Tối ưu hóa thiết kế khung thân máy xé lưới cao tốc bằng phương pháp mô phỏng số

NGHIEN CUfU - TRAO DOI

T 6 | [y\J HOA THIET KE KHUNG THAN MAY XE LlfQI
CAO TOC BANG PHUONG PHAP MO M 6 N G S 6

OPTIMIZATION DESIGN FOR BODY FRAME OF EXPANDED MACHINE
BASED ON NUMERICAL SIMULATION

Pham Van Nghe, Le Trung Kien, Vii Thanh Hai
Truang Dai hgc Bach Khoa Ha Ngi

TOM TAT

Thiit ki mdy ca Ian su dving kit cdu ca khi Id c6ng viec doi hoi phai tieu ton nhieu thai gian y
c6ng sice. Di co thi gidm thiiu nhitng chi phi kh6ng cdn thiet thi can phai dp dung cdc ky thuat tien
tiin trong qud trinh tinh todn vd thiit ki. Di tdng cuang do cimg khung thdn mdy, cdn thietphdi tinh
todn gidm biin dgng Ian nhdt bdng tii im kit cdu khung mdy. Bdi bdo trinh bay nhitng nguyen tdc ti
todn thiit ki dua tren ca sa m6 phong si qud trinh bien dgng khung thdn khi thiet ke mdy xe luai Sau
khi phdn tich vd toi uu hoa thiit ki khung thdn cua mdy xe luai, do cung vd do ben cua mdy dugc dam
bdo.
r,

r

r

Tir khoa: Mdy xe luai; Khung mdy; ung sudt; Bien dgng, ...

ABSTRACT
Frame Mechanical Press designing involves to spend a lot of time and effort. To reduce
the unnecessary cost, it is necessary to put the advanced technique into calculation and design

process. In order to enhance the body frame rigidity, it is necessary to reduce the maximum body
frame deformation by optimizing the body frame structure. Presenting the separate principles when
designing bodyframeof machine basing on numerical simulation results of deformation process for
expanded machine is the aim of the paper. After the performance analysis of the optimized designed
body frame of expanded machine, its rigidity and strength are proved.
Keywords: Expanded metal machine; Frame; Stress; Strain,...

I

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NGHIEN CUfU - TRAO Q6\
1. DAT VAN DE

phu thugc vao cac ylu t6 sau:

Hien nay, cac may ep ca Ian dan dgng co
- Luc ep danh nghia: Xac dinh do ciing
khi SU dung trong cac nganh c6ng nghiep a Viet ciia may;
Nam chii yeu van dugc nhap ve tir cac hang san
- Kich thuac dung cu: Anh huomg den
xuat may Ian nhu: Sertom (Italia); Nieland (Ita- kich thuac gia c6ng;
- Kich thuac khoang kh6ng gian lam viec
ha); Sicmi (Italia); Hefei (Trung Qulc)...Vi?c
thiet ke khung than cac may nay dua tren ca sa may: Xac dinh hinh dang khung than may;
- Do chinh xac dan huang: Anh huang ca
m6 phong s6 qua trinh bien dang la mgt ITnh vuc
con kha mai me a nuac ta, chiing ta chii ylu vin ve hinh dang va do ciing khung than may.

r

r

can cii vao kinh nghiem, sau khi hoan chinh thilt
Voi cac khung than may co luc ep danh
ke se thuc hien che tao may vai he s6 ben cao.
nghia nho ban 2500 kN, khung may thuang co ke
Dieu nay se kh6ng tranh khoi nhiing tin that vl
cau ha - chu: C. Neu may co luc ep danh nghia Ian
kinh te ciing nhu thai gian. Bai vay, viec nghien
thuang dugc thiet ke dang than km (hinh 2). Cac
ciiu va trinh bay nhiing nguyen tac ciing nhu ky
bien dang khung than may tiiy theo ket cau ciing
thuat thiet ke khung than may ep tren co so m6 dugc tinh toan khac nhau (hinh 3).
phong s6 qua trinh bien dang la bet siic can thiet.
Hinh 1 la ket cau t6ng the cua may xe luai luc
ep danh nghia 120 tan voi khung than dang ban.
Khung than may mang dau trugt chuyen dgng se
hi bien dang trong qua trinh gia c6ng th6ng qua
he th6ng true truyen tac dung luc true tiep len
cac g6i tren khung. Giai ban bien dang Ion nhat
Hinh 2: Ket cdu thdn T^.dy dgng ha vd kin
cua khung may la 1.2 mm. Vat lieu lam khung la
thep 45 CO giai ban dan h6i a^ = 360 MPa, giai
ban ben o = 610 Mpa, trong qua trinh tinh toan
T
va thiet ke can thiet bien dang t6ng va ling suat
tuang duong nho ban cac gia tri giai han nay.
r

r

Hinh 3: Cdc kieu Men dgng khung mdy theo kit cdu

Hinh 1: Tdng the mdy xe luoi cao t6c
Khung may la chi tiet Ian hap thu lire
ciia may ep. Khung may giiip cho diu trugt, dan
huang va cac bg phan din dgng cho may chuyen
dgng chinh xac. Thiet ke cau tnic khung than may

Khung may xe luai voi dac diem luc ep
danh nghia kh6ng Ion, tuy nhien, do ket ciu dung
cu gia c6ng Ian, khoang kh6ng lam viec rgng
nen khi thiet ke can lira chgn ket cau khung may
dang kin. Vai dieu kien san xuat tai Viet Nam,
lua chgn phuang an che tao khung may xe luoi tu
thep ban. Viec sii dung than may ban se giam. nhe
khIi lugng than may, tang do ciing so vai than
may che tao bang gang diic, thay the mgt phan
hoac hoan toan thep diic hiem bang cac tam thep
va cac vat diic bang thep co kh6i lugng nho ban,
tang tinh gia c6ng khi dieu kien gia c6ng ca khi
^
ban che.

TAP CHI CO KHI VIET NAM, S6 6 nam 2014
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NGHIEN CUfU-TRAO 061
2. CO Sd TINH TOAN KHUNG MAY BANG
Hien nay, dii voi loai khung thuang dung
PHU^ONG PHAP GIAI TICH
nhit, ta tinh cac tri sl m6men tai cac diem dac
trung ciia no (bo qua tai trgng diing tam tac dung
Tinh toan khung than may dugc tinh theo len bg phan din huang). Hinh 4 thi hien cac hi sl
hai phuang phap:
m6men tai cac diem dac trung d6i vai mgt trong
nhirng so d6 ph6 bien nhat:
- Phuang phap m6 phong s6: Sii dung
phuang phap phan tir huu ban vai cac phan mem
h^.v -h^.v -h_
Caches6:
(^-Y''^^^~Y'^^^~1.
m6 phong chuyen dung de tinh toan cac gia tri
ling suat, chuyen vi tai ban cho khung than may
Cac m6 men dugc tinh bang c6ng thiic:
tir do lua chgn ket cau t6i uu.
- Phuong phap truyen th6ng sii dung giai
tich: Do than may la ket phiic tap bao g6m cac
phan hinh dang khac nhau va tiet dien ngang thay
d6i, vi the, kh6ng biet dugc he s6 kich thuac
tuyet d6i eva he s6 tap trung ling suat k va k^ nen
kh6ng tinh than may theo siic ben moi ma thuong
tinh theo siic ben tinh va tinh do ciing. Khi do he
s6 an toan r^. thuang lay bang 10 d6i voi than may
bang gang, n^, = 4 ^ 5 d6i vai thep diic va Oj, = 2,5
-^ 3 d6i voi thep ban. So di he s6 an toan lay Ian.
Nhu vay, mgt mat de tranh hong chi tilt dit tiln

do qua tai khi kh6ng co co cau bao hilm, bu lai
su phan b6 ]di6ng ding diu luc dat vao than may
mat khac de dam bao do ciing cin thilt cua than
may.

3.P.L, - a K j j

1 2 P . c | - - —I-8M,

\ 2
\2)
8(2a.K3^ + 3 )

M,

'

PL

4
M, + M , - - . P . c
M, = M,

.a

M, = M . +-.P.C

3.Pa, -4c
M,=

ry---(r0-.-->

•JO.

g[{2a.K,,+3X3J:„+2a)-a=.K„]

Sau do xac dinh cac tilt dien nguy hilm
Khi m6 hinh tinh toan than may la dang va ling suit tai do. iTng suit a tru ben cua khung
khung, ta ve so d6 than may a dang khung a hai tinh theo c6ng thiic:
hinh chieu: d6i vai than may thing diing dang
A ± Mi + M^
chieu diing va chieu canh. Tren so dl do ve tai
2.L
2F
Iv
trgng tac dung len than may. Da sl cac may ep tai
h-gng tac dung len ban may coi la tai trgng phan
b6 diu tren chilu dai C = 2L/3 (L la khoang each
Trong do:
giiia cac duong hric cua tru may). Nhiing luc tac - P: Luc danh nghia ciia may;
dung len bg phan din huang do tai trgng ciia diu - M.: M6men uln a bilu dl m6men uln cua
trugt thuang bo qua [1].
khung;
- M^ = P. Lj 2: M6men a mat phing vu6ng goc voi
JiJmat phang ciia khung;
- Lj 2: Khoang each hi duong tac dung luc P din
mat phang qua trgng tam tru tuang ling;
v.
- F: Dien tich tiet dien ngang nguy hilm tru;
- ly, I^: M6men quan tinh ciia tilt dien nguy hilm

ciia tru tuang ling d6i vai fruc y, x di qua trgng
tam tiet dien,
Hinh 4: Sa do dgng khung ciia thdn mdy - h^, h : Khoang each tir tha ngoai cung cua tilt
" , ^

Z

"j

ij.fj

TAP CHI CO KHI VIET NAM, Sl 6 nam 2014
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NGHIEN CUfU-TRAO DOI
dien din true trung boa x, y.

M6 hinh dugc thilt kl dang khung hop
vai ket cau ban. Qua trinh m6 phong s6 nham
Do bien dang theo phuang tac dung luc muc dich tli uu cac kich thuac hinh hgc tir do tilt
tim dugc hi bilu thiic:
Idem vat lieu.
5, = ^ ^ [ p x , - 2 ( M , - . M , x J - . J ^ + ^ : ^ + ^ ^
48EJ

2E.Fj

G.Fj

Ta su dung m6 hinh vat lieu la thep CT3
dang tam vai cac th6ng s6 nhu sau:

Trong do:
K = 1,2: d6i vai tiet dien hinh chir nhat;
K = 1,7 -^ 2: vai tiet dien hinh chii nhat
rong.

3.2. Mo hinh vat lieu

G.F3

Gioi ban dan
hIi a ,(MPa)
220 - 240

Gioi han ben
a, (MPa)
380-470

Do dan dai
tuong doi 6%
25-21

3. TINH TOAN KHUNG MAY BANG
Ta tien hanh kiem nghiem do ben ciia
PHU^ONG PHAP M O PHONG SO
khung may dua tren nhung tieu chuan ve ling suat
3.1. Xay dimg mo hinh hinh hoc

sau:
r

r

- Ung suat tuang duong von-Mises cho
M6 hinh hinh hgc khung may ep bao g6m
phep: [ a j < a/1.5 = 220/1.5 = 146 (MPa).
hai vach ben, xa tren, xa dual dugc xay dung
dua tren yeu cau chinh xac ve hinh dang va kich
- Ung suat cho phep Ian nhat: [<^^^]<0.1
thuac. Hinh 5 the hien m6 hinh 3D ciia ciia he a, = 0.7* 380 = 266 (MPa).
th6ng may xe luai.
Ung suat tuong duong von-Mises dugc
tinh toan nha m6 phong s6 khi may thuc hien luc
c6ng nghe 120 tan (Phuang phap s6).
LTng suat IOTI nhat khi chiu keo cua tru
may dugc tinh dua tren ly thuyet siic ben vat lieu
(Phuang phap giai tich).
Hinh 5: M6 hinh 3D khung thdn mdy xe luai 3.3. Chia luroi va dat dieu kien bien
Chieu cao: 3000 (mm);
Chilu rgng: 1400 (mm);
Chilu ngang: 2900 (mm);

I

Hinh 7: Chia luai khung thdn mdy xe luai

Dat luc phan b6 P = 1,200 kN vao mat
Hinh 6: M6 hinh 3D vdch mdy, kich thuoc bao 2200 dual dim tren va mat tren cua ban may tren chil

CF
X 1300 X 550 (mm) thep tam ddy 15 mm.
dai 2L/3 cua dam (hinh 8).
TAP CHI CO KHI VIET NAM, S6 6 nam 2014
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NGHIEN CUfU-TRAO D 6 I
tuong duong VON-MISES cho phep.
XlTrtll

Khi cac gia tri ling suit va biln dang vugt
qua cac gia tri cho phep, tiln hanh tang chilu day
vach len 20mm va chilu day dim tren kit hgp
tang cuang cac gan tai dim tren nhim tang do
Cling ciia khung.

"TTT
I Ii
Traaxv

1 Xidim

I^-2L1-*: ^,i-

Hinh 8: So dd dat luc len he thdng khung
Dilu kien bien chuyin vi: Kh6ng che tat
ca cac bac hr do dich chuyin va xoay tren cac mat
ciia de may (c6 dinh de may).

fp^^^ JQ. M6 hinh 3D khung thdn mdy xe luoi dugc
tdng cuang gdn vd tdng cimg khung

3.4. Giai bai toan

Tiln hanh m6 phong s6 vai cac th6ng so
dilu kien bien giii nguyen. Ket qua cu6i cimg
Thong sl diu vao la tai h-gng tac dyng len nhan dugc nhu sau:
mat duoi dim tren va mat tren ban may Ian lugt Modes: 120917
dugc thay d6i trong cac Ian giai bai toan.
Bements:64443
Type; Vcn Mses Stress
Lint; MPa
12/25/2013, 10:12:57 AM

Type: Von Mises Stress
Unit: MPa
12/25/2013,, 09:36:05 Af

138 Ma;<

303.9 Max

107

Wn: OHPa ^

49
45
Nn

\

k.
Hinh 11. ung sudt Von Mises a khung mdy
Hinh 9: ung sudt Von Mises a khung mdy
Vai dieu kien img suat tuong duong
kh6ng vugt qua gia tri ling suat cho phep ciia vat
lieu. Gia tri ling suat Ian nhat trong khung may
la o^^^^ = 303.9 MPa > [aJ = 146 MPa, ling suit

Ung suat tuang duong ciia khung may, khi
luc c6ng nghe 120 tan tac dgng, dugc minh boa
a hinh 11. Gia tri ung suat Ian nhat trong khung
may la a^,^^^ =138 MPa < [aJ = 146 MPa, ling
suit hrang duang VON-MISES cho phep.

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NGHIEN CUfU - TRAO D O I
Type: Displacement
UW: mm

Vay, viec kiem nghiem bang phuang phap
s6 bang phan mem m6 ph6ng s6 chi ra ring khung
may ep da thilt kl dat dugc chi sl vl tieu vl do
Cling va ling suat tuong duong.

12/25/2013,10:30:5^ AM
1.086 Max
0,919
0,612

5. KET LUAN

0.437

•
0.274

Voi nhirng ket qua nghien ciiu do bin va
do Cling cua khung than may xe luoi bing phuang
phap phan tii huu ban dugc thuc hien tren phin
mem m6 phong s6, da cho thiy su diing din ciia
phuang phap nay trong viec nghien ciiu tli uu cac
kich thuac khi thilt kl may. Kit qua m6 phong
da dua ra dugc cac gia tri ling suat, biln dang Ion
nhat khi thuc hien luc c6ng nghe tir do tli uu cac
gia tri dau vao la m6 hinh hinh hgc ciia khung
may.

ONti

Hinh 12: Bien dgng cua khung mdy
Bien dang cua khung may dugc the hien
a hinh 12. Gia tri biln dang dan hIi Ian nhit doi
voi khung may voi luc c6ng nghe 120 tin la 1.086
mm, gia tri nay nho han bien dang toi han cho

phep cua khung may la 1.2 mm (may co lire ep
danh nghia 120 tan cho phep chuyen vi 1.2 mm).
Nghia la khi may thuc hien c6ng nghe 120 tin thi
trang thai bien dang ciia khung may la dan h6i.
Dieu do dam bao kha nang lam viec 6n dinh ciia
khung may.

M6 hmh hinh hgc dugc tli uu kich thuac
khang dinh c6ng trinh thilt kl dam bao dilu kien
an toan ve do ben va do ciing de ap dung vao thuc
te (cu the la de tai nghien ciiu khoa hgc va c6ng
nghe cap Thanh phi Ha Ngi mang ma s l OlC01/08-2013-2). Viec thilt kl tli uu nhim kilm
soat su pha huy cua ket cau sau khi gia c6ng thuc
r

t

y

' ,

te khi trien khai de tai diing nhu muc tieu thiet

Ngay nhan bai: 04/5/2014
Ngay phan bien: 17/6/2014
Tai lieu tham khao:
*

[1]. Pham Van Nghe, D6 Van Phiic, Le Trung Kien, Thiet bi dap tgo hinh - Mdy ep co khi (2011) NXB. Khoa
hoc Ky thuat.

[2]. Cong nghe chi tgo mdy, Khoa Co khi Truang Dai hgc Bach khoa Ha Ngi.
[3]. Schuler Inc., Metalforming handbook. Springer, Germany, 1998, 33-44.
[4]. Tschaetsch, H., Metal forming practice. Springer, Germany, 2005, 295-310.
[5]. Rao, S.S., Thefiniteelement method in engineering,fifthedition, Elsevier, 2011, 53-63.
[6]. en. com. tw/products-3_9526-english. html.
[7]. Neumann, M., and Hahn, H., "Computer simulation and dynamic analysis of a mechanical press based on
different engineer models", Mathematics and Computers m Simulation, Vol. 46, Issues 5-6, 1998, 559-574.
[8]. Neumann, M., Dynamic analysis of mechanical presses, RTS Scientific rapport, Kassel University,
Germany, 1994.

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