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 kh
Trang 1NGHIEN 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
Trang 2NGHIEN CUfU TRAO DOI
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'^
Trang 3NGHIEN 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):
Trang 4NGHIEN COU TRAGOPl
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 '
Trang 5NGHIEN CUU-TRAO Dpi
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thdnh 2 nguyen cdng: nguyen cdng 1: tien true bdc (^34, ^ 4 1 5 , ^ 6 1 ; nguyen cdng 2 gom cac bfldc: phay ranh xoan, khoan Id tdm ^12 & phay hoc luc gidc
it
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
• j ^ * > ;:^ -i-t3^.-Si.j.3[5i.aE£
Htnh 11 Tien true bac dau nho
" ™ • -•:.'-.• r^.y.-S^
Hinh 12 Phay ranh xodn
Hinh 13 Khoan loipM
Trang 6NGHIEN CtifU - TRAO D(!)l
V »• r a ^ iA'.M*9t
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
Trang 7NGHIEN 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:
[Ij Ta Duy Liem (1999), He thong dieu khien sd cho mdy cong cu, NXB Khoa hoc va Ky thuat, HaNoi, pp 178 [2] Doan Thi Minh Tnnh (1998), Cong nghe CAD/CAM, NXB Khoa hgc vd Ky thuat Ho Chi Minh
[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