NGHIEN CliU-TRAO D I CONG NGHE MAI BANH RANG TRU TREN MAY MAI RANG CNC TRUC NILES ZE 800 GRINDING T E C H N I Q U E FOR C Y L I N D E R G E A R S IN C N C A X I S G E A R PROFILE G R I N D I N G M A C H I N E N I L E S ZE 800 Nguygn Hdng Son', Nguyen Hdng LTnh^ 'Trudng Dai hpc Giao thdng Van tai ^Trudng Dai hpc Dien lire T O M TAT V&i suphdt trien cua nen kinh te thi yeu cdu cua cdc ngdnh sdn xudt noi chung vd ngdnh Ca che tgo noi rieng cdn phdi doi m&i cdng nghe nhdm ndng cao chdi luang sdn phdm Cdc logi bdnh rdng dung to, mdy xdy dimg vd mdy khai thdc mo thu&ng co yeu cdu rdt cao ve chinh xdc che tgo, vi vgy & nu&c ta hien cdc logi sdn phdm ndy chu yeu la nhdp khdu cdc nhd mdy ca nu&c chua tu sdn xudt duac Viec nghien cim dp dung thdnh cong cong nghe mdi bdnh rdng sau nhiet luyen tren mdy mdi bdnh rdng the he m&i NILES ZE 800 cua Cong hoa Lien bang Due dd mang lgi mot y nghia het sue quan sdn xudt phu tung thay the sdn phdm nhdp ngogi tgi cong ty Co phdn Ca Hong LTnh Cdc sdn phdm bdnh rdng qua mdi rdng da dgt duac cdc tieu chudn ve chinh xdc theo tieu chudn DIN vd cd the duac sir dung de thay the nhdp ngogi dem lgi hieu qud kinh te cho cdc doanh nghiep Til' khoa: Bdnh rdng; Mdy mdi rdng; Cong nghe CNC ABSTRACT In the economics development, the requirement of improving technologies in mechanical manufacturing to enhance the quality of products is mandatory Gears used in cars, construction machines or mine machines usually have high-accuracy requirement in manufacturing, hence this kind of products is usually imported, since the domestic mechanical factories couldn 't manufacture them The study of grinding gear technique after thermal treatment by Gear Profile Grinding Machine NILES ZE 800 has important meaning in manufacturing imported changeable attachments in Hong Linh Mechanical Joint Stock Company Gear products after grinding can achieve DIN standard in accuracy, so can be used alternately for imported products to improve economic effect Keywords: Gears, Gear grinding machine, CNC technology ISSN 0866 - 7056 TAP CHi CO KHi VIET NAM, Sd 1+2 nam 2019 www.cokhivietnam.vn NGHIEN CU'U-TRAO OOl DAT VAN DE De san xuat cac loai banh rang cd chat lugng an khdp cao can phai cd nguyen cdng mai Profile rang sau nhiet luyen Hien nay, tren the gidi ngudi ta thudng sir dung cac loai may mai CNC vdi da mai dang dia hoac dang true vit dd mai cac loai banh rang tru rang thang, hoac rang nghieng de san xuat cac banh rang cd dp chinh xac va nang suat cao[l,5] nude ta hien ciing cd mpt sd nha may da va dang sii dung cdng nghe mai banh rang sau nhiet luyen nhung sii dung cac may mai banh rang ciia Lign Xd va Dire the he cii, cac loai may mai thudng cd dp cbinh xac va nang sudt thip nen khd dap img duoc cac ydu cau cao ciia san pham hien Viec img dung cdng nghe mai rang tren cac may mai rang CNC hidn dai se la nhu cau tat yeu cua su phat trign nganh Co che tao d nuoc ta Qua thdi gian sii dung may mai rang, CNC the be mdi Niles ZE 800 ciia cpng hda Lien bang Dire tai Cdng ty Cd phan Ca Hdng Linh da minh chimg dugc su vugt trdi ve nang suat gia cdng va dat dp chinb xac cao tbeo tieu chuan danh gia DIN [3] Hinh Mdy mdi rang CNC ZE800 Dd kidm soat duoc chat lugng cua cac banh rang sau gia cdng, may mai ZE800 dupe trang bi be thdng VMS dd kigm tra va danh gia chat lugng cua banh rang trude va sau mai theo cac bd tbdng sd theo tigu chuan DIN Do may mai Profile rang theo dang mai chdp hinh ndn nhin chung se cd nang suat cao hon so vdi cac phuang phapraaibao hinh ma cac may mai the he cii thuc hien Bdng Thdng sd ky thudt mdy mdi rdng ZE800 Thong so Don vi Gia tri Dudng kinh mai ngoai ldn nhat mm 800 Duong kinh mai ngoai nho nhat mm 50 Modul mai ldn nhat Modul mai nho nhat 16 - Goc nghieng mai Idn nhat Dp 45° Be rong rang ldn nhat mm 390 Trpng luong phoi ldn nhat Kg mm 1500 mm 300 m/s 45 Chigu cao chdng tam Dudng kinh ldn nhat cua da Tdc dp mai ldn nhat 900 Cong nghe mai rang tren may mai ZE800 [2,3] May mai banh rang tru ZE800 la may mai banh rang cd da mai d dang dia Profile rang dupe tao hinh theo nguyen ly ehep hinh Dp chinh xac cau bien dang da mai dugc kidm soat tbdng qua qua trinb tao hinh tir dia sira da kim cuong vdi chuyen ddng tuong iing, chuyen dpng tao binb bien dang da dupe didu khidn bang Macro Qua trinh gia cdng mai rang trdn may mai ZE800 dugc tdng hgp tir chuyen ddng ridng bidt va dugc dieu khidn bdi he digu hanh SIEMENS 840D Cac true chuygn dgng dupe digu khign qua trinh lam viec la cac true tinh tign theo cac phuong X,Y,Z va quay theo cac phuang A, B, +C, KA Cac chigu chuygn ddng cu thg ciia may dugc md ta nhu tren hinh c ISSN 0866 - 7056 | TAP CHI CO KHl VIET NAM, Sd +2 nam 20191 www.cokhivietnam.vn NGHIEN CLfU - TRAO D O I Quy trinh mai rang dugc thyc hien theo cac budc: - Budc 1: Nhap thdng sd banh rang, da mai, dia sira da kim cuong, lua chpn thong so dich chinb Profile va hudng rang neu can I r - Budc 2: Bd didu khidn D300 se tinh toan tbdng sd hinh hpc cua banh rang va hmh dang ciia da mai • Budc 3: Tinh toan va hoan thien Macro chuang trinh siia da - Budc 4: Tidn hanh sita bien dang da mai theo thdng sd dau vao Hinh Cdc true chuyin dpng trin mdy ZE 800 Chu trinh mai banh rang tru dupe md ta theo so dd khdi hinh 3, cac thu tuc giao tidp giua ngudi sii dung vdi may dugc thuc hien thdng qua giao dien vdi cac phim chiic nang: - Budc 5: Nhap thdng sd mai (budc fien, sd dudng chuygn dao, van tdc cat, ); - Budc 6: Mai thir dd xac dinh gia tri mai cudi cung; - Budc 7: Kidm tra thdng sd Profile va hudng rang cua be mat mai thu - Budc 8: Didu chinh dudng tao hinh sita da va cac gia tri tpa dp (X,Y) dg cd thdng sd tdt nhat trude mai tinh - Budc 9: Neu kgt qua chua thda man cac dieu kien gia cdng may se quay ve budc va thuc hien den budc de gia cdng thong sd Profile va budng rang mdi; Neu kgt qua Profile da thao man dieu kien gia cdng, may se quay vd budc ma van giii nguygn dudng sita da va gia tri X,Y dg gia cdng dat gia tri phap tuyen chung - Budc 10: Tidn hanh mai tinh; Hinh Quy trinh thuc hiin mdi rdng - Budc 11: Do kigm cac thdng sd va dimg chu trinh mai ISSN 0866 - 7056 TAP CHi CO KHi VIET NAM, Sd 1+2 nam 2019 www.cokhivietnam.vn NGHIEN CU'U - TRAO D C I De dam bao dp chinh xac ciia be mat banh rang mai Profile rang thi qua trinh sira da, ddi bdi phai dat dp chinh xac cao Dg thuc bien dugc yeu cSu thi qua trinh mai, may phai thuc hien qua trinh tu dpng sira da theo chu ky thich hgp Qua binh tao hinh bign dang da mai dugc thuc bien nhd dia sua da kim cuang, chuygn ddng tao binh bign dang da dugc dieu khien bang chuong trinh NC dugc may tii dpng thiet lap sau nhap cac thdng sd dau vao can thigt Dp cbinh xac cua bg mat gia cdng phu thudc rat ldn vao qua trinh sita da Viec lua chpn cac thdng sd frong qua trinh sita da phu bgp se cho ta dp bdng, dp chinh xac bien dang rang theo ydu cau +) Lugng chay dao dia kim cuang a^ Lugng chay dao cua dia kim cuong ad dugc tinh bang fim, gia tri ciia a^ cang ldn thi be mat da mai cang thd, ta co the chpn a^ khoang [2-20] pm U4 = coasaiei ta ~ consiaiu Cac ydu td cdnjlg nghe chil ydu anh hudng dgn qua trinh sira da la: Hinh Quan hi giiia luang chay dao ad v&i dp nhdm be mat RZ +) Ty Id tiep xiic U^: Ty le tigp xuc U^ cang ldn tbi be mat da mai cang min, vi vay qua trinh mai tiiy theo ygu cau vg dp bdng Profile va dp chinb xac cua banh rang ma chimg ta lira chpn gia tri Uj hop ly thudng U^ nam khoang: 2-16 {binb 4) , U,=i^ (1) Trong dd: b^^: Bd rdng hieu dung cua dia sita da; S^: Lugng chay dao sira da +) Ty le van tdc siia da q^ Ty le van tdc q^ duoc xac dinh: ?„=— (2) Trong dd: V: Van tdc cua digm tiep xiic sira da cua dia kim cuong; V^j! Van tdc cua diem figp xiic sira da cua da mai; Ddi vdi cac banh rang tru, ta nen chpn q^ nam khoang [0.4 -^ 0.8] Hinh Quan he gid-a ty le tiep xuc Ud v&i dp nhdm bimdtR^ Tat ca cac gia tri tren dupe lua chpn chii yeu dua vao kinh nghiem sir dung may ngoai tni gia trj van tdc diem tigp tiep xuc sira da ciia da mai v ^ '^ ISSN 0866 - 7056 TAP CHI CO KHf VIET NAM, Sd 1+2 nam 2015 www cokhivietn am v n NGHIEN ciiu-TRAO DCI Chu trinb sua da cd thd lua chpn theo cac kigu sau (hinh -^ 8): thudng ban che dp dao ciia true ga < 0,003 mip Sau ga l4p va kep chat phdi chiing ta tign hanh nhap cac thdng sd cSn thidt cua banh rang mai vao may nhu trgn hinh Hinh Chu trinh keo Hinh Giao dien nhdp thdng sd mdi bdnh rdng THlTC NGHIEM VA KET QUA Sau nghign ciru cdng nghe mai banh rang ttii trdn may mai CNC ZE800 cua hang Niles, chung tdi da thuc hien qua trinh mai banh rang hanh tinh Z24-m5 ciia xe HM4002R tai Cdng ty Cd phin Ca Hdng LTnh vai bp thdng sd nhu trdn bang Hinh Chu trinh ddy Bdng Thong sd mdi cua bdnh rdng Z24 m5: Ky hieu Gia tri Sd rang 24 Md dun m Gdc ap lire tto (^9) 20" Goc nghieng B(dQ) Thong so Hinh Chu trinh keo vd day Dg dat dugc kgt qua mai cd dp chinh xac cao, chung ta can phai lira chpn phuang an ga lap banh rang ldn may phu hgp, ddi vdi cac banh rang cd Id lap rap thi phuang an ga lap phii hgp nhat la diing true ga dau chdng tam kgt hgp kep tdc, cdn vdi cac dang true rang chiing ta sii dung Id tam cdng nghd dau true rang de dinb vi True ga tren may mai rang can pbai dugc kiem tra dp dao cua true, chiing tdi Dudng kinh vong chia D(mm) 120 Dudng kinh dinh rang d^ (mm) 130,7 Dudng kinh chan rang d (mm) 109 Be rpng rang B(mm) 77 Chieu dai phap tuyen chung Lj (mm) 39^32_o.o4 A Dp chinh xac yeu cSu tdi thigu ISSN 0866 - 7056 M Thang Hudng rang TAP CHi CO KHi VIET NAM, Sd +2 nam 2019 www.cokhivietnam.vn NGHIEN CLfU - TRAO OOl Vdi sd lugng 16 banh rang da dugc mai va kiem tra danh gia dp chinh xac tren he thdng VMC ciia may ZE 800, chiing tdi da tbu dugc ket qua rat kha quan, cac cbi sd danh gia vg sai sd hudng rang (Lead) dat cdp cbinh xac 1, sai sd budc rang (Pitch) dat cSp chinh xac I va sai sd bien dang rang (Profile) dat cdp cbinh xac I - theo tigu chuan cua DIN (hinh 10 -^ 12) Nhu vay, theo tieu chudn DIN thi dp chinh xac ciia banh rang sau mai rang cd cap chinh xac la 3, ddi vdi cac baiih rang hop giam tdc canh cua xe d td cd ydu cau chung vg dp chinh xac la cdp Ngoai kdt qua cac thdng sd hinh bpc vg dp bdng bg mat rang dugc kigm tra tren tbiet bi dp bdng cdm tay Mibitoyo SJ 210 cho kdt qua Ra - (0,192 ^ 0,223) pm ằã ã" đ- ::^ " Hinh 12 Sai so bu&c rdng (Pitch) KET LUAN Ket qua cua nghien ciiu cho chiing ta thay, viec iing dung cdng nghe CNC vao mai rang cd the giiip chung ta gia cdng dugc cac banh rang chat lugng cao theo tigu chudn qudc tg (ISO, DIN, AGMA, JGMA) tai Viet Nam Ngoai ra, mai rang trgn cac may CNC hien dai ngoai viec dat dp chinb xac gia cdng cdn cbo ta nang suat lao ddng cao, dac biet la cac loai may mai cd da mai dang binh tru at \ • ! Hinh 10 Sai sd biin dgng rdng (Profile) Kgt qua nghign ciiu ciing da khang dinh dugc rang: Dpi ngii ky su, cdng nhan ciia Viet Nam boan toan du kha nang tiep tbu va lara chii cdng nghe mai rang tign tign cua thg gidi de ap dung cho ITnh vuc chg tao banh rang chat lupng cao nude Ngay nhdn bai: 10/12/2018 Ngay phdn bien: 25/12/2018 L, Tai lieu tham khao: [1] [2] t;: [3] [4] Hinh 11 Sai so hudng rdng (Lead) [5] DudlleyD W (1962), Gear Handbook, st Edition, McGrawhiU, New York Litvin F L, Fuentes A (2004), Gear Goemetiy and applied Theoiy 2"'' ed, Cambndge Umversity Press, UK Niles Werkzeuginasciimen GmbH (2002), User Manual Nordring 20 D - 12681 Berlm Niles Werkzeugmaschinen GmbH (2002), Operating Instruction, Nordnng 20 D - 12681 Berlin Tran Van Dich (2009); Cong nghe gia cong bdnh rang, NXB Khoa hoc Ky thuat ISSN 6 - TAP CHI CO KHi VIET NAM, Sd 1+2 nam 2019 www.cokhivietnam.vn ... phoi ldn nhat Kg mm 150 0 mm 300 m/s 45 Chigu cao chdng tam Dudng kinh ldn nhat cua da Tdc dp mai ldn nhat 900 Cong nghe mai rang tren may mai ZE8 00 [2,3] May mai banh rang tru ZE8 00 la may mai banh... cao tbeo tieu chuan danh gia DIN [3] Hinh Mdy mdi rang CNC ZE8 00 Dd kidm soat duoc chat lugng cua cac banh rang sau gia cdng, may mai ZE8 00 dupe trang bi be thdng VMS dd kigm tra va danh gia... mdi rdng ZE8 00 Thong so Don vi Gia tri Dudng kinh mai ngoai ldn nhat mm 800 Duong kinh mai ngoai nho nhat mm 50 Modul mai ldn nhat Modul mai nho nhat 16 - Goc nghieng mai Idn nhat Dp 45? ? 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