI LIỆU
ISSN: 2354-0575 / \ ^« ^ ^ % ^ / ^•^^^ NGHIEN c u t ! DU" DOAN VA CAI THIEN KHA NANG TAO HINH CHO SAN PHAM KHAY COM BANG C N G NGHE DAP THEP TAM A STUDY ON PREDICTING AND IMPROVING FORMABILITV FOR LUNCH TRAY PRODUCTION BY SHEET STEEL FORMING PROCESS Nguyen Dire Todn^, L l Van Nam^, Bdnh Tien Long' Tru&ng Dgi hgc Suphgm Ky thugt Hung Yin Tru&ng Dai hgc Bdch khoa Hd Noi Tru&ng Cao ddng Cdng nghiep Hung Yen Tom tdt: Di du dodn vd cdi thiin khd ndng tgo hinh cho qud trinh ddp vudt sdn phdm khay cam tir tdm fam logi Cdc tham sd cdng nghe vd hinh hgc ciia qud trinh gia cdng nhu: lire chgn, bdn kinh gdc lupn eua chdy/ coi vd gdc hinh hoe cua sdn phdm duoc phdi hpp su diing theo thudt todn phuong phdp mdng true giao cua Taguchi vd kit hgp vin cdc md phong phuang phdp phdn tuhHv hgn (FEM) Cdc dif li^u tir phuang trinh img sudt - bien dang vd duang cong gioi hgn tgo hinh cua bien dgng chinh/phyi dugc su dung ldm dir liiu ddu vdo cho qud trinh md phdng de du dodn chdt lugng cdc sdn phdm sau tgo hinh Trin casa dnh hu&ng cua cdc tham sd da lua chgn din chdt lugng sau tgo hinh vdt lieu, phdn tieh phuang sai da dugc tiin hdnh di ddnh gid mirc dnh hu&ng cua cdc tham sd din ehdt lugng sdn phdm vd dua dugc bd thdng sd hap ly Tir khda: Dap vudt, khay com, FEM, vdt liiu tdm, phd huy deo Ky hiiu sd dung FLC: dudng cong gifli han tao hinh FLD: bieu gidi ban tao hinh FEM: phuang phap phan tu hihi ban K be so deo ny la sfl rau ciing hoa a: ung suat tuang duong [MPal i : bien dang tuong duang E^ bien dang chinh £,: biln dang phu t^^y chieu day nho nhat ciia chi tilt [mm] 7),: ti sfl nhilu [dB] Q: lyc chan [tdn] Ry ban kinh efli [mm] R^y ban kinh chay [mm] a: goc hinh hgc ["] m: gia tn trung binh eua ti sfl nhilu [dB] m^_: gid tri trung binh ti sfl nhieu cho tham sfly va gia tri cap thu i [dB] I Dat \kn de Cflng nghe gia cflng ap lyc cfl tu rdt lau ddi, nhung mai den vai the ky mdi dugc phdt triin cao dp nhd sy tien bg ciia khoa hpc vat lieu, ly thuyet bien dang deo va cac phuang phap gia cdng tao hinh mfli dya trin ca sd co hgc mfli trudng liln tyc, CO hpc vat ran biln dang, ly thuyit deo, kim loai vat ly, dai sfl tuyin tinh Cae tyu ky thuat, ly thuyet va mfl phflng cho cong nghe gia cflng ap lyc la budc tiln mdi manh me cho viec tfli im hfla, su dyng het kha nang biin dang eua vat lieu Tin dung ky thuat mfl phflng rtong nganh gia eong ap luc d i 24 Khoa hoc & Cong ngh? - S6 3/2014 gidi quylt cac bai toan v l kha nang tao hinh ciia vat lieu ma khflng can che thu giam ehi phi raua vdt lieu va gia eflng khufln thu nghiem ban dau, Phuong phap gia eflng ap lyc hay biln dang tao hinh vua la cflng nghe ehuan bi tao phfli cho eflng n g b | co vua la cong nghe tgo hinh san pham cufli cung, khflng nhirng cho phep tao hinh dang kich thude san phdm raa cfln cho san phim kim loai chat lugng cao v i tinh co-ly-hfla, tiit kilm nguyen vat lieu va cho nang sudt lao ddng cao, tir dfl gia san pham Day eung la cong nghe nhat ciing mflt lue biin dfli ea hinh dang kich thudc va tfl ehuc kim loai, nen chiing dupc su dung yeu cdu chat lugng san phdm cao Khi che tao cac san pham tit tam kim loai, diiu kiln gia cong thyc t i nhu cac thflng sfl cflng nghe va thflng so hinh hgc anh huflng nhilu din chat lugng san pham sau tao hinh Trong nghien euu de dy bao trude cac hien tiln pha buy xay san xuat san pham khay com bdng phuang phap dap vuit, phuong phap mfl phong phdn tii hihi han da dugc su dung va dugc chi la mflt phuong phap hiiu hieu cho viec kiim tra anh huflng ciia cac tham so cflng nghe, gia cong va hinh hpc din chat lugng san phdm sau tao hinh Cae nghien cuu trudc day cua Nguyen DT [1,2,3] da su dung phucmg phap phdn tu biiu han kit hgp vdi thuat todn ttye giao Taguchi [4] d i lua chpn dugc cac bg tham sfl gia eflng cho mflt sfl san phdm cflng nghiep Di dy doan pha buy deo, cfl nhiiu mfl hinh dy doan khac Trong rao hinh phd hiiy deo dya vao dudng cong gioi ban tao hinh (FLC) dugc chi la Journal of Science and Technology ISSN: 2354-0575 phii hgp lot nhat cho vdt li|u tdm Do du lieu thuc nghiim td dudng cong t^o hinh FLC cua vat ligu gia cong da dugc dua vao de md phflng qua trinh d^p vuot tao hinh khay cam Cac tham sfl dnh hudng chinh la luc kep, ban kinh gflc lugn cua chay/ efli va goc hinh hpc eiia san phdm duac su dung dl kilm tra anh huong cua chung din kha nang tao hinh qua trinh tao hinh sdn phara khay com Cae kit qua mo phdng theo bang tryc giao Taguchi duge su dung dl phan tich cac cap dp anh hudng ciia cdc tham sfl din chat lugng tao hinh san pham Bg thflng sfl hgp ly se dugc lya chon thflng qua phan tieh phuong sai va duge sic dyng dl mfl phong cho sdn phdm hoan thign chinh (Major Strain £,), biln dang cd tri sfl nhfl ban dugc ggi Id biin dang phy (Minor Strain s^) Khi phfli tdm biln dang, iing suat gay nen £•, lufln la img suit keo, ling sudt gay nin e^ co thi la iing sudt keo hoac nen Do do, vl gia tri £, lufln luon duong, £',cd the duong hoac am Dl xdc dinh dudng cong gioi ban tao hinh cua v^t lieu eo thi diing phuong phap thyc nghiem pha buy deo [5] tren cae may tao hinh bang eae chay ddu cdu kich thudc bdn kinh tieu chuan 50,8 mm, cac tdm vat mau cfl kich thude chieu dai bang va chilu rpng thay dfli theo tiiu ehuan dugc phii cac luoi ddnh ddu hinh trfln tren be mat vdi kich thudc 2.54 mm Sau ga dat va kep chat cae tdra vat mau len may, chay dap se di ehuyln vdi tflc khflng dfli dl biln dang vat mau den bi niit, rach Gidi h^n tao hinh (FLD) cua vdt lilu Hinh mfl td dudng cong img sudt biln dang (Hinh 2a) Cae dudng tron trin bl ra|t tai cac vi tri cho vat lieu thep khong gi SS304 duge su dung dl nut, rdcb va khdng rach ciia vat mau se dupe dac tinh toan cae biin d^ng chinh, phy Cdc dii lieu dd ehi tao khay cam theo phuong trinh lien tuc (1) se dugc ve tren bieu dfl trye, duflng cong bao giiia a{s)=Ki£, + i)'^ cae dilm pha buy va cac diem an toan toan chinh Id gioi ban tao hinh eua vat lilu thi nghiem nhu hinh = 864.2(0.000177 + e ) ' ' " ' Trong dfl: K la be sfl deo; n^ la so mu ciing 2b boa; 0, eo, e la img suat tuang duong, biln dang ban ddu va biln dang tuang duong , , , , , , \ Bi^dar^thLFc Hinh Duong cong irng sudt biin dang cua vgt lieu thep khdng gi Di ddnh gia kha nang xay eae hien tupng nhan, raeh, biin dang trin chi tilt dap vuot, hdu bit cac phdn raim ta thuflng ldy kit qud phan tich qua trinh dap vuot so sanh vdi biiu dfl gidi han tao binh FLD (Forming Limit Diagram) FLD la biiu mfl ta gidi han biin dang ma d trang thai kira lo^i tdm cd thi chiu dyng raa khdng hi rach Nhiing biin dang cua eac pban tu tren san phara tao hinh dugc danh gia, pban tieh va so sanh vdi dudng cong gidi han biin dang FLD di kilm tra kha nang tao hinh cua v|t lieu Trudng hgp biln dang tam thudng dugc xem la bai toan biin d^ng phang, d dfl biin dang theo phuang vudng gflc voi mat phdng tdm eoi bdng Hai thdnh phdn biin dang cfln lai, biin dang cd tri s6 Ion ban dugc ggi la bien dang Khoa hoc & Cdng nehe - S6 3/2014 II ] \\^ M M \ \ \ ' I i\^v^»o; ;: •"i \ g in 02 ~ AtJS -at -03 -02 01 • Dl a2 03 0.4 a s Bien dang phu £2 •>' Hinh a) Vdt mdu sau bjphd hiiy deo; b) Du&ng cong gioi hgn tgo hinh Phutmg phap mfl phong phan tir huu ban 3.1 Md hinh chi tiit Nghien ciiu su dung phdn raem Dynaform 5.6 di mfl phflng qua trinh dap vuot chi tiit khay com tu vat lieu tam thep khflng gi (SS304) Hinh la mfl hinh eho qua trinh dap vuflt Trong COI dugc giir co djnb, chay va tdm chdn mang gan Journal of Science and Technology 25 ISSN: 2354-0575 vuflt CO thi di chuyin tbeo phuang thang dung He sfl ma sat giiia phfli vdi chay, cdi va tam chan dugc gia dinh la 0,1 Chiiu eao gan vuflt gia dinh la 5ram FEM se dugc kit hgp vdi phuong phdp mang tryc giao Taguchi Hinh Md hinh ddp vudt cho chi tiet khay ecrm Hinh Ket qud md phdng vai tieu chuan phd huy tren phdn mem Dynaform FLD Trong qua trinh dap vuflt ta can tfli uu hda sdn phdm di giam bdt sy phd buy dang ke ciia vat lieu ciing nhu cac phdn nhan, rach san pham 3.2 Mang trwc giao Taguchi Khi dap vuflt khay cam tu phfli dang tam dfl kieh thudc phfli ban dau can phai duge xac dinh day cflng cu ttai phfli ciia phan mim Catia mong thi sy pha buy deo efl khuynh huong xuat dugc su dyng dl ty dgng tinh toan kich thudc hien gdn chfl ban kinh gflc lugn ciia chay vd coi phfli tu mfl hinh san pham thiet ke nhu hinh Hien tugng dfl xay la img suat va biln dang tai Ifln ban cac viing khae Do vay niu ta thay dfli cac diiu ki|n tao hinh hoac cac thong sfl hinh hpc cua chay va efli thi Ion ciia ung suat va biln dang cung se thay dot keo theo cae gia tri phd buy deo (FLD) Cling thay dfli Dfl chinh Id y tudng cho viec cai thien kha nang tao hinh cua qua trinh dap vuot Phuang phap Taguchi la phuang phap xii iy thflng kl thuc nghiem, phuong phap da cfl tu lau va hien da dugc dp dung phfl bien cho nganh ky thuat Phuang phap Taguchi dugc su dung rong rai trin thi gidi, dae biet rat hiiu ich cho viec lam thi nghiera rfli thflng kl sfl lieu Thflng qua phuong phdp eac ky su se de dang tim phuang an toi uu nhat sau cac ldn thi nghiim lay sfl lieu Su dung phuang phap Taguchi se tim sfl lieu toi im nhat tiiy thupe vao ede yeu tfl dnh hudng den qua trinh thi nghiem va chdt lugng san phdm cung nhu gia i ^ H H i m il\^yy/ Theo phuang phap Taguchi thi cae gid tri (FLD) cang nhfl, day nhfl nhdt {t^J ciia chi tilt sau gia cflng cang ldn thi kha nang tao hinh cua san |T"TT pham cang tflt Ty le S/N (;?, {dB) signal-to-noise) dugc xdc djnh theo cdng thdc : MM-_ 2l "Q WC- Hinh a) Sdn phdm cdn gia cong b) Phdi sau trdi nho phdn mim Catia Dl dy doan cac hien tugng pha hiiy deo dya trin tiiu chuan duong eong gidi ban tao hinh FLD Cac dii lieu thyc nghiim muc dugc dua vao phan mem de mfl phflng hien tupng xay ehi tao khay com Nhu dupe chi hinh niu cac diiu kiln tao hinh nhu luc kep, ban kinh goc lugn ciia ehay/cfli va gflc nghiing tao hinh khflng phii hgp thi hien tugng pha huy se xay Do di cai thien chat luang qua trinh tao hmh, mfl phflng sfl 26 Khoa hoc & Cong nghe - S6 3/2014 J?,('(iB;=-10Iog,o(dn) (2) Bang I Cdc he sd vd cdp ciia chiing md phdng Cap Cac he s6 Luc chan - Q (tdn) 10 15 Ban kinh c6l - R^{mm) Ban kinh chay - R^ (mm) Goc hinh hoc - a (do) 15 17 19 Journal of Science and Technology ISSN: 2354-0575 Cdc dnb hudng cua lue ehan, bdn kinh efli, bdn kinh chay, gflc binh hgc din khd ndng tao hinh eua san phara se dugc tim hiiu Bang I lilt kl eac cap dp lya chgn cac tham sfl Bang Kit qua md phdng theo mdng true giao Taguchi Cac h | so STT e R^ (mm) Ket qua (mm) A (do) 6,34 (tan) R^ (imn) Kl, (mm) a L 7, (dB) (tan) 1(5) 1(4) 1(4) 1(15) 0,42 7,576 1(5) 2(6) 2(6) 2(17) 0,48 6,339 1(5) 3(8) 3(8) 3(19) 0,55 5,114 2(10) 1(4) 2(6) 3(19) 0,48 6,339 2(10) 2(6) 3(8) 1(15) 0,51 5,815 2(10) 3(8) 1(4) 2(17) 0,43 7,230 3(15) 1(4) 3(8) 2(17) 0,51 5,900 3(15) 2(6) 1(4) 3(19) 0,44 3(15) 3(8) 2(6) 1(15) 0,46 6,651 Trong qua trin mo p long CO cap ciia (do) (•) 6,46 6,60 6,44 7,33 6,44 6,68 6,49 6,58 6,33 (*) (*) 6,2 (*) 5,61 Tatca 0,084 1,68 0,114 2,27 4,449 88,56 0,330 6,58 5,024 (Ljoyi I 7,190 timg h| so duac lua chpn nin mang tryc giao L^ se dugc diing de thiet ke quy hoach thyc nghiera Khi dfl tfli thiiu thi nghiem la can thilt cho vile kiem tra dnh huong cua cdc tham sfl thay dfli qua trinh mfl phong Vi|c su dung thudt toan tryc giao Taguchi se giam so luong thilt ke thyc nghiem tu 4^ thi nghiim xuflng efln thi nghiim, Cac kit qua mfl phflng theo bang thuc nghiim Taguchi dugc ehi nhu bang Kit qua md phdng theo mdng true giao Taguchi: Theo nhu phuang phap Taguchi, phan tich phuang sai (ANOVA) duoc sd dung de mieu ta cae quan h | giiia cac tham sfl va gid tri quan sat dugc eua phd buy deo, day nhfl nhat eiia chi tilt sau gia eflng Tong hgp cac kit qua tinh loan vdi cflng thiic tinh tdng binh phuong nhu sau (mji - m) ^ + (m^^ ~ m) + (mj3 ~ m) ^3^ Trong do: m la gia tri trung binh cua tat cac ti so nhilu oa ' *•••*' :^^ ^ Hinh Kit qud md phdng cho dieu kiin tdi uu a) chieu ddy nhd nhdt vd b) tdt cd cdc diim Men dang deu ndm du&i duang gi&i hgn tgo hinh Qua vile mo phdng va thyc hien eac dieu kiln tfli uu boa qud trinh dap vuflt Thi phuang an vdi lyc chan-Q^5 tdn, ban kinh coi-R =8 mm, ban kinh chay - /?, = mm, gflc hinh hpc - a = 19° tao chat lugng san phara tot nhat khong cfl (S/N), m = ( / ) ^ ' =6,462 pha huy deo xay Qua vile su dung raang tryc giao Taguchi ta thay tham so lyc chan va ban kinh m la gia tri trung binh ti sd nhilu cho tham COI dnh huflng it tdi chat lugng san pham, ma chu yeu la ban kinh chdy (88,561%) va tilp theo la gfle sfl j va gia tri cdp dg thii i, m^, ^ (1 / ) j (^j.' • • hinh hgc (6,582%) Vay ban kinh ehay la tham sfl quan trgng nhat anh hudng den kha ndng tao hinh Bang Anh huong cua cdc thdng sd theo ANOVA cua vat lieu qua trinh mfl phong Gia tri (dB) Gia tri trung binh r/ Tong ciia cac cap cho timg tham sfl dugc chi ro Phin cua timg cap dg binh Hls6 bang Theo nhu Taguchi gia tri nhfl nhdt eda 7} se bo 1 phirtfng cho kha nang tao hinh tflt nhat do cae he sfl nen •" Khoa hoc & Cona nehe - S6 3/2014 Journal of Science and Technology 27 ISSN: 2354-0575 duac lua chgn vdi edp dp nhfl nhdt eua n Nhu vdy ta se thiit k i bg khufln chi tao chi tiit khay com theo cac thflng sfl sau: Luc c h a n - = tdn, ban kinh efli - i?, = mm, ban kinh chay - R^,^ = mm, gflc binh h g e ' - a = 19° se cho kit qua san phdm tflt ban Hinh mo ta kit qua mo phflng cho diiu kien tfli uu h-ong qua trinh chi tao khay cam lam tu v^t heu thep khong gi bdng phuang phdp dap vuflt Trin dudng cong gioi ban tao hmh khdng tin tai bdt ki mflt diim phd buy ho^c xudt hi|n vit n ^ nao Ket luSn Nghien edu da su dung kit hgp phdn m i m Dynaform vd Catia d i tinh toan vd thiet k i san phdm Md phong qua trinh dap vudt b-ln Dynaform, tim phuong an tdi uu curig nhu thdng s6 anh huong qua trinh dap tdm d i td dfl tiiii tdi viec thiit k i vd dua quy trinh cflng nghi, ehi t^io khufln dap khay com khong cd sdn phdm bi nhdn, rach Bdng phucmg phap Taguchi kit hgp mo phong qua phdn m i m Dynaform, nghiin cuu da chi dupe vung rach, vung co v i t nut va vung an toan trsn b i m | t san phdm khay cam sau dap vuot; dua duge ban kinh chay la thflng sfl anh hudng quan trpng nhat den chat lugng t£io hinh san phdm khay com Tai Ueu tham khao [1 ] Nguyen, D.T and Kim, Y.S., "Combination of isotropic and kinematic hardening to predict fracture and improve press formabihty of a door hinge", Proe Inst Mech Eng., Part B: J Eng, Manuf., Vol.224, pp 435-445, 2010 [2] Nguyen, D.T., Park, J.G., Lee, H.J and Kim, Y.S., "Finite element method study of incremental sheet forming for complex shape and its improvement", Proe Inst Mech Eng., Part B: J Eng Manuf., Vol.224, pp 913-924, 2010 [3] Nguyen, D.T., Kim, Y.S and Jung, D.W., "Finite element method study to predict spring-back in roll-bending ofpre-coated material and select bending parameters ") " Int J Precis Eng Manuf., Vol 13(8), pp 1425-1432, 2012 [4] Taguchi, G., On-line Quality Control during Production, Japan Standard Association, Tokyo, 1981 [5] Heeker, SS., "Simple technique for determining forming limit curves" Sheet Metal Industr Vol 52,pp 671-676, 1975 Abstract: To predict and improve formabihty of deep drawing process for steel lunch tray made by sheet metal forming, processing and geometric parameters of blanking force, die/punch comer radius and wall angle of product were considered according to Taguchi s orthogonal array then coupled with the finite element method (FEM) simulations The data from the stress-strain curve equation and forming limit curves of major/minor strain were adopted as the input data for simulation process in order to predict the product formabihty after deep drawing Depend on the effect of selected parameters on formabihty of lunch tray, ANOVA analysis was performed to evaluate their contribution levels on the press formability and give the optimum conditions Keywords: Deep drawing Lunch tray, FEM, Sheet material, ductile fracture criterion Ngirdi phan Men: PGS.TS T r m m g Ngoc TXian 28 Khoa hoc & Cong nghf - S6 3/2014 Journal of Science and Technolosv ... 2354-0575 phii hgp lot nhat cho vdt li|u tdm Do du lieu thuc nghiim td dudng cong t^o hinh FLC cua vat ligu gia cong da dugc dua vao de md phflng qua trinh d^p vuot tao hinh khay cam Cac tham sfl dnh... phara khay com Cae kit qua mo phdng theo bang tryc giao Taguchi duge su dung dl phan tich cac cap dp anh hudng ciia cdc tham sfl din chat lugng tao hinh san pham Bg thflng sfl hgp ly se dugc lya chon... ra|t tai cac vi tri cho vat lieu thep khong gi SS304 duge su dung dl nut, rdcb va khdng rach ciia vat mau se dupe dac tinh toan cae biin d^ng chinh, phy Cdc dii lieu dd ehi tao khay cam theo phuong
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