NGHieNCCfU-TRAODOl PHAN TiCH QUY T R I N H C N G NGHE DAP CHr TlgT T A M MONG UNG DUNG TREN CABIN Td TAI NHE ANALYSIS PROCEDURE TECHNOLOGY OF SHEET METAL PRESSWORK APPLICATION ON CABIN OF LIGHT TRUCK ThS Nguyin li-jng Minh', PGS,TS Ngnyfa Thanh Quang^ 'Tntcmg Cao dang nghS Giao thong VSn tai Trung uong ^Tniong Bai hpc Su pham Ky thuat Hung YSn TOM TAT Bdi bdo trinh bdy tong qudt thiet ke vo Cdbin xe tdi nhe vdphdn tich quy trinh cong nghe ch tgo chi tiet tdm mong cua no Tinh todn luc cong nghe de chon mdy vd thiet ke khuon ddp Phdn tich cong nghe dgp tam mong co xet den dnh huong cua he so ma sdt den chdt luong chi tiet dgp Kit qud nghien citu thiet ke khuon phii hap v&i dieu kien hien t^i vd chii dgng che tgo cdc chi tie tdm mong tren cabin xe tdi nhe Tir khoa: Cabin xe tdi, tdm mong, dgp vuot ABSTRACT This article presents a generalized design light truck cabin and drmlysis procedure technolog ofmanufacturing its sheet metal part Calculate technologicalforce to select machine and desigi thepresswork die Analysis sheet metal presswork technology takes into account the influence o the coefficient of friction to the quality of the product The study resultsfitthe mold design curren conditions and proacttvely fabricating thin sheet details on the cabin of light trucks Keywords: Cabin of light truck, sheet metal, stretch forming presswork M- I,-, I„n * ! r w ' ^ ! * t ™ "S ""^^ ™°8 °gl'^ luon dupe chu y dau tu phat trien tai cac doanh nohim >ji„-,„„ „i,i I, /"",""='"?' ''IC aoann " ^ ^ S ^ ^ ^ ^ ^ ^ ^ don vi chu dong san x u C g l L gia t S Z pham va tang tinh canh tranh tren thi tnrdna cabin to tai miic dp phiie tap eia cong °8he chS tao tu cac chi tiet tim mong VifC nghien ciiu phan tieh mo phong qua trinh dap „£.;- • ! • _ j - •- • Ichi tiet vo cabin tren cac may dap hien co da conh^gkatquacthedadu^raLphlmca ^ " ' ' • * " ' P ^''• NOI DUNG NGHltN CUtJ Tren xe to, cabm chidm vi tri quan Irpng^tao hinh dang xe phii hop va dam bao tot dieu kien van hanh cua xe D8n ttong nuoc chua CO don vi nao diu tu ch^ tan • " '^ '^"^ * ° 2.1 T6ng quat vl vo cabin xe tai nhe r^ u • _ , Cabm tren to tai eo eac cong dung ISSN 0866-7056 TAP CHl CO KHi VIET NAM, S6 1+2 nam 2017 www.cokhivictnam.vn N G H I E N CO'U - TF_' chinh: Tao khdng gian cho ngudi Idi va ngudi ngdi, la kdt cdu chiu tdi la ca sd dd bd tri, lap dat cdc cum vd cdc he thdng trdn xe [1] Nhimg yeu can chung ddi vdi cabin: Phii hgp vdi chiic nang cua xe d td, dam bao ydu cdu vd mdi trudng van hanh cua xe, dam bao mdi trudng gjao thdng Ydu cau che tao cabin: Dam bao dugc yen cau chiic nang cua cabin (la tinh tien nghi cua xe, gidm met mdi cho ngudi Idi xe), du khdng gian bd tri nhiing ciim va he thdng didu Idiidn, cd kdt cau chiu tai tot, cd phuomg phdp che tao phu hop vdi trang bi cdng nghe nude tien to: cdng nghe hien dai, cd tinh lien tuc cdng nghd, tdn it nguyen vat Heu, chi phi san xudt thdp va cd kha nang thay thd phu tiing qud trinh su dung xe Trong van hanh xe cabin dam bdo tinh an toan tich cue (an toan chii ddng) vd tinh an toan Ihu ddng (bao gdm cdc dac tinh va chat lugmg ket can khung vd de xay tai nan dam bao tdn thdt la it nhat) Cabin d td tai gdm cdc bd phan chinh: Vd cabin, ndi that cabin (ghe ngdi, bang tdp Id, kinh chan gid, guong chidu hau), he thdng didu khien (didu khidu chuydn ddng, dieu khien din hudng, dieu khidn an todn, dieu Miiin tinh nang) vd he thdng dien, am thanh, didu hda Ididng va sudi ndng Vd cabin d td tdi dugc can tao thdng thudng tu khoang trdn 100 chi tidt don le [2] Cac chi tidt tdm mdng bdng kim loai cd dp ddy tir 0,8mm ddn 2mm dugc hdn vdi tao thdnh cdc mdng tdm vd ldp ghep bdi cac bu Idng hoac cac khdp ndi ban 16 tao than vd cabin hoan thien, hinh 1.1 < - < Hinh 1.1 Cdu tao vo cabin to tdi nhe: }) Tdng the cabin; 2) Cytn nac va.iam trudc cabin; 3) Cum tdm sau va khung sitcm, 4)Cifmsanxe; 5) Ci/m cdnh cuaxe 2.2 Thiet ki chi ti^t vo cabin Thidt kd vd cabin ngoai dgt cac, yeu cdu da neu tren muc 2.1 cdn nham gdp phdn tao dang xe td phu hgp my quan hien dai Cdc phuong phdp thidt ke tdm vd cabin thudng su dung gdm co; Phuang phdp cd dien: Su dung nhiing dung cu ca ban la thudc tren vdt mdu, tinh todn kiem nghiem theo truyen thdng bao gdm chu yeu tinh toan dp bdn Phuang phdp ung dung tin hpc thidt ke: Sii dung nhihig dung cu ca bdn Id thudc trdn vdt mau va ve phdn mem chuyen dung nhu AutoCAD, Solidworks, Catia va nhung p h ^ mem ve khdc Phuang phdp cdng nghe ky thuat sd: Su dung phuang phdp tidp xiic va khdng tiep xiic Cdc thiet bi CMM sii dung dd tidp xuc (Coordinate Measuring Machine la cac thiet bi van nang cd the thuc hien vide cdc thdng sd hinh hgc theo phuang phap tpa dp) Cdc thiit bi laser va quang hgc sii dung dd khdng tidp xuc Dien hinh cua quang hgc la quet bang mdy tao"^ ISSN 0866 - 7056 T^ CHl CO KHl V I £ T NAM, Sd 1+2 nam www.cokhivietnam.vn 2017 NGHIEN CCrU - TRAO Ddi anh sang xanh s6 hoa bi mat hinh hpc theo timg vung nho (vi du may ATOS), giam hot cac di&n d cic vi tri khong cin thiSt Nho co su giao thoa anh sang (patented ftinge) da tao dam may diem dft lieu chinh xac vk day dac Sau qua trinh qu6t, cae vung dupe sap xSp lai mpt each t6ng thi bdi phSn tnita chuyen dung (vi du phan mem GOM) de tao nen mpt dai may diem ba chiSu Kieh thudfc ciia dai may co the len den hang trieu diem Tpa dp cua nhiing diem dupe tinh toan dS thu dupe la dam mSy diem djly dac eo mat cit nhieu duong hay mo hinh da giac Kit qua nhJn dupe la mo hinh 3D ciia chi tiet c6 be mat phiic tgp Kiem tra chinh xac ciia mo hinh 3D nha sii dung phan mem ehuyen dung (vi du phSn mSm Geomagic Qualify) phan tich sai s5 cua toan bo qua trmh xft ly, thiSt k i Ta sft dyng kSt qua de hoan thien thiet kS nhSm lap quy trinh c6ng nghe ch8 tgo tftng chi ti6t phta Cac chi tiet tfim mong co chi^u day S < mm thuang dupe d|p vu6t vdi phoi o trang thai nguoi ma khong cin phai nung phoi Vat lieu su dung dl chg tgo cac chi tiSt dap va6t H kim loai tim co tmh deo cao nhu thep cac boa thip chit lupng va thep kSt ciu hpp kun thip, nhom, hpp kun nh6m, va cac kim logi khac, a) Tinh todn lire cong nghe dap vitdt * Luc cong nghS loo nhit nguySn cong dap vu6t CO tbi tinh theo c6ng thfte kinh nghi|i;i (2.1): P.„ = Lt.a, (2.1) Trong do; L - Kich thudc vung biin dang (mm); t - Chieu day ph6i (mm); a,, - LTng suit bin keo ciia vSt li?u (N/ mm^) b) Tinh todn lite chan phoi Lue chan ph6i hpp ly se tranh dujc khuySt tat co ban xay qua trinh dsip vuot la hien tupng nhan tren phin vtah hoac be mat cua chi tiit Cong thiic xae djnh lire chgn phoi co the xac dinh gin dung theo cong thuc kinh nghiem(2.2): a) Vo cabin scan 3D Q = (0,1+0,3) P,^„ c) Tdm noc scan 3D Hmh 2.1 Vo cabin xe Idi nhe sau Ichi scan 3D va lap bdn ve thiitki 2.3 Phan tfch quy trinh c6ng nghS dap chi ti§t vo tam mong tren cabin 2-3.1 Cas& hfa chon thong sdcSng nghe dap (12) Trong do: Q - Luc chgn phoi; ^mw" Lue c6ng nghe lan nhit c) Lifa chon he sdma sdt va chatboitnth Trong qua trinh dap ma sat da tao luc eta chuygn dpng trupt tuong dii giua kim loai va be mat dung cu DS giam ma sat chuag ta eta phai tiin htoh gia cong b6 mat khuSn dat dp bong ein thilt, ding thai nghiSn ciu ISSN 0866-7056 TAP CHi CO KHl VI£T NAM, Si 1+2 nam 2017 www.cokhivietnam.vn NGHIEN c u u - T F thay ddi vdt lieu lam khudn Dd xdc dinh l\rc ma sat trdn bd mat tidp xiic ta cd thd dua vdo cdc md hinh tinh todn Chat bdi tran ciing can dupe lua chpn hgp ly, thudng chpn loai ddu vdi he sd ma sdt cho khudn ddp la p, = 0,15 ndn diidt kd cdn tranh tac ddng udn hay keo dd tang dp cung viing ciia hai chi tiet due bang each thiet ke cho khdng sut dyng cdc tam ddm va ao khudn Vi dy bd khudn dgp vudt tam ndc cabin dugc md td ttdn hinh 2.2 d) Anh hif&ttg cua biin dcmg dan hdi t&i qua trinh d^p vuot Bidn dmig dan hdi lam thay ddi kich ihudc cua phdi so vcd kich thudc Idng khudn, hien tugng gpi la dan hdi ngupe Trong qud trinh udn, cac ldp kim logi nam viing keo se cd xu huong co ngdn lai, cdc ldp kim loai nam vung nen cd xu hudng gian Dg dam bao tinh chinh xdc kich thudc cua san phdm cdn giam tac ddng cua ddn hdi ngugc v ^ P cac phuong phdp gidm tac ddng cua ^ i ^ h d i ngugc la thay ddi kdt cdu chi tidt udn hoac cd the su dung chay uon co gdc lugn vd gdc udn nhd hon gdc udn cua chi tidt Kich thudc gdc lugn ciia chay udn cd thd tinh todn theo cdng thiic (2.3) ^k.r (2.3) r- Ban kinh cua ehdy udn; k - He sd bien d£ing dan hdi; r^-Gdc udn sau bien dang dan hdi 2.3.2 Thiet ke khudn d$p vuot tg.o hinh cdc chi tiet vo cabin Khudn dap vudt tao hinh chi tidt tam mdng vd cabin gdm khudn tren vd khudn dudi dugc che tao bdng phuong phdp due va gia cong CO sau due Vat lieu lam khudn tu gang cdu nhdm tiet kiem chi phi sdn xudt khudn Khudn lam tii gang cau cd dp ben cao can tnic tmh thd dang cau trdn bao gdm ba loai ndn 1dm loai: Phe rit, phe rit -pec lit va pec lit Bd m^t Idng khudn trdn va khudn dudi tao hmh chi tiet dgp dugc gia cdng vai kich thudc ciia san pi^m Do kich thudc tdm vd Idn cd thd chilm hiu hdt khoang khdng gian cua may dap IRnh 2.2 BQ khuon da duac thietfeedap vuot tdm noc cabin: a) Khuon duoi; b) Khuon tren 2.3.3 Mo phong qud trinh dap vuot t^o hinh cac chi tiit t&m mong vo cabin a) MS phong so chpn may dap vuot Ta chgn thdng sd theo kich thudc chi tidt dap Luc cdng nghd gidi ban: 250 (T), phdi tam cd chidu day 1mm, hd s6 ma sat 0.15, luc chan phdi dugc tinh todn theo luc chan toi da cua may Q^^=125 (T), kich thudc phln tu Idn nhdt 40nim va kich thudc phdn tii nhd nhdt la 0.3 Imm Tix kich tiiudc phdi hinh chii nhat ta chan phdi hai phia theo chiiu dai ciia tdm, kdt qua md phdng ttdn phan m i m Autoform vdi hai thdng sd luc chan 70 (T) vd Itrc chdn 80 (T), Mnh 2.3 a) b) Hinh 2.3 Bieu lifc cong ngh$ dgp vudt: a) Khi luc chgn 70 (T); b) Khi luc chgn 80 (T) ISSN 0866 - 7056 TAP CHI CO KHf V I E T NAM, Sd 1+2 nam www.cokhivietnam.vn 2017 NGHIEN COU - TRAO D I Tft k^t qua trinh bay trSn hinh 2.3, ta nhgn duoc gia tri lire Sp ISn long khuon trucmg hpp luc chan 70 (T) la 2826.1 kN thip ban 2969.6 kN cua truong hop sft dung luc chta 80 (T) Tuong tu cae lire Sp trSn khuSn trSn la 2126.1 kN va luc uin 14 700.0 kN truong hpp a) va luc ep tren khuon tren la 2169.6 kN vh lire uin la 800.0 kN cua truong hpp b), vgy luc ehgn phoi Ion thi cac lire Sp, luc uin dSu 16n han Tu cac kSt qua khao sat ta chpn dupe luc cong nghe Ion nhit la 217 (T) valua chpn may dap co luc dap Ion hon 217 (T), thirc tS nen chpn may dap eo l\rc dip tii thiSu la 250 (T) b) Sifph&n bo biSn mong chi tiit Trong kSt qua mo phong cho ta thiy sir bien mong ciia phoi dap sau gia cong khong vupt qud 30% chiSu day phoi Nhung vi tri bien mong nhiSu nhit la vi hi thtah hoac goc uon, gia tri biSn mong khong qua 20% Vol gia tti phta bi biSn mong ttSn dam bao phoi khang bi pha buy ttong quatiinhtao hmh (hinh 2.4) •^r'• Hinh 2.5 Phdn bd viing nhgn tren vien mep chi tii V- d) Sir biin dftng Oan hit ciia chi tiit d^ BiSn dgng dan hii xay sau qui trinli tgo hhih gay sai khac vS kich thudc so vcSi'kfcli thuoc chi ti& Tft kSt qua mo phong ta phan tich su thay dii goc biin dang dta hii trSa bS mat chi tiSt, hmh 2.6, ta dS nhgn thiy 4'^ thay dii goc ion nhit * vi tti chhih giiia chig| dai sto phim Nhiing vj tti du6ng go hien ttipng biSn dgng dta hii gin nhu khong xay BiSn dang dto hii khong toh huong toi kicli thuoc cua chi tiit " ^ Gioi hfAp\ibli j t :sai^.-.'^'^-'-^-j ^^F Hinh 2.4 Phdn bd bidn mdng tren sdn phdm dgp c) PhSn ba vung nhan tren san phdm KSt qua me phong ciing cho ta thiy su phan bo vung nhta tten sta phim, cac vung nhan se xuat hien xung quanh vi^n mep cH het, hmh 2.5 NguySn nhta la ttong qua tthS tgo hinh biSn dii vS kich t h u o c ' r e S n ;:^.Zdr"^"""°''"'^"«^^"''"^ Hinh 2.5 Phdn bSgoc bien dgng tgn hoi trin lie mgt chi tih dgp e) Lua chon he s6 ma sat cho qud trinh ifp Ket qua mo phong cho thiy, he s6 ma sit eao (hogc kh6ng co boi tean), sto phim co nguy ca biSn mong, bi rach tai nhimg vi tti gan vu6t ttag cung, hinh 2.6a, su phan hi pha hiiy vupt len tten duong gidi ban pha huy Khi co boi tton thi Men tupng pha buy se khong coo xuat hiSn, hinh 2.6b Theo kmh nghiem boi tton qua hinh dap vol he si ma sdt n < 0,15 la phu hop va vat liSu boi ttuon btagdiu CO the dapftngdupe ISSN 0866-7056 TAPCH,COKHIVIETNAM,Si W„am2017 www.cokhivietnam.vn NGHIEN CCrU - TF;.- chi tidt Cdc chi tiit t i m mdng sau chd tao (hinh 2.7) dugc umg dimg tten cabin d td tdi nhe cd t h i phdt trien cdng nghd n h i m chu ddng ddp ling nhu cdu lap rap d td ttong nude Hinh 2.6a Phdn bo bien mong cua sdn phdm sir dung chdt boi tron cohi so ma sdtfi=0,20 Hinh 2.7 Cabin to tdi nhe da dugc ung dung cong nghe ddp vuot Hinh 2.6b Phdn bo bien mong cua sdn pham sH dtmg dau boi tran co hi so ma sdtfi^O.lS i | T # QUA D^T BirOC \ i g m '• Qua tinh toan va md phdng ta nhan dupe cdc thdng so ky thuat cua qud trinh dap vudt tao hinh gdm: Luc cdng nghp, he so ma sat, cac thdng so hinh hgc ciia chay va cdi, bang 2.1 Bdng 2.1 Thdng so ky thugt cua qud trinh ddp vuot tgo hinh: ^itSngsfi DSp vudt tao hinh noc cabin D^p vu6t tao hinh san cabiD D^p vu6t tao hinh t^m sau cabin 50 (T) Luc chan 70 (T) 60 (T) Luc cong 219;2 (T) 212,6 (T) 225,8 (T) nghe Hes6ma 0,15 0,15 0,15 sat Thong s6 Theo kich TheoIdch Theo kich hinh hoc cua khuon thuoc chi tilt fliuocchiti^ tniocdiiti^ Cac thdng sd dat dugc tinh todn ciing nhu md phong dam bao dugc phu hgp cua nhiing tiiet hi sdn cd dang d mdt sd nhd mdy ttpng nude vdi gja tiidp, tiet kiem chi phi dau tu cdc mdy ddp chuyen diing hidn dai cd gia thdnh dau tu Idn anh hudng ddn gid thdnh K E T LUAN Ket qud thih todn phan tich sii dung phdn mem chuydn dung Autoform md phdng qua trinh ddp vu6t chi ttdt tdm mdng tao san pham dap khdng bi iihan, rach^ tien tdi che tao loat va md rdng cdc chi tidt khdc nhu dap vd bao che may keo ndng nghiep, vd bao che ddng CO mgt xylanh vd thiing ddu, ket nude lam mat dgng ca Kdt qud nghien cuu ciing hudng tdi gdp phdn ndng cao nang luc thiit ke va che tgo ddi vdi ddi ngu ky su ngdjih Co dgng hic CO the lam chu cdng nghe che tao tien tidn de su dung tten d td.*t* Ngay n h | n bdi: 12/01/2017 Ngdy phan bien: 15/02/2017 Tai lieu t h a m k h a o : NgiQ^KhScTrai (2006); Oso-cW^I'Md/o, NXB Giao ihongVantai Nguy^ Thanh Quang va cac tac gia (2008); SB liiv/i«A y^jCT! phu timgo to iMthongdyngjtiXB Khoahpc va KyfliuatHa NoL N g i ^ Mau I ^ (200Q; Cong f # £ Mo/ofiA AoM/o(ri ia«, NXB Khoa hoc va Ky Auat Ha Noi Phani Van Nghe, D6 Van Phuc (2012); Miyfeiavd wttiv ep My bee, NXB Giao due N g i ^ Die Thm^ Lg Thai Hiing, Ngiiyin Nhu HiQnh, Nguy&i Tnmg Kiai ^ 1 ) ; iWo^jfiong so ^ trinh biSi (&ng,NXB Bach Khoa HSNgi Pham Van N ^ Nguy&i Mm Hi^Tih (2005); Afo sai wi &d7 trcmtmng gia cong apiifcliXB Daih9cQu5cgaHaN6i Scbuler (1998); Metal Forming Handborfc/(c) SpringerVerlag Berlin Heidelberg ISSN 0866-7056 TAP CHf C O KHt VI$T NAM, Sd 1+2 nam 2017 www.cokhivietnam.vn ... xay tai nan dam bao tdn thdt la it nhat) Cabin d td tai gdm cdc bd phan chinh: Vd cabin, ndi that cabin (ghe ngdi, bang tdp Id, kinh chan gid, guong chidu hau), he thdng didu khien (didu khidu... che tao cabin: Dam bao dugc yen cau chiic nang cua cabin (la tinh tien nghi cua xe, gidm met mdi cho ngudi Idi xe), du khdng gian bd tri nhiing ciim va he thdng didu Idiidn, cd kdt cau chiu tai... TF_'' chinh: Tao khdng gian cho ngudi Idi va ngudi ngdi, la kdt cdu chiu tdi la ca sd dd bd tri, lap dat cdc cum vd cdc he thdng trdn xe [1] Nhimg yeu can chung ddi vdi cabin: Phii hgp vdi chiic