Ti liu v khun n p

I. qu trnh n p nhm.

1. Nguyn tc n p:
Nguyn tc c bn ca n p nhm rt n gin: mt thi
nhm hnh tr qua x l gia nhit trc c t trong my n p
thu lc v c p p sut cao qua mt khun p bng thp m
khi thi n ra khi my p s c hnh dng theo mun. Bn v biu
ca mt chu trnh sn xut c th hin Hnh 1: trng tm ca
chu trnh l khun . Kiu khun n gin nht l loi khun thp c
qua x l nng, c mt l, c gia cng c kh c bit, c hnh dng
theo thit k. Cng vi cc ph kin khc, khun c gi trong mt trt
khun - mt b phn ca my p. Gn cht vi trt khun l mt
container (bung p). Trong bung p l mt billet c chn vo sau khi
n c nung nng nhit khong 5000C. Bung p cng c gia
nhit bng mt dng c cch in tt, nhm m bo billet lun c
gi nhit ng nht. Ram (pittng) s to p lc ln Billet v u
ca ram (dummy block: chy p) phi c thay nh k, bi v chc
nng ca n l hp th mi mn do s tip xc vi kim loi nng gy ra.
p lc c thc hin bi Main piston (pitng chnh) vn hnh bng du
thu lc. Du thy lc sinh ra di p lc ca bm du. p lc ny s lm
thanh nhm c p qua l trong khun, to thnh thanh c hnh dng
ging vi hnh ca l trong khun.
My ct
Khun

Xilanh chnh

Billet
Chy p

Du thu lc

Tr t khun

Container

Ram

Piston chnh

Hnh 1: Mt ct ng ca my n p.

Chu trnh phi dng trc khi mi Ram chm khun. Container quay tr li
xilanh nh khun cn gi phn cn li ca Billet; Ram cng s li li v
mu Billet s b tch ra khi khun bi mt li ct t trn. Cng sut ln
nht m pitng chnh thc hin c gi l cng sut p. Cng sut p
c o bng tn. Cc my p cng nghip c cng sut t 500 n
20.000 tn, nhng hu ht nm trong khong 1.200 - 3.500 tn.
2. Cc kiu my p:
V ng dng thc t, cc kiu c bn ca my n p c ch ra
hnh 2.
a. My n p trc tip loi n gin :(bn v A, hnh 2)
y l k thut c bn.
b. My n p trc tip c li rng :(bn v B, hnh 2)
Kiu ny c s dng n p cc thanh rng v n khng th s
dng cc khun truyn thng.
Cc bc c bn ca my p ny c thc hin nh sau:
Pitng v thit b rng cng tin ln cho n khi Ram chm n Billet
Li rng trung tm tin trong khi Ram dng li, to ng qua Billet v
xuyn qua n (nhng thng th Billet c khoan trc) v dng li khi u
ca n vo l khun.
Lc ny thit b rng dng trong khi Ram tin v Billet c n qua
khong hnh khuyn gia khun v li rng.
c. My n p gin tip hoc my p ngc: (bn v C, hnh 2)
Trong qu trnh n p gin tip, lc my p to ra mt p lc rt
cao trong bung p. lc p ny lm b mt ca billet dnh cht vo
thnh bung p. Khi Billet tin vo bung p, cc tng bn trong bung
p di chuyn d dng hn cc tng gn b mt. iu ny do phn ng
ma st ng k to ra.Cc phn ng ny c th hp th hn 20% lc p
khi vn hnh trn cc hp kim cng. iu ny lm hn ch kh nng n
p, c bit vi cc thanh mng.
i vi loi my p ngc, bung p c lm di chuyn cng tc
v cng hng vi Ram , m khng c s di chuyn tng ng gia
Billet v bung p , khng c cc phn ng ma st v ton b lc p s
c tn dng n p Billet. V c cng lc p, do , c th t c tc p cao hn: v d i vi cc my p c vch mng hn. Mt
thun li khc i vi loi my p nghch ny l vi h thng ny th c
th trnh c im lm vic cng v hn ch c hin tng to ra th

kt tinh pha cui khi s dng hp kim cng, gim s cc thanh b

khuyt tt.
Tuy nhin, cng vi cc thun li trn th kiu my p ny cng c
nhng bt li ng k. Mt trong nhng bt li chnh l, i vi loi my
p trc tip, v ca Billet c cha nhiu oxit v cht kt ta cn nm
trn vch bung p v c Ram thu li s c chuyn n khu thi. Qu
trnh ny li khng xy ra vi my p nghch ni m v Billet hnh
thnh trc tip trn b mt ca thanh p, gm c cc khuyt tt b
mt. Mt hn ch quan trng khc ca my p nghch l cc sn phm
c n p phi i qua bn trong trc
gi khun v iu ny lm hn ch cc thanh t c.

Hnh 2: Ba kiu my p c bn
II. Khun n p:

1. Cc loi khun:
Cc tiu ch thit k c bn cho vic ch to khun phi theo cc
nhn t nn tng di y:
- Khun l mt kt cu c kh phc tp, c lm bng cht liu cng
v bn.Do , khun cng nh cng tt v l do chi ph v l do lm
vic.
- Khun phi qua p lc cao v phi chu c p lc p ca my p
m khng b nt gy.
T hai nguyn tc c bn n gin ny, khun cn c cc thit b ph
kin c th tr gip n thc hin ng chc nng. Cng c cc tiu
ch quan trng m c nhiu hoc t nh hng n dng khun tng
ng kiu my p c s dng. Khun p c th c chia thnh 3 loi c
bn da trn nhng nhn t trn:
a. Khun c:
y l loi khun dng cho n p cc thanh l thin, v hnh 5
ch cch lp rp khun loi kiu ny. u tin, mt vng kp khun (die
ring), ln cho php vic lp t c chn vo phn trt
khun(die holder slide), c h tr bi mt Die Backer c ming rng
hn mt cht so vi khun v cc vng m ng b cho s h tr v
lm kn khong cch trn phn trt. Cc b phn ny (khun, vng
khun, backer v m khun) to thnh ci gi l b trn gi ca s
lp rp dng c n p.
b. Khun porhole:
Dng cho n p cc thanh rng. D dng thy rng vn lin
quan y l vic to ra mt l v hnh 6 ch ra cch gii quyt
vn ny bng mt ng c mt ct hnh trn.
Mt khun sau to ra hnh dng bn ngoi ca thanh v mt l trc
(mandrel) to hnh dng bn trong. Mandrel c gn vi khun trc, v di sc p ca Ram p lc, billet c chia thnh 4 lung tng ng vi cc
knh np hoc cc l ABCD ca khun trc.
Sau , bi v c p lc cao, 4 lung ny t gn vi nhau ln na, v
kim loi c p qua mt khong gia ming ca Mandrel v ming
khun sau, to thnh thanh p rng n.
Khun kiu spider cho cc thanh rng (hnh 7): c s dng theo cch
tng t vi kiu porhole. Tuy nhin khc bit ch Mandrel hon ton
m, vi c Mandrel v khun c thit lp theo b mt hnh nn. iu
c ngha l vng kp khun phi c lm c v bn trong hnh nn.

Ci tn spider-con nhn xut pht t dng ca Mandrel tc l c cc

chn.
Cng ngh tin tin c khuynh hng s dng loi khun kiu spider bi
v kiu dng ca Mandrel lm cho chng d bi trn hn v gim chi
ph v v c th t c tc p cao hn vi dng c ny. Tuy nhin,
do s h tr tng i yu, iu ny c nghi l cc loi khun kiu ny
s c chu thp i vi lu lng kim loi khi n p, v do chng
ph hp nht i vi cc profile i xng.T quan im ny th loi
khun porthole s ph hp vi cc profile khng i xng v phc tp.
R rng rng, mi h thng c thun li v hn ch ring. V cc nh
thit k khun phi da nhiu vo kinh nghim ca mnh v kh nng
trc gic trong vic chn kiu khun ph hp cho cc thanh n p rng,
ng thi xem xt loi kiu thanh, hp kim c s dng cng nh chi ph
v bn ca chng.
nh gi cui cng phi c a ra v cc profile rng.
Trong nhng trng hp ny, khng c s la chn no tt hn vic s
dng mt Bore Mandrel m cho php cc thanh n p hnh ng c
sn xut m khng phi phn chia kim loi. Tt nhin thng th khi mt
Bore Mandrel c s dng th Billet phi c khoan trc. V trong thc
t, khot l trn my p c th dn ti s chch hng ca Mandrel, c
bit l khi lm vic vi cc hp kim cng hoc trong mi trng hp c th
to nn mt l c khot khng ng u dn n hnh dng ngho
nn bn trong ng.
Mc du vic s dng mt Bore Mandrel s gii quyt vn ny, tuy
nhin lun phi nh rng k thut ny cng c nhng hn ch ca n cho
nn tt hn ht l ch s dng cho cc thanh rn chc, n gin v
i xng.
Khng i xng dn ti sc p khng i xng trn Mandrel, gy ra s
lch tm ca l hoc thm ch gy ra rn nt ca chnh Mandrel.
Khun l trung tm ca qui trnh p v ngay c my p tinh vi nht
cng s khng th sn xut ra cc sn phm tt m khng c khun ph
hp. V l do ny, ci thin quy trnh p cn c nhng n lc cho
cc tiu ch thit k v cc phng php ch to khun.

2. Cc b phn ca khun:
Lp rp dng c khun c bn c ch ra hnh 3.

khu n

v ng khu n

khu n ph
m k hu n

m ph

b phn c h a d ng c

Hnh 3: Mt b lp rp khun in hnh

Cc b phn bao gm khun, khun ph, i km l o khun, m
khun v m ph. Cc b phn ny c lp vo mt b phn gi l b
phn cha dng c (tool carrier), hoc l container. Mt ca trt ng
gi vic lp t bo v khi lc ca my p. Khun ph v m
khun gip phn b p lc ng u v h tr khun.
a. Container:
y l mt xylanh thp, c mt tm m lt c th thay chuyn
c. Container c ng knh bn trong ln hn mt cht so vi ng
knh billet c n p. Chiu di ca n thay i theo lng cng sut
v nh ch to my p.
b. Vng khun (Die ring):
L mt ng lng (bc ngoi) gi khun v khun ph trong mi
lin kt trc vi nhau.
c. Khun ph (backer):
Khun ph ging nh khun nhng thng dy hn 2 n 3 ln.
N nh l mt a thp v n c mt l ln hn l ca khun. Khun ph
thng c trang b cc cht hoc vu li c th gn n vi khun
n p hp l. Khun ph h tr khun chng li p lc billet v l phng
tin gi khun.
d. m khun (Bolster):
L mt b phn bng thp hp kim hnh a c gia cng cng,
c ng knh bng ng knh o khun. m khun h tr khun v

khun ph v nhm gim thiu vnh lch. m ph (Sub-boster) tng t nh m khun.

e. Gi khun (Die holder):
y l mt b phn ca my p. N nm gia container v trc p. N
c th tho ra c hoc c th vung gc vi hng n p (tu thuc
vo kiu my p) m c th tho khun ra nhm loi b u mu
hoc ph phm.
f. Stem (ram):
L mt b phn n p c chc nng cho billet vo trong container
v n tip xc vi dummy block. L mt on ca xylanh chnh, stem
phi c kh nng chu c lng p ti a. Chy p (dummy block) l
mt a thp, dy khong 3, c ng knh nh hn bn trong
container mt cht(khong 0.025). N to thnh mt s bo v khi
vic np ngc gia billet nng v Stem.
Thut ng stem c s dng thay cho hoc i khi ng ngha
vi ram trong nhng trng hp nht nh.
3. Mc thp ch to khun v ch nhit luyn khun:
a. Cc mc thp ch to khun:
Khun n p chu ti trng va p nh nhng phi chu ma st
ln, p sut cao, nhit mt khun ti (400500)0C do phi tip xc
lu vi phi nng. c tnh cng nng cao, khun n p phi dng
thp c (0,300,40)%C vi lng hp kim Cr, W cao, ngoi ra c thm 1%V
nng cao tnh chng mi mn, gi ht nh v 1%Mo trnh rn
ram.
Mc thp dng ph bin l 30Cr2W8V (tng ng 3X2B8 ca Nga,
H21 ca M v SKD5 ca Nht.
Thnh phn ho hc ca mt s mc thp thng dng lm khun
n p:
Tiu

Mc

%C

%W

chun
TCVN

thp
50CrNiM

0,500,

(Mn)
0,500,8

0,150,

0,500,

OCT

o
5XHM

60
0,500,

0
-

30
0,150,

JIS

SKT4

60
0,500,

0,601,0

50CrMn

60
0,500,

Mo

60

TCVN

%Mo

%Cr

%V

%Si

(Ni)
1,401,

80
0,500,

80
0,100,

30
0,200,

80
0,701,

40
1,302,

0
1,201,6

50
0,150,

00
0,600,

00
0,250,

30

90

60

TCVN

30Cr2W8

0,300,

7,509,0

2,202,

0,200,

JIS

V
SKD5

40
0,250,

0
9,0010,

Mn(0,6

70
2,003,

50
0,300,

H21

35
0,260,

00
8,5010,

0)
-

00
3,003,

50
0,300,

0,150,

36

00

75

60

50

AISI

b. Ch nhit luyn khun:

i b phn khun c hnh dng phc tp, phn lm vic bn trong
c nhiu gc cnh, cn thit phi trnh s tng bin dng trong qu
trnh nhit luyn. Vi nhng c im trn nn nhit luyn khun
phi t c y c tnh nh khng c vt nt v bin dng
i vi mc thp ph bin dng ch to khun dp l 30Cr2W8V
th nhit ti l 105011000C. Khi nung ti, khun dp c cht
vo l c nhit 6006500C, gi nhit trong khong 2h, sau nng
nhit ln ti nhit yu cu vi tc 751000C/h. Thi gian gi nhit
trong l c tnh 4050 pht cho tng 25mm chiu dy b nht ca
khun. Mi trng lm ngui l du nhng khng cho php ngui hon
ton (ti nhit phng). Nhng khun ln cn phi lm ngui trong
du khong nhit 1001500C v chuyn ngay vo l ram. Nu
khng tin hnh ram ngay c th to ra vt nt. cng sau khi ti t
c 4952HRC.
Nhit ram khun t 6006500C, thi gian ram c tnh 4045 pht
cho tng 25mm chiu dy b nht ca khun. cng sau khi ram t
4048HR
T0C

1050-11000C
600-6500C
ngui trong du

600-6500C

Ti

ngui trong du

Ram

(h)

Sau khi ti v ram cao khun cn ho nhit luyn nng cao

cng, tnh chng mi mn. Ho nhit luyn khun c th l thm N
hoc thm C-N nhit thp. Thm N c tnh chng mi mn cao tuy
nhin thi gian thm lu, lp thm gin, Thm C-N tnh chng mi mn
thp hn nhng lp thm n nh tuy nhin tnh chng mi mn vn
t yu cu.
Thm N khun tin hnh nhit 5005200C, thi gian thm 2024h,
lp thm t 0,20,3mm.
Thm C-N khun tin hnh nhit 5006000C, thi gian thm
2024h, lp thm t 0,20,3mm, cng t 65HRC.
III. Cc loi nhm bin dng ph bin dng cho n p:

C rt nhiu loi nhm hp kim bin dng. Tuy nhin, a s cc sn

phm n p u t cc nhm hp kim nhm di y:

Nhm

Si

Fe

Cu

Mn

Mg

Cr

Ni

Zn

Ga

Thnh
phn
khc

Ti

1050
A

0.25

0.4
0

0.05

0.05

0.05

0.05

0.0
5

0.0
3

1350

0.10

0.4
0

0.05

0.01

0.01

0.05

0.0
3

3.95.0
3.54.5
0.05
-0.2

0.041.2
0.041

0.20.8

0.10

0.25

0.1
5

0.10

0.41.0

0.25

0.25Zr+T
i

1-1.5

0.1

0.1

0.2

0.0
5

0.15

0.2

0.2

0.0
5

0.15

0.25

0.1
5

0.0
5

0.15

0.25

0.1
5

0.0
5

0.15

0.25

0.1
5

0.0
5

0.15

1000

2017
A

0.05
-1.2
0.20.8

3003

0.6

0.7

5052

0.25

0.4

0.1

0.1

2.22.8

5154

0.25

0.4

0.1

0.1

3.13.9

5454

0.25

0.4

0.1

0.5-1

2.43

5438

0.40

0.4
0

0.10

0.4-1

44.9

5086

0.40

0.5
0

0.1

0.20.7

3.54.5

2014
2000

3000

Tp cht
Mi Tn
TP
g
0.0
3

K
hiu

0.7
0.7

0.15
0.35
0.15
0.35
0.05
-0.2
0.05
0.25
0.05
0.25

0.05B
0.02V+Ti
0.0
5
0.0
5
0.0
5

0.15
0.15
0.15

6000

7000

6101

0.30.7

0.5
0

0.1

0.03

0.35
-0.8

0.03

0.10

0.06B

0.0
3

0.01

6005
A

0.50.9

0.3
5

0.3

0.5

0.40.7

0.3

0.20

0.120.5Mn+C
r

0.1
0

0.0
5

0.15

6060

0.30.6

0.1
0.3

0.1

0.1

0.35
-0.6

0.05

0.15

0.1
0

0.0
5

0.15

6061

0.40.8

0.7

0.15
-0.4

0.15

0.81.2

0.25

0.1
5

0.0
5

0.15

6262

0.40.8

0.7

0.15
-0.4

0.15

0.81.2

0.25

0.040.7Bi
0.4-0.7Pb

0.1
5

0.0
5

0.15

6063
A

0.30.6

0.1

0.15

0.60.9

0.05

0.15

0.1

0.0
5

0.15

6463
A

0.20.6

0.1
50.3
5
0.1
5

0.25

0.05

0.30.9

0.05

0.0
5

0.15

6763

0.20.6

0.0
8

0.04
0.16

0.03

0.45
-0.9

0.03

0.0
5

0.0
3

0.10

6082

0.71.3

0.5
0

0.1

0.4

0.61.2

0.25

0.20

0.1
0

0.0
5

0.15

7003

0.30

0.3
5

0.2

0.3

0.51.0

0.20

5.06.5

0.050.25Zr

0.2

0.0
5

0.15

7010

0.12

0.0
5

0.15

1.52.0
0.81.2

0.05

7012

0.1
5
0.2
5

0.04

7020

0.35

0.4
0

7075

0.40

0.5
0

0.080.15

2.12.6
1.82.2

0.2

0.050.5

1.01.4

0.12
-2.0

0.3

2.12.9

0.1

0.04
0.35
0.04
0.14

0.10
0.35
0.18
0.28

5.76.7
5.86.5

0.110.17Zr
0.100.18Zr

0.0
5
0.0
5

0.15
0.15

4.05.0

0.0
5

0.15

5.16.1

0.2
0

0.0
5

0.15

1. Hp kim h Al-Mg-Si:
Cc hp kim c seri Al- Mg-Si chng minh cc c tnh kinh t v
k thut nht i vi loi kiu ng dng ny, cho thy kh nng lm vic
v tc p cao, s n gin ca x l nhit, tnh dn in tt, cc
c tnh c kh hon ho, kh nng da ra cc thnh phm c b mt
tt, chu mi mn cao v tnh d hn. c tnh rng vi triu tn hp
kim loi ny c n p hng nm, i khi c hnh dng phc tp, c
s dng cho ca v khung ca, trang tr xe hi, cu trc nh cao tng,
thanh dn in, my trao i nhit, v.v....
Nhng hp kim nhm i din nht v ni ting nht trong seri
ny, bao gm mt s thnh phn tiu chun ho mt s quc gia c
chi tit hnh di.
6060 v 6063: ni ting di ci tn Al-Mg-Si 0.5. Nhng hp kim ny l
nhng vt liu c kh nng n p tt nht v chng c n p tc
rt cao.

10

Chng chu mn trong iu kin mnh v c th dng cho vic nh

bng b mt, anod v sn.
C nhng thnh phm dng cho trang tr, v d nh trang tr t, hay
s dng loi 6463 hoc 6763. Cc loi ny c nhm nguyn cht t
treen 99.8% v hm lng Fe cc thp.
Al-Mg-Si 0.7 (6005): Hp kim ny , vi cc bin th 6005 A, 6105 v.v...l
mt trong nhng cng thc ph bin nht trong s cc hp kim Al-Mg-Si
c mnh c kh trung bnh. Mc cao hn ca hp kim khi c so
snh vi 6060 cho thy c s gia tng cng c kh m cho php n
c s dng cho cc mc ch xy dng v bn xy dng. Vic thun
li khi lm vic vi hp kim ny l mt nn tng tt i vi s pht trin
rng ri hn cc ng dng.
Al-Mg-Si-Cu (6061) v Al-Mg-Si-Mn (6082): Cc hp kim ny c cc c
tnh c kh rt tt trong s cc hp kim ang c s dng rng ri dy
6000, v c bit l 6082.
6061 a ra c tnh bn, dai rt tt. y l mt nhn t c tnh
quan trng trong vic quyt nh chnh xc ng n nhng hp kim
cho cc mc ch xy dng. Hp kim ny cng c a chung bi v
tnh nhy i vi kh nng ti trong cc hot ng hn, cho thy c
tnh c kh cc tt trong vng hn ch thng qua bng ho gi m
khng cn gii php x l nhit. Khng c s khc bit trong kh nng
chu mn v trong c tnh sn phm gia hai hp kim 6061 v 6068.
Tm li, C hai loi hp kim ny u ph hp cho luyn kim.
2. Cc hp kim h 7000 Al-Zn-Mg vi cng trung bnh:
Trong vng 30 nm qua c s quan tm ng k n b ba
hp kim Al-Zn-Mg (7020, 7005, 7003 v cc loi tng t) m c ng dng
c bit trong thanh cun ng ray v cc kt cu hn ni chung. Cc
hp kim c x l nhit ny cho thy kh nng t ti cc tt v kh nng
phc hi cc c tnh c kh trong vng luyn kim b thay i do hn
m khng cn x l nhit ton b.
Cc hp kim ny c cng c kh tt. V kha cnh k thut th
c kh nng cnh tranh vi thp cc cu trc hn. Chng c bn
tt. iu ny c ngha rng chng c th c dng cho cc thanh khng
phc tp v khp kn. trong mt s trng hp, nu khng c s dng
hp l, chng c th b trc v n mn.
3.Cc hp kim h 2000 Al-Cu v h 7000 Al-Zn-Mg-Cu vi cng
cao:

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Lp hp kim ny bao gm cc hp kim ca dy Al-Cu (loi 2014, 2024,

2017) v ca dy Al-Zn-Mg-Cu (loi 7075 v 7021). Nhng hp kim ny l
nhng hp kim yu, c x l nhit, c mnh c kh cao nht, vi gi
tr chu cng cao bng 700 N/mm2 hoc hn th. Kh nng lm vic
ca chng hn ch, v d, chng c th c s dng cho cc thanh n
p mt ct h nu hnh dng khng qu phc tp v cc thanh mt
ct kn bng cch s dng mt li rng. Cc cht liu ny hoc l
khng th c hn hoc c th c hn nhng rt kh khn. Thm ch
khi hn c th cng c th gy ra nhng thay i kt cu vi c
tnh c kh b gim mnh. Bt li ny lm cho chng t c la chn
trong hn.
Tt c cc hp kim ny phi c bo v chng n mn.
Cc hp kim ca dy 2000 v 7000 thng c s dng cho kt cu
my bay, v ni chung, chng c s dng trong cc trng hp c t l cng /trng lng l mt trong nhng mc tiu c bn ca thit k.
4. Hp kim khng nhit luyn h 3000 Al-Mn v cc hp kim n
p h 5000 Al-Mg: Hp kim Al-Mn dy 3000 rt thch hp cho nh my
ho cht v cc ng trao i nhit, bn v su v cho n p va p.
Kh nng chu mi mn cao, tt nh nhm nguyn cht.
Cc hp kim nhm tt nht m khng th b lm cng bng x l
nhit l nhng loi thuc seri 5000 Al-Mg. Tng lng Mg (T l cao nht
trong nhm thng mi l 5%) nng cao c tnh c kh nhng li gim
kh nng lm vic, m thm ch trong nhng trng hp tt nht cng
khng bao gi cao. V l do ny m cc thanh p trong 5000 hp kim
lun c nhng hnh dng n gin hoc ch hi phc tp mt cht.
Cc hp kim Al-Mg chu mi mn cao. Nhng s dng c bn i vi
5000 hp kim bao gm cc ng dng trang tr , kin trc, cc bin ch
ng, tu thuyn v bnh ng lnh.

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