Ydu cau trong 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,
Trang 1NGHieNCCfU-TRAODOl
PHAN TiCH QUY T R I N H C 6 N G NGHE DAP CHr TlgT T A M
MONG UNG DUNG TREN CABIN 6 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 1
^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 che 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 tiet 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 technology, ofmanufacturing its sheet metal part Calculate technological force to select machine and desigi thepresswork die Analysis sheet metal presswork technology takes into account the influence of the coefficient of friction to the quality of the product The study results fit the mold design current conditions and proacttvely fabricating thin sheet details on the cabin of light trucks
Keywords: Cabin of light truck, sheet metal, stretch forming presswork
cabin 6 to tai do miic dp phiie tap eia cong M- I,-, - °8he chS tao tu cac chi tiet tim mong VifC
I„n * ! r w ' ^ ! * t ™ "S ""^^ ™°8 °gl'^ nghien ciiu phan tieh mo phong qua trinh dap luon dupe chu y dau tu phat trien tai cac doanh „ £ ; - • ! • _ - j - •- •
I-nohim >ji„-,„„ „i,i I, /"",""='"?' ''IC aoann chi tiet vo cabin tren cac may dap hien co da
" ^ ^ S ^ ^ ^ ^ ^ ^ ^ c o n h ^ g k a t q u a c t h e d a d u ^ r a L p h l m c a don vi chu dong san x u C g l L gia t S Z ^ " ' ' • * " ' P ^''•
pham va tang tinh canh tranh tren thi tnrdna
2 NOI DUNG NGHltN CUtJ
Tren xe 6 to, cabm chidm vi tri quan
Irpng^tao thanh hinh dang xe phii hop va dam 2.1 T6ng quat vl vo cabin xe tai nhe
bao tot dieu kien van hanh cua xe D8n nay 6
ttong nuoc chua CO don vi nao diu tu ch^ tan r^ u • _ ,
• " '^ '^"^ * ° Cabm tren 6 to tai eo eac cong dung ISSN 0866-7056
TAP CHl CO KHi VIET NAM, S6 1+2 nam 2017
Trang 2chinh: 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 trong 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 trong 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 trong 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 khi xay ra 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 khi 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 nhau 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 6 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 6 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 do
ca ban la thudc do tren vdt mdu, tinh todn kiem nghiem theo truyen thdng bao gdm chu yeu tinh toan dp bdn Phuang phdp ung dung tin hpc trong thidt ke: Sii dung nhihig dung cu do ca bdn Id thudc do trdn vdt mau
va ve trong 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 do tidp xiic va khdng tiep xiic Cdc thiet
bi CMM sii dung dd do tidp xuc (Coordinate Measuring Machine la cac thiet bi van nang cd the thuc hien vide
do cdc thdng sd hinh hgc theo phuang phap tpa dp) Cdc thiit bi laser va quang hgc sii dung dd do khdng tidp xuc Dien hinh cua do quang hgc la quet bang mdy tao"^
ISSN 0866 - 7056
T ^ CHl CO KHl V I £ T NAM, Sd 1+2 nam 2017
Trang 3NGHIEN CCrU - TRAO Ddi
ra 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
ra 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
nay co the len den hang trieu diem Tpa dp cua
nhiing diem nay 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 do chinh xac ciia mo hinh 3D nha sii dung
phan mem ehuyen dung (vi du phSn mSm
Geo-magic 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 thanh phta
a) Vo cabin scan 3D
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
Cac chi tiet tfim mong co chi^u day S <
2 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):
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 ra trong 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):
Q = (0,1+0,3) P,^„ (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 do ma sat da tao ra 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
Trang 4NGHIEN 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
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 nay gpi la dan hdi ngupe Trong
qud trinh udn, cac ldp kim logi nam trong viing
keo se cd xu huong co ngdn lai, cdc ldp kim
loai nam trong vung nen cd xu hudng gian ra
Dg dam bao tinh chinh xdc kich thudc cua san
phdm cdn giam tac ddng cua ddn hdi ngugc
v ^ P trong 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)
r- Ban kinh cua ehdy udn;
k - He sd bien d£ing dan hdi;
r^-Gdc udn sau khi bien dang dan hdi
2.3.2 Thiet ke khudn d$p vuot tg.o hinh cdc chi
tiet vo cabin
Khudn dap vudt tao hinh chi tidt tam
mdng vd cabin gdm khudn tren vd khudn dudi
dugc che tao bdng phuong phdp due va gia
cong CO sau due Vat lieu lam khudn tu gang
cdu nhdm tiet kiem chi phi sdn xudt khudn
Khudn lam tii gang cau cd dp ben cao do can
tnic tmh thd dang cau trdn bao gdm ba loai ndn
1dm loai: Phe rit, phe rit - p e c lit va pec lit Bd
m^t Idng khudn trdn va khudn dudi tao hmh chi
tiet dgp dugc gia cdng vai kich thudc ciia san
pi^m Do kich thudc tdm vd Idn cd thd chilm
h i u hdt khoang khdng gian trong cua may dap
ndn khi diidt kd cdn tranh tac ddng udn hay keo
dd tang dp cung viing ciia hai chi tiet due bang each thiet ke sao cho khdng sut dyng cdc tam ddm va ao khudn Vi dy bd khudn dgp vudt tam ndc cabin dugc md td ttdn hinh 2.2
IRnh 2.2 BQ khuon da duac thiet fee dap vuot tdm
noc cabin:
a) Khuon duoi; b) Khuon tren
2.3.3 Mo phong qud trinh dap vuot t^o hinh
cac chi tiit t&m mong vo cabin a) MS phong so chpn may dap vuot
Ta chgn thdng sd theo kich thudc chi tidt dap Luc cdng nghd gidi ban: 250 (T), phdi tam cd chidu day 1mm, hd s6 ma sat 0.15, luc chan phdi dugc tinh todn theo luc chan toi da cua may Q^^=125 (T), kich thudc p h l n tu Idn nhdt 40nim va kich thudc phdn tii nhd nhdt la 0.3 Imm
Tix kich tiiudc phdi hinh chii nhat ta chan phdi hai phia theo chiiu dai ciia tdm, kdt qua
md phdng ttdn phan m i m Autoform vdi hai thdng sd luc chan 70 (T) vd Itrc chdn 80 (T), Mnh 2.3
a) b) Hinh 2.3 Bieu do lifc cong ngh$ 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 2017
Trang 5NGHIEN COU - TRAO D 6 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 khi luc ehgn
phoi Ion thi cac lire Sp, luc uin dSu 16n han Tu
cac kSt qua khao sat do ta chpn dupe luc cong
nghe Ion nhit la 217 (T) valua chpn may dap co
luc dap Ion hon 217 (T), trong 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 khi 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 qua tiinh tao hmh
(hinh 2.4)
Hinh 2.5 Phdn bd viing nhgn tren vien mep chi tiit
V-d) Sir biin dftng Oan hit ciia chi tiit d^
BiSn dgng dan hii xay ra 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 do 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 ra BiSn dang dto hii khong toh huong toi kicli thuoc cua chi tiit
j
t
:sa
•^r'• " ^ Gioi hfAp\ibli
i^.-.'^'^-'-^-j
Hinh 2.4 Phdn bd bidn mdng
^ ^ F 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 do 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, khi 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 trong qua hinh dap vol he si ma sdt n < 0,15 la phu hop va vat liSu boi ttuon btagdiu
CO the dap ftng dupe
ISSN 0866-7056 TAPCH,COKHIVIETNAM,Si W„am2017
Trang 6Hinh 2.6a Phdn bo bien mong cua sdn phdm khi
sir dung chdt boi tron cohi so ma sdtfi=0,20
Hinh 2.6b Phdn bo bien mong cua sdn pham khi
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
Luc chan
Luc cong
nghe
Hes6ma
sat
Thong s6
hinh hoc
cua khuon
DSp vudt
tao hinh
noc cabin
70 (T)
212,6 (T)
0,15
Theo kich
thuoc chi tilt
D^p vu6t tao hinh san cabiD
60 (T) 225,8 (T) 0,15 TheoIdch fliuocchiti^
D^p vu6t tao hinh t^m sau cabin
50 (T) 219;2 (T) 0,15 Theo kich tniocdiiti^
Cac thdng sd dat dugc do tinh todn ciing
nhu md phong dam bao dugc do phu hgp cua
nhiing tiiet hi sdn cd dang d mdt sd nhd mdy
ttpng nude vdi gja thanh 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
chi tidt Cdc chi tiit t i m mdng sau chd tao (hinh 2.7) d u g c 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 2.7 Cabin 6 to tdi nhe da dugc ung dung cong nghe ddp vuot
4 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 ra san pham dap khdng bi iihan, rach^ tien tdi che tao loat va md rdng ra 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 C o khi 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 Ky fliuat Ha
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); Miy feia vd wttiv ep
My bee, NXB Giao due
N g i ^ Die Thm^ Lg Thai Hiing, Ngiiyin Nhu HiQnh,
Nguy&i Tnmg Kiai ^ 1 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) Springer-Verlag Berlin Heidelberg
ISSN 0866-7056 TAP CHf C O KHt V I $ T NAM, Sd 1+2 nam 2017