Thiết kế, chế tạo hệ thống thiết bị dập thủy tĩnh chi tiết dạng tấm có hình dạng phức tạp

NGHIEN CUfU-TRAO Ddi THIET KE, CHE TAO HE THONG THIET Bj DAP THUY TTNH CHI TIET DANG TAM CO HlNH DANG PHLTC TAP DESIGN, MANUFACTURING EQUIPMENT SYSTEM FOR HYDRO-STATIC FORMING OF COMPLEX SHAPED SHEET Le Trung Kiin', Pham Van Nghe', Dinh Van Duy^ 'TrUdng Dai hpe Bach khoa Ha Npi ^Vien Miy va Dung cu Cong nghiep IMI, Bp Cong ThUpng Cong nghe dap thuy tinh la mgt nhdngphUdngphdp gia cong tgo hinh vdt lieu tdm vd ong tien tien sd dung chat long cao dp de tgo hinh cdc chi tiet dang tdm, ong Cong nghe ndy phdt trien tU ddu nhdng ndm 90 vd dUdc dng dung rgng rdi sdn xudt tgi cdc nUdc cong nghiep phdt trii'n bdi co nhdng Uu diem ndi bgt nhu gidm so lUdng nguyen cong, be mat khong chdy xUdc, mde dap vuot ldn Viet Nam hien chUa co mgt cd sd ndo trien khai dng dung cong nghe ndy, do viec nghien cdu cong nghe vd thiet bi chi tgo cdc chi tiet co hinh dgng phdc tgp Bdi viet ndy trinh bdy nhdng ket qud nghien cdu, thiet kevd chi'tgo thiet bi vd cong nghi dap thuy tinh cho chi tiet dgng tdm co hinh dgng phdc tgp ABSTRACT Hydrostatic forming is one special technology using of fluid with high-pressure for forming of sheet or tube parts This technology was researched from the early 90's and is widely applied in industrial production fields in the country developed cause prominent advantages such as reducing the amount of raw, non-abrasive surface, high drawing rate In Vietnam, upto now, there are only a few studies on this technology and equipments for manufacturing of complex parts and there is not nany factory, which applies this advanced technology Therefore, this article presents the research results about design and manufacture of technology and equipments for hydrostatic forming sheet parts with complex shapes D A T VAN DE kin khit eho khudn gap nhieu khd khan Cong nghe dap thuy tmh ehi tiet dang tam cd hinh dang phdc tap doi hdi thiet bj, eong nghi di kim k h i phdc tap Chat long cao ap dUpc dUa vao ldng edi tao hinh khoang 500 den 10,000 bar Diy la khd khan Idn eho eong nghi niy bdi van de tao nguon chat Idng cao i p va Hien tai, trin the gidi eo nhiiu nha sin xuat thiet hi eung cap nguon chat long eao ap nhU: Novaswiss, Maximator, SC Hydraulic Engineering Corporation, Bohler nhien eac thiet bi niy dit tien, viee dau tU ddng bp he thong dap eong nghi dap thuy tinh k h i ton kem ^ TAP CHf CO KHf VIET NAM V S6 l+2(Thang 1+2 n a m I ) NGHIEN CUU - TRAO D O I bp tai phan trung tam cua s i n pham Cac thong so qua trinh, i p suat tao hinh can thiet, lUc ehan, lUe ddi i p se dUpc h i thong thu thap v i xd Iy tin hiiu lUu dudi dang file *.txt Thiet ke tong the he thong d i p phoi tam bang cong nghe d i p thiiy tinh dupe trinh biy hinh Thanh phan h i thdng thiet bi dap thuy tinh bao gom: Nguon : Linee P.Sunny, Nijil Ismail Htnh Sddohi thong ddp thuy tinh phoi tdm H i thong n h i m d i m bio dap dng theo yiu eau eong nghe theo sP hinh - He thong cap chat long eao i p (1) May ep (hi thong chin thuy lUe) - (2) Khudn thi nghiem (3) He thong doi ap eho khuon (4) He thong thu thip v i xd ly tin hiiu (5) 2.1 H i thong cung cap chat long cao ap Ngoii mue dieh nham dUa cong nghe niy vio san xuat tbUc tiin, h i thong eon ket hpp thu thip dd liiu va kiem soit cie tinh nang can thiet cho nghiin edu He thong tang ap cung cap chat long ap suit cao vio long coi thuy tinh Nguyin li boat dpng cua he thong khuon thuy tinh phoi: Sau he thong ehan thuy lUc di xuong, ehat Idng eao ap dUpe cung cap bdi he thdng tang ap si dupe bPm vio eoi, lUc thuy tinh tie dung len b i mat phoi se q u i trinh bien dang deo do phoi dUpc bien dang theo long eoi Van de dat thiit ke, lUa chpn h i thong tang ap eho bp khuon li: Nguon: Taylan Altan - H i thong tang i p phii tao dupe ap suat thuy tinh du ldn de thUe hien qua trinh bien dang deo tao hinh chi tiet Hinh Qud trinh ddp thuy tinh phoi tdm THIET KE HE THONG THIET BI D A P THUY TINH P H I TAM * Qua trinh va dieu kiin bien la mpt nhdng thong so quan trpng thiet ke thiit hi Thong sd lUe ehan q u i trinh tao hinh la mpt thong so danh gia ning lUc cua may ep, thong so niy ed the Ude tinh thd tUong duong vdi lUc chin nguyin eong d i p vuot truyen thong, hiin miy ep ldn nhi't dat lue chan khoang 500 to 600 meganewtons H i thong doi ap cung dupe tinh toin va thiet ke nham giim sU bien mdng cue TAP CHi CO KHi VIET NAM • - The tich ting ap phai dia de tao hinh ehi tiet / / • ^ 0' ) I'T Hmh Sd he thong thi nghiem thiiy tinh S6 1+2 (Thang 1-1-2 nSm 2013) NGHIEN C I A J - TRAO D O I Hien nay, d Viet Nam, van de dau tU mdt he thong cap chat long eao i p khd khan bdi gii cao Chung tdi da lUa chpn h i thong tang i p ciia miy eat tia nUde DYNATRONIC 403s de nghien cdu thd nghiim vdi ngudn eao i p 500 H-4000 bar sd dung chin hay khong chin Stf dung ehan de dam bao cho san pham dUpc tao hmh nhU mong muon, khong hi nhan, rich Chan thUdng dung la eic cP cau chin ca hoae ehan 16 xo, thuy lUc, dupe liin dpng vdi chuyen dpng cua chiy, cd the sd miy hoac ehan dpc lap He thong ehan eP (16 xo) ed die diim lUe ehan tao li tuyen tinh tang theo banh trinh, khd cd the dieu chinh dUpc qui trinh ehan dong thdi Mat khic, dng vdi moi khuon nhat dinh thi phai cd mpt he thong chan di kem, h i thong chin edn phii thiet ke cho phu hpp vdi loai may sd dung Chinh vi nhdng Ii nhU trin, viee lUa ehpn he thdng ehan thuy lUc cho khudn dap thuy tinh va thiet ke dpc lip vdi he thong tang ap la phupng i n toi Uu -Bg tdng dp; - Nguon thuy lUc; - Bg dieu khien dien; - He thong loc nUdc vd cdp nUdc trUdc tgo dp Hinh Sd kit cdu he thdng chdn thuy lUc Kit eau bao gdm hai hi thdng cbinb la hi thong thuy lUc vi hi thong eo Thanh phan tram ngudn bao gom: Hinh Sd thuy lUc he thong tdng dp Thung dau BPm Van phan phoi 4/3, 3/2 - Dpng CO - Van an toin - Ddng ho 2.2 H^ thdng chan thuy lUc Hi thong chin thuy lUc la mot miy ep thuy lUc vdi kha nang tao lUe chin cho eic chi liet dip vuot Can ed vio ty li gii3a chiiu cao/ dudng kinh hoae chieu eao/ b i rpng ehi tiet hpp cua nguyin cong dap vuot de quyet dinh viic ed Thinh phan eO bao gom bao gom: - xi lanh 4)100mm - Tam tren - Tam dudi - He thdng xe - Cac kep khuon - Ga khuon dudi TAP CHf C O KHf V I £ T NAM V S6 l+2{Thang 1+2 nim2013) Q NGHIEN CUfU TRAO OOl 2.4 H i thdng ddi ap cho khuon Hmh Chi'tgo phdn cd hi thong chdn •• 1 Hinh 10 He thong doi dp khuon ddp thuy tinh Hinh Che tgo phdn thuy lUc he thong chdn He thong doi i p eho khuon thi nghiim dupe thiet ke nham Iam giam sU bien mdng cue bp tai phan trung t i m cua ehi tiet phan niy bi bien dang tU Ngoai ra, he thong doi ap co nhiem vu nham han che sU ap sat cua chi tiet vio long eoi tai nhdng diem bat dau di qua goe lupn eua cdi l i m ma sat tang lin dan den khd keo vit lieu vao eoi Chung toi thiet ke he thong ddi i p sd dung xilanh chieu dong thdi kit hpp hinh trinh chi tiet dip Kit cau eua he thong dUpc trieh tif nguon dau cua h i thong miy ep chin Hinh Lap rdp tong the hi thong chan 2.3 Khuon thi nghiem 2.5 He thong thu thap va xu( ly tin hieu Cin cd vio mo hinh san pham nghien cdu cie thong so ep ban gia eong ehe tao ehi tiet dang cau dudng kinh D50 mm Khuon DTT gdm bp phin: _, Cau true cua h i thong i p suat • hanh trinh gom 03 bp phin itDJuiia i Citabka I t p UMT K? nnfTBiGu CONOTiS HIEU DO r—» AOClH ckqM IV-lip " Viplu ncTtiJ L_:— ».«iJ!l Hinh Khuon ddp thuy tinh I Di-khuon dUcii Tam,lemc6i,i.Bu{6ngMS,4 Cat, Tdm Khuon tren, De khuon tren, S Buldng MS, Gioang, 10 Bu II Chot dfii ap, 12 Tarn day, li Biso ve, U.Xilanh dot dp TAP CHl CO KHi VIET NAM Hmh ll.Sddo khoi he thong vd thu thdp tin hieu S6 1+2 (Thang 1+2 nam 2013) NGHIEN CUfU-TRAO Ddi Khi CO sU thay doi v i i p suit tao hinh, i p suat ehan, i p suat doi i p va hanh trinh dap, cie cam bien se tiep n h i n sU thay doi va chuyen doi tin hieu diin Tin hiiu dien dxiac dUa tdi thiet bi gia cong tin hiiu Tai diy, tin hieu dUpc khuech dai v i lpc nhiiu cao tan roi dUa tdi bp phin chuyen doi tUPng tU - so roi vio miy tinh Tai miy tinh, tin hiiu dupc hien thi v i luu trd nhd phan m i m Dasy Lab 7.0 © H i thong dupe cac thdng so tao binh Hinh 14 Hi thong thi nghiem lap rap hoan chinh Hmh 12 Cdc thiet hi dp sudt I Sensor ap suat H^ thSng thu thdp tin hieu Phdn mSm xH ty vd hiin thi 3.2 Thd nghiem h i thdng Sd dung md hinh thi nghiim de tao binh chi tiet dang eau dUdng kinh D50mm Bang mo phong so, lan lupt tim eae thong so tao hinh gom lUe ehan, ip lUe tao hinh cac ket qua md phdng dupe dat vao he thdng thUc nghiim Sau diy Ii kit q u i mo phdng vdi cae thong so eua eic thong so: LUc chin: 38 Mpa V '"^^^^ Hmh 13 He thong cdc thdng sd Ket qua mo phong LAP R A P V A THU' NGHlfiM HE THONG THIET BI p iuai [barj 3.1 Ldp rdp vd cdn chinh he thong He thong thiet bi difoc lap rap va can chinh dim bao cac yeu cau nhii: ^ Ltfc chan : + 300 Mpa Ap suat tao hinh : 0+ 4,000 Bar Life doi ap : + 100 Mpa HJnh trinh : + 150 mm TAP CHf CO KHf Ket qua ihilc nghiem Hinh 15 Chi tiet thUc nghiem tren he thong thiet Icl ^ h ^ ^ 10 ^^.-^"-'^^ ,^'^ 15 a j JS J> HaiLJKn.u, [nimll Htnh 16 Bieu dp sudt - hdnh trinh tao hinh chi tiit cdu bdng thUc nghiem '^^ VI£T NAM S6 1+2 (Thing 1+2 nam 2013) Q NGHIEN CUfU-TRAO Ddi Thuc nghiem cho thay i p suit can thiet de tao hinh chi tiet chdm cau D50 m m hanh trinh dat 25 mm la 300 bar Khi ap suit tiep tue tang len khong anh hUdng hay Iam rich sin pham vi phoi da i p sat long cdi Hudng nghien edu tiep theo se tien hanh thUe nghiem dac eae thong so nham toi Uu mien i p suit lam viec, xiy dUng dUdng quan he ap suit tao hinh, lUc ehan, lUc doi i p theo h i n h trinh gida mo phong v i thue nghiem KET LUAN Dap thuy lUe ndi ehung hay Cong nghe d i p thuy tmh ndi riing li mpt phUPng phap gia eong ap lUe tiem ning, dng dung rat nhieu thUc te san xuat nginh oto xe may tai eae nUde phit trii'n H i thong dUPe thiet ki phu hdp vdi dieu kien san xuat tai Viet Nam Vdi h i thdng tao hinh cic ehi tiet dang tam dpn dam bao san pham chat lupng va k h i n i n g tao hinh He thong thUe nghiem dUpe xiy dUng ca ban dam b i o dp ehinh xac de thi nghiim va lay ket q u i dong thdi ed Uu diem thuan Ipi eho viec trii'n khai sin xuat thd nghiem va cong nghiep sau niy tai eic nha m i y Viet Nam • Ngay nhan bai: 05/01/2013 Ngiy phan biin: 05/02/2013 NgUdi phan biin: TS Tran Anh Quan, Giim doc Trung tam Dao tao, Viin May va Dung eu Cong nghiip IMI, Bp Cong ThUPng Tai lieu tham khao: [ ] Pham Van Nghe Cong nghe ddp thuy tinh, NXB Bach khoa - Ha Noi, 2006 |2] Nguyen Mau Dang Cong nghi tgo hinh kim logi tdm, NXB Khoa hoc Ky thuat - Ha Npi, 2006 [3].LANGEK: Handbookof metal forming: McGraw-Hill, New York, 1985 [4] Taylan Altan Processes for hydroforming sheet metal, www.stampingjournal.com, February 2006 TAP CHf CO KHf VIET NAM • S6 1+2 (Thing 1+2 nam 2013) ... thdng chan thuy lUc Hi thong chin thuy lUc la mot miy ep thuy lUc vdi kha nang tao lUe chin cho eic chi liet dip vuot Can ed vio ty li gii3a chiiu cao/ dudng kinh hoae chieu eao/ b i rpng ehi tiet... i p 500 H-4000 bar sd dung chin hay khong chin Stf dung ehan de dam bao cho san pham dUpc tao hmh nhU mong muon, khong hi nhan, rich Chan thUdng dung la eic cP cau chin ca hoae ehan 16 xo, thuy... dpng vdi chuyen dpng cua chiy, cd the sd miy hoac ehan dpc lap He thong ehan eP (16 xo) ed die diim lUe ehan tao li tuyen tinh tang theo banh trinh, khd cd the dieu chinh dUpc qui trinh ehan