Trong qud trinh ndy, chdy chdt long tdc dung len phoi tdm ldm biin dang theo hinh dang cua cdi.. Cdc gid tri dinh lUpng thu dupc nhd md phong so dUPc cdi ddt trong qud trinh thiic nghiem
Trang 1EN CUU-TRAO Dc: XAC DjNH THONG S6 CONG NGHE TAO HJNH KHI DAP THOY TINH
CHI TI^T HiNH CAU DU^ONG KINH 50 MM TLT PHOI TAM
DETERMINATION OF TECHNOLOGICAL PARAMETERS IN SHEET HYDRO FORMING PROCESS TO PRODUCE THE SPHERE PARTS WITH DIAMETER 50MM
Le Trung Kiln, Pham Van Nghe
Trfldng Dai hpc Bach Khoa Ha Ndi
T O M TAT
Cdng nghe sdn xudt tien tiin Id cd sd cua ngdnh Cong nghiep hien dai Cdng nghe dap thuy tinh (DTT) Id mdt hUdng nghien ciiu vd iing dung trong ngdnh Cdng nghiep sdn xudt did xe mdy Trong qud trinh ndy, chdy chdt long tdc dung len phoi tdm ldm biin dang theo hinh dang cua cdi Bdi bdo trinh hdy phuong phdp xdc dinh vd phdn tich tdc dpng cua cdc thdng s6 tao hinh quan trpng den khd ndng hinh thdnh chi tiit
Cdc yiu to dnh hUdng din qud trinh tao hinh chi tiet dUpc xdc dinh qua viic nghidn ctiu trqng thdi Ung sudt, biin dang tai cdc vimg nguy hiim bdngphtiPngphdp mo phong so Cdc gid tri dinh lUpng thu dupc nhd md phong so dUPc cdi ddt trong qud trinh thiic nghiem nhdm xdc dinh mien ldm viec cda cdc thdng sd cdng nghe Thi nghiem dUpc tien hdnh trin ddng Latong A70 tdm ddy 0,8 mm Kit qud thiic nghiem se dUpc Ung dung de sdn xudt cdc chi tiet dang tdm co hinh dang phiic tap dUpc chat lUdng vd hieu qud
Tfl khda: Ddp vudt; Dap th-dy tinh; FEM; Nhdn; Rach
ABSTRACT
Advanced manufacturing technology plays importantrole for moderning and developing of industry Hydro forming is a researching direction and new application in the automobile industry
In this process, this fluid affects on the blank to deform it on the cavity of die This paper presents the methods to determine influences of some important parameters on the ability forming details The factors affect to the process details are determined by researching the stress, strain in the danger zone
by numerical simulation The quantitative values obtained by numerical simulation are installed in the experimental work to determine the domain of the parameters The experiment was carried out by 0,8
mm thickness brass sheet (Latong A70) The reseach results will be applied to produce complex shaped products from sheet metal with quality and efficiency
Keywords: Drawing, hydrostatic, FEM, wrinkle, crack
Trang 2l D A T V A N D E
Cdng nghe dap thuy tinh dfldc phat trien
va Ung dung de khac phue nhflng nhupc diem cua
cdng nghe dap vudt truyln thdng Muc dich nham
tang mflc do dap vudt, giam biln day, giam chi
phi che t^o khudn, giam sd nguyin cdng Cdng
nghe dap thuy tinh chi ddi hdi che tao long cdi cd
hinh dang cua chi tilt
ch4t
H I thdng thi n g h i i m dfldc xay dflng theo
sd dd n h u hinh 2, trong dd bao gdm:
- H I thdng cung cap chat long cao dp (1);
- H I thdng chan (may ep - 2);
- Khudn thfly tinh (3);
- He thdng ddi dp (4);
- He thdng thu thap vd xfl ly tin hieu (5)
Kei ilmc
Ngudn: [3]
Ifinh 1 Nguyen ly va qud trinh dap thuy tmh phoi tdm
Hinh 1 la nguyen ly va qua trinh hinh
thanh chi tilt khi dap thuy tinh phdi tdm Phdi
dfldc biln dang theo bien dang coi vdi kha nang
tao hinh tdt nhat Gidng nhU dap vudt truyen
thdng, cac yeu td chinh dnh hudng d i n qud trinh
tao hinh bao gdm:
- Thdng sd cdng nghe: Ap suat can thilt de
tao hinh, lUc chdn, lUc ddi dp;
- Thdng sd hinh hpc: Ban kinh gdc Ifldn
cdi, mflc dp phflc tap cua chi tiet;
- Thdng sd vat lieu: Vat lieu phdi;
- Ma sat gifla phdi vdi chan va coi;
D l che tao cac chi tilt dam bao chat lUdng
mong mudn, can thiet phai nghien cflu va xdc
dinh cdc thdng sd tao hinh tien tdi xdy dflng mien
Iam vile cua cac thdng sd cho cac dang san pham
cd hinh dang phflc tap
2 HE THONG VA VAT Ll£U NGHIEN CUXJ
2.1 Thilt k l h e thdng thi nghiem
0000 0
Hinh 2 SO d6 hi thdng thi nghiem thuy tinh
Ngudn chat ldng cao ap dfldc cung cdp bdi
he thdng kich thuy liic k i t hdp binh tich dp
Hinh 3 He thong tang dp cung cdp chdt long
He thdng ddi ap cho khudn dUdc sfl dung mdy nen khi cung cap vao he thdng bao gdm 1 xilanh khi nen dfldng kinh trong £|)50mm
Hmh 4 Khuon vd hi thong doi dp
Trang 3NGHIEN CUTU-TRAO Ddi
HI thdng chan dfldc sfl dung la mdy ep
thfly lflc 125 tan cd the dilu chlnh dfldc ap suat
chan va do thdng sd bang he thdng do va xfl ly tin
h i l u
Bdngl: Tinh chdtvdtiieu dong Latong A70
Hmh 5 Hi thdng thi nghiim lap rdp hodn chinh
Khudn thfly tinh dfldc thilt k l nham
nghiin cflu eac thdng sd cd ban gia cdng c h l tao
chi tilt dang cau dfldng kinh D = 50 mm
Hinh 6 Khuon ddp thuy tinh:
I Dekiiudndit3i:2 TAindem:
3 Bul6ngMS;4.C6i-,
5 T^m chin giodngi 6 Khuon I
S.GiodngilO Bul6ngM4,
I! (Mt ddi dp: 12 TSm day,
13 Bda v4; 14 Xilanh dSi dp
2.2 Vat lilu nghien cflu va thii nghiim
Dd cflng theo thang Vickers
Md dun Young
Md dun cat
Md dun nen
He sd Poisson
369 MPa 128GPa 48GPa
140 GPa 0,34
Bang thi nghiim keo nen theo 3 hUdng Kit qua cho thay thdy quan he gifla flng sudt va biln dang theo 3 hfldng gdn nhfl nhau, ta cd t h i eoi la vdt lieu dang hfldng tren cd sd dd md phdng
sd vdi md hinh vdt heu dflpc dp dung vdi bai todn biln dang ngudi la md hinh deo tflc thdi tuyln tinh dang hfldng cfla Von Mises Tfl dd xdc dinh dfldc dfldng cong chay bang phfldng phdp thflc nghiem
Hinh 7 Hi thong, ket qua keo mau vat Ueu trin mdy MTS-809 Axial/Torsional Test System
; - -•••flw ,.; ;" " I -flMwy
Sfl dung vat lieu thi nghiem ddng Latong Hmh 9 Do thi g««" bi itng sudt - bien dang cua vdt A70 vdi thanh phdn va tinh chat nhfl sau : I'?" khi keo theo cdc hudng (f, 45" vd 90" so vdi
hudng cdn
Bdng 1: Thdnh phdn hoa hoc dong Latong A70:
3 SU" DUNG M 6 PHONG SO DINH LU'ONG CAC T H O N G SO ANH HU'DNG TRONG D A P THUY TiNH
Md phdng la mpt cdng cu rat hieu qua trong^
Thanh phSn hoa hpc dong Latong A70 (%)
Copper
70
zinc
30
Trang 4NGHIEN CUfU-TRAO D 6 |
viec giam thieu qua trinh gia cdng thfl Nd cho
chung ta biet nhflng ket qua gan dung nhat trong
thflc tl CJ day, nhdm nghien cflu sfl dung phan
mim dl tien hanh md phdng cac trfldng hdp khi
lan Ifldt cd dinh cac thdng sd de tim thdng sd cdn
lai
Md hinh hinh hpe cfla san pham Id chi tilt
dang edu dfldng kinh D = 50 mm, day 0,8 mm
2
3
Ap suSt can thiet: 250 bar Lite chan: 60 kN San phim dat y6u cau
Ap suit can thiet: 250 bar LUc chan: 65 kN San pham co dau hieu bi pha hiiy
<k ^ i
' ^ ^ '
^^^y^
Cac kit qua md phdng tren la cdc gia tri thdng sd gidi han khi tao hinh, rdeh hoac dn dinh Tfl cdc gia tri thdng sd nay, ta dp dung cai^dat cac thdng sd cho phan thflc nghiem
4 THl/C NGHlfiM Kit qua thflc nghiem
Hmh 8 Md hinh vd chia lUdiphdn td
Vdi md hinh ddc tinh vdt lieu, phan mim
md phdng cho phep nhap dfldng cong thflc
nghiem mdi quan hi gifla flng suat va bien dang
vat lieu (hinh 9)
^ili
J 5 _ _ , ^ ^ _ _ J
Ta dfldc kit qua md phdng vdi eac trUdng
hpp nhfl sau:
Bdng 3 Kit qud mo phong sd
TT
1
Thong sd cong nghe tao
hinh thuy tinh
LUc chan : 50 kN
Ap suat tao hinh trong long
coi 250 bar
San pham dat yeu cau
San pham
' ^ ^
T T
1
2
3
4
5
6
6
M i u
fl
f2
a
14 (5
F6
F7
Ap suat long c6i Pbar
73
100
150
200
256
243
235
Liic chan
kN
45
55
55
55
55
62
65
San pham
" ^ ^
' if
' ^
Nhan thay mau fl do ap lflc chan thdp nen khi dp suat chat long tang len thi xay ra hien tudng nhan nen dp suat trong long cdi theo ranh nhan Ipt ra ngoai Phdi chUa tao hinh dat kich thUdc Mau f2, f3, f4 dp liic chan hdp ly ddng thdi
dp sudt chat ldng can thiet chfla du de tao hinh
Trang 5NGHIEN CUfU - TRAO D O I
cho phdi bdm sat vao thdnh cdi, san pham chfla 5 KET L U A N
dat kich thflde
Da thilt kl, che tao thanh cdng he thdng Mau f5 la vdi lflc chan hdp ly, dp suat ehat thi nghiem hoan toan phfl hdp de xac dinh thdng ldng can thilt dfl tgo hinh n i n san pham tao hinh sd cdng nghl trong qua trinh khi dap thuy tinh dfl kich thflde ehi tiet dang tam cd hinh dang phflc tap
Khi lUc chjn tdng len 62 kN (mau f6), luc Cde kit qua nhan dUdc bang md phdng nay la ngfldng miln ldm vile cua lflc chan San sd khdng sai khdc nhieu ve hinh dang, thdng sd phdm t?o hinh gan dp sdt ldng edi nhflng vdn xdy dp suat va lflc chan gidi ban so vdi eac kit qua
ra rdeh tai dinh cdu co biln mdng tai phdn tfl do nhan dfldc bang thiic nghiem vdi sd lUpng mau ndy qud ldn du danh gid
Mau f7 do dp lflc ehan qua ldn nen phdi Trong gidi han bai bdo, thdng sd ddi dp khdng the keo vdo trong edi Sfl biln mdng manh vdn chfla dfldc de c|.p d i n khi thflc nghiem Khi liet bat dau xuat hien tai dinh chi tilt va phd hfly sfl dung he thdng ddi dp se lam giam sfl biln mdng tai dinh cfla chi tilt khi san pham chfla tao hinh manh lilt tai dinh chdm cdu tfl dd md rdng m i l n dat kich thflde lam vile eua thdng so lflc chan •
Ngdy nhdn bdi: 12/6/2013
Ngay phan bien: 12/7/2013
Ngfldi phan biln: TS Nguyen Trpng Hilu, Van phdng Hdi ddng Chinh sach Khoa hpc va Cdng nghe
Qudc Gia
Tai lieu tham khao:
[ 1 ] Ph^m Van Ngh^ Cdng nghi ddp thuy tinh, NXB Bach Khoa, Ha Ngi, 2006
[2], Nguyen Mdu Ddng, Cong nghi tao hinh kim loai tdm, NXB Khoa hpc Ky thuat, Ha Noi, 2006
[3] Bai gidng cdng nghe gia cong ap lflc (2009), Bo mon Gia cong dp lUc, TrUdng Dai hpc Bach Khoa Ha Noi [4] L& Trung Kien, Pham Van Nghe, Dinh Van Duy, Thiet ke, che tao he thong thiet bi dap thuy tinh chi tiit dang
tdm CO hinh dangphHc tap, T^p chf Co khi Viet Nam (ISSN 0866 - 7056), So 1 + 2, thang 1+2/2013 trang 81-86
l5].LeTrungKiln, Pham Van Nghe, Ng/iie« CU'U tao hmh khi dap vudt chi tiet phiic tap bdng cong nghe ddp thiiy
tinh sii dung phUOng phdp md phong sd kit hpp thUc nghiem Tap chi Khoa hoc &Cdng nghe, TrUdng Dai hoc
Cong nghiep Ha Npi (ISSN 1859-3585), Sd 14, 2/2013, trang 23-26
[6] By M, K09 (2009), Book: Hydroforming for advanced manufacturing, Woodhead Publishing Limited
[7] Le Trung Ki^n, Pham Van Nghe, Dinh Van Duy, Ong dung dap thuy tinh dap vuot chi tiit dang tdm trong
ngdnh Cdng nghiip dtd, Tap chi CO khi Via Nam (ISSN 0866 - 7056), So 05 thang 5/2012, trang 14-18
[8], Taylan Altan (2006), Processes for hydroforming sheet metal l,Stamping Journal, (Feb 2006), Pages 40-41 19] Taylan Altan (2006), Processes for hydroforming sheet metal 2, Stamping Journal, (Mar 2006), Pages 44-46
[10] R Narayanaswamy, S.M Doraivelu, V.Gopinathanand, V.CVenkatesh A comparative study of deep
draw-ing with conventional, isostatic, and hydrostatic pressure, Journalof Mechanical Workdraw-ing Technology, 6 (1982),
Pages: 227-^ 234