(Đồ án hcmute) compose exercises and operation materials on the 5 axis cnc milling machine for teaching cad cam cnc subject

MINISTRY OF EDUCATION AND TRAINING HCM CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY OF MECHANICAL ENGINEERING GRADUATION THESIS MACHINERY MANUFACTURING TECHNOLOGY COMPOSE EXERCISES AND OPERATION MATERIALS ON THE 5-AXIS CNC MILLING MACHINE FOR TEACHING CAD/CAM - CNC SUBJECT Advisor: M.E DUONG THI VAN ANH Students: TRUONG XUAN THAI Student’s ID: 13143312 Students: LE MINH TAI Student’s ID: 13143292 SKL 0 Ho Chi Minh City, July 2017 an MINISTRY OF EDUCATION AND TRAINING HCM CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY OF MECHANICAL ENGINEERING GRADUATION THESIS COMPOSE EXERCISES ON THE 5-AXIS CNC MILLING MACHINE FOR TEACHING CAD/CAM-CNC SUBJECT Advisor: M.E DUONG THI VAN ANH Students: TRUONG XUAN THAI LE MINH TAI Ho Chi Minh City, July 2017 an HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY OF MECHANICAL ENGINEERING CAPSTONE PROJECT EVALUATION FORM (FOR REVIEWER USE ONLY) Title of thesis: Compose exercises on the 5-axis CNC machine for teaching CAD/CAM-CNC subject Major: MACHINERY MANUFACTURING TECHNOLOGY Student’ s name: Truong Xuan Thai Student’s ID: 13143312 Student’ s name: Le Minh Tai Student’s ID: 13143292 Advisor: Duong Thi Van Anh Academic Position: Engineering Master of Name of Institute: MACHINERY MANUFACTURING TECHNOLOGY COMMENTS COMMENTS ON ATTITUDE AND BEHAVIOR OF STUDENTS COMMENTS ON RESULTS OF CAPSTONE PROJECT 2.1 Structure of the capstone project 2.2 Main contents 2.3 Results of capstone project an 2.4 Capstone strengths and weaknesses EVALUATION No MAX POINT CONTENT Structure of the capstone project 30 Student follows exactly the format for capstone project given by FME 10 The motivation of the project is clearly provided in the thesis 10 The NEED of project is clearly showed in the thesis 10 Main contents (demonstration that students have ability to): 50 Apply knowledge of math, engineering, and science Analyze and interpret data 10 Design and manufacturing the system, component or process to meet needs 15 Improvement and development in future 15 Use the software and technical tool to solve the problem Real-life applications of capstone project 10 Products of capstone project 10 Total 100 CONCLUSIONS  Accept  Reject HCMC, 15/7/2017: Advisor (Signature and Name) an ACHIEVED POINT HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY OF MECHANICAL ENGINEERING CAPSTONE PROJECT EVALUATION FORM (FOR REVIEWER USE ONLY) Title of thesis: Compose exercises on the 5-axis CNC machine for teaching CAD/CAM-CNC subject Major: MACHINERY MANUFACTURING TECHNOLOGY Student’ s name: Truong Xuan Thai Student’s ID: 13143312 Student’ s name: Le Minh Tai Student’s ID: 13143292 Reviewer: Hoang Trung Kien Academic Position: Doctor of Philosophy Name of Institute: MACHINERY MANUFACTURING TECHNOLOGY COMMENTS Structure of the capstone project Main contents Results of capstone project Capstone strengths and weaknesses an Questions and Suggestions EVALUATION No MAX POINT CONTENT Structure of the capstone project 30 Student follows exactly the format for capstone project given by FME 10 The motivation of the project is clearly provided in the thesis 10 The NEED of project is clearly showed in the thesis 10 Main contents (demonstration that students have ability to): 50 Apply knowledge of math, engineering, and science Analyze and interpret data 10 Design and manufacturing the system, component or process to meet needs 15 Improvement and development in future 15 Use the software and technical tool to solve the problem Real-life applications of capstone project 10 Products of capstone project 10 Total 100 CONCLUSIONS  Accept  Reject HCMC, 15/07/2017 REVIEWER (Signature and Name) an ACHIEVED POINT COMMITMENT Project name : Compose exercises on the 5-axis CNC machine for teaching CAD/CAM-CNC subject Advisor: M.E Duong Thi Van Anh Student’s name : Truong Xuan Thai Student’s ID number : 13143312 Student’s name : Le Minh Tai Student’s ID number : 13143292 Address: Thu Duc District, Ho Chi Minh City Contact number: 01207.07.02.07 Email: truongxuanthai1995@gmail.com Commitment: "We commitment that this good essay is the work we study and make We not copy or retrieve any source of personal or corporate material without specific source If there is any mistake we take full responsibility " TP Ho Chi Minh City, June 19, 2017 Confirmation of student: Truong Xuan Thai an Le Minh Tai ACKNOWLEDGEMENT With each student of Mechanical Engineering, graduation project is important It could help them to improve, complete and know more about major knowledge There for, we effectuated the project “Compose exercises on the 5-axis CNC machine for teaching CAD/CAM-CNC subject.” for months After finishing this project, we will know more to accomplish and meet requirements of mechanical engineer Firstly, we would like to say thanks Faculty of Mechanical Engineering for assigning this project for us This is challenge for us to study, ameliorate knowledge about mechanical Secondly, we sincere thanks M.E Duong Thi Van Anh for supporting She teaches us how to create G-code, load in CNC milling machine and operate it to processing components She provides general CNC knowledge, which help us to this project easier Nextly, we extend our thanks to M.E Dang Minh Phung He is always beside us throughout processing this project With his provision and support about mechanical, we could make this project better Lastly, we want to send deeply thanks to teachers in Ho Chi Minh city University of Technology and Education, who has been teaching, communicating useful knowledge for us That is the basic foundation for our career in the future Sincerely thanks Ho Chi Minh city, July 15th – 2017 Students perform Le Minh Tai Truong Xuan Thai an ABSTRACTS Compose exercises on the 5-axis CNC machine for teaching CAD/CAM-CNC subject When technology and science are more and more development, CNC field create many tools, machines, equipment in responding to manufacturing and assembling Many complex texture components are manufactured Therefore, components are processed in 5-axis CNC milling machine, which are necessary This is reason why this project is researched With project assignments, we have to perform processing some 3D, 4D and 5D components in 5-axis CNC milling machine to create model components and compose exercises for CAD/CAM/CNC subject To respond project schedule, we had to study in documents about mechanic and CNC basic, which we were received from our lecturers Addition to learning knowledge in Internet, books… we researched about 5-axis CNC milling machine current design At the same time, we learned how to operate and process in this machine From that, we improved necessary parts, which couldn’t run axis When completed mechanic, we started to program G-code and load in CNC machine, ran simulation If it had stability, we manufactured from workpieces to components After completing this project, we will have knowledge about designing machine, necessary skills about CNC machine such as operation, programming 5-axis G-code We know how to improve a machine tools However, the project has some limitations such as change tools automatically, machine spindle’s power is low, working area is narrow … So that, we hope the project to develop better by improving this disadvantages and to help the people who is learning, researching about 4,5-axis machine as well as how to processing 4D, 5D model an Table of Contents Chapter 1: OVERVIEW 1.1 The old version of the CNC machine 1.2 The necessity of this project 1.3 Scientific and practical significance 1.4 Researching object of the project 1.5 Researching object and scope 1.6 Researching methods 1.6.1 Methodological basis 1.6.2 Researching specific methods 1.7 Technical and practical significance Chapter 2: THEORATICAL BASIC 2.1 General information about CNC machine 2.2 General configuration about CNC machine 2.3 Types of control systems in CNC machine Chapter 3: GENERAL INTRODUCTION AXIS CNC MILLING MACHINE IN THE BEGINNING Some pictures of the vailable 5-axis CNC Milling machine 3.2 The available mechanism 5-axis CNC milling Machine 3.2.1 The limited itinerary of the axes: 3.3 The Mach3 Mill controling software: 10 3.3.1 Setting Mach3 Mill software parameters 10 3.3.2 Conducting Mach3 Mill software 16 Chapter 4: THE 5-AXIS CNC MILLING MACHINE OPERATION AND COMPOSE EXERCISES ON THE 5-AXIS CNC MACHINE 28 4.1 The 5-axis CNC milling machine operation 28 4.1.1 Introduce about 5-axis CNC milling machine 28 4.1.2 The basic operations on axis CNC milling machine 29 4.1.3 Operation and Determination about workpiece reference in 5-axis CNC milling machine 31 4.1.4 Load G-code, edit and check errors 34 4.1.5 Processing 35 4.2 Compose exercises on the 5-axis CNC milling machine 36 4.2.1 Programming process by Creo parametric 3.0 36 4.2.3 Processing simulation 42 4.2.4 Exporting NC File 44 4.2.5 Compose exercises on the 5-axis CNC milling machine 45 Chapter 5: CONCLUSION AND RECOMMENDATIONS 90 5.1 Solution 90 an c Processing technology Exercise – 5D Workpiece dimension (mm) Material Clamp Ø60x50 PP plastic Three – jaw Chock W reference The Reference A, C axis are adjusted suitably Processing Ø (mm) S (R/m) F (mm/m ) t (mm) No Technology step Tool type Volume milling Endmill 1800 600 2 Cut line milling Ballmill 2500 1000 0.2 Drilling Ø5 x 4mm Driling 2500 500 Table 4.11 Processing Technology of Exercise 78 an d Simulation result and product Figure 4.93 Simulation result and product 4.2.5.4.2 Exercise  The exercise will present about using trajectory, engraving cycles and adjusting parameters of this cycles to program manufacturing, adjusting port, choosing zero points for a 5D model Besides, the exercise will be useful for creating keyseatings, engraving on complex 5D models 79 an  The exercise meets learning outcomes which has been mention in section 1.7 a Drawing Figure 4.94 Exercise drawing 80 an b Technology Processing Step 1: Volume Rough: Endmill Ø6, t = (mm), S = 1800 (revolution/ min), F = 600 (mm/min) Step 2: Trajectory: Endmill Ø6, t = 0.2 (mm), S = 2500 (revolution/ min), F = 1000 (mm/min) Step 3: Engraving: Grooving, t = 0.3 (mm), S = 2300 (revolution/ min), F = 1000 (mm/min) Step 4: Benchwork: File Rotary and burr  Volume Rough Figure 4.95 Volume Rough Having 10 parameters need to declare: Cut_feed, Step_depth, Step_over, Clear_dist, Spindle_speed, Prof_tock_allow, Rough_tock_allow, Bottom_stock_allow, Scan_type, Rough_option  Enter Edit tool: Choose the Grooving tool, tool diameter, suitable tool  Length Reference / machining Reference: chọn thể tích gia cơng  Trajectory Figure 4.96 Trajectory Edit tool : choose Ballmill to processing follow line current Edit parameters : Cut_feed, Clear_dist, Spindle_speed, Number_cuts 81 an  Engraving Figure 4.97 Engraving Engraving is used to be decoration, create pattern To engraving, you must create the geometric decorative element, which is called Groove  Enter Edit tool: Choose the Grooving tool, tool diameter, suitable tool length Figure 4.98 Declaring the tool  Reference: Choose Sketch surface need to handle Figure 4.99 Reference dialog box  Parameters: There are many parameters but has seven parameters that are required to declare : Cut_feed, Pluge_feed, Step_depth,Groove_depth, Number_cuts, Clear_dist, Spindle_speed 82 an c Technology Parameter : Exercise – 5D Workpiece dimension (mm) Material Clamp Ø60x55 PP Plastic Three – jaw Chock W Reference The Reference A, C axis are adjusted suitably Processing No Technology Step Tool type Ø (mm) S (r/min) F (mm/m) t (mm) Volume milling Endmill 1800 600 Trajectory Endlmill 2500 1000 0.2 Engraving Grooving 2000 1000 0.3 Table 4.12 Processing Technology of Exercise 83 an d Simulation result and product Figure 4.100 Simulation result and product 4.2.5.4.2 Exercise 3:  The exercise will present about using trajectory, drilling cycles and adjusting parameters of this cycles to program manufacturing, adjusting port, choosing zero points for a 5D model Besides, the exercise will be useful for holding, creating keyseating on complex 5D models  The exercise meets learning outcomes which has been mention in section 1.7 84 an a Drawing Figure 4.101 Exercise drawing b Technology Processing Step 1: Volume Rough  Tool: Endmill Ø6, t = (mm), S = 1800 (revolution/min), F = 600 (mm/min) Step 2: Trajectory  Tool: Endmill Ø6, t = 0.2 (mm), S = 2500 (revolution/min), F = 1000 (mm/min) Step 3: Drilling Ø4 x 5,5mm  Tool: Driling Ø5, t = (mm), S = 2500 (revolution/min), F = 500 (mm/min) 85 an Step 4: Benchwork c Technology parameter : Exercise – 5D Workpiece’s dimension Materials (mm) Ø60x60 PP Plastic W reference The References of A, C axis No Technology step Volume milling Trajectory Drilling Ø4 x 5,5mm Processing Tool Ø type Endmill Endlmill Driling Clamp Three – jaw Chock are S (v/p) 1800 2500 2500 adjusted F (mm/p) 600 1000 500 suitably t (mm) 0.2 Table 4.13 Processing Technology of Exercise d Simulation result and product Figure 4.102 Simulation result and product 4.2.5.4.2 Exercise  The exercise will present about using trajectory, drilling cycles and adjusting parameters of this cycles to program manufacturing, 86 an adjusting port, choosing zero points for a 5D model Besides, the exercise will be useful for holding on complex models  The exercise meets learning outcomes which has been mention in section 1.7 a Drawing: Figure 4.103 Drawing exercise 4, 5-axis processing b Technology Procesing Step 1: Volume Rough  Tool: Endmill Ø6, t = (mm), S = 1800 (revolution/min), F = 600 (mm/min) Step 2: Drilling Ø6 x 5mm 87 an  Tool: Drilling Ø6, t = (mm), S = 2500 (revolution/min), F = 500 (mm/min) Step 3: Drilling Ø4 x 9mm  Tool: Driling Ø4, t = (mm), S = 2500 (revolution/min), F = 500 (mm/min) Step 4: Benchwork   Tool: File Rotary and burr The Volume Rough processings, Drilling (exercise 1, 3) c Technology parameter : 5D Exercise Workpiece dimension (mm) Ø62x55 Materials clamp PP plastic Three – jaw chock W Reference The Reference A, C axis are adjusted suitably Processing NO Technology step Tool type Ø S (v/p) F (mm/p) t Volume milling Endmill 1800 600 Drilling Ø6 x 5mm Driling 2500 500 Drilling Ø4 x 9mm Driling 2500 500 Table 4.14 Processing Technology of Exercise 88 an d Simulation result and product Figure 4.104 Simulation result and product 89 an Chapter 5: CONCLUSION AND RECOMMENDATIONS 5.1 Conclusion After a long period of time made the subject group has achieved the following:  Dependent on the learned knowledge, research the document on the internet, refer the designing and manufacturing methods for 5-axis CNC Finally we knew the operating methods of 5-axis CNC machine From that approaching to CNC milling machine in the industry market  Mach3 software with the 4-axis interface can NOT show C-axis coordinate in handling After discussing we upgrade the Mach3 interface to the 6-axis mach3 interface  We designed and programed with designing and manufacturing software And then, we were checking, adjusting and testing part by part on the 5-axis CNC machine After researching and using the 5-axis CNC machine, we recognize and adjust parameters of the machine to handling 5-axis components stably  The final part of the project, we compose constructing documents to operating machine And Handling the model components (The 2D model components, 3D model components, 4D model components, 5D model components) Meet the needs of teaching, studying 5.2 Limitations and Development methods: Limitations:  Because the initial project made a 3-axis CNC milling machine, which was improved and upgraded to 4-axis and 5-axis milling machine Designing parameters for 3-axis machine is better but unsuitable for 5-axis CNC milling machine leading to the working area is narrow  The limitation of the working area made our team having many difficulty when designing and programming as well as manufacturing We must to designed model complying with a standard of this machine  Manufacturing 5-D model components are not high Precision and reliability  A Step (0.72 degrees/pulse) is too big  Zero set point and holder set too hard Development methods:  Adjusting the machine more rigorous by digimatic indicator and Digital Protractor  Improving the machine structure to make the area is more spacious  Change step motors of A and C-axis into AC servo motor to accurately operate, achieve higher manufacturing accuracy  Design, manufacture more the automatical tools changing  Change Spindle to manufacture steel workpiece 90 an REFERENCES Vietnamese documents: [1] Nguyễn Ngọc Đào, “The syllabus of CAD/CAM/CNC Basis”, Ho Chi Minh City University of Technology and Education [2] Ass.Prof,Dr Lê Hiếu Giang, Ass.Prof,Dr Nguyễn Trường Thịnh, “Máy điều khiển theo chương trình số”, Ho Chi Minh City 2005 [3] TS Bùi Quý Lực, “Hệ thống điều khiển số công nghiệp”, Publisher of Science and Engineering, Ha Noi 2006 [4] Nguyễn Ngọc Đào, Trần Thế San, Hồ Viết Bình, “Chế độ cắt gia cơng khí”, Ho Chi Minh City University of Technology and Education [5] Ass.Prof,Dr Trần Văn Địch, “Thiết kế đồ án công nghệ chế tạo máy”, Publisher of Science and Engineering [6] Me Trần Quốc Hùng, “Dung sai kỹ thuật đo”, Ho Chi Minh City University of Technology and Education English documents: [7] James Floys, Kelly, Patrick Hood - Daniel, Build your own CNC machine [8] Karlo Arpo, Secrets of - Axis Machining [9] CNC Robotic – Geoff Williams Others: [10] Mach3 CNC controler software installation and configuration [11] Nguyễn Lê Quang Nhật, Trần Thanh Lộc, Võ Văn Mạnh, Advisor: Me Đặng Minh Phụng, Thesis: Research design and manufacture 5-axis of 4axis CNC Machine Complete and manufacture the controlling system of 4axis CNC machine Ho Chi Minh City University of Technology and Education, 2016 [12] Việt Nam electronic Forum: http://dientuvietnam.net [13] “CNC world” Forum: http://thegioicnc.com [14] Việt electronic encyclopedia forum: http://codientuviet.com 91 an S an K L 0 ... MILLING MACHINE 4.1 The 5- axis CNC milling machine operation 4.1.1 Introduce about 5- axis CNC milling machine The 5- axis CNC milling machine Panel Figure 4.1: The 5- axis CNC milling machine Panel The. .. 3.3.2 Conducting Mach3 Mill software 16 Chapter 4: THE 5- AXIS CNC MILLING MACHINE OPERATION AND COMPOSE EXERCISES ON THE 5- AXIS CNC MACHINE 28 4.1 The 5- axis CNC milling machine. .. MECHANICAL ENGINEERING CAPSTONE PROJECT EVALUATION FORM (FOR REVIEWER USE ONLY) Title of thesis: Compose exercises on the 5- axis CNC machine for teaching CAD/ CAM -CNC subject Major: MACHINERY MANUFACTURING