Tap chi Khoa hoe va Cdng nghe 102 (2014) 074-079 Nghien CIJU img dung ky thuat ngvffc va cong nghe CAD/CAM thiet ke, che tao va kiem tra be mat tur Study of Applying Reverse Engmeering and CAD/CAM Technology to Free Form Sixrfaces Design, Manufacture and Measurement Bui Ngoc Tuyen'*, Nguyen Van Tho^ 'Trudng Dai hoc Bach Khoa Ha Noi - SS 1, Dai CS Viet, Hai Bd Trung Hd Not, Viet Nam ^Trudng Dgi hpc Hdi Phong - So 171, Phan Ddng Luu Kiin An, Hdi Phdng Din Toa soan 15-05-2014 chdp nhqn ddng 25-08-2014 Trong nganh ca hien nay, ky thuat ngwac duac xem la giai phap mdi quit trinh thiit ki va cdng nghe CAD/CAM se la bwdc tiip theo di hien thwc hda qua trinh thiit ki dd Si/ kit hgp c()a RE ri CAD/CAM dwa giai phap thiit ki, chi tao cac bi mat tw mdt each phi truyin thing, rut ngin thdi gian thiit ke va dan gian hda quy trinh cdng nghe Trong bai b^o niiy, cac tic gia trinh bay mgt hwdng ngtiHn ciru phi truyin thing bing viec img dung RE va cdng ngh$ CAD/CAM thiit ki chi tao v^ kiim tra be mat tw tai Viet Nam hien Cac tac gia da thwc nghiem kiim chCmg bing mi hinh cinh tuitine vdi sw tra giup cua phin mim ky thuat ngwac Rapidform, Geomagic Catia V5 vA Mastercam V9 Ju klioa: Ky thuat ngu'gc, dam may diem, b l mat ty do, CAD/CAM, Rapidform, Catia, Geomagic Abstract In mechanical engineering, reverse engineering (RE) is a new solution for the process of designing, antf technology CAD/CAM will be the next step of realizing the pnDcess of designing The combination of RE and CAD/CAM launches design solutions, produces free form surfaces by a non-traditional way, shortens time of designing, and simplifies manufacturing technology In this paper, the authors present a research on non-traditional method which applies reverse engineering and technology CAD/CAM in designing, manufacturing and measuring free form surfaces in Vietnam, today The authors had veiifiei experimentally by turbine model, which supported by Rapidform, Geometric Catia V5 and Mastercam V9 Keywords: RE, Point cloud, Freeform surface, CAD/CAM, Rapidform, Catia, Geomagic Trong rat nhieu truang hop, chiing ta co mot doi tirgng hay san pham vat ly ma khong co cac thong tm ky thuat kem theo nhu ban ve, thong so ky thuat,., Qua trinh tao nhung ban tir chi tiet goc ma khong co ban ve, tai lieu hoac mo hinh CAD cua chung duoc goi la ky thuat ngugc Ky thuat ngugc {Reverse Engineering) dugc xem la qua trinh thu nhan hinh dang hinh hgc tii mgt chi tiet ton tai bang each so hoa no, xay dung chinh siia mo hinh CAD ciia no va sir dung dir lieu CAD de che tao san pham bang cong nghe CAM.[I] ^ J , , , , - - , i, u I ren the giai hien nay, ky thuat nguac ket hop '• u~%AT^ir^Ki.t,i 1' - • vai cong nghe CAD/CAM duac xem la mot cac • u'•• u i ,i^., ^.> i ux ,-x ^ giai phap uu Viet nhat de thiet ke, che tao kiem tra cac u1 u- ' u' L ^- L- - J T-.- 1san pham c o cau tu be mat tu Day la , T: , , , , • " , / cac be mat khong gian voi cac thuat ngir thuang duac sir dung nhu Sculptured Surfaces, Freeform surfaces hay NURBS surfaces la cac b e mat cong tron, hen tuc vai cac tham so dac trung cho cau tnic hinh hgc ciic ~ o^mn,.^ Dia chi hen he' 04 3869,2007 Email: en, hui ngoc @hust edu.vn bg (do cong, tiep tuyen, phap tuyin,, ) tai hai diem Ian can ciia viing be mat la khac Cac be mjl thuang duac dung de tiong thiet ke cac be n^l khuon mau, canh turbine, canh quat [2].Vi^c kiem tia dp chinh xac hinh hoc sau che tao gap rat nhieu kho khan neu kiem bang cac c6ng cu truyen thong nhu: panme, thucrc cap, Ngay ca vai may toa dp chieu viec kiem tra cac be mat t\r ciing cSn phai co cac ga chuyen diing, chi phi Ion, mat nhieu tl gian, Cac nha khoa hgc the giai da nghien ciiu ling dung RE vai cac phan mem chuyen diing niiu Rapidform, Geomagic, de thiet ke, kiem tra danh gia chinh xac hinh hgc cac be mat tu Mgt so bai bao gioi thieu vk phuang phap thiit ke lai hay vai tro , ur-^ t.- -i • li r-i r.% - L-;^ cua RE phat tnen san pham [31, [4] Tuy nhien s , ,/^ ,; • • ,i * van chua thay co cong bo mot quy trinh ky t h # u - i.-•• - *•,'•• >; , j ngugc hoan thien voi cac danh gia cu the sai so cua A > • • u • cac giai doan qua tnnh Trong bai bao nay, cac tac gia d^ xuit mot quy trinh thuc hien ky thuat ngugc gSm d i y dii cac giai doan, vein phuong phap danh gia sai s6 ciia ca qui trinh De minh boa va kiem chiimg, cac tac gia ifi '^**'?" ""^ '^'"** "^^" *b^*^ nghiem la chi tifet turbine v* ^g mat canh co dang b6 mat ty T^p chi Khoa hoc va Cong nghf 102 (2014) 074-079 L Giai quyet vdn de 2.1 Quy trinh uTig^ dfing ky thuat ngu^c vd cong ngh^ CAD/CAM de thiet kS, chi tao vd kiim tra bi mat tlf Quy trinh day dii co the dugc md ta nhu sa tren hinh 1: Thiet ke lai be mat bang phan mSm ky thuSt ngugc (Rapidform, ) Lfng dung Cong ngbe CAD/CAM/ CNC che tao chi tiat So boa be m | t chi tiet Kiem tra danh gia chinh xac bang ky thuat ngugc Hinh Quy trinh ling dung RE va CAD/CAM I Xac dinh sai so cua qua trinh Hinh Sa danh gia sai so qua trinh Gia thiet rang sai so quet mau va sai so qu^l chi tiet gia cong co ciing sai so trung binh va lech chuan E]=e4=e , =04 = Theo quy trinh img dung RE & CAD/CAM nhu hinh I, cac tac gia dua phuang phap xac dinh sai so trung bmh tong cua qua tnnh er vai lech chuSn CT {hinh 2) nhu sau: Do'=Do+ei ; D2=Di + e3 ; Ky hieu vecta hinh hgc xac djnh vi tri tap digm md ta be mat ciia vat mau, dam may diem mlu, mo hinh CAD thiet ke lai, be mat chi tiet sau gia cong, dam may diem quet be mat chi tiet tuang ling la: Do, Do',Di,D2vaD2' Sai so trung binh va lech chuan tucmg ung cac giai dogn nhu sau: Giai doan quet mau la Si va tJi Giai doan thiet ke lai bang phan mem ky thuJit ngugc (Rapidform) la Zj va CT2 Giai doan gia cong CNC vai trg giiip ciia ph5n m i m CAD/CAM (CATIA V5) la £3 va 03 Giai doan quet chi tiet la £4 va C4 => 2.2 Th^c Di-Do'+ez D':= D2+£4 £T = D ' - D O ' =£2 +£3 +£4 (I) nghiem 2.2.1 So hoa be mat mau Do chinh xac dugc quyet dinh bai dg phan giai ciia camera va khoang each toi be mat Phai quet nhieu vimg be mat vat mau de dam bao rang tat ca eac doi tugng tren chi tiet dugc quet bet Do vay can CO ga xoay vat mau chinh xac vi tri cho moi viing quet Dir heu quet cac vimg diem sau dugc dang nhap chinh xac vi tri tao dam may diim hoan thien [5] Tap chi Khoa hoc va Cong nghe 102 (2014) 074-079 Hinh May scan 3D ATOSI (2M) h 5, Canh turbine dmh dang {,*stl) Vol nh&ng yeu cau tren, tac gia chgn thuc nghiem so boa be mat bang may quet 3D ATOS I, vai thong so ky thuat trinh bay bang Bang Thong so ky thuat may quet 3D ATOS I Cau hinh be thong ATOS (2M) So diem lan scan trieu diem Do lech chuan oi 0,05 Sai so trung binh ei ±0,05 Khoang each diem 0,06-0,25 Thai gian I lan scan 1,3 giay Sau qua trinh Scan ket thiic, tien hanh luu cac dCr iieu duoi dang cac file dmh dang dir lieu diem (.•sti) 2.2 Sir dung phan mem Rapidform thiet ke lai be mdt [6J Rapidform la phan mem thiet ke ngugc, ho trg nguai dung lao mo hinh tham so 3D thong qua viec xu iy dir lieu tir eac file quel 3D Quan ly mo hinh tham so CAD vai Feature tree giiip ngudi diing tien Igi \iec thay doi hoac sua chiia bat cii liic nao, ngoai Rapidform ho trg nguoi diing chuyen Hinh Thiet ke lai be mat canh Turbine doi dinh dang file hoan sang rat nhieu dinli dang ciia phan mem CAD/CAM khac nhu ProE, Catia, Autocad, de ket noi true tiep vai trung tam gia cong Doi voi chi tiet canh turbine, mot nhiim yeu to quan trgng la' Goc nghieng cua canh, te rong ciia canh, bien dang cong ciia canh,,.Cac ySi|# co anh huong lan den kha nang sinh p h a n ' ^ dgng cua canh turbine Vi vay can thiet ke chinh m be mat cong ciia canh turbine Quy trinh thiet U ngugc canh turbiner bang phan mem Rapidform th\ic hien theo eac budc sau: Buac 1: Khdi dong Rapidform, dang nhap (B heu da scan vao Rapidform theo dudng dan: Insert Import/ va chgn file canh turbine co dinh dang ( *stl) Budc 2- Gan tam ciia lo true turbine trung vdi tam ciia he toa XYZ ph^n mim Buac 3, Ket hgp su dyng cac lenh: Exmide, Blend, Revole Trong cong cu 3D Mesh Sketch xay dung cac Sketch tren mat ca sd bSng each biin thi phdn giao tuyin giira cac mal phSng co sd Plane vtii du lieu dam may diim Tir cac Sketch da dung dUQC Rapidform cho phep tao bien dang ciia chi tiet dudi mo hinh CAD T9P chi Khoa hqe vk CoDg nghf 102 (2014) 074-079 Budc 4; Xay d\mg bien d^ng cong tir ciia canh turbine Chiic nang Region Group cho phep phan vimg mau dii lieu scan, cac viing mau rieng biet se hien thi de chi cac bien dang cong tiep xiic D\ra vao thong sd ciia vimg mau rieng biet tren Point Cloud, giiip xay d^ng be mat cong cua canh turbine bang chiic nang Mesh Fit Dimg l?nh tao mang Circular Pattern de t^o 11 canh, Budc So sanh sai so giCta dir lieu dam may diim va mo hinh CAD da thiet ke Rapidform cd chiic nang Accuracy Analyzer cho phep kiim tra, danh gia sai sd giiia mo hinh CAD thiet ke lai va dam may diem Accuracy Analyzer xuat bang hien thi cdc thang mau ve dg lech thiet k i va tir dgng tinh toan sai l^ch giira hai mo hinh so sanh Sai lech trung binh cua mo hinh thiet ke lai khoang £2 = ± 0.1 mm, dg lech chuan 02 = 0,03 mm, 2.2.3 Tgo hinh be mgt tu bang gia cong CNC v&i hStrfxcua CATIA V5.[7] [8] Cac tac gia sii dung phan mem CATIA V5 nhan d& lieu CAD da thiet ke ngugc bSng Rapidform d i tien hanh lap trinh gia cong biSn dang cong ciia canh turbine Quy trinh lap trinh gia cong, tao ma Code NC theo cac budc: Budc 1: Khdi dgng CATIA V5, dang nhap bien dang cong canh turbine vao chiic nang Machining theo dudng dan Machining/Surface Machining/chgn file bien dang cong canh turbine Budc 2: Trong cay Productlist tiin hanh khai bao kich thudc phdi, goc phdi G54 va ga hd trg Kich thudc phdi khai bao' 60x40x30 mm, goc phdi tai tam cila phdi va nam tai mat Top plane, Budc 3: Chiic nang Manufacturing cay thu muc Surface Machining cho phep lap trinh gia cdng va cai dat cac thong so: tools Feed rate Feed plane, Tien hanh chay Demo gia cdng va phan tich kha nang xay sai hdng chi tiet qua trinh chay dao Budc 4: CATiA V5 cho phep kiem tra chat lugng be mgt gia cdng bang chiic nang Anlysis xuat bang hien thi cac thang man ve dd lech thiet ke va tu ddng tinh toan sai lech giira md hinh CAD thiit k i vdi be mat gia cong ly thuyet Theo hinh 9, anh thang mau hien thi ket qua cho thay be mat cong canh turbine gia cong ed sai sd tnmg binh £3 = ± 0,02 mm va lech chuan CJ3 ^ 0,02 mm Tir chuang trinh da lap trinh gia cdng md phdng CATIA V5, xuat chuong trinh gia cong dang ma CODE NC, hen hanh chi tao san phSm, Hinh So sanh md hinh CAD canh turbine va dii lieu dam may diem Hinh Khai bao phdi bien dang canh Turbine Hinh Xac dinh sai s6 gia cdng bang CATIA Hinh 10 Chi tiet gia cdng canh Turbine Tap chi Khoa h^c v^ Cdng nghe 102 (2014) 074-079 Dung cu gia cdng: flast mill C&IO hgp kim ciing va ball mill O I hgp kim cirng C h i gia cong: feed rate 400 mm/phiit, plunge rate 30 mm/phtit, retract rate 300 mm/phiit Vdi chiic nang Deviation phan mem, Geomagic cho ket qua nhu sau: Thiit bi gia cong: May phay CNC MANFORD MCB 850 tai Trudng Dai hgc Hai Phdng Vat tieu chi tao m§u: nhdm hgp kim Phan mim dd ma CODE NC: mastercam V9 Thdi gian gia cdng: I gid 45 phiit 2.2.4 Xac dinh sai so qua trinh Xac dmh sai sd qua trinh theo (I) va (2) > Sai sd va dd lech chuan thiet ke lai bang Rapidform £2 = ± 0,1 mm va = 0,03 mm > Sai sd va lech chu§n gia cdng vdi su trg giiip ciia CATIA V5 la £3 = + 0,02 mm va 03 - 0,02 mm Bang Kit qua xac dinh sai sd qua trinh Thdng sd Phuang phap tinh So sanh toan Sai sd TB ±0,17 mm Do lech chuan OT 0,061 mm Geomagic +0,205 mm -0,201 mm 0,0564 mm Banh gia ket qua: Qua so sanh sd li|u sai s6 qua trinh bing tinh toan va bJng phan mem Geomagic {bang 2) thiy rSng cd sir sai lech ve ket qua cua hai phuang phap Day cd the nhiSu nguyen nhan nhu sau: qua trinh xac djnh sai sS gia cong b^ng CATIA chi tinli den sai sd ly thuyet gia cdng ma chua tinh den sai sd cua may, dao, ga dat,.,,Sai sd cua phSn m i m , sai sd ciia nhieu qua trinh quet,, RSt khd xac dinh va chua cd phuang phap tinh toan chinh xac sai sd nay, Thuc te cd the su dyng ket qua xac dmh bSng phan mem Geomagic dang nhap dii lieu quet mau va dii li^u quet chi tiet gia cdng d i danh gia tuong ddi sai sd ciia qua trinh Ket lu$n > Sai sd quet mau san pham la £4 = 0,05 mm va 04 = 0,05 mm => £T = £2 + E3 + £ = i T= V*^ ' + O", i 0,17 mm +(7, = 0,061 mm • Xac dinh sai sd qua trinh bang phan mem ky thuat ngugc Geomagic [9], Dang nhap dii lieu dam may diem chi tiet gia cdng va dam may diem be mat mau Geomagic xac dinh dugc sai sd ciia qua trinh Hinh 11 Xac dinh sai sd qua trinh bang Geomagic > Sai so Idn nhat: -t-/-' 0,9345/-0,9595 mm r Sai sd trung binh ET: + / - : 0,205/-0,201 mm Do lech chuan:CTT= 0,0564 mm Bai viit dua phuang phap irng dyng ky thual ngugc va cdng nghe CAD/CAM thiet kS, che t^o va kiim tra b i mat tu do, Ngi dung bai viet cho thiy hieu qua to Idn ma nd mang lai cho san xuat, nhat la san xuat va kiem tra cac san pham co cau tir cac be m|it ty Phuang phap danh gia sai sd timg giai doan va ca qua trinii, cimg vdi thuc nghiem kiem chiing ciing dugc trinh bay chi tiet is day Qua thyc nghiem cd thS thSy rang sai sd qua trinh thiet ke lai la Idn nhat rdi den sai so quel mau, va sai sd gia cdng la nhd nhat Day la ca sd de de dung sai cho chi tiSt gia cdng thuc hien theo quy trinh nay, cd the dy bao va khac phyc cac sai so cac giai doan ciia qua trinh Ket qua nghien ciiu ciia bai bao mang tinh thirc tien, cd the irng dung thiet ke, che tao cac san pham ca cau tir cac be mat ty nhu: canh turbine, canh quat, be mat khuon mau, Trong tuong lai, cac tac gia se phat trien nghien cuu theo hudng- Nghien cwu nang cao tfp chinh xac thiit ke, che tao vd kiSm tra cdc be mat ttf tren cO s& ung dung RE vd cong ngh^ CAD/CAM Tai lieu tham Ithao [I] Biii Ngoc Tuyen, Bai giang "VJy thuat ngucrc va tao mSu nhanh" cho hgc vien cao hgc Trudng Dai hgc Bach Khoa Ha Ngi, 2010 [2] Banh Tien Long, Biii Ngoc Tuyen, Ly thuyet tao hliA be mat va ling dyng ky thuat co khi, Nh^ xuSt bin giao dye, 2013 T9P chi Khoa h^c va Cong nghf 102 (2014) 074-079 [3] Kevin N Otto, Kristin L, Wood, A Reverse engineering and redesign method logy for production evolution, Proceedings of The 1996 ASME Design Engineering Technical Conferences and Design Theory and Methodology Conference, 1996 [4] M Sokovic *, J, Kopac, RE (reverse engineering) as necessary phase by rapid product development, Joumal of Materials Processing Technology, 2005 [5] Alexandru C.Telea Reverse Engineering - Recent Advances, anApplications Publisher; InTech, 2012 [6] htlp://vi'ww rapidform.com/ [7] Advanced Modelling Heidelberg 1991 for CAD/CAM System [8] Mechanical Design Solutions 1,2,3, Catia V5R19 [9] httpV/www geomagic com/ ... (Rapidform, ) Lfng dung Cong ngbe CAD/ CAM/ CNC che tao chi tiat So boa be m | t chi tiet Kiem tra danh gia chinh xac bang ky thuat ngugc Hinh Quy trinh ling dung RE va CAD/ CAM I Xac dinh sai so cua qua... hinh CAD thiet ke lai, be mat chi tiet sau gia cong, dam may diem quet be mat chi tiet tuang ling la: Do, Do'' ,Di,D2vaD2'' Sai so trung binh va lech chuan tucmg ung cac giai dogn nhu sau: Giai doan... Si va tJi Giai doan thiet ke lai bang phan mem ky thuJit ngugc (Rapidform) la Zj va CT2 Giai doan gia cong CNC vai trg giiip ciia ph5n m i m CAD/ CAM (CATIA V5) la £3 va 03 Giai doan quet chi tiet