ứng dụng dập thuỷ tĩnh dập vuốt chi tiết dạng tấm trong ngành công nghiệp ôtô

NGHIEN CUU LFNG DUNG DAP THUY TTNH DAP V U O T CHI TI^T DANG TAM TRONG NGANH C N G NGHIEP OTd U Trung Ki^n', Pham Van Nghf', Dinh VSn Duy= 'Traesng Dai hgc Bdch khoa H i N6i, 'Vi$n Miy vi Dyng CM C6ng nghifp - IMI TOM TAT Cong nghe d^p thuy tinh Id mot nhvCngphUOngphdp gia cdng tao hinh vAt liiu tdtn tiin tih sit dung chdt ldng cao dp di'ddp vuot cdc chi tiifl dang tdm Nhd nhSng Uu diim noi bdt ciia phUdng phdp nhu tdng khd ndng bien dang cua vdt lieu, ndng cao chinh xdc cdng nhUchdt lUdng bi mdt, cO ~ ly tinh cua vdt hiu tot, khong cdn gia cdng chdy nin gidm cht phi chi tao khudn Cdng nghi dap thuy tinh dang dUdc dp dung hieu qud dctao hinh cdc chi ttet dang tdm vd ong, ddc biit Id ngdnh Cdng nghiip to de chi tao cnc chi tiet phdc tap md cdng nghi ddp vudt truyin thdng khd thtic hiin Bdi viit ndy trinh bdy nhdng kit qud nghiin cUu ban ddu vi cdng nghi ddp thiiy tinh diiu kiin sdn xudt tqi Viit Nam ABSTRACT Hydroforming - advance technology is a method for deep drawing of sheet using high pressure oflitpdd Based on many outstanding advantages such us increasing of deformation limit of material improving accuracy of product as well as surface quality reducing of costs for die manufacturing, this method is widely usii^^ many Industrial fields, especially In the automobile Industry, to producing of complicated partsfrom sheets and tubes This article presents the research results of this technology with considering of Vietnam's conditions I.DATVANDE Viec tao hinh chi tiet c6 chi^u sau dap vuot ldn tii tam bang cong nghe truyen thong diigc gi6i han bdi cac yeu to nhii: tinh deo vat lifu, ilng suat chiy, ma sit giiia phoi vi dung cu, cac yeu to thong thucmg dugc danh gia bdi he so dam vuot m Khi dap cac chi tiet dang cau bing chiy ciJng - coi Cling thong thudng kho khan bdi vi phan ldn be mat cua phoi khdng bj ep bdi chiy d giai doan bat dau dap vuot dd chi tiet sau djp de bi nhan va bien djng khong ddng deu Phuang phap dap tao hinh thuy tinh (hinh 1, 2) li i p suat chSt cong tic se tac dung dtfu len be mat ciia phdi, dd chi tiet dap se bien dang dong deu, nang suat cao Cdng nghe niy ap dyng cho cac chi lift ddi hdi chinh xac cao vi ciu triic dong nhat, hinh dang khdng gian phUc tap, ho?ic vat Heu vdi tinh d^o tUdng ddi thap TAP CHl CO KHl VIETNAM • nguon: lUL, Dortinun lio nguyen ly dap tliuy tinh chi tiel CK" tru Iihung sii' dung doi ap ,f^ n — — • ^ ^ _ nguon: lUL, DdBK Hinh 2: So dfi nguyen ly dap thuy tinh chi tiet dang coc try co ddi ap s a (Thang nam 2012) m2012) NGHIEN CUU - TRAO e(!)l Tuy nhiin, phuong phap van cdn mpt sd nhuoc diem nhU sU chay khdng dn dinh eiia mat bich phdi d cde phan khdc tren vdnh mep cua chi tilt ddn din nhdn mpt phia cua mat bich phdi Nguyen nhdn Id sU khdng ddng dlu eua trd lUc biln dgng vd lUe ma sdt xuat hien giUa mat bich phdi vd dung cu; lUflng biln mdng qud ldn va dp khdng ddng dlu theo ehilu ddi eiia chi tilt la dang ke ldm gidm chat lUflng eua ehi tiet dap vi vdy nd cUng cho thay khd nang cdng nghe edn han chl ldng cdi Cling cd hai phuong phap chinh la cd sU dieh ehuyln mat bich va khdng cd sU dich chuyen mat bich (hinh 4) ^C^ 1-Chan 2-Cdi nguon: [1] 3- Mat bich phoi Hinh 4: Cac phUOng phap thUc hien qua trinh ddp vudt bang chay chat Idng theo cdi cUng a - Khi Ididng dich chuyin mat bich b - Khi CO dich chuyen mat bich Dap thuy tTnh nguon: Burk( 1963) Dap vuot truyen thong Hinh 3: Cong nghi dap thiiy tinh lam giam so lUOng nguyen cong So vdi ddp vudt truyin thong, dap thuy tinh cd khd nang riit ngan sd lUflng nguyen cdng mpt each ddng ke (hinh 3), ddng thdi ndng cao chat lUflng b l mat, hinh dgng chi tilt thudng phUe tgp Vdi nhUng Uu dilm trln day cdng nghe dap thuy tinh phdi tdm can thiet nghiin cUu va phdt triln vdi dieu kiln Viet Nam nham hUdng tdi npi dia hda eac chi tilt dgng tam vd dtd vd xe may CAC T H N G S O ANH HlTdNG TC(I QUA TWNH TAO HINH THUY TiNH VA CHAT LUONG S A N PHAM Dap thuy tinh kim logi tdm bang chay chat Cd nhieu cac thdng sd cdng nghe, yeu td anh hudng qua trinh dap thuy tinh tdi chat lUflng cua sdn pham nhu be mat chdn, lUc chan, ban kinh gdc luon long cdi, dp suat chat long cdng tde, hinh dgng cdi, lUc ma sat giUa phdi vd b l mat chan Cdc thdng sd quan he ham sd vdi nen nghiin cUu ddng thdi cae thdng sd ndy thudng gap nhilu khd khan Trong gidi hgn bdi bdo ndy, xin trinh bdy mdt trUdng hpp dien hinh ddp thuy tinh theo phuong phdp cd dich chuyen phdi, khdng ddi dp vd gidi hgn cae thdng sd bao gdm: - Ap suat thuy tinh tao hinh q^ - Ap lUc chan lln phdi q^j^ - Ban kinh long cdi r^ THf NGHIEM XAC DINH KHA N A N G CONG NGHE D A P THUY TINH P H O I TAM Bang phuong phap thUc nghiem chung ta cd the xac dinh sU thay ddi cae thdng so q^, q^j^, r din chat luong va sU hinh sdn pham TAP CHf CO KHi VIET NAM V Sd (Thang nam 2012) NGHIEN CUfU - TRAO D C I qua trinh djp thuy tinh Stend thi nghifm dUcJc thiet ke bao gdm cic phan thd sau (hinh 5); ilir I.in, lii.iJuiii i.ii phjn gi' l.nn ili.iii v.i kcl nm cii iil lliniij;ill.lll|.l - Hf thdng cung cap chit Idng cao i p (1) - Hf thdng chan phdi (2) - Hf thdng ludng cac thdng sd: ip suit, [^ • hinh trinh, (3) \ ^ - Khudn thd nghifm (2) • * ^ ''JS^'^ S o d d h f t h d n g d U g c t h i f t k^ n h i l sau: _ _ ^ ^ ' *fr ^^"' I ^•''* • t- III ik^c A-A C Hinh 5: So dd thi nghiem cac thong sd dnh hUdng IL He thdng tdng dp dung d l cung cap chat long dp suat cao vao long cdi Sau he thdng chdn thuy lUc di xudng de chan phdi, chat long cao dp dUflc cung cap bdi he thdng tang dp se dUflc bom vdo edi, lUe thuy tinh tdc dung lln b l mat phdi si qua trinh biln dang deo dd phdi dupe biln dgng theo long cdi He thdng tdng dp dynatronic cho dp suat chat ldng cdng tdc den 4000 bar - -4^ y ! • —q il , i v a i i u i m liuo l.iinilcni S : -; -^srw I ' : Cdi De tren Tim bao vf Ngudn: ngudn tang ap dynatronic Hinh 6: He thong tang ap DYNATRONIC 403s He thdng chin dugc tinh toin, thiet ke TAP CHl CO KHl VIET NAiM • Hinli 7: Hiin veva liinli anli klmdn thi nghiem Sd (Thing nam 2012) NGHIEN CUfU TRAO 061 K i : i Q U A VA I H A O I.IIAN T ,.\p suat siuil chan cdi San p l i i m (Ml bar bai S.iii p h a m Tiich lai d i n h ciiu :i()() bar bar San p h a m t a o h i n h c h u a d a t H i n h S: He thong d o cac ihong so 30 350, bar 600 bar San p h a m l a o h i n h c h u a d a t 45 700 bar bar S 111 p h a m d a t y e u c a u n h u i i g H i n h 9: Khuon - Nguon cao ap - cliai c