NGHIEN CUU-TRAO Dpi
NGHIEN CLfU QUY TRINH CAD/CAM/CAE/CNC TREN CATU CHO TRUNG TAM GIA CONG NHIEU TRUC DIEU KHIEN SO
THE CAD/CAM/CAE/CNC PROCESS USING CATIA FOR CNC MACHINING CENTER
Le Giang Nam", Chu Viet CiJdngS Trinh Kieu Tuan^
'TrUdng Dai hoc Bach Khoa Ha Npi ' T r a t o g Dai hoc Kinh te Ky thuat Cong nghiep.
TOM TAT
Gia cong dieu khien so ngdy mgt pho bien, nhdng hgn che cua lap trinh thu cong dd ddn den sU ra ddi cua cdc he thong lap trinh tU dgng, he thong CAD/CAM. Bdi bdo ndy trinh bdy mgt quy trinh cong nghe CAD/CAM/CAE/CNC tich hdp tren CATIA hodn chinh nhd cdc mo-dun dinh hiidng dng dung cho nhiem vu lap chUdng trinh gia cong nhieu true dieu khien so. Trong do dddng ddn dung cu dugc thilt lap mgt cdch tu dgng tren cdsd dd lieu hinh hgc cua chi tiet, chi tiet Igng phoi, thiet bigd kep vd hinh hgc ditng cu cdt. Mg phing so vd CAE Id kenh thong tin phdn hoi cho viec kie'm dinh tinh dung ddn cua phUdng phdp gd ddt vd chddng trinh dugc sinh ra.
Ket qud mo phong vd thUc nghiem cho thdy quy trinh CAD/CAM/CAE/CNC dUdc xdy ddng trin phdn mem CATM CO the ddp dng nhanh cdc nhiem vu gia cong khac nhau, heed cdc chi tiet co bien dgng phdc tgp cdn nhieu true dieu khien tren mdy.
Til khoa: ChUdng trinh diiu khien so, trung tdm gia cong CATIA, CAD/CAM/CAE/CNC.
ABSTRACT
The CNC programming plays an important role in the CNC machining. The inconvenient of manual programming causes the invention of the automatic programming tools, CAD/CAM systems. This paper presented a based on CATIA process of CAD/CAM/CAE/CNC integration with oriented applications for task of multiple-axis numerical control Where tool paths were automatically generated based on geometnc data, part, work piece, fix and fig as well as cutting tool geometry. Simulation was used to verify the fixing and the CNC program. The experimental and simulated results showed the useful and advantage of this procedure. It could be used to generate the different tasks including complex shapes that require multiple-axis numerical control.
Keywords: CAD/CAM/CAE, CNC program, CNC machining center, CATIA.
TAP CHi CO KHi VIET NAM V S6 4 (Thang 4 nim 2013)
1. GlOl THiEU
Trong nhflng nam gan day, linh vflc Co khi che tao nfldc ta da phdt triln vUpt bac cung sfl ra ddi cua may cong cu dieu khien theo chflong trinh so vdi sfl trp giup ciia may tinh (mdy CNC).
Tinh kinh te cua cdng nghe gia cdng tren cdc mdy CNC mdt phan ldn chiu dnh hfldng cua gid thdnh lap trinh CNC, ma gid thdnh nay tUpng ddi ldn khi lap trinh bang tay vi ddi hoi thdi gian rat ldn tai vi tri ldm cdc viec; lap trinh, tim ldi, tdi Uu hda chflpng trinh(l-7). Khi lap trinh bang tay, ngUdi lap trinh can can cfl vao ban ve cua chi tiet de nh^p cdc dfl lieu theo cdc lenh tfl bdn phim cua may vao bd nhd. Nhfl vdy, viec lap trinh bang tay ton nhieu thdi gian, de nham lan ddc biet Id ddi vdi cdc chi tiet phflc tap. Do nhflng nhflpc diem do md phflpng phdp lap trinh bdng tay dflpc dung cho cac chi tiet cd quy trinh cdng nghe don gidn hoac di hieu chinh nhflng chUPng trinh san cd.
Phflpng tien hd trp cho ngUdi lap trinh bdng tay Id cac bang tra sd lieu, Catalog may vd may tinh bd tui. May tinh bd tui chi giflp cho ngfldi lap trinh tinh todn hinh bpc (tpa dp cac diem tren bien dang chi tiet) va tinh toan cdng nghe. Nhu vay, lap trinh bang tay ddi hdi ngUdi lap trinh ngoai vi?c ldm chu phuong phdp lap trinh cdn ddi hdi phdi cd kiln thflc toan hoc va kien thflc ve cdng ngh? che tao mdy(8.9).
Khi lap trinh cd sU trp giup cua may tinh, ngudi lap trinh md td hinh ddng hinh hpe cua chi tiit gia cdng, cdc quy dao chuyen ddng cua dung cy cat vd cac chflc ndng cila mdy theo mdt ngdn ngfl md may cd the hieu dflpc(8). Ddc biet, vdi nhijtng chi tiet phflc tap thi viec tinh todn (bang tay) tpa dp cua cdc diem thupc bien dang chi tiet do trong khdng gian la rat nhieu, ddi khi la rat khd khdn. Nhflng vdi lap trinh bang mdy thi ta chi cdn md ta bien dang cua chi tiet gia cdng bang ngdn ngfl lap trinh, sau dd mdy tinh se tfl dpng tinh toan gid tri tpa dp cac diem thupc bien dang dd. Nhflng h ^ che cua lap trinh bdng tay ke tren da dan den sfl ra ddi cua cdc he thdng lap trinh tfl d^ng bdng may tinh, he thdng CAD/CAM.
Vi?c (ing dung cac phan mem CAD/CAM
da giup chung ta gidm thieu tdi da khdi lupng cdng viec cho ngfldi lap trinh chi tiet. Ngfldi lap trinh chi tiet chi phdi tinh todn van de gia cdng vd sau do lap trinh dUa mdt ngdn ngfl Id phan mem CAD/CAM thich hpp. l/u diem cfla khuynh hfldng nay Id: Tiet kiem ddng ke thdi gian md ta chi tiet vd qua trinh gia cdng can thiet; sd Iflpng cdc ldi giam xuong khi lap chflong trinh chi tiet do giam sd lupng dfl Ueu dau vdo, viec kiem tra tinh dung dan Id nhd may tinh; Gidm dang ke ve thdi gian va gid thdnh so vdi chuan bi sdn xuat thdng thfldng; sfl dung mdt ngdn ngfl lap trinh thdng dung; The hien bang do hpa cdc md phdng dpng bpc vd hinh hpe cfla chi tiet trong qua trinh cat, mpt sd trfldng hpp md phdng cd dao.. .de tfl do dfla ra cdc phUPng dn lUa chpn tdi Uu cho nhd sdn xuat ddng thdi ho trp quan ly sdn xuat, qudn Iy dfl lieu... gdp phdn ndng cao ndng suat che tao cdc sdn pham co khi. Thudn Ipi nhat ddi vdi ngfldi lap trinh la mdt he thdng lap trinh cd sfl ket hpp vdi do hpa. Ngfldi lap trinh cd the Idem tra dau vao theo tflng bfldc mdt va cd the sfla chfla so lieu trong khi viet chflPng trinh, cudi cung cd the Idem tra chflpng trinh bdng md phdng do hpa.
Dieu ndy, giup cho ngfldi lap trinh tfl tin vd cd tdc dung tdi cd tdc dp vd kha nang lap trinh(10-12).
Nhfl vay lap trinh tU dpng (lap trinh bdng may) cd hieu qua cao hon han so vdi lap trinh bang tay
2. CATIA VA CAC U N G DUNG CHO C O N G NGHE CAD/CAM/CAE/CNC
Qua nhflng phan tich tren ta thay viec dp dung cac phdn mem CAD/CAM trong thiet ke vd sdn xuat la vd cflng quan trpng. Hien nay cd rat nhieu phan mem tich hpp ra ddi nhdm giai quyet cac van de dd, nhfl: Unigraphic, Cimatron, CATIA, Pro-E...nhflng chung tdi chpn phan mem tich hpp CATIA (Computer Aided Three Dimensional Interactive Application - Xfl ly tflPng tdc khdng gian ba chieu vdi sfl trp giup cua may tinh) do nhflng Uu diem sau: CATIA Id phan mem tich hpp gom rat nhieu cdc md-dun vdi sU dung chung CP sd dfl lieu nen viec chuyen doi mdi trfldng ldm viec dien ra rat nhanh vd linh hoat nhd sfl dyng thanh cdng cu Start. Cho den thdi diem nay thi CATIA la mpt he thdng CAD/CAM/CAE/CNC'^
TAP CHf C O KHf VI$T NAM *t* Sd 4 (Thang 4 ii.iiii :IILM
NGHIEN CUTU - TRAO eOl
hodn chinh nhat, nhieu md-dun chuyen mdn hda nhat. Nd giai quyet cdng viec mot each triet de tfl khau thiet ke md hinh CAD den khau sdn xuat dfla tren cd sd C-AM cung vdi kha nang phdn tich tinh toan, toi flu hda ldi giai dfla tren CAE vd xudt chflpng trinh gia cdng cho may CNC.
2.1. Quy trinh tong quat
Sau mpt thdi gian dieu tra tU lieu vd thu thdp thdng tin tfl cac doanh nghiep san xuat nhfl Makino, Carbomill, Plasan Carbon Composite, tap dodn FANUC... chung tdi nhan thay quy trinh gia cdng chi tiet tren mdy dieu khien sd dUpc cac doanh nghiep viet rieng de cho phii hpp vdi day chuyen sdn xuat cua rieng hp(13-14).
Hmh 1. Quy trinh CAD/CAM/CAE tongqudt NhUng tflu trung, cdc quy trinh do deu dupc viet dudi dang sP do tong qudt nhU hinh tren (hinh 1):
2.2. Quy trinh de xuat mdi
Tuy nhien, vdi viec flng dung cdc phan mem CAD/CAM thi hau het cac bfldc trong quy trinh cdng nghe gia cdng chi tiet tren may dieu khien sd dUPc thflc hien ngay tren phan mem vd ket qua cua chflpng trinh dau ra cd the dfla trflc tiep xudng phdn xfldng gia cdng md khong can thong qua ban giay (Paper less). Bd phan mem tich hpp CATIA, vdi he thdng CAD/CAM/CAE/
CNC hodn chinh nhfl da ndi d tren hodn todn dap flng dflpc cac yeu ve viec ho trp cdc bfldc trong quy trinh cdng nghe gia cdng chi tiet:
- Mo hinh hoa chi ti^t: Dflpc thflc hien n h d md-dun Part Design, Shape Design...Nhd cdc md-dun nay ta cd the thiet ke dflpc md hinh cdc chi tiet cd bien dang tfl dPn gian den phflc tap.
- Phan tich ky thuat: Sau khi mo hinh hda, chi tiet dflpc dfla vdo mdi trUdng Analysis de phdn tich tinh dung dan bang each dat cdc tai trpng, tfl dd dUa ra dUpc cac trUdng dng suat va chuyen vi nham khang dinh chi tiet da dUpc thiet ke la dat hay khdng dat.
- PhUPng p h a p ga dat phoi: CATIA co s i n cdc cdng cu hd trp thiet ke, lap rdp, kiem tra, bd tri phupng an dd ga hpp ly vd gd dat phdi nhd md-dun Assembly.
- PhUPng an dung cu: Trong mo-dun Machining, CATIA cung cap todn bd cdc dung cu cho qud trinh gia cdng. Vdi cdc flng dung md cua CATIA trong md-dun nay, ta hodn todn cd the doi ten, dieu chinh kich thflde dung cu sao cho phu hpp vdi dieu kien cfla phdn xfldng sdn xuat.
- Chuan hi dfl lieu lap trinh vd thiet lap chflpng trinh: Md-dun Machining trong CATIA dfla ra cdc cdng cu cho viec lap trinh vd md phong dudng chay dao cho vile gia cdng chi tiet. ChUdng trinh gia cdng dflpc xuat ra dfldi dang G-Code File hodc APT.
- Chflpng trinh sau khi dflpc thilt lap xong thi dupc chuyen trUc tiep qua md-dun Machming Simulation cua CATIA d l md phong qud trinh gia cdng chi tiet tren may dieu k h i l n so de kiem tra va cdt thfl.
Ngodi viec dng dung xii li nhU tren, hfi thdng phan mem CATIA cdn hd trp viec phan tich ky thudt trong rat n h i l u cdng doan d l giiip quan ly chu trinh san pham nham nang cao chat Iflpng sdn pham tao ra va ddm bao mpi yeu cau ky thudt ngay tfl lan c h l tao ddu tien.
TU dd, chung tdi de xuat mdi mdt quy trinh cong nghe gia cdng chi tilt nhfl hinh ben (hinh 2):
TAP CHI CO KHf VIET NAM Sd 4 (Thang 4 nam 2013)
mnh 2. Quy trinh CAD/CAM/CAE dexuat mdi.
2,3, (Jng dung quy trinh tren CATIA De lam vi du, chung toi xin trinh bay quy trinh cong nghe (de xuat mdi) gia cong chi tiet
"True vit me canh ta" trong cum truyen dpng co khi tren may bay.
- Budrc 1: Mo hinh hoa chi tiet diipc thuc hi?n nhd mo-dun Part Design (hinh 3)
Hinh 3. Md hinh hoa chi tiet gia cong.
- Btfdc 2: Phan tich ley thuat nhcf mo-dun Analysis & Simulation d€ khang dinh tinh diing din ciia mo hinh (hinh 4 & 5).
Hmh 5. Phdn tich dng sudt - Bii6c 3: Thiet ke va lap rap do ga nhcf cac mo-dun Part Design va Assembly (hinh 6).
Hinh 6. Thiet ke do gd.
- Bd6c 4: Chuan bi phoi CO kich thUdc 2x120(hinh 7).
Hinh 7. Budc chudn hi phoi.
- Biicfc 5: PhUOng an dung cu (chpn theo tieu chuan ciia hang Seco).
Hinh 4. Phin tich chuyen vi. '
TAP CHi C O KHi VIET NA.\I • 56 4 (Thang 4 nam 20 ..i ( P
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Hinh 8. Bdng ke dung cti cdt.
• Budc 6: Chuan bi dfl lieu lap trinh sfl dung md-dun Machining (hinh 9 & 10)
Hinh 9. Thiet lap dudng dung cu trong nguyen cdng tien true bdc.
Hinh 10. Thiet lap dudng dung cu trong nguyen cdng phay ranh xodn.
3. MO PHONG SO
3.1. Qua trinh gia cdng tren CATU nhU sau Qud trinh gia cdng chi tiet dflpc chia
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Htnh 11 Tien true bac dau nho
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Hinh 12. Phay ranh xodn.
TAP C H I C O KHf VIET NAM
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Hmh 14. phay hoc luc gidc.
3.2. Chiidng trinh gia cong
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OOOOl (CATIA EO. COMMENTS) (COMPANY: ICAM Technologies Corporation).
(MACHINE: VMC - Fanuc 30i).
(CLFILE: NC 1 Tien dau nho l_Part_
Operation_l_l_I.aptsource).
(DATE&TIME: 6-Dec-2012- 16:09:59).
(TOOL* TOOL NAME).
NI G94 GOI X123I.9 YO. Z3009.9 F600. S2000 M4.
N2X1181.1.
N3 XO. F800.
N4 X5.388 Z3015.288 F1600.
N5G00X123I.9.
N179 XU48.388 Z950.268 F1600.
N180 G5 PO N181M5 N182 G91 0 2 8 ZO N183 G28 XO. YO
(Total Machining Time: 1:36:51) N184 M30 %
4. KET QUA THU'C NGHIEM
Viec gia cong chi tiet duoc thUc hien tren trung tam tien CNC 4 true CTX310 GILDE- MEISTER. Chuong trinh gia cong tren dupc dua vao trung tam tien de gia cong. So sanh ket qua thuc nghiem va ket qua mo phong, chung toi thay dudng chay dao la hoan toan trimg khdp. Sau day la mpt so hinh anh so sanh.
Hinh IS. Chl tiet mo phing Hinh 16. Chi tiet duoc gia cdng trin Hinh ;7, Anh chup san phdm thUc te.
hodn thien. trung tdm tien 4 true GILDEMEISTER.
5. KET LUAN
Mo hinh hda, phan tich danh gia mo hinh tr^n CO sd phan tich ket cau, thiet lap dudng chay dao gia cdng trong mdi quan he tiidng tac cd kiem ha vdi thiet bi ga ldp tai mdi trudng lam vi^c, tU dOng sinh chUdng trinh phii hdp vdi may cong cu
thuc hien cflng nhu mo phdng kiem tra tinh dung dSn ciia giai phap dudng chay dao gia cdng vdi quy trinh CAD/CAM/CAE/CNC, cho phep kiem tra cac phUdng an khac nhau ciia giai phap cdng nghe, k h k phuc va chinh dung cac loi lap trinh cd the mSc phai trUdc khi cd mot quyet dinh chinh thilc cho thao tac gia cong.
TAP CHI CO KHi VIET NA.M
NGHIEN c f l u - TRAO DOI
Nhd giai phap tich hpp, cho phep dimg chung co sd dfl heu vdi cac qua trmh cong nghe khac nhau, quy trinh de xuat trong bai bao cd the dap ilng nhanh cac nhu cau thUc te san xuat du doi tupng gia cdng phvic tap va can nhieu true dieu khien sd, giam thieu thdi gian san xuat til khau thift ke den khau gia cdng, til dd nang cao dUdc nang lUc san xuat, ha gia thanh san pham. •
Ngay nhan bai: 04/3/2013 Ngay phan bien: 20/4/2013
NgUdi phan bien: TS. Biii Tuan Anh, Bp mon May & Ma sat hpe, Vien Co khi, TrUdng Dai hpe Bach Khoa Ha Npi.
Tai lieu tham khao:
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[3]. Rudolf Sauter (1985), Numerische Steurung fuer Werkzeugmaschine, Vogei Buchverlag Wuerzburg BRD.
[4]. C.B.Besant (1980), Computer aided design and manufacture, Ellis Horwood Limited, New York USA.
[5]. Kunwoo Lee (1999), Principles of CAD/CAM/CAE System, Addison Wesley Longman, Inc.
[6]. Kurian K. Thomas, Gary W.Fischer, Journal of Materials Processing Technology 61 (1996) 87-92, [7]. Hayong Shin, Gustav J. Oiling, Yun C. Chung, Bo H. Kim, Su K. Cho, Computer - Aided Design 35 (2003) 203-213.
[8]. Tran Van Dich (2004), Cong nghe CNC, Nha xudt bdn Khoa hoc vd ky thudt Ha Npi, pp 76-77.
[9]. Bernard Mery (1998), Machine a commande numerique, HERMES.
[10], Nguyen Dac Loc, Tang Huy (2000), Dieu khien so 8: Cong nghe tren may dieu khiln so CNC, Nhaxuat ban Khoa hoc va ky thuat. Ha Npi, pp 55-56.
[llj. Hans. B. Kief, T. Frederick Waters (1992), Computer Numerical Control, International Editions.
[12]. I.D. Dillman (1983), Computer - aided manufacturing. Springer Verlag.
[13], MAKINO Inc. (2011). Vertical IVtachining Center Programming Manual, Makino.
[14]. FANUC Series O - MCFANUC Series 0 0 - MC.FANUC Series O, Master for Lathe Operator's Manual, FANUC, LTD 1988.
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