ISSN: 2354-0575 ^ ^ « - ^^ ( ^M^^ ^ \ ~^t / NGHIEN c i r u ANH HlTdNG CUA CAC THONG SO CONG NGHE ^^^ CHAT LU'gfNG GIA C N G T R £ N MAY TIEN CNC THEO PHU'ONG PHAP THIET KE THU^C N G H I E M (DOE) '°™°^ RESEARCH THE EFFECTS OF TECHNOLOGICAL PARAMETERS TO PROCESSING QUALITY IN THE CNC LATHE MACHINE BY DESIGN OF EXPERIMENTS METHOD (DOE) Nguyen Van Tung^ Nguyen Trgng Hiing', L l Quang Long^ Biii Long Vmh" Tru&ng Dgi hpc Su pham Ky thudt Hung Yen Tru&ng Cao ddng nghe Co dien vd Xdy dung Bac Ninh Truang Cao ddng nghi Co diin vd Thiiy lgi Tru&ng Dgi hgc Bdch khoa Hd Ndi T6m tdt; Bdi bdo ndy trinh bdy phuong phdp nghiin ciru dnh hudng cua cdc yeu td cdng nghi den chdt lugng gia cdng trin mdy tien CNC theo phucmg phdp thiit ke thuc nghiim (DOE), ldm gidm so lugng thuc nghiim, tgo sdn phdm chdt lugng cao vai ehi phi thdp cho cdc nhd sdn xudt Kit qud nghiin euu cho quan he giira dd chinh xdc kich thuoc vd nhdm be mat vol cdc thdng so cdng nghi gdm tdc dd quay, lugng chgy dao, ehteu sdu cdt vd xdc dinh dupc thdng sd cdng nghe tdi uu cue bd (trong phgm vi khdo sdt) cd dp nhdm be mat nhd nhdt gia cdng tren mdy tien CNC Do dd, ndng cao chdt lugng vd ndng sudt gia cdng Tir khda: Anh hu&ng yeu td cdng nghe, Dp chinh xde kich thu&c, Dd nhdm bi mat, Thiit ke thuc nghiem, Ma trdn true giao, Tdc dg quay, Lugng chgy dao vd Chieu sdu cdt, Mdy tiin CNC I Md dau Vile nghien cuu anh hudng cae thdng so cflng nghe den chat lugng gia eflng trin may tien CA^C, theo phuang phap thiit ke thyc nghiim {DOE) su dung ma tran tryc giao, d l nang eao ehat lugng gia cflng {ndng cao dp ehinh xdc kich thu&c vd bdng be mat) va xay dyng moi quan be giua chinh xac kich thudc va dp nham be mat vdi cac thdng sd cdng nghe gdm toc dg quay, lugng chay dao va chiiu sau edt, dieu kiln san xuat hang loat theo phuang phdp diiu chinh sdn tren may tiln CA'C Do do, nang eao chdt lugng lam viec cua eac chi tiit may, dae biet la cae ehi tiit may tham gia vao m i l ldp ghep co dg ehinh xac cao va nang cao nang sudt gia eflng Theo phuang phap nay, hien dang dugc iing dung nghiin ciiu d nudc ngoai va cac cong trinh d nudc chua nghien cuu mgt each ddy du v i vdn d i linh vyc chi t£io may Qua nghiin cim nit nhiing van d l efl tinh quy luat, kiem chung tren thyc tl Tu do, xay dyng thu vien chi cong nghe gia eflng cho qud trinh san xudt tuang ty, gnip cho ngudi thao tac de dang iing dung, nham tdi uu cae thflng sfl eflng nghe pham vi khdo sat C g s d phirong phdp nghien cihi theo thiet k l thyx nghiem (DOE) Phuong phap quy hoach thyc nghiim Id rapt Khoa hoc & Cong nehe - So 3/2014 nhirng phuong phdp thiet ke thuc nghiem (DOE) dang dupe ung dyng ITnh vuc chi tao may [2] Phuong trinh hfli quy {md hinh todn hoc) nhan dugc bdng phuang phap quy hoach thyc nghiem co the dung d l xac dinh cac thflng sfl dau vao tfli uu mufln dat thflng sfl dau cue trj {l&n nhdt hodc nhd nhat) Theo phuang phap quy hoach su dung ma tran tryc giao, cap eua ma ydn tryc giao phy thuflc vdo bde cda bien sfl khao sat, nfl cfl dang cap biln sd la bac nhat va cap biln so la bae hai Phuang phap phan tich hdi quy: Cae phuang phap phan tich hfli quy gflm efl Phuong phdp binh phuong nhd nhdt; Hdt quy tuyin tinh mpt biin; Hdi quy parabol; Hdi quy hdm sd mU vd Hdi quy nhieu bien Chii y rdng, sir dgng ham nhieu bien tong quat va cho kit qua vdi chinh xae cao hon Khi tiln hanh quy hoach su dyng ma tran tryc giao cap vdi ba thflng sfl nghien ciiu, ham hfli quy nhiiu biln cfl dang nhu sau: Y = bg + 6|.X| + djXj + byc^ + b^yc^x.^ + b.^^yc^ > dj/jj:, + bj^^jc^jc^.x^ Trong dfl: X - Biln khao sat bae nhat bg - HI so hoi qui b - H I sfl tuyen tinh b ; , - H I sfl tuong tae cap va tucmg tae ba Journal of Science and Technology 29 ISSN: 2354-0575 Xdj dung bai toan nghiin ciru va thuc nghiem 3.L Bdi toan nghiin ciru Nghien cuu anh hudng cila che dp cflng nghe din chit luang gia cflng cua loat chi tilt tren may tien CNC thay dfli che dp cong nghe: Tflc quay n (vg/ph), Luang chay dao S (mm/vg) va Chiiu sdu cat / (mm/ 3.2 Lira ehgn gia tri cdc thong s8 cong n g h i Viec lya chpn cac thflng sfl cflng nghe phy thuflc vao phuong phdp gia eflng, thiet bi, dung cu cdt, vat heu lam dao, vat lieu dugc gia cflng vd cd the duge Ua cuu tu tai lieu [5], [6] Dieu kien thuc nghiem: - Su dung may tiln true CNC Concept Tum 250 (Cpng hfla Ao) che tao, he dieu hanh FANUC2L - Dao tiln ngoai chi tilt try eae nguyen cflng gia cflng thfl, ban tinh vd tinh: su dung ciing than dao va miii dao thay dfli ciia Hang EMCO (Cflng hfla Ao) Ky hieu mui dao tien ngoai chi tilt tru duoe chi ddn trin hinh Hinh l.Ky hiiu mill dao tien ngodi chi tiit tru - Vat lieu phfli: thep cacbon C45 - Chi tiet gia cong co dang b l mat try Tu cdc tdi lieu [6], [7] va [10] cdc muc gia tri thong so chi dfl cflng nghe bao gflm tflc dfl quay, lugng ehay dao va chilu sau edt cac thyc nghiem cua luan van lua chpn cac thflng so che dp cflng nghe trin may tien CNC theo bdng 4,1 Bang 4.1 Gid tri cdc thdng sd cdng nghe thuc Phuang phdp td chute thfrc nghidm trirc giao cdp I Sd thuc nghiim: N = 2'' So yeu tfl anh hudng d i n dp ehinh xac kich thudc gflm cfl Tflc quay: n (vong/phut); Lupng chay dao: S (mm/vong); Chieu sau cat: ((mm) Suy ra: k = Do dfl: N, - 2^ = So thyc nghiim tai tdm, iing vdi sfl thflng sfl nghiin cuu k = 3, suy chpn: Nn = k + = Tflng so thuc nghiem: N i : - N j + No = + = 2 Mirc CO bdn: n^^^ ^ 500 vong/phut; S^^^ = 0,05 mm/vong; ;^,j, = 0,l mm " ^ ^ = ^^^^ vdng/phiit; S^ = 0,15 mm/ vdng; / - 0,2 mm Suy ra: Tij^ 1000 vong/phut; j = O.I mm/vong; f°= 0.15 rara Khodng bien thiin: Al- 500 vong/phut; Ai^ 0.05 mm/vong; A\ = 0.05 mm Cdc bien khdng thu nguyin: - Biln khflng thii nguyen tflc quay: xT''=\', 3:"™"=-!; 3:1° = - Bien khflng thii nguyen lugng chay dao: xf""=*=!; j f ' " = - l ; xf=Q - Bien khdng thu nguyin chieu sau cdt: xr^\; xr=-\', 3;j'=o h Ma trdn thue nghiem Ma trdn thyc nghi|m cfl dang tryc giao cap vdi ba thong so nghiin cuu, hara hfli quy nhiiu biln cfl dang nhu sau: Y ^ bg + byc^ + byx:^ + byc,^ + b^ycyc^ + fe^jX^x, Thong so dng nghe Ky hiiu thong so Tflc quay {vong/phut) Lugng ehay dao (mm/vdng) Chieu sau eat (mm) n Cac muc gid tri Muc Muc Muc thap trung cao binh 500 1000 1500 S 0,05 0,1 0,15 t 0,1 0,15 0,2 3.3 Thiet k l thuc nghiem 3.3.1 Thiet k i thuc nghiem nghien cii-u anh hudng cua thong so cong nghe den chat lugng gia cong 30 Khoa hoc & cang nghe - S6 3/2014 Trong dfl: X - Biln khao sdt bac nhdt bg - He so hfli qui d - He sd tuyen tinh b^^; b^^^ - He sfl tuong tac cap va tuong tdc ba Suy ra, ma tran thi nghiera voi k = va thyc nghiim tai tara phuong an vfli cac thflng so dau vao (n S t) va cac biin raa boa la Xg, X^, X^ va X3 dugc chi dan trin bang Trong dfl: X^ - Biln ao dupe dua them vao ma tran; X| - Bien ma hfla img voi tfle dp quay; Xj - Biln md hfla img voi lugng ehay dao; Xj - Biln ma hfla irng voi chieu sdu cat Journal of Science and Technology ISSN: 2354-0575 TT X, X, X, x,.x x,.x, x,.x, x,.x,.x, n S t 500 0.05 01 -1 1500 0.05 0,1 500 0,15 01 -1 1500 0.15 0,1 -1 500 0,05 0.2 1500 0,05 0.2 -1 500 0.15 0.2 1500 0,15 0,2 Xj -1 -1 -1 -1 -1 0 0 0 1000 0.1 0,2 10 0 0 0 1000 0.1 015 11 0 0 0 1000 0,1 015 12 0 0 0 1000 0,1 015 3.3.2 Lira chgn phirong p h a p va thiet hi tL Mdu sau tien tinh - Dfl ga do: su dung khfli "V" dai, dinh vi bdc tg e Do nhdm - Phuong phdp do: nhara theo phuang phap dau - Thiit bl do: SJ400-Mitutoyo (Nhat Bdn) chinh xae: 0,000125nm; co ket noi voi may tinh - Dfl ga do: su dyng khfli "V" dai, dinh vi bac tu Hinh Mdu sau gia cdng tren mdy lien CNC Concept Turn 250 b Do kieh thu&c - Phuong phap do: sai lech kich thude theo phuong phap tpa - Thiit bi van ndng UIM21 (LB Nga), chi thi sfl Mitutoyo (Nhat Ban): chinh xac 0,OOIram Hinh Thiet bi do nhdm SJ400-Mitutoyo Bdn) 3.3.3 K i t qua - Gia tri trung binh cua sai lech kich thudc so vdi dudng kinh danh nghia ciia N = 33 mm eac b i mat gia cdng tu -12 (bang 2) Hinh Thiit bi van ndng UIM21 (LB Nga), chi tht sd Mitutoyo (Nhdt Bdn) TT Ad, -17 Adi -63 Ada -46 M, -23 Adi -23 (Nhdt Ad, -19 Ad, -87 Ads -20 Ad, - 14 Adio Ad„ Ad,2 -045 -52 -43 - Gia tri tmng binh cua nham cua cac be mat gia cong tir - 12 {bang 3) Bang TT R., K R_j R_ R^ R_^ R„ R_, R_, R_„ R_i, R„ 1,89 2,03 5,45 1,40 2,89 0,52 4,69 1,33 5,29 3,38 2,71 2,79 Khoa hoc & Cong nghg - S6 3/2014 Journal of Science and Technology ISSN: 2354-0575 - Kiim tra sy ddng nhat eua cdc phuang sai 3.3.4 Xu- ly va kilm tra s6 lifu thuc nghifm theo bang gia Iri gidi han cua chi tieu Cochoren a Sd li^u kich thu&c raaxju - Vdi ham nhiiu biin da chgn cfl dang: ^0,426 G = Y = b^ + byc^ + byc^ + byc^ + b^ycyc^ + b^yxyc^ + b^yc^x^ + b^^yX^JCJ.x^ Suy ra, dang cua phuong trinh hoi quy cd ma G^ = 0,547 trdn true giao can tim: Suy ra, G^^ < G^ i = ft, + b^X^ + bJC, + djZj + , ^ , ^ , + b^^^, + b^^^X^ + 6,,3 Jr,.x^.i"j b Sd lieu nhdm Theo phuang phap binh phuang nhfl nhat, Cflng thue tdng quat d i tinh cac he sfl b: cflng thiic tflng quat d l tinh eae he sfl b tt"ong phuang trinh hfli quy ciia ma tran true giao, tuong bo— J^ZJ Xa^ Y,= 2,86416 dng vdi k = yiu tfl anh hudng nhu sau: tsi &D = ^ l ] ; f ( „ K ^ 37,666 Y,= -0,80333 b2 = Y,= 0,46166 -j;iZjX2,, '^ ^3 — "/V Z J ''^3" r 2^j^XX2 Y.=-i,5 ^= " bi ~ •jv^Zj'^i" = 0,32916 '^ ^ix-Mi.Y.=-i,m bl2 = J^2-, X\:i• n=jrJ]x, X2 Yn=n Xl, b-23 = Jf2^ Xl^ X, .Y =-0,02666 bn^j^lLx^ Xa, jj-YiXiu.X3 Y.^7,8: ' ~fj2^X\,t F =-0,43166 '^ X2u• Xau -1^1 - -0,5 Phuong trinh hoi quy cfl dang: Y = -37,66 + 4.X^ - 4,5X,- Uied^iTj + II X^X^ 6,333Ji;jf3 + 7,833JfiJTj - 0,5JT, JT^JT^ Sau kilm tra y nghTa cua cac he b phuang trinh hoi qui tbeo phuong an thyc nghiem tai tdm va y nghia cua cac he sfl b duge kiem dinh theo chuan Student (I) Suy ra, cac he so b^, b^, by d|^, i^j,- 6j3 cfl y ngbia va dlu dugc giu lai phuong trinh hfli quy Do do, Phuang trinh hfli quy cd dang nhu sau: Y = -37,66 + 4^:^ - 4,5Jr^- 1,166^:3 + H-^i-^^ 6,333 J : , J : + 7,833 j r ^ X (1) - Kilm tra sy tucmg thich ciia phuang trinh hdi quy voi thyc nghiem tbeo bang gia tri gidi ban ciia chi tieu Fissher F ^ y =-0,15166 X, Xi y, = 0,26 Phuong trinh hoi quy co dang: Y = 2,86416 - 0,80333^1 + 0,46166^3 + 0,32916 X3 - 0,43l66Jr,X3 + 0,02666X2X3 - 0,15166X,X3 - 0,2666X^X3X3 Sau kiem tra, cdc he sfl 6,; 6^; b^, b^^; 6^3 cfl y nghia va deu dupe giiJ lai phuang trinh boi quy Do do, phuong trinh hfli quy eo dang nhu sau: Y = 2,86416 - 0,80333X, + 0,46166X3 + 0,32916 X^ - 0,43166X,X3- 0,15166X,X3 - 0,2666X1X3X3 Gia tri gidi han ciia chi tieu Fissher F: 1,062 si 4,25833 Ftn = ' Su, F(0,95)(f,,f3) = F(O,05)(6,3) = 5,31 F^ < F,^, phuong trinh h i i quy tim dugc la tuong thich vdi thuc nghiem voi muc y nghTa 95% Gia tri gioi ban cua chi tiiu Cochoren: maxSu Gi„ = 0,42878 •Lsi F(0,95)(f,,f,) = F(0,05)(6,3) = 5,31 ^in "^ ^(b' phtrong trinh hfli quy tim dugc la tuong thich vdi thyc nghiem voi mde y nghia 95% Gj - 0,547 Suy ra, G < G 32 Journal of Science and Technnlnov Khoa hoc & Cong nghS - S6 3/2014 ISSN: 2354-0575 3.3.5 D^ thj thuc nghiem Su dyng phdn mim Microsoft Excel - 2007 di tinh toan va phin mim Tableeurve 3D V4.0.0.1 de bieu dien quan be cua tflc dg quay n, luang chay dao S vd ebilu sau eat t din dp ehinh xae kich thudc vd nham bi mat Anh hudng cua tflc quay n, lupng chay dao S vd chilu sau cat din dp chinh xac kich thudc (hinh 5) va dp nham bi mat (hinh 6) gia cflng tren may tiln CNC Hinh 5a Anh huong ciia n, S den chinh xdc Hinh 6a Anh huong cua n, S den nhdm Hinh 5b Anh hu&ng cua van n t den chinh xdc Hinh 6b Anh hu&ng eda n, t din nhdm Hmh 5c Anh huang cua S t din dp chinh xdc Hinhflc.Anh hu&ng ciia S t din nhdm Kit qua thirc nghiem va danh gia kit qua " * nghien ciru Theo phuong phap thiet kl thiic nghiem (DOE) cac phuong ttinh hdi quy ham nhiSu biill tim tatfc, bi6u diin m6i quan hS giiia cac thong s6 Khoa hoc * Cone noh^-^'^ 3/7(114 cong nghe (n, S, t) vdi chinh xac kieh thudc va -\.J uA mat S l.UI gia „'.n cong ^Ann tinh t i n t , tren frSn may mi.i tien tiar CNC r'Klf^ nham be Concept Tum 250 (LB Thuy Sy), sir dimg may v?n nang mM21 (LB Nga), chi thi s6 MITUTOYO (Nhat ban) va thilt bi nham MITUTOYO SJ400 Journal of Science and Technology 33 ISSN: 2354-0575 dam bao dfl chinh xac va tm cay cua kit qua Trong phuang trinh eo cdc be so tuang tdc cap vd tuong tac ba biiu dien anh huflng dflng thdi ciia cdc thflng sfl cflng nghe din dg chinh xdc kich thudc va nham b i mat Day la su khac biet eo ban vdi cac nghiin cuu trudc day, k i cd d nudc va nudc ngodi [11], [12] Tu phuang trinh (1) thdy rdng, dp chinh xac kich thudc ty 11 thuan vdi van tflc (diu he sfl X / duong) va ty le nghich vdi lugng chay dao vd chiiu sau cdt (ddu he sfl X, va X^ am) Tu phuang trinh (2) thdy rdng, gia tri nham ty 11 nghich vdi van tflc (ddu he sfl Xf am) va ty II thuan vdi lugng chay dao va chiiu sdu cdt (ddu he sfl X, va Xy duang) 3, Chi cflng nghe tfli uu cue bp (trong pham vi khao sat) co sai leeh kich thudc nhfl nhat lya chgn bfl thflng sfl cong nghe tu cac dilm cd sai leeh nhd nhdt- T u h i n h a : n = 1500 (vong/phut), = , mm/vong Ad——20pm - Tu hinh 5b: « = 1500 (vflng/phiit); t = 0,2 mm A d -— ^ m - Tu hinh 5c: S = 0,2 mm/vflng; chiiu sdu cdt ( = , mm va gia tri sai l|ch A d - - ^ m Suy ra, chi cflng nghe tfli uu cue bg se cfl gia tri nhu sau: n = 1500 (vong/phut); = 0,15 mm/ vdng; ^ = 0,1 mm Che dp cflng nghe tfli uu eye bg (trong pham vi khao sat) cd nham b l mat nhfl nhat (dp bong caonhdt) lya chgn bg thong so cong nghe tir cac diim co sai lech nhd nhat: - Tu hmh 6a: n = 1300 (vflng/phut); S = 0,07 mm/vflng - Tu hinh 6b: n = 1200 (vdng/phiit); ( = 0,13 mra - Tu hinh 6c: S = 0,08 mm/vdng; t = 0,13 mm Suy ra, che dg cong nghe tfli uu cue bo se cfl gia tri nhu sau: n = 1300 (vdng/phut); S - 0,08 mm/ vong; ( = 0,13 mm Tai lieu tham khao [I] Tran Van Dich, Nghiin cuu chinh xde gia cdng bdng thue nghiem, NXB Khoa hgc vd ky thudt, Ha Npi 2003 [2] Nguyen Trgng Hung, Thiit ki thue nghiem ehe tgo mdy, Trudng Dai hgc Su pham Ky thuat Hung Yen, Hung Yin 2013 [3] Ll Quang Long, Nghiin ciru ehinh xdc kich thu&c ehi tiit true gia cdng tren mdy tien CNC dieu lain sdn xudt hdng loat, Luan van Thac sy Ky thuat, Trudng Dai bpc Su pham Ky thuat Hung Yen, Hung Yen 2014 [4] Nguyin van Tiing, Wg/fien ciru dnh hu&ng ciia cdc thdng sd edng nghe din nhdm be mat ^a cdng chi tiet true trin mdy tien CNC, Luan vdn Thac sy Ky thuat, Trudng Dai hge Su pham Ky thuat Himg Yen, Hung Yen 2014 [5] Ninh Due Tfln, Nguyen Trpng Hiing, Ky thugt Tap I - Dung sai lap ghep vd Tieu chudn hoa, NXB Giao due Viet Nam, Ha Nfli 2006 [6] Nguyin Ddc Lpe ya eae tac gia So tay Cdng nghe chi tgo mdy NXB KHKT, Ha Ngi 2000 [7] NTU, Tra cuu ehi dp cat, Khoa Co khi, Trudng Dai hgc Nha Trang [8] Haas automation Inc.: Lathe Programming Book 2800 Sturgis Road Oxnard, California 93030 [9] Version EE IIT, Kharagpur, Introduction to Computer numerical controlled (CNC) Machine [10] Mukesh Kumarl, Sandeep Malik2, Optimizing the process parameters of machinability through the Taguchi Technique, International Joumal of Enhanced Research in Science Technology & Engmeenng, ISSN: 2319-7463 Vol Issue 8, August-2013, pp: (48-57), Haryana, India [ I I ] Nitin Agarwal, Surface Roughness Modeling with Machining Parameters (Speed, Feed & Depth of Cut) in CNC Milling, MIT Intemational Joumal of Mechanical Engineering, Vol 2, No lU, Jan 2012, pp (55-61) [12], Lulzim Balal, Afiim Gjelajl, Avdyl Bunjaku2 and Avdi Salihul, Surface Roughness of Material Processing during Milling Process, Joumal of Mechanics Engineering and Automation (2012)601-605 Abstract: This article presents a research method the effects of the technological parameters to processing quality in the CNC lathe machine by design of experiments (DOE) method, which reduces the number of experiments, produces high quality products with low cost for manufacturers Results of research for 34 Khoa hoc & Cong nghe - S6 3/2014 Journal of Science and Technolocy ISSN: 2354-0575 the relations between the accuracy dimensions and the surface roughness and technological parameters including rotational speed, feed intake ranging, depth of cut and determine the local optimum technological parameters (within the survey) with minimum surface roughness when processing on CNC lathe machine Therefore, the quality and productivity processing are improved Keywords: Effect factors oftechnology The accuracy dimensions Surface roughness Design of experiments (DOE), Orthogonal array, rotational speed Flow range and Depth of cut, CNC lathe machine Ngirdi phan b i l n : T S Bui Nggc Tuyin Khoa hoc & C6n2 nehe - S6 3/2014 Journal of Science and Technology 35 ... nghe din chit luang gia cflng cua loat chi tilt tren may tien CNC thay dfli che dp cong nghe: Tflc quay n (vg/ph), Luang chay dao S (mm/vg) va Chiiu sdu cat / (mm/ 3.2 Lira ehgn gia tri cdc thong... vao phuong phdp gia eflng, thiet bi, dung cu cdt, vat heu lam dao, vat lieu dugc gia cflng vd cd the duge Ua cuu tu tai lieu [5], [6] Dieu kien thuc nghiem: - Su dung may tiln true CNC Concept Tum... cac thflng so che dp cflng nghe trin may tien CNC theo bdng 4,1 Bang 4.1 Gid tri cdc thdng sd cdng nghe thuc Phuang phdp td chute thfrc nghidm trirc giao cdp I Sd thuc nghiim: N = 2'''' So yeu tfl