Nghiên cứu thiết kế máy tạo màu kim loại tấm sử dụng công nghệ biến dạng cục bộ liên tục ISF

NGHIEN CUfU-TRAO D | NGHIEN CU'U THIET KE MAY TAG M A U KIM LOAI T A M SLT DUNG CONG NGHE BI^N DANG CUC BO LIEN TUC ISF DESIGN OF SHEET METAL PROTOTYPING MACHINE USING INCREMENTAL SHEET FORMING (ISF) TECHNOLOGY Phan Dinh Huan\ Le Khinh Dien', Phan Dinh TuanS Nguyen Thien Binh^ Nguyin Thanh Nam^ 'Khoa C P khi, TrUdng Dai hpe Bach khoa TR HCM ^PTN Dieu khien sd va Ky thuat He thong DCSELAB, VNU - HCM Bdi bdo trinh bdy mgt thie't ke mdy tgo mdu sd dung cong nghe bien dgng cue bg lien tue (ISF) Thiet ke cd khi cita mdy co nhdng diem khac biet so vdi mot mdy phay CNC truyen thong Do cdng vdngdUdc tdng cUdng cho true chinh mdy de co the ddp dnglUc dgc true vdi gid tri ldn gia cong bang cong nghe ISF Mdy dUdc che tgo thdnh cong vd hogt dgng on dinh gia cdng bien dgng tdm thep CT3 vudng 210 mm vd be ddy tdm mm Dieu ndy cho thdy thiet ke cd vd dieu khien cua mdy ddp dng tot, CO the dp dung degia cdng cdc mdu tdm phuc vu cho cdc ngdnh cong nghiep hien tgi Tfl khoa: Incremental Sheet Forming (ISF), Die-less NC forming machine, SPIF This paper present a design of prototyping machine using for incremental sheet forming (ISF) technology Mechanical design of this machine has specified feature in compared with a traditional CNC machine Stability of spindle is considered to apply high value of axial force when forming sheet metal by ISF technology Machine is manufactured and working properly when forming mm - CT3 sheet steel 210 mm square size This proves that mechanical and control design of the machine is capable of requirements and can be applied on forming sheet metal using for current industrial fields Key words: Incremental Sheet Forming (ISF), Die-less NC forming machine, SPIF TAP CHf CO KHf VIET NAM •> S6 1+2 (Thing 1+2 nam 2013) NGHIEN CUfU-TRAO D O I l.GIOiITHl£u xie cua miy CNC va sU eflng vflng ddi vdi true ehinh gifl dung eu tao hinh theo phUPng dpc true Trong nhflng nam gin diy, cic phUPng phap tao mau nhanh da phat trien manh me Cac phflong p h i p cing tdt ei v i dp ehinh xac, dp phfle tap cua ehi tiet v i thdi gian tao mau ngiy cang ngan hfln Ben canh sfl tien bp cua cac phflpng phap tao mau nhanh truyen thong, cac phflpng phip tao mau nhanh mdi eung dflpc nghiin cflu phat trien Cdng nghi bien dang cue b0 liin tue (ISF) l i mpt nhflng phflong phip mdi cd nhieu tiem nang Unh vflc niy [ ] C O sd TfNH TOAN WC CHO MAY ISF Trong q u i trinh thiet ke miy tao mau ISF, can phai tim bie'u vi co che bien dang kim loai bing cdng nghi ISF va xac dinh gii tri eae lUe t i c diing len dau dung eu Trong thiit k i may, ta thiit lap mo hinh tinh Iflc trin dau dung eu tao hinh nhfl sau: Trong eong nghi ISF, mot dung cu tao hinh dau b i n cau dflpc dieu khii'n bdi may gia cong CNC bing chflpng trinh GCODE lap trfldc va theo tam kim Ioai si dflpc bien dang din din Bang each bien dang tao hinh tam kim loai theo tflng vi tri tiep xue tai dau dung cu (bien dang cue bp) m i eong nghi ISF cd the tao bien dang Idn hpn tren cung mot vat lieu so vdi eic phflpng phip tao hinh kim loai tam khie [2] Cie sin pham ed the i p dung edng nghe ISF rat da dang v i khong can dung khudn hoae gi phflc tap Hinh dang dflpc tao binb cung ed the thay doi linh boat bang each thay doi trflc tiep tfl md hinh CAD m i kliong phii di qua giai doan gia cong lai bp khudn Do do, phflong phip ISF rut ngan thdi gian den thj trfldng cua sin pham va cung giim gia eho nghiin cflu va thay ddi thiet ke ban dau [3] Cong nghi biin dang cue bp lien tue ISF phit trien nhanh cung vdi sfl phit trii'n cac miy CNC hien dai Nhflng ngfldi ta nhanh chdng nhin eic miy gia cong CNC hiin tai ehi thieh hpp cho qua trinh cat gpt kim loai ma lflc cit gpt trin dung eu cat theo phflpng ngang ldn hpn phflpng dpe true Trong dd, ddi vdi cong nghi ISF thi Iflc bien dang tie dung theo phflong ngang Iai nhd bon so vdi Ifle dpc true [4] Do dd, can thiet phai nghien cflu che tao mpt thiet bi diiu kbii'n sd thieh hpp cho gia eong ISF Thiet bi niy can co sfl kit hpp gifla sfl chinh Hinh L Mo hinh sd dung tinh todn lUc cho mdy ISF cii:^ - -de, dt:,, - Cl dt:, O — ^ cr cr — ~ a/2 -cr, ( D - 2/) D.cr, n -h l.t -Iter, D-k-ll < CTy " Trong dd: - 0|, o^, o, la phin flng suat ehinh - a=a^ tao phin lflc nen F^ lin b i mat eau eua dung cu tao hinh Ap lflc F^ tao Iflc ma sit F,, v d i / i a he sd ma sat gifla dung cu tao hinh vi tam (hinh 1) - Og tao lflc vdng F|, nim mat phang ngang, cflng chieu vdi phan ma sit F^ vfla phin tich d trin TAP CHf C O KHf VI$T NAM V S6 +2 (Thing 1+2 nam 2013) NGHIEN CUfU-TRAO D O I Do thi cho ta thay gia tri ldn n h i t cua life - tao Iflc cang tiep tuyen F^ lin be mat dung cu tao hinh theo phUPng x la 2000N Mot eieh tflong tao hinh tfl cd the xac dinh gia tri cua lflc tao hinh theo - la be day tam phUPng y v i z la 2.000N va 4.500N - r^^^^ li ban kinh dung cii tao hinh r^^^=D/2 - Oy li flng suit ehay cua vat lieu tam TINH TOAN THIET KE Bing cac tinh toin so hpe, ta dfla gii tri 3.1 Tmh toan thiet ke khung may lflc tie dung theo eic phUPng x, y, z nhU sau: F.(e) = TT ^ '^' (Dsin' a + 2t(\ - cos' a) ^^ ^ 3(D + 2/) Fy{0) = K ^ •^' ( D ^ - ^ ~ ' ^ + f ( / + l) s i n ' a "^ 2{D + 2.t) r = ; r - ^ - ^ ^ ( / + 2/+D) ^ 6(D + 2.0 Xiy dUng thi bieu diin moi quan h i gifla lUe tie dung vdi gdc tao hinh theo phflpng x eho trfldng hpp tai Idn nhat: Khung m i y la mot yeu to quan trpng doi vdi dp on dinh cua miy Cac may CNC thong thudng cd ket eau dau true ehinh c6ng-x6n v i ban miy di ehuyen theo hai phUPng x-y Tuy nhiin, ket cau niy thich hpp vdi eat gpt kim loai hon la bien dang ISF vi lUe dpc true eua phUPng phap cat gpt ldn Trong trUdng hpp bai bao dUa mpt so lita chpn phflong an khung may dfla vao dac diem di chuyen cua ban may nhfl sau: - Dudng kinh dung eu D=20mm Bdng Bdngltia chgn cdcphUdngdn - Lfng suit chay eua vat lieu tam o =215x10^ Pa (Inox 304) PhUcfng an DSp dng lue Dp cdng Do x " ^ ^ V V Ban may di chuyen theo phuong (may CNC iruyen thong) V V V x V Ban may di chuyen theo phuong V V ^ X V - Chieu day tam gia eong t = l m m - Gde bien dang tao hinh trin tam a - Gdc gia cong theo phUPng ngang 9=0 (ehay dung eu theo phUPng x) - H i so ma sat gifla tam va dung cu tao hinh f= 0.05 F