Nghiên cứu quy trình CAD CAM CAE CNC trên catia cho trung tâm gia công nhiều trục điều khiển số

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 bien, nhdng hgn che cua lap trinh thu cong dd ddn den sU 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 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 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 (Thang nim 2013) NGHIEN CUfU TRAO DOI GlOl THiEU Trong nhflng nam gan day, linh vflc Co che tao nfldc ta da phdt triln vUpt bac cung sfl 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 tUpng ddi ldn 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 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 khdng gian la rat nhieu, ddi 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 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 lap trinh dUa mdt ngdn ngfl Id phan mem CAD/CAM thich hpp l/u diem cfla khuynh hfldng Id: Tiet kiem ddng ke thdi gian md ta chi tiet vd qua trinh gia cdng can thiet; sd Iflpng cdc ldi giam xuong lap chflong trinh chi tiet 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 hpa cdc md phdng dpng bpc vd hinh hpe cfla chi tiet qua trinh cat, mpt sd trfldng hpp md phdng cd dao de tfl dfla 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 Thudn Ipi nhat ddi vdi ngfldi lap trinh la mdt he thdng lap trinh cd sfl ket hpp vdi hpa Ngfldi lap trinh cd the Idem tra dau vao theo tflng bfldc mdt va cd the sfla chfla so lieu viet chflPng trinh, cudi cung cd the Idem tra chflpng trinh bdng md phdng 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 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 thiet ke vd sdn xuat la vd cflng quan trpng Hien cd rat nhieu phan mem tich hpp 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) 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 rat nhanh vd linh hoat nhd sfl dyng cdng cu Start Cho den thdi diem thi CATIA la mpt he thdng CAD/CAM/CAE/CNC'^ TAP CHf C O KHf VI$T NAM *t* Sd (Thang 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) - Mo hinh hoa chi ti^t: Dflpc thflc hien nhd md-dun Part Design, Shape Design Nhd cdc md-dun 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 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 dUpc cac trUdng dng suat va chuyen vi nham khang dinh chi tiet da dUpc thiet ke la dat hay khdng dat - PhUPng phap ga dat phoi: CATIA co sin 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 md-dun nay, ta hodn todn cd the doi ten, dieu chinh kich thflde dung cu 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 CATIA dfla 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 dfldi dang G-Code File hodc APT Hmh Quy trinh CAD/CAM/CAE tongqudt NhUng tflu trung, cdc quy trinh deu dupc viet dudi dang sP 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 quy trinh cdng nghe gia cdng chi tiet tren may dieu khien sd dUPc thflc hien tren phan mem vd ket qua cua chflpng trinh dau 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 quy trinh cdng nghe gia cdng chi tiet: TAP CHI CO KHf VIET NAM - Chflpng trinh sau 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 khiln 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 rat nhilu cdng doan dl giiip quan ly chu trinh san pham nham nang cao chat Iflpng sdn pham tao va ddm bao mpi yeu cau ky thudt 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): Sd (Thang nam 2013) NGHIEN COU TRAGOPl Hmh Phdn tich dng sudt mnh Quy trinh CAD/CAM/CAE dexuat mdi 2,3, (Jng dung quy trinh tren CATIA - Bii6c 3: Thiet ke va lap rap ga nhcf cac mo-dun Part Design va Assembly (hinh 6) 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" cum truyen dpng co tren may bay - Budrc 1: Mo hinh hoa chi tiet diipc thuc hi?n nhd mo-dun Part Design (hinh 3) Hinh Thiet ke gd - Bd6c 4: Chuan bi phoi CO kich thUdc 2x120(hinh 7) Hinh 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 & 5) Hinh Budc chudn hi phoi - Biicfc 5: PhUOng an dung cu (chpn theo tieu chuan ciia hang Seco) Hinh Phin tich chuyen vi TAP CHi C O KHi VIET NA.\I ' • 56 (Thang nam 20 i ( P NGHIEN CUU-TRAO Dpi thdnh nguyen cdng: nguyen cdng 1: tien true U, !,, '^""™" ^ ,., sis's" — ^ "- £•!;„ :c±r^': ™ r»-"* ^ : : ^ "^ S T — " " ^ ^ , '•»• T ^^>g7^"—i ™ ^„^D.^ ^ Q.l-T.l~p Ita,= bdc (^34, ^ , ^ ; nguyen cdng gom cac bfldc: phay ranh xoan, khoan Id tdm ^12 & phay hoc luc gidc it Hinh Bdng ke dung cti cdt • Budc 6: Chuan bi dfl lieu lap trinh sfl dung md-dun Machining (hinh & 10) •.j^*> ;:^ -i-t3^.-Si.j.3[5i.aE£ Htnh 11 Tien true bac dau nho Hinh Thiet lap dudng dung cu nguyen cdng tien true bdc " ™ • -•:.'-.• r^.y.-S^ Hinh 12 Phay ranh xodn Hinh 10 Thiet lap dudng dung cu nguyen cdng phay ranh xodn MO PHONG SO 3.1 Qua trinh gia cdng tren CATU nhU sau Qud trinh gia cdng chi tiet dflpc chia TAP CHI CO KHf VIET NAM Hinh 13 Khoan loipM Sd (Thang nam 2013) NGHIEN CtifU - TRAO D(!)l V »• r a ^ iA'.M*9t Hmh 14 phay hoc luc gidc 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 028 ZO N183 G28 XO YO (Total Machining Time: 1:36:51) N184 M30 % 3.2 Chiidng trinh gia cong KET QUA THU'C NGHIEM % OOOOl (CATIA EO COMMENTS) (COMPANY: ICAM Technologies Corporation) (MACHINE: VMC - Fanuc 30i) (CLFILE: NC Tien dau nho l_Part_ Operation_l_l_I.aptsource) (DATE&TIME: 6-Dec-2012- 16:09:59) (TOOL* TOOL NAME) Hinh IS Chl tiet mo phing hodn thien Viec gia cong chi tiet duoc thUc hien tren trung tam tien CNC true CTX310 GILDEMEISTER 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 16 Chi tiet duoc gia cdng trin trung tdm tien true GILDEMEISTER Hinh ;7, Anh chup san phdm thUc te thuc hien cflng nhu mo phdng kiem tra tinh dung KET LUAN dSn ciia giai phap dudng chay dao gia cdng vdi Mo hinh hda, phan tich danh gia mo hinh tr^n CO sd phan tich ket cau, thiet lap dudng chay dao gia cdng mdi quan he tiidng tac cd kiem vdi thiet bi ga ldp tai mdi trudng lam vi^c, tU dOng sinh chUdng trinh phii hdp vdi may cong cu quy trinh CAD/CAM/CAE/CNC, cho phep kiem tra cac phUdng an khac ciia giai phap cdng nghe, k h k phuc va chinh dung cac loi lap trinh cd the mSc phai trUdc 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 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, gia 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 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aided manufacturing Springer Verlag [13], MAKINO Inc (2011) Vertical IVtachining Center Programming Manual, Makino [14] FANUC Series O - MCFANUC Series 0 - MC.FANUC Series O, Master for Lathe Operator's Manual, FANUC, LTD 1988 TAP CHi CO KHi VI$T NAM • S6 (Thang nam 2013) ... Machining CATIA dfla 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 dfldi dang G-Code File hodc APT Hmh Quy trinh CAD/ CAM/ CAE. .. cu quy trinh CAD/ CAM/ CAE/ CNC, cho phep kiem tra cac phUdng an khac ciia giai phap cdng nghe, k h k phuc va chinh dung cac loi lap trinh cd the mSc phai trUdc cd mot quyet dinh chinh thilc cho. .. 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 thiet ke vd sdn xuat la vd cflng quan trpng Hien cd rat nhieu phan mem tich hpp ddi nhdm giai