(Đồ án tốt nghiệp) 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 SKL004867 Ho Chi Minh City, July 2017 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 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 name: Le Minh Tai Advisor: Duong Thi Van Anh 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 2.4 Capstone strengths and weaknesses EVALUATION No CONTENT Structure of the capstone project Student follows exactly the format for capstone project given by FME The motivation of the project is clearly provided in the thesis The NEED of project is clearly showed in the thesis Main contents (demonstration that students have ability to): Apply knowledge of math, engineering, and science Analyze and interpret data Design and manufacturing the system, component or process to meet needs Improvement and development in future Use the software and technical tool to solve the problem Real-life applications of capstone project Products of capstone project Total CONCLUSIONS  Accept  Reject HCMC, 15/7/2017: Advisor (Signature and Name) 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 name: Le Minh Tai Reviewer: Hoang Trung Kien Name of Institute: MACHINERY MANUFACTURING TECHNOLOGY COMMENTS Structure of the capstone project Main contents Results of capstone project Capstone strengths and weaknesses Questions and Suggestions EVALUATION No CONTENT Structure of the capstone project Student follows exactly the format for capstone project given by FME The motivation of the project is clearly provided in the thesis The NEED of project is clearly showed in the thesis Main contents (demonstration that students have ability to): Apply knowledge of math, engineering, and science Analyze and interpret data Design and manufacturing the system, component or process to meet needs Improvement and development in future Use the software and technical tool to solve the problem Real-life applications of capstone project Products of capstone project Total  CONCLUSIONS Accept  Reject HCMC, 15/07/2017 REVIEWER (Signature and Name) 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 ID number : 13143312 Student’s name : Truong Xuan Thai 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 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 th Ho Chi Minh city, July 15 – 2017 Students perform Le Minh Tai Truong Xuan Thai  The exercise meets learning outcomes which has been mention in section 1.7 b.Drawing Figure 4.94 Exercise drawing 80 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 gia công   Length Reference / machining Reference: chọn thể tích 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  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 c Technology Parameter : Exercise – 5D The Reference A, C axis are adjusted suitab No Table 4.12 Processing Technology of Exerci 83 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 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 Step 4: Benchwork c Technology parameter : Exercise – 5D The No 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 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 b 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  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 The Reference A, C axis are adjusted suitab NO Table 4.14 Processing Technology of Exerci 88 d Simulation result and product Figure 4.104 Simulation result and product 89 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 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 4-axis 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 ... 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. .. 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... of the axes: 3.3 The Mach3 Mill controling softwa 3.3.1 Setting Mach3 M 3.3.2 Conducting Mach Chapter 4: THE 5- AXIS CNC MILLING MACHINE OPERATION AND COMPOSE EXERCISES ON THE 5- AXIS CNC