A STUDY END MILL CUTTER AND MACHINING EXPERIMENTALLY CRAFTED WITH END MILL CUTTER ON 3 AXIS CNC MILLING MACHINE
ThS. Dang V i n Hoa
Trucmg Dai hpc Kinh t^ - Ky thuat Cong nghiep TOM TAT
Hien nay, viec nghien cuu mgt cdch day du vd ung (Jung trong cdc phdn mem CAD/CAM, cOng nhu ling dung CAD/CAM vdo thiet ke, che Igo vg kiem tra sdn phdm con khd hgn che hodc mtmg tinh rieng re. Trong bdo cdo ndy, ldc gid di sdu vdo nghien ciru img dung quy trinh cong nghe CAD/CAW CNC trong thuc nghiem gia cong Igo hinh bdng dao phay ngon tren mdy phay CNC 3 true.
Ta khoa: CAD/CAM/CNC. dao phay ngon, gia cong Ihuc nghiem.
ABSTRACT
Today, Ihe research fully cmd software applications in CAD/CAM like applications CAD/CAM lo design, manufacturing and test products is rather limited or separately identifiable. In this report Ihe authors delve into the research and application of technological processes of CAD/CAM/CNC in machining experimentally crcxfted wilh end mill culler on 3-axis CNC milling machine.
Keywords: CAD/CAM/CNC. end mill cutter, machining experimentally.
1. GIOI THIEU
Phay la phuong phap gia cong cit got btog dung cu cit co luoi, duoc diing ph6 bifa trong gia cong cat got kim loai. Trong do, chung ta thay ring voi phuong phap phay cac be mat khong gian tren may phay CNC la phuang phap phay bao hmh, dung cu c i t la cac dao phay ngon. Do cac be mat khuon m i u co hinh dang hinh hpc rit da dang nen hinh dang hinh hpc cua cac dao phay ngon dupc su dung cung co cac loai khac nhau Sh phii hop voi bk mat c i n gia cong, dam bao l i y di duoc nhieu lupng du nhit, chit lupng b^ mat t6t nhit, nang suit cao nhit. Cac loai dung cu cit thuong dimg: Dao phay ngon d i u phang, dao phay ngon d i u p h i n ^ c o goc lupn, dao phay ngon d i u ciu,...
Hmh hpc tdng quit va cac dang dao phay ngon dupc thS hien trong cac hinh anh duoi diy:
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NGHIEN cufu - TRAO D 6 |
tD
> Mi.Aa.««A«Hinh 1: Hinh hgc tong qudt cua dao Hinh 2: Cdc dgng dao phay ngdn Chat lugng be mat chi tiet gia cdng phu thudc nhidu vao hinh dang hinh hpc cua dung cu, do dd can phai chpn hinh dang cua dung cu phu hgp vdi be mat can gia cdng. Khi phay cac hoc, cac be mat khdng gian tu do thi dao phay ngdn cd rat nhieu uu diem.
2. THirC NGHIEM, THIET KE VA GIA CONG T^O HINH M A U TREN MAY PHAY CNC 2.1. u'ng dung Rapidform trong thiet k^ m i u
Cac budc thiet ke mau gia cdng iing dung phan mem Rapidform dugc thuc hien nhu sau:
Kh&i dgng phdn mem Nhdp lu&i diem Tgo mdng mdu
m
Tgo Sketch ditng cho viic cdtmgf mdnh chi tiit Cdl chi tiet
Hinh 3: Thiet ke mdu trin Rapidform
Mdnh chi tiet sie diing lap trinh vd gia cong thuc nghiem
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Pham VI gia cone Thay dao tu dong Spindle speed
600x4400x600 Co
60-8400 vdng/phiit
CS tudi ngupi Tra\eling Speed Sai so may tai thdi diem van hanh
201/phLit 16000 mm/phiit 0,005-0,01mm
Thdng sd dung cu diing trong thi nghiem:
Hinh 4 • Hinh dnh dung cu cdt dimg trong thi nghiem
- Dao cat thd: Dao ngdn hgp kim {K45) D16 Flat, Flute:4, Comer Rad:0 (Sir dung gia cong tren ca 4 mau).
- Dao cat tinh: KiSu dao: K45, thir tu timg dao ian lupt sir dung Ciu D8, Cku DIO, Cku D12. Flute:
2 (Sir dung gia cong 3 mau: 1,2,3).
- Daocattinh(Kieududngchay dao gach mat cat)- Kieu dao: K45. C4u D12. Flute-2 (Sir dung gia cong mau 4).
Qua trinh lap trinh gia cong chi ti§t dugc thuc hien tren ph5n m^m MasterCam X6 vdi vat lieu gia cong bang hpp kim nhdm 6061 dugc bieu dien nhu hinh 6.
Giao dien phdn mem MasterCam X6
Nhdp mo hinh chi tiet vdo
phdnmem Thiet lap mdy. phoi vd g
phoi
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NGHIEN cufu - TRAO DPi
Thiit lap cdc fhong so gia cong chi tiit
" • • ^ ^ s ;
Kiim tra du&ng ditng cu gia cong tinh chi tiit v&i dao phay ngon ddu cdu 08
Du&ng chgy dao gia cong tho chi tiit
H*.!^;»5BBVPy* -*.^f^.:^.,.,^;-
Du&ng dung cu gia cong chi tiet theo kieu ggch
mat cdt
Kiiu du&ng chgy dao song song gia cong chi tiit
15fPB!5!^^S^ir
Kiem tra duong dung cu gia cong chi tiet theo du&ng chgy dao kiiu ggch
Hinh 5. Cdc bu&c lgp frinh gia cong vd mdu chi tiet sau khi gia cong 3. DANH GIA K E T QUA THlTC N G H I E M
*!* L y a chon p h u o n g ^n danh gi^
Trong nghien cuu nay, tac gia da lua chpn phuang an do bang may quet hinh. Viec kiSm tra chat lugng san pham bang each so sanh md hinh CAD vdi dir lieu quet tir san pham gia cdng. Tir dd, danh gia dugc sai sd hinh hpc cua be mat da gia cdng.
<* Ket q u a danh gia
Sau khi quet va thu thap du lieu cac mau thuc nghiem, viec phan tich sai sd b^ mat dugc thuc hien bang each ghep dii lieu quet vdi dir lieu CAD 3D cd dinh dang *.IGS bing phkn m8m thiSt k^
ngugc Rapidform. cl
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Hiin thi kit qud do bdng phdn mim Bdng gid tri sai so cho phep cua cdc mdu do dugc nhu sau:
Miu do 1 2 3 4
Sai lech duoi -0,324 -0,242 -0,183 -0,095
Sai lech tren +0,258 +0,212 +0,193 +0,076
Ghi chii
4. KET QUA THUC NGHIEM
Dvra tren ket qua thuc nghiem trong qua trinh lap trinh va gia cdng mau, thi nghiem do be mat 3D, tac gia nit ra mdt sd ket luan nhu sau:
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NGHIEN cufu-TRAOeCl
PhuOTig phap phay Suface/ Parallel Dao d^u cau D8 - Thdi gian qua trinh gia cong ly thuygt tren phan mem la 59 phiit.
- Thdi gian gia cong thuc te tren may phay CNC la 75 phut - Neu tang lugng tidn dao tren bang dieu khien cua may CNC thi lugng tien dao tang.
- Dir lieu dudng chay dao dugc tao ra nhieu lenh va dung lugng rat nhd chi 434KB.
- Do bdng be mat thap.
- Lugng mdn dao sau khi gia cdng nhieu hon.
- Sai lech hinh hpc ldn.
Phuong phap phay Suface/ Parallel Dao d k can DIO - Thdi gian qua trinh gia cdng ly thuyet tren phan mem 59 phiit.
- Thdi gian gia cdng thuc te tren may phay CNC la 75 phiit.
- Neu tang lupng tien dao tren bang dieu khien cua may CNC thi lugng tien dao hau nhu khong thay doi.
- Dil lieu dudng chay dao dugc tao ra it lenh va dung lupng 413KB.
- Dp bdng be mat cao hem diing dao D8.
- Lugng mdn dao sau khi gia cong it han.
- Sai lech hinh hpc nhd hon.
Phu<mg phap phay Suface/ Parallel Dao d4u cau D12 - Thdi gian qua trinh gia cdng ly thuyet tren phan mem 59 phiit.
- Thai gian gia cdng thuc te tren may phay CNC la 75 phut.
- Neu tang lugng tien dao tren bang dieu khien cua may CNC thi lugng tien dao hau nhu khdng thay ddi.
- Dli lieu dudng chay dao dupc tao ra nhieu lenh dung lugng 408KB.
- Dp bdng be mat cao hem diing dao DIO.
- Lugng mdn dao sau khi gia cong it han.
- Sai lech hinh hgc nhd hon.
Phu-trag phap phay Suface/ Hatch Finish
Dao 6ku cku D12 - Thdi gian qua trinh gia cdng ly thuyet tren phin mem la 105 phiit.
- Thdi gian gia cong thuc ti tren may phay CNC la 125 phiit - N^u tang lugng tien dao tren bang dieu khien ciia may CNC thi lupng tien dao tang.
- Dii lieu dudng chay dao dugc tao ra nhieu lenh va dung lugng rat nhd chi 1097KB.
- Dp bdng be mat dat duac la cao nhat.
- Lugng mdn dao sau khi gia cdng it han.
- Sai lech hinh hgc la nhd nhat.
Tir cac ket qua thuc nghiem tren tac gia dua ra mpt sd ket luan nhu sau:
- Khi gia cong hh mat cong ldi voi cung che dp gia cong, neu tang dudng kinh diing cu cat trong mdt khoang nhat dinh thi dp chinh xac gia cdng tang dan.
- Vdi Cling mdt duang kinh dung cu, cung che dp gia cdng thi kieu chay dao Hatch Finish cho dp chinh xac gia cdng cao han kieu chay dao Parallel nhung thdi gian gia cdng ldn han.
•^Tiiy theo yeu ciu dp chinh xac gia cdng cua rirng chi tiet ma ta lira chpn phuang an gia cdng toi uu nhat.
5. KET LUAN
- Co rkt nhidu loai dao phay ngdn, nhung khi phay be mat dinh hinh dac biet la tren may CNC thi dao phay ngdn chip manh hgp kim ciing cd lgi th6 nhit.
- Khi gia cdng tren may CNC thi dao phay ngdn phii hgp vdi kigu dudng chay dao Suface/
Hatch Finish. ^
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dinh thi dp chinh xac gia cong tang Ien.
+ Kieu chay dao Hatch Finish cho dp chinh xac gia cong cao hon kieu chay dao Parallel nhung thoi gian gia cong lon hon.
- Huong nghien cuu tiep theo la khi gia cong be mat khong gian phuc tap va tren mdy phay CNC 5 true,...*
Ngay nhjn bai: 25/5/2015 Ngay phan bien: 02/6/2015
Tdi lieu tham khao:
[1]. IbiahimZeid, Department of Mechanical Engineenng Northeastern Universily, CAD/CAM Theory and Practice, McGraw-Hill, Inc. 335^35.
[2]. GS,TSKH. Banh Tiln Long, PGS,TS. Trta Van Nghia, TS. Hoang Vinh Sinh, ThS. Trjn Xuan Thai, ThS. Biii Ngpc Tuyen (Chii bien: GS.TSKH. Banh Tiln Long) (2005); Tin hgc ky thudt ting dung, NXB.
Khoa hpc v^ KJ thuat.
[3]. B4nh Tien Long, Biii Ngpc Tuyen (2013); Ly thuyel Igo hinh bi mat vd img dung trong ky thudt ca khi, NXB. Gido due.
[4]. GS,TS. Trin VSn Djch (tai ban l k 3,2009), Cong nghi CNC, NXB. Khoa hpc Ky thuat Ha Noi.
[5]. GS,TS. Tran Van Bich; Hf Ihdng sdn xudi linh hogt FMS va lich hgp CIM.
[6]. GS.TS. NguySn Cong Hiin, TS. Nguyin Pham Thuc Anh; Mo hinh hda he thdng va mo phong, NXB.
Khoa hoc vd Ky thual
[7]. GS,TS. Nguyin DSc Lpc, PGS,TS. Tang Huy (2002); Diiu khiin sti va cong nghi trin mdy dik khiin MCAfC, NXB. Khoa hpc Ky thuat Ha Npi.
[8]. Chau Manh Lire (2011); Cong nghe gia cong Iren mdy CNC, Ba Ning.
[9]. PGS.TS. Ta Duy Liim; Mdy dieu khien sd, Trucmg Dai hoc Bach Khoa Ha Npi.
[10]. Bill Quy Luc (2006); Phuang phdp xdy dung bi mdt CAD/CAM, NXB. Khoa hoc Ky thuat Ha Npi [I I]. ThS. Le Trang Thuc (2008); r/iie/fcl jdn;)/io"»i v * PTOfegmee^
[12]. Nguyen Van Thanh; Huang ddn su dung Pro Engineer Wildfire 5.0
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