Tong Quan Cong Nghe Duc AP Luc

- 1 -
CHNG 1
TNG QUAN V CNG NGH C P LC
I. LCH S HNH THNH V PHT TRIN CA NGNH C
P LC.
1. Trn th gii.
c p lc l mt ngnh sn xut phi nhm to ra cc chi tit c kch
thc chnh xc do nhng chuyn ng ca d ng lu cht kim lai lng di tc
dng ca ngai lc to nn dng p sut vo trong khun kim loi. c p lc l
mt nhnh ca ngnh c tn ti rt lu i, cc nhnh cn li l ngnh c trng
lc v c p lc thp. C nhng bng chng kho c hc cho thy rng c trong
lc c thi thi k ng Thic c ngi nguyn thy dng c cc dng
c lao ng nh : ru, n,Ngy xa t tin chng ta cng thy c nhng u
im nht nh ca c nh : c th sn xut ra cc sn phm vi s l ng ln c
cng kiu dng. V ngy nay pht huy nhng c tnh u vit ny pht trin
ngnh c ln thm mt bc, c th l ngnh c p lc.
Cng ging nh cc ngnh k thut khc, ngi ta khng bit chc chn thi
gian xut hin ca ngnh c p lc vo thi gian c th no m ch c th c
lng thi gian ra i ca n vo khong u th k 19, mc d c mt vi
tng hnh thnh ngnh c p lc c t sm hn na bi v n c s lin h vi
vic sn xut my in
My c p lc u tin Sturgiss c pht minh vo nm 1849 (hnh 1),
my ny c bung nu chy kim loi c t pha di. Vo nm 1877, Dusenbery
da trn nguyn l ca my Sturiss hnh thnh nn my th h mi c b sung
thm mt pitng rng c gn van mt chiu cho php kim loi lng c th chy t
khoang trn xung khoang di. c bit k t nm 1904 ngnh c p lc thc s
- 2 -
bt u pht trin khi m cng ty H.H. Franklin bt u cho xut hin nhng my
c p lc c gn cc thit b t ng bt u t y ngnh c p lc chuyn
sang mt bc ngot mi cng song hnh tn ti vi ngnh cng nghip xe my, xe
hi v ngnh cng nghip ny tr thnh khch hng ln ca ngnh c p lc.
Vo nhng thi gian u, ngi ta s dng hp kim ch, thic lm nguyn liu
cho c p lc bi v hp kim ny d dng c nhit thp, hn na hp kim
ny c kh nng chng n mn tt nhng chng li c nhc im l rt mm v
kh nng chu ko thp. Ngy nay hai hp kim ny khng cn c s dng trong
ngnh c p lc na. khc phc nhc im ca hp kim trn th vo nm
1906 ngi ta s dng hp kim km thay th. Vo nm 1914 cng vi s pht
trin ca ngnh sn xut ng c xe my v t ngi ta nghin cu v a vo
s dng hp kim nhm do n c nhng u im sau : c kh nng chng mi mn
nhit cao, tnh c tt, kh kt tinh v l kim lai tng i nh,
Hnh 1.1. S nguyn l ca my c p lc
Sturgiss nm 1849
- 3 -
Hnh 1.2: My c p lc Dusenbery nm 1877
Hnh 1.3 : S my c p lc ca cng ty H.H Franklin ch to
nm 1904
- 4 -
2. Ti Vit Nam.
Trong nhng nm gn y cng ngh c p lc cao ti Vit Nam ang
dn ci thin v khng nh vai tr ln trong cc c s sn xut. Cc sn phm ca
c p lc ngy cng a dng nh: np hng, tay bin Nhng nhn chung cng
ngh c p lc cc c s sn xut u c hiu qu l m vic khng cao th hin l
lng ph phm trong mi ca l m vic kh ln. Nguyn nhn chnh ca thc trng
ny l: Cht lng khun c v vt liu kim loi c cha tt, cha ng dng
CAE trong thit k khun.
Hnh 1.4. Mt s sn phm ca c p lc.
II. TM HIU CHUNG V CNG NGH C P LC CAO.
1. Th no l c p lc cao.
c p lc cao l cng ngh trong kim loi lng in y khun v
ng c di tc dng ca p lc cao do dng kh nng hoc du p trong xilanh
p to ra. C th hnh dung qu trnh cng ngh nh hnh 1.5.
- 5 -
Khun c p lc cao bao gm hai na khun, na khun tnh 7 v na
khun ng . Bt u chu trnh c, hai na khun ng li. Rt kim loi lng
nh lng vo bung p qua l rt trn xilanh p 2. Sau khi rt, pittng 1 trong
xilanh 2 y kim loi lng in y hc khun. Khong thi gian in y ch
khong phn chc giy vi tc hng trm m/s v p sut khong vi trm ti
hng nghn atmtphe. p sut c duy tr n khi vt c c ng c hon
ton. Rt rut khi vt c. Na khun di ng tch khi na khun tnh. Cht y
4 tng vt c khi khun. Chu tr nh c mi li bt u.
Hnh 1.5. Quy trnh c p lc
a. Giai on cp liu, b. Giai on in y khun,
c. Giai on p tnh, d. Giai on tho khun.
2. Quy trnh c p lc cao.
- Giai on I: Giai on cp liu.
Kim loi lng c y vo xilanh, Pittng 1 i qua v bt l rt.
Vn tc ca pittng p v p lc trong bung p cn nh. V khi p lc ch cn
thng ma st trong bung p.
- 6 -
- Giai on II: Giai on in y hc khun.
Kim loi lng in y ton b bung p. Tc ca pittng tng ln v
t gi tr cc i v
2
. Gi tr ca p sut p
2
tng mt cht do phi thng cc tr lc
ca dng chy trong bung p.
- Giai on III: Giai on p tnh.
Kim loi lng in y l rt v hc khun. Do thit din r nh dn thu hp
li cho nn tc pittng gim xung thnh v
3
nhng p sut p li tng ln. Kt
thc giai on ny, pttng dng li nhng do hin tng thy kch (qun tnh p)
m p sut p lin tc tng ln. Khi cc dao ng p sut tng dn, p sut t gi tr
khng i. y l p sut thy tnh cn thit cho qu tr nh kt tinh. Giai on p
tnh.p sut c th t ti 50-5000 daN/cm
2
, ty thuc vo bn cht vt liu c v
yu cu cng ngh. Khi p lc t gi tr thy tnh m ti rnh dn vn cn kim
loi lng th p lc s truyn vo vt c kim loi lng th p lc s truyn vo vt
c kim loi kt tinh trong trng thi p lc cao.
- Giai on IV: Giai on tho khun.
Gia on ny vt c ng c hon ton. Tm khun m tch ra khi
khun dng, sau h thng y sn phm y vt c ra ngo i.
Di y l hnh m phng hnh trnh pittng tng ng vi th vn tc,
p sut trong bung p.
- 7 -
Hnh 1.6. th vn tc v p sut bung t.
nh hng ca p lc ti qu tr nh kt tinh ca khi loi.
Tt c cc tnh cht ca kim loi ( tnh cht nhit , c hc , in , t .) u
b thay i khi chu p lc. Xu hng chung l tng p lc th nhit nng chy
ca kim loi s tng l n, kim
loi lng s chuyn thnh pha
rn. Tuy nhin, p lc p tc
dng ln kim loi lng s thc
y qu trnh thm kim loi
lng trong vng 2 pha v iu
chnh qu trnh tc ng nhit
hnh thnh vt c. Khi ,
lng pha lng thm lc qua
vng hai pha ca hp kim,
theo nh lut asi, tnh theo
cng thc [1, trang 65]
580 590 600 610 T
0
C
24
20
16
12
8
4
0
Hnh 1.7 : Quan h ph thuc ca h s
thm vo nhit vng 2 pha hp kim
nhm
1).Al9, 2). Al4Si.
K
- 8 -
p
L
F
k Q A = (1.1)
Trong : k h s thm ( hnh 1.7 ); F- din tch tit din ngang vt c; L-
chiu rng vng hai pha ln, c th tnh ton theo cng thc [1, trang 65] :
- Trong giai on ng c ban u (Bi<1)
bm S
kt
T T
T
L
A
= (1.2)
- Trong giai on ng c cui cng, sau khi hnh thnh l p v rn ca
vt c v Bi>> T
kt
(T
s
- T
bm
):
|
.
|
\
|
+
A
=
2 2
D
T T
T
L
bm S
kt
(1.3)
Trong : T= T
1
T
s
: T
bm
v D nhit b mt v chiu dy vt c; h
s dn nhit t b mt vt c.
p lc bn ngoi s gy ra cc nh hng sau:
1. Nng cao h s dn nhit ca kim loi lng v h s trao i nhit gia
vt c v khun.
2. Lm gim kch thc ca mm kt tinh ti hn v nng cao s lng tm
mm kt tinh .
3. Gim ht trung bnh ca kim loi, gim tnh khng ng nht cc
nhnh cy .
4. Gim h s khuch tn v gim tc khuch tn t ng i ca tp cht .
5. Lm tt iu kin lc thm ca vng 2 pha, do cu trc kim loi s c
chc hn.
6. Gim nhit bt u co ngui v gim co ngt ca hp kim
trong khong kt tinh c hiu qu .
- 9 -
7. Gim khuynh hng nt nng ca kim loi .
3. Thy ng hc qu trnh in y khun.
a. Nguyn tc.
Trong c p lc cao, giai on in y khun c tnh bt u ti thi
im gia tc ca pittng bng 0 v pittng t trong trng thi chuyn ng n nh
v khi dng kim loi s b phn tn, khi kh v khng kh trong hc khun s b
ngp trong hp kim lng. Khi tc v p lc ca dng np n nh sau khi qua
rnh dn, dng kim loi s bo ton c hnh dng ca mnh. Nguyn tc bo ton
hnh dng ca dng np l c s thy ng hc ca qu tr nh in y khun trong
c p lc
Khi kim loi lng chuyn ng n nh, dng kim loi lng vn d b nhiu
li v n s mt i hnh dng n nh ca mnh. Mt trong nhng nguyn nhn lm
nhiu lon dng chy l ng sut trong v sc cng b mt lm sut hin sng dao
ng ngang trong dng chy. Chiu di bc sng ca dao ng ngang tnh theo
cng thc 2.1 [1, trang 67] .
2 . . . 2 v C L = (1.4)
Trong : C- l hng s ph thuc nht kim loi
v- tc dng np (m/s).
- chiu dy rnh dn (m).
- khi lng ring kim loi lng (kg/m
3
).
Khi tc dng np trn 50 (m/s) dng chy s khng lin tc do khun
thng kh km, p l c trong khun tng ln v xut hin dao ng hnh Sin theo
chiu dc ca dng chy. Chiu di gii hn ca dng chy ch vo khong 100-200
ln chiu dy rnh dn l thch hp.
Vic gin on dng np cng c th xy ra khi xut hin hin t ng xm
thc trong knh ca h thng rt do s gi m p.
- 10 -
T phng trnh Becnuli, c th miu t dng chy n nh vic cho dng
chy trong 2 knh ni tip c tc v
1
v v
2
; p sut p
1
,p
2
tng ng. Nu p
2
=0 th
v
2
=v
max
xc nh theo cng thc [1, trang 68, 2.2]
1 1 max
2
v p v + =
(1.5)
Gi tr tc v
max
vi hp kim nhm c th at 200 (m/s). Vi tc ,
cc tia ca dng kim loi phn tn gy ra hin t ng n mn b mt knh dn .
ngn nga hin tng xm thc, ngi ta dng h thng rt thu hp c chuyn tip
u n t phn y sang phn mng m khng c php gi m p lc dng chy
xung 0.
a. Va p ca dng np ln thnh khun.
p sut thy ng p ca dng chy ln thnh khun c xc nh t dng
chy i xng [1, trang 68, 2.3]
) cos 1 ( .
2
= v p (1.6)
Trong : - gc nghing thnh khun (hc rut) so vi hng chuyn
ng ca dng chy.
p sut p cng ln, cht lng b mt ca vt c cng tt. T phng
trnh trn thy r, gi tr p lc p trc ht ph thuc vo tc v, nhng tc v
cng ln, khun b xm thc cng mnh. Bi vy, phi chn hng ca dng np
khi va p vi khun sao cho gc l nh nht.
Th d, khi c km c khi l ng ring 700 Kg/m
3
; tc dng l 40 m/s,
gc nghing = 45
0
, p lc s l p = 7000*40
2
*(1-cos 45
0
) = 3,5Mpa. Khi khun
phng, = 90
0
, th p lc p = 11Mpa, gn 3 ln ln hn.
Khi va p vo thnh khun, dng kim loi s b bin dng, thm ch cn b
v vn thnh cc ht nh. hn ch hi n tng ny v m bo h thng chy
tng trong h thng rt, tc dng np khng c vt qu mt gi tr ti hn v
th
,
c xc nh theo cng thc [1, trang 68, 2.4]
) ( 2
. Re

=
vd
th
v
v (1.7)
- 11 -
Trong : - nht ng hc
Re - tiu chun Reynold
vd
chiu dy thnh vt c
- chiu dy rnh dn.
Trong cng thc (2.4), gi tr Re nh nht la 2300, ln nht 20000 i vi
dng chy dc theo mt phng v cng trn.
Gi tr tc ti hn i vi hp kim rt trng thi lng b nh thng
khng vt qu 2 - 5 m/s.
Gi tr tc ti hn tnh theo cng thc (1.7) cho vt c dy 5mm, rnh
dy 3mm ca mt s hp kim cho trn bng 1.1
Bng 1.1. Tc ti hn ca mt s hp kim theo cng thc 1.1
Hp kim T,
0
C V,10
6
,m
2
/s V
th
,m/s
Hp kim km 450
395
0.42
1.90
0.45
2.36
Hp kim nhm
A2(AK12)
650
585
0.51
2.23
0.55
2.67
Hp kim nhm
A7-4(AlCu4)
650
580
0.48
3.35
0.57
4.57
Khi tc dng np vt qu tc gii hn, dng ch trong knh s l
dng chy ri, cc th nghim ch ra, khi t l chiu dy ca vt c
vd v
chiu
dy rnh dn c quan h nh sau:
vd
/ < 1/4 thi dng chy ri xut hin khong tc 0.3-10 m/s;
vd
/ > 1/4 thi dng chy ri xut hin khong tc 0.5-20 m/s.
Nu chn gi tr cn tr n, dng chy s l dng chy ri v chnh l
nguyn nhn ca cc khuyt tt vt c nh: ngm khi, xp. Bi vy, khng nn
thit k h thng rt cho dng chy trong giai on in y khun ban u li l
dng chy ri.
- 12 -
Ti nhng ch va p ca kim loi vi hc khun, vt c s c cht lng
tuyt ho nu to c mt ch chuyn ng phn tn, mi tr ng phn
tn l kh trong hc khun, pha phn tn v l cc git kim loi va bn ra khi
thnh khun. Khi hn hp ca cc git kim loi v cht kh in y ton b th
tch ca hc khun, ang c dng np chy qua thi cc tia phun c ng ngy
cng bo ha kim loi lng, qu trnh ny lin t c cho n khi khng hnh thnh
c mi trng phn tn na. Trong mi tr ng lc , cc bt kh b v vn
thnh cc ht nh li ti v khng c nh hng g n cht lng vt c.
Mi trng phn tn s xut hin khi tc d ng np vt qu mt tc
ti hn th 2, tnh theo cng thc thc nghim:
]
]
]
=
vd
m
th
C v
2
(1.8)
Trong : C,m,n l nhng h s thc nghim (bng 1.7)
Bng 1.2. Cc hng s thc nghim ca cng thc 1.8
Hp kim C M n
Ch antimon 32 0.35 0.4
Km 59 0.42 0.54
Nhm 82 0.4 0.61
Magie 75 0.52 0.65
ng thau 71 0.53 0.68
b. in y hc khun:
Vt c c chiu di thnh ng u ( l t hp cc mt phng vung gc
vi nhau ) u c in y theo nguyn l dng phn tn bt u t ch dng np
va p vi chng ngi vt ( hnh 1.8 ).
- 13 -
Hnh 1.8 . S phn tn dng trong hc khun.
y l im khc bit ca c p lc so vi c thng th ng. Nung s b
khun s hn ch c vic hnh thnh sm mt lp v ng c, ng thi to
iu kin loi b mt phn kh qua h thng thot h i v qua mt phn khun. Ti
thi im kim loi in y khun, khong 3 0% lng kh vn cn nm trong kim
loi lng di dng phn tn ri rc u tr n tit din ngang vt c. Tc dng
np cng ln, git kim loi phn tn cng mn v kch thc bt kh cng mn. Khi
tc dng np trn 100 (m/s), mn ca kh nh n mc khng th phn bit
c ngay c khi nh bng b mt.
a s vt c u c hnh dng phc tp hn so vi cu hnh trnh by
trn, th d, vu li, gn tng cng, chuyn tip thnh dy, mng Nhng yu t
trn u lm gim tc in y vt c, v bi vy, trong khun rt t khi c ch
chuyn ng phn tn. Thng th ng trong khun c ch in y hn hp
ca dng phn tn v dng y. Giai on th nht, ng vi thi gian in y hc
khun c chiu dy thnh u nhau, dng phn tn c duy tr. Giai on th 2,
ng vi thi im in y c thnh mng ln thnh dy , tc dng gim i, ch
l chy ri nhng dng l lin tc.
Dng phn tn to thnh trong khong 5.10
-3
s k t khi bt u np kim
loi lng vo khun trong phn vt c mng, v chuyn thnh dng chy ri sau
17.10
-3
s. Ti thi im kt thc qu trnh in y, cc loi kh phn tn rt u v
- 14 -
mn trn ton b tit din vt c. phn vu li hoc th nh dy, s c mt hoc
vi r kh kch thc ln (hnh 1.9).
Hnh 1.9: S in y khun ch dng phn
c. iu kin thy ng hc ca qu trnh thot kh.
Khi kim loi chy theo dng lin tc t rnh dn vo hc khun, cc cht kh
b dn v phn cui cng ca hc khun, cc rnh thot hi v cc vu li. Khi
kim loi in y y khun bng dng phn tn, cc cht kh b dn ko theo
hng v rnh dn. Bi vy, rnh thot hi phi c b tr trn ton b mt phn
khun. Tc chy ca dng kh trong iu kin on nhit xc nh theo cng
thc:
|
|
.
|
\
|
=

k
k
k
k
k
RT g v
1
1
1
. 2 (1.9)
Trong :
k - ch s on nhit, vi khng kh k = 1.4;
R - hng s cht kh;
- 15 -
h s khng th nguyn, tnh bng t s ca p lc mi
trng v p lc kh trong khun.
Lng kh q
k
chy qua cc knh thot hi c tng din tch f s ph thuc
vo ch chy. Vi dng chy c p sut kh p
k
nh hn p sut gii hn 0.19
Mpa (p
k
<0.19 Mpa) th:

k
k
k
T
p
f q
71 . 1 41 . 1
12 . 0

=

(1.10)
Khi p sut p
k
> 0.19 Mpa:

k
k
k
T
p
f q

= 4 . 0 (1.11)
i p ca kh p
k
trong cc cng thc (1.10) v (1.11) khng phi l hng s,
n tng dn trong qu trnh in y, bi vy khi tnh ton p
k
s ly gi tr trung
bnh trong sut thi gian in y khun.
d. Chn khng ha
Khi ch to vt c c kn kht v bn cao, c th l m gim r xp
bng cch to chn khng trong hc khun. Chn khng cn c tc dng lm gim
tr lc thy lc trong khun. iu cho php ch to c vt c c chiu dy
nh hn 1mm. Gi tr p sut d trong khun p
d
ph thuc vo chiu dy thnh vt
c
vd
,mm 2.5 2.0 1.5 1.0 0.6
P
d
,10
4
,Mpa 15 18 12 - 16 10 - 15 9 - 12 7 - 10
Ring i vi km p sut d nn ly ln hn 30.14
-4
MPa.
- 16 -
Vic tnh ton h thng chn khng c thc hin xut pht t iu kin
dng chy on nhit. din tch thit din ngang f
ck
ca rnh ht chn khng tnh
theo cng thc:

ck b k mt
k ck k
ck
t p p T
T l V
f
.
0045 . 0
=

(1.12)
Trong : V
k
th tch kh cn loi khi bung p, k nh dn , hc
khun, m
3
;
l
ck
chiu di knh dn chn khng, m;
T
mt
nhit mi trng,
o
C;
p
b
p sut trong bnh cha,MPa;
t
ck
khoang thi gian to chn khng, s.
Th tch bnh cha cn thit:
b
mt ck ck
k b
p
p L D
V V
|
|
.
|
\
|
+ =

4
.
2
(1.13)
Trong : D
ck
v L
ck
ng knh v chiu di ca ng t bung chn khng ti
bnh cha, m.
4. Khun c p lc cao.
Khun p trong my c p l c cao kiu bung p ngui nm ngang (hnh
1.10) bao gm hai na khun, na khun c nh 2 hay cn gi l na khun tnh
v na khun ng 16. Sau khi vt c kt tinh, hai na khun tch ri khi
nhau, vt c rt d ri khi na khun ng nhng vn bm cht ly na khun
tnh. Bi vy, cn thit k rut 8 nm na khun ng. H thng rt bao gm
bung p; knh dn E v rnh dn D. Vt dc c tng khi khun tnh nh cc
cht y gn trn tm y s 13. nng cao tui bn ca khun v tng tc
ngui, trn cc tm 20 v 21 cn c thit k cc h thng l m ngui bng nc.
- 17 -
Hnh 1.10. Kt cu b khun c kim loi .
Vt liu ch to khun, rut v cc cht y thng phi c bn, chu ma st
mi mn, dn nhit tt Tha mn cc tnh cht trn ngi ta hay s dng cc loi
thp hp kim nh: 4Cr5W2PPb, SHD61 hoc 3Cr2W8b cho c nhm, magi v
ng thau, dng thp 5CrMnNi c hp kim km. Khun v cc chi tit ca
khun u phi nhit luyn rt phc tp nng cao tnh nng l m vic, nhng b
mt lm vic cn phi mi nhn, nh bng v m Crom, ph Niken. Cng c th
dng cc cng ngh khc nh nhum mu, anot ha hoc photphat ha b mt
khun.
5. Thit b c p lc cao.
a. My c p lc cao:
Trong cc my c p l c cao, loi my no cng bao gm hai b phn
thy lc, mt b phn ng m, mt b phn p kim loi lng. B phn ng m
khun gi l c cu kha khun, b phn p hay c n gi l c cu p. Hu ht cc
my u c c cu kha khun kiu nm ngang. C cu p c th l p thng ng
- 18 -
hoc p nm ngang, ph thuc cch b tr ph ng p. Dn ng cho cc c cu ny
l bm thy lc ku pittng hoc bm kiu cnh. Bm thy lc c th lp trc tip
trn my hoc b tr c lp
Hnh 1.11. M hnh khun c p lc nm ngang.
Cht lng cng tc trong my c p l c thng l du khong vt hoc huyn
ph du nc hoc du khc. Du khong vt c tnh bi tr n v chng n mn
tt, tnh cht lm vic kh n nh, gi thnh thp cho nn c s dng kh ph
bin. Nhc im ca du khong vt l d chy, lm nhim mi trng v t
hn nh tng du nc.
- 19 -
Hinh 1.12. My c p lc bung p ngui nm ngang
tit kim cht lng cng tc l m vic trong iu kin p sut cao, tr n
my ngi ta thng lp thm bnh cha chuyn dng. Bnh cha chu p lc cao,
c lp m kh cho nn ch cn s dng bm hoc ng c in c cng sut nh
cng am bo c p lc lm vic.
Trong sn xut hin nay, my c p lc cao c sn xut theo hai kiu
chnh: my p bung p nng v my p bung p ngui. Trong s cc loi my
bung p nng th kiu bung p nng dng thng ng c s dng rng ri hn
c
My c bung p ngui li c chia ra thnh kiu nm ngang, kiu p
thng ng t di ln , kiu p thng ng t trn xung. c p lc trong bung
p ngui kiu thng ng, p t trn xung (hnh 1.13a), c th coi l phng
php p trc tip. Nguyn l lm vic m t nh sau: Khi pittng 1 i ln, kim lo i
lng c np vo bung p nhng s ng c ngay ti ch tht dng 2 m khng
th i vo hc khun c. Khi Pittng 1 i xung, di tc dng ca p lc cao,
phn kim loi ng c ti ch tht dng 2 s b y xung di v kim loi lng
- 20 -
in y hc khun trong khun c 3. Ph ng php p ny ph hp vi c km,
magi v nhm.
Hnh 1.13. Mt s kiu p bung ngui
C cu c p lc trong bung p ngui kiu thng ng, p t d i ln
c m t nh trn hnh 1.13b, bung p b tr na khun di. Khi pittng 1 i
xung, kim loi lng c np vo bung p. Khi pittng i l n v vt qua l np,
qu trnh in y v p khun bt u xy ra v duy tr cho n khi vt c ng
c hon ton. u nhc im ca phng php ny l vi c s dng mt phn
khun nm ngang .Khi nhc na khun 3, vt c vn kh ng ri xung. Phi s
dng h thng cn y tng vt c ra khi khun. Ph ng php ny c m t
trn hnh 1.13c. Nguyn l lm vi c nh sau : Ban u, chy 2 nm v tr cao
nht, kim loi lng rt vo bung p. Pittng 1 cng vi chy i xung ng thi
to lc p ln kim loi lng, kim loi in y hc khun d i tc dng p lc ca
pittng 1. Thc cht y l phng php p trn xung.
c p lc trong bung p ngui nm ngang, mt phn khun thng ng
(hnh 1.13d). a s cc my c hin i u c thit k theo nguyn tc ny.
- 21 -
Nguyn l hot ng nh sau: Pittng 1 dch sang phi, ngoi l rt, rt kim loi
vo xilanh p 2. Pittng 1 dch chuyn sang pha tri, y kim loi lng v o hc
khun v duy tr p lc p cho n khi kim loi ng c hon ton.
6. Khuyt tt c v cc bin php phng nga.
Mt trong nhng thng s nh gi cht l ng vt c trong cng ngh c
p lc cao l chnh xc ca vt c. chnh xc ca vt c ph thuc tr c
ht vo n nh khe h gia hai na khun m khe h ny li ph thuc vo
n nh ca c cu p v c cu ha khun. mn ca cc chi tit my c cng
nh vic vn hnh v iu khin my c hp l hay khng cng l cc yu t nh
hng n chnh xc ca vt c.
Cng ging nh cc phng php c khc, vt c trong cng ngh c p
lc cao cng c cc khuyt tt c. Trong s cc khuyt tt phi k n dng
khuyt tt b mt v r xp trong vt c. C th tm tt cc dng khuyt tt v
bin php ngn nga trong bng 1.3.
Dng khuyt tt Nguyn nhn Bin php phng nga
Khng lin ng kim loi hoc dng kh
trong khun chy i khng.
Tng tc dng np v p lc
p; gim thi gian in y;
thay i v tr dn kim loi v
vt c kh p lc i khng.
Khng y Kim loi ngui v ng c
qu sm; p lc kh trong
khun qu ln. Thiu kim
loi lng.
Tng nhit rt, tc np v
tc p; t thm mng lc
kh ch vt c dy; tng
dung tch gu nh lng v
bung p.
Vt nt nng Qu nhit kim loi; cu trc Gim nhit rt hoc nng cao
- 22 -
kim loi khng u. nhit khun; kh oxy v
khuy kim loi trc khi rt.
Vt nt xuyn
sut
ng sut do ngui khng
u; l xp ln lm gim
bn trng thi nng; tng
vt c khng u.
Thay i kt cu vt c; tng
din tch rnh hi; tng thi
gian in y khun; thay i
kt cu tng vt c.
B mt li lm
khng u
Tc dng qu nh; tr lc
thy lc trong khun qu
ln.
Tng tc dng v tc p;
thay i kt cu vt c, tng
rnh thot hi.
R co Chiu dy thnh vt c
khng u; hp kim co qu
nhiu.
iu chnh chiu dy vt c;
tng din tch rnh dn, lc p
khun. Gim nhit rt, thay
i hp kim c.
Bng 1.3: Khuyt tt vt c
7. Lnh vc ng dng c p lc cao.
Vt liu ng dng cho c p lc:
V c bn, c p lc cao p dng ch yu d sn xut nhng vt c bng hp
kim nhm, magie, km v ng. Cng c th dng cng ngh c p lc cao c
thp hoc gang nhng rt t v nhit nng chy v t trng ca gang v thp rt
ln.
Do kim loi in y khun v kt tinh trong trng thi p lc nn phng
php c ny rt nhiu u vit .Nhng u im c bn ny: c c vt c thnh
rt mng (0,5 mm), chnh xc, cht l ng vt c rt tt, nng sut lao ng cao.
Trong qu trnh thi t k chi tit c, hai iu cn l u l chiu dy thnh v
tnh ng u ca thnh vt c. Vic la chn chiu dy thnh v kch thc l
trn thnh vt c c tnh quyt nh n c tnh v khuyt tt sinh ra trong qu
- 23 -
trnh c. Cc s liu v chiu dy v kch thc l c c th tham kho tr n bng
1.4 .
Bng 1.4. Chiu dy cho php ca thnh vt c ,mm
Din tch thnh vt c .cm
2
Di 25 25-100 100-250 250-500 Trn 500
Km 0,5 0.8 1.0 1.2 1.8
Magie 0.7 1.0 1.5 2.0 3.0
Nhm 0.8 1.2 1.6 2.2 3.0
ng thau 1.5 2.5 3.0 3.0 -
Bng 1.5. Kch thc l c trn thnh vt c,mm.
ng knh l nh nht.mm Chiu su cc i .mm
Kh nng Nn dng L ct L thng
Km 1.0 1.5 6d 12d
Magie 1.5 2.0 5d 10d
Nhm 1.5 2.0 4d 8d
ng thau 2.5 3.0 3d 6d
- 24 -
CHNG 2
TNG QUAN V CNG NGH CAD/CAM/CNC
V NG DNG.
I. TNG QUAN V CNG NGH CAD\CAM \CNC.
1. Cc chc nng c bn ca h thng CAD\CAM.
Chng ta bit CAD xut hin vo nm 1960, vi cng dng l cng c v
(Drafting Tool). Bi vy, n c gi l cy bt ch in t (Electronic Pencil).
Cho n nhng nm 80 ca th k tr c, v vn l chc nng c bn ca cc phn
mm CAD. Cc cng c v khng ngng c ci tin, c b sung thm cc tin
ch, khin cho cng c v c tin hnh nhanh chng hn, chnh xc hn v gip
cho vic qun l, trao i t i liu thit k c d dng hn. Vi chc nng v th
theo tn gi ban u, CAD ch l cng c tr gip v trn my tnh (Computer Aide
Drafting).
Theo thi gian, CAD c pht trin theo 2 hng:
- Mt mt, CAD c tch hp nhiu chc nng mi. Vi cc tnh nng ho
c trng ca mnh, CAD tr thnh mi trng pht trin cc cng c tnh ton,
phn tch, sn xut (nh tnh ton ng hc, ng lc hc c cu, tnh ton kh
ng, nhit, t; lp trnh cho my CNC, qun l cng ngh,). Ni cch khc,
CAD ngy cng c tch hp nhng chc nng mi. Nh cc chc nng n y m
CAD tr thnh cng c tuyt vi khng ch cho cc nh thit k m c cc nh
kinh doanh, qun l, ngh thut, qun s,Gii k thut ng y nay quen vi cc
thut ng CAE (Computer Aided Engineering), CAM (Computer Aided
Manufacturing). Tuy c chc nng rt khc nhau, cc phm mm CAE v CAM c
- 25 -
c im chung l c pht trin trong mi tr ng ho ca CAD hoc s dng
trc tip d liu ho ca CAD. Mt cch t nhi n, nhiu h CAD, nh CATIA
(ca IBM), Pro/Engineer (ca PTC), Cimatron (ca Cimatron), tch hp trong
nhiu chc nng ca CAM v CAE. Chng thc s tr thnh cc phm mm
CAD/CAM/CAE.
- Mt khc, mt s hng sn xut phm mm CAD khc, nh Autodesk,
SolidWorks Corp (vi phm mm SolidWorks), to ra mi tr ng m, cho php
v khuyn khch tt c cc nh pht trin s dng d liu v cng c iu hnh ca
CAD, to ra cc phn mm CAM v CAE khc. Chin lc hp tc trn c s
chuyn mn ho cho php t o ra cc sn phm phn mm cht l ng cao, gi
thnh h v gii phng cho khch hnh khi s l thuc vo mt vi h nht nh.
D bng cch no th cc chc nng CAM v CAE cng c pht trin trn
nn CAD. Nu khng phn bit cc chc nng CAD, CAM, CAE do h ng phn
mm no to ra (i vi ngi dng th iu khng quan trng) th c th quan
nim ni cc phm mm CAD hin i c tch hp thm cc chc nng CAM
v CAE. Phn sau y gii thch r hn cc chc nng ca CAD hin i.
a. Chc nng m hnh ho.
Cc h thng CAD hin i cho php chng ta m h nh ha hnh hc mt
cch chi tit v hin thc
- 26 -
Hnh 2.1: Xy dng m hnh chn vt khi g t ln bn my
Bn v ng l ngn ng giao tip ca ngi k s, nhng n cha cc hnh
chiu, hnh ct, kch thc, cc ch gii vi nhng quy c m ch ngi k s mi
hiu c v ch dng cho con ngi lu tr hoc trao i thng tin vi nhau.
Bn v l mt ti liu cht. Cn vi m hnh, chng ta c th tho, lp, quan
st t cc gc , c ly khc nhau, c th tra khi l ng, th tch ca cc chi tit
hoc cm chi tit; c th vn hnh n kho st ng hc. Quan st trn hnh
2.1 do kch thc ca bn my c hn nn cn phi tnh ton m phng vic g lp
khi chn vt v g m bo cho dao c th qut ht bi n dng chn vt. Sau
c th xy dng bn v lp mt cch d dng. V hn th na gia m hnh v cc
bn v c to t n c mi quan h vi nhau: mi chnh sa trong m h nh s
c cp nht vo bn v v ngc li. Di y l mt ng dng khc ca m
hnh ha hnh hc
- 27 -
Hnh 2.2: M phng qu trnh gia cng.
M hnh ha hnh hc khng ch dng li mt chi tit hay cm chi tit m
chng ta hon ton c kh nng xy dng c m hnh ca c mt my cng c,
g, v thc hin qu trnh m phng qu trnh gia cng trn m hnh thc t o.
Trong qu trnh m phng chng ta c th thu thp c cc hin tng c th gp
thc t v a ra phng n gi i quyt. Hnh 2.2 m phng qu trnh gia cng chi
tit s dng trung tm gia cng ca h ng Decken Maho. Trong qu trnh m phng
chng ta khng ch quan st c ng chy dao, thi gian gia cng v cn pht
hin dao n lm c g t a ra phng n iu chnh hp l.
b. Chc nng v CAD
To bn v k thut vn l chc nng khng th thiu c ca CAD. Cc phn
mm CAD hin i c 2 cng c gip to ra cc bn v k thut.
Dng chc nng Sketch
Sketcher l cng c phc tho, c nhim v chnh to ra cc Profile 2D hoc 3D
t hnh thnh cc m hnh vt c (Solid) hoc b mt (Surface). Tuy nhin,
- 28 -
do k tha c cc cng c v ca CAD truyn thng, li c b xung thm cng
c tham s ha, Sketcher ca CAD hin i tr th nh cng c v mnh v linh hot
to ra cc bn v k thut. Ngi ta thng dng Sketcher to cc bn v n
gin.
To bn v t m hnh
Trong CAD hin i, bn v l s biu hin bng ngn ng k thut ca m hnh.
V vy, cch thng thng nht to bn v l xut trc tip cc hnh chiu, hnh
ct t m hnh. V vy, ngoi cch gi thng thng (Draw) bn v cn c tn khc
l Lay Out. T mt m hnh c th to nhanh chng t mt hay nhiu bn v.
Gia m hnh v cc bn v c to t c mi li n h qua li. Mi thay i t
m hnh s c cp nht sang bn v v ngc li.
Hnh 2.3: To bn v t m hnh.
c. Chc nng phn tch CAE.
l chc nng tnh ton ng hc, ng lc hc, nhit, ng sut, bin
dng,ca cc chi tit, c cu, thit b v h thng. Cc cng c tnh ton, phn
tch trn xut hin c lp vi CAD, nhng c tch hp vo CAD tn dng
- 29 -
kh nng ho k thut ngy cng mnh ca n. S tch hp cc
chc nng phn tch vo CAD lm xut hin mt thut ng mi: CAE ( Computer
Aided Engineering).
Hnh 2.4: ng dng CAE tnh ng sut cho chi tit my .
Trn hnh 2.4 ta ng dng CAE trong vic tnh ton ng xut cho chi tit my.
Phn mm cho php chng ta xc nh c ng sut ti tt c cc v tr tr n chi
tit. Cn c vo kt qu trn ta c th iu chnh kch thc, kt cu cho ph hp.
Phn ln h CAD c chc nng tnh ton cc b truyn c kh thng dng, nh
bnh rng, xch, ai, cam, km theo th vi n chi tit tiu chun, nh ln, vng
bt, trc, chi tit kp cht, chng c n c th ni ghp cc modul chuyn dng,
nh thit k khun, thit k ng ng, thit k chi tit v mng,
d. Chc nng CAM.
CAM xut hin mt cch c lp vi CAD, nhm mc ch ri ng l tr gip
lp trnh cho my NC. Xu hng tch hp CAD/CAM ny sinh t nhng nm 70
ca th k trc tn dng mi trng ho hp dn ca CAD. Hin nay phn
- 30 -
ln cc h CAD hin i u c chc nng CAM v tr thnh cc h CAD/CAM.
Chc nng CAM c hnh thnh trong CAD theo hai hng nh phn tch
u chng.
- Theo hng th nht, cc nh sn xut phn mm CAD b xung thm chc
nng CAM vo sn phm CAD ca h to cc phn mm CAD/CAM thng
nht. l trng hp ca cc phn mm Pro/Engineer, Cimatron, CATIA ...
- Theo hng th hai, cc nh chuyn vit phn mm CAM pht trin cc Modul
CAM trn nn ca cc phn mm CAD ca h ng khc. Bng cch ny, cc sn
phm CAD/CAM k tha c tinh hoa ca cc hng sn xut hng u th gii
trong c 2 lnh vc. V d, hng Pathrace chn cc phn mm CAD c u
chung nht th gii, nh Mechanical Desktop, Inventor, Solid Work pht trin
phn mm EdgeCAM ca h. Kt qu l sinh ra cc t hp CAD/CAM lai
(EdgeCAM for Mechanical Desktop, EdgeCAM for Inventor, EdgeCAM for Solid
Work) tt hn nhiu so vi phn mm EdgeCAM chnh gc ca Pathrace.
Hnh 2.5: Lp trnh gia cng khun gh nha.
- 31 -
2. Chc nng c bn ca h thng iu khin s.
a. Khi nim v iu khin s (NC)
Theo nh ngha ca Hip Hi Cng Nghip in T ( Electronic Industries
Association - EIA), iu khin s (Numerical Control - NC) l h thng trong cc
hot ng c iu khin trc tip bi d liu s. iu khin s l mt hnh thc
t ng ho bng lp tr nh, trong my cng c c iu khin bi chng trnh
bao gm cc ch th c m ho di dng k t ch, s v cc k t c bit
khc. Ch th iu khin c chuyn i thnh hai dng tn hiu: tn hiu xung in
v tn hiu ng / ngt (ON/OFF). Tn hiu xung in iu khin tc ng c
truyn ng to nn di chuyn tng i gia dao ct v chi tit gia cng. Tn hiu
ON/OFF thc hin chc nng chuyn mch, i chiu quay trc chnh; iu khin
cc thit b ph tr nh cung cp cht bi trn v lm ngui, chn v thay dao v
cc chc nng khc nh dng my kp phi, nh phi,
iu khin s trc tip.
Gia nhng nm 60, cc hng Cincinnati Milacron v General Electric chng
minh kh nng iu khin trc tip my cng c iu khin s t b n ngoi bi my
tnh thc hin chc nng lp tr nh truyn chng trnh, iu khin qu trnh gia
cng. Phng thc iu khin ny gi l iu khin s trc tip.
iu khin s bng my tnh
- 32 -
C th ni, k thut iu khin s bng my tnh ( Computer Numerical Control -
CNC) c pht trin t ng dng iu khin s trc tip khi nhng th nh tu ca
cng ngh vi in t, vi x l cho thit lp trc t ip my tnh trn h iu khin my
(Machine Control Unit - MCU) iu khin my NC. V t , hnh thnh
phng thc iu khin v th h my iu khin s bng my tnh ( my CNC). Do
c th nh ngha CNC l h thng NC s dng my tnh thit lp tr c tip trn
h iu khin my v
c iu khin bi cc
ch th lu tr trn b
nh my tnh thc
hin mt phn hoc
ton b cc chc nng
iu khin s.
iu khin s phn
phi.
c trng ca iu
khin CNC l kh nng
thc hin lu tr ng
thi nhiu chng trnh
trn b nh, cho php
vn hnh my CNC khng ph thuc vo my tnh ch thc hin nhim v khc
ca h thng. Vo nhng nm u ca thp k 80, kh nng ca CNC c ng vi s
pht trin ca khoa hc my tnh, k thut truyn thng, phn phi, trong c
mng my tnh c s dng phi hp hot ng ca nhiu my CNC.
Ngoi chc nng truyn chng trnh ti cc my CNC, h thng iu khin
s phn phi c kh nng gim st v iu khin ton b h thng, nh hin th
Hnh 2.6 : iu khin s phn phi.
- 33 -
thng tin v trng thi lm vic ca h thng, xut thng tin hay ch th iu khin,
iu hnh,
b. iu khin s bng my tnh (CNC)
Cu trc h thng CNC
H thng CNC bao gm 6 thnh phn chnh: chng trnh gia cng (part
program); thit b c chng trnh (program input device); h iu khin my
(MCU); h thng chuyn ng (drive system); my cng c; h thng phn hi
(feedback system).
Chng trnh gia cng bao gm cc ch th c m ho (m lnh) iu
khin qu trnh gia cng chi tit. H iu khin chuyn i cc ch th ny thnh tn
hiu in kch hot cc chc nng hot ng ca my.
H iu khin my (MCU) thc hin chc nng c v bin dch m lnh iu
khin v sau xut cc tn hiu in tng ng. Nhng tn hiu iu khin ny
c truyn ti b khuch i servo iu hnh c cu servo (ng c in hoc
ng c thu lc). Hot ng ca c cu servo cho php nh v tr chnh xc bn
my hoc trc chnh theo h thng truyn ng, thng thng l b truyn vitme
ai c bi. Thit b phn hi (gn trn ai c bi) cm bin v tr, chiu, tc dch
chuyn v phn hi cc tn hiu ny v h iu khin my. H iu khin my so
snh cc tn hiu ny vi tn hiu tham chiu cho trc bi cc m lnh iu khin
v xut cc tn hiu tham chiu cho trc bi cc m lnh iu khin v xut cc tn
hiu iu chnh ti b khuch i servo cho ti khi t v tr yu cu.
H thng truyn ng: thng thng bao gm b khuch i servo, c cu
servo, b truyn ai c vitme bi v bn trt. H thng ny quyt nh chnh
xc, cng sut ca my.
Kh nng ca CNC
So vi NC (iu khin bi mch c nh), CNC (iu khin bng phn mm)
c nhiu chc nng s l v iu khin linh hot hn:
- 34 -
- Hin th chng trnh v m phng bng ha qu trnh gia cng: Mn hnh
iu khin vi cu hnh c bn c kh nng hin th thng tin v thng s vn hnh
nh v tr, lng chy dao, tc trc chnh, cng nh gi tr cc tham s, trong
qu trnh thc hin chng trnh. H thng ha trn cc h iu khin hin i
cn cho php kh nng quan st chi tit, dao ct v m phng ng chy dao trc
tip trong qu trnh gia cng.
- Nhp d liu: Hu ht cc h CNC c trang b bn phm vi y cc k
t c th nhp d liu bng tay. Ngoi ra, cc thit b c bng v cng RS 232-C
hoc b kt ni mch iu khin vi cng 20 mA cho php nhp chng trnh
gia cng t cc thit b ngoi vi v xut chng trnh v my tnh lu tr trn b
nh hoc bng c l.
- Lu tr chng trnh: C hai loi b nh c s dng cho h iu khin :
ROM v RAM. Chng trnh h thng c lu tr trn ROM v ch c th xo b
bi thit b c bit. Chng trnh gia cng c lu tr trn RAM. D liu trn
RAM c th b xo b khi ngun in b mt, tuy nhin c th s dng pin lm
ngun d tr v c th bo ton chng trnh gia cng ngay c khi tt h iu khin.
- Bin tp chng trnh: Sau khi nhp chng trnh t thit b ngoi vi, c th
thay i hoc cp nht chng trnh ny ngay trn h iu khin v lu tr trn
RAM. Chc nng ny hn ch vic lm li bng khc, nh thng c thc hin
trn cc my truyn thng.
- Kim tra chng trnh: Nhiu h iu khin CNC hin i c trang b chc
nng m phng chng trnh (hin th ho ng chy dao v cc chc nng ph
tr nh ngha trong chng trnh gia cng) trc khi gia cng thc hin trn my.
- Chun on li: Phn mm chun on ci t trn h iu khin gim st mi
ch vn hnh v chc nng ca h thng CNC. Nu chng trnh d c li ,
th d nh li chng trnh, li vn hnh hoc li trong c ch servo, tn hiu bo
ng hoc thng bo thch hp s c hin th trn mn hnh.
- Tin ch giao tip: H iu khin CNC c kh nng giao tip vi cc thit b
s l khc nh my tnh, h iu khin robot v cc thit b iu khin lp trnh
- 35 -
logic (PLC). Kh nng ny cho php nhp chng trnh gia cng t my tnh ch
hoc mng my tnh, lin kt vi thit b my tnh trong iu khin s phn phi v
h thng sn xut linh hot.
- Qun l d liu: Do c kh nng iu khin hu ht cc chc nng hot ng
ca h thng bi my tnh thit lp trong MCU, h iu khin CNC c th qun l
v cung cp cc thng tin quan trng nh thi gian quay trc chnh, thi gian gia
cng, thi gian chy my v s lng chi tit gia cng cho cc chc nng phn tch.
- H to v h n v: Phn ln cc h iu khin CNC cho php s dng c
hai phng thc o to tuyt i v tng i trn cng mt chng trnh gia
cng v hu ht cc h iu khin CNC cho php s dng c hai h n v inch v
mt.
- nh dng m iu khin: Phn ln cc h iu khin CNC c th hot ng
vi c hai m EIA v ASCII.
- Kh nng tnh ton: Ngoi kh nng thc hin cc php tnh s hc, cc chc
nng iu khin (r nhnh v lp li), cc hm logic, nh ngha v thao tc vi cc
bin, cc h iu khin CNC u c kh nng lp trnh macro. Chc nng ny c
bit hu ch khi qui trnh gia cng c tnh lp li nh phay phng, phay ph, hay qu
o gia cng nh ngha bi quan h ton hc. Lp trnh macro rt ngn ng k
chng trnh gia cng do hn ch lp li cc m lnh cho cc kiu ng chy dao
tng t.
- B tr ng knh v chiu di dao: Chc nng ny cho php bin tp
chng trnh theo kch thc chi tit gia cng m khng cn quan tm ti ng
knh v chiu di ca dao, do cho php s dng cng mt chng trnh gia cng
cho cc bc gia cng th v tinh vi dao kch thc khc nhau.
- Ni suy hnh hc: Trn cc h NC truyn thng chc nng ni suy c thc
hin bi mch in t, trong khi CNC s dng kh nng ca b vi x l thc
hin ni suy thng qua phn mm. Phng php ni suy thng dng nht trn phn
ln cc h NC v CNC l ni suy ng thng v cung trn. Mt s h CNC hin
i c c chc nng ni suy parabol, ng xon v ng cong bc 3.
- 36 -
- Chc nng lp trnh: c thit lp trn c s vi x l, cc h CNC c kh
nng thc hin chc nng tnh ton, do c th thc hin mt s chc nng lp
trnh nh thu phng hnh, to nh i xng, xoay hnh.
- Kh nng hu x l: Mt s h CNC hin i c kh nng hu x l
(postprocessing) tip nhn trc tip d liu v qu o chy dao di dng m
nh phn (Binary Cutter Location -BCL). Vi my c b hu x l ci t trn b
nh h iu khin, khng cn b hu x l ngoi tuyn. Phng thc hu x l ny
c thc hin trong thi gian thc (real time) trong qu trnh thc hin chng
trnh gia cng v yu cu dung lng b nh nht nh cng nh cc kh nng x l
logic khc.
u im ca CNC
T nm 1952 khi my phay NC u tin c phng th nghim c cu MIT
gii thiu thnh cng, cho ti nay k thut CNC to nn cuc cch mng trong
k thut ch to, vi nhng u im chnh nh sau :
- Nng cao nng sut: Nng sut ca my CNC thng cao gp 3-4 ln so vi
my truyn thng cng loi; thi gian chun b my, thi gian dng my v thi
gian kim tra t hn.
- chnh xc v chnh xc lp li cao: chnh xc l s o s khc bit
gia v tr nh v dao ct so vi v tr yu cu. chnh xc lp li l kh nng ca
my lp li chnh xc ca chng. My CNC vi h iu khin vng kn c kh
nng gia cng vi chnh xc lp li v hnh dng cng nh kch thc. Chc
nng ny cho php ch to cc chi tit lp ln vi lng vt liu tiu hao v thi
gian gia cng thp nht.
- H gi thnh sn xut: S dng my CNC cho php gim gi thnh gia cng
do tit kim dao, g,; tng tui th dao ct do s dng ch gia cng ti u;
tit kim do ph liu v cng vic lm li t; tit kim v chi ph lao ng do yu
cu k nng thp v nng sut lao ng cao; tit kim do c th ti s dng chng
trnh gia cng; gim ton b thi giam sn xut; h s s dng thit b cao thi gian
- 37 -
dng my t; gim vic vn chuyn phi liu bng phng php th cng v nhng
sai st do con ngi gy ra cng c gim nhiu.
- Gim gi thnh iu hnh gin tip: Qu trnh gia cng trn my CNC c
thc hin t ng theo chng trnh lp.
II. THC TRNG VIC NG DNG H THNG
CAD/CAM/CNC TI VIT NAM.
1. Khi qut v h thng CAD/CAM/CNC c mt ti Vit Nam.
S h CAD/CAM c mt Vit Nam c th n vi chc, trong c sn phm
ca cc nh cung cp ni ting bc nht th gii. Trong phn nghin cu ca em ch
tm hiu mt s h c bit n nh CATIA, Cimatron, Pro/Engineer,
SolidWorks.
- Pro/Engineer l sn phm ca PTC (Pramachic Technology Corp). y l
hng ln, c b dy v doanh thu cao trong th trng CAD th gii. Mi cng vic
v c kh: thit k thng thng, khun, phn t hu hn, lp rp, CAM (lp trnh
cho my phay ti 5 trc, tin vi trc C, ct dy,) u c th thc hin trn Pro/E
v cc Modul m rng ca n. Nhc im ln nht ca Pro/E l rt kh hc v
kh s dng. Cc phin bn trc ca Pro/E chy trong Unix. Gn y PTC cho ra
cc phin bn Windows v k t phin bn Pro/E 2000i rt c gng ci tin giao
din ngi dng theo chun Windows. Cc phin bn Pro/E Wildfire (phin bn
mi mt l Pro/Wildfire 4.0 M080) ra i th hin bc tin ng ghi nhn v
giao din ngi dng ca Pro/E. Tuy nhin, ngay c trong cc phin bn mi ca
Pro/E, kh nng s l ti nguyn cn hn ch. Cng mt cng vic, Pro/E i hi
cu hnh phn cng my tnh my cao v chy kh nng n.
- Catia mt trong nhng phn mm c coi l mnh nht i trong lnh vc
CAD/CAM. S tch hp ca rt nhiu modul khc nhau p hc v nhiu lnh vc sn
xut l yu im ln nht ca phn mm , Cng cc cng c to mt a dng, kh
nng thit k, tch khun, gia cng nhanh a Catia thnh mt s hng cho cho
- 38 -
tt c k s CAD/CAM. Nhc im ln nht ca phn mm l dao din cng
nhc, khi chy tn nhiu t i nguyn my.
- Cimatron l sn phm ca hng cng tn (Israel), c tnh nng v c im
tng t ca Pro/E. l phm mm m hnh ho 3D mnh, c bit v thit k
khun mu, m hnh ho v gia cng b mt. Cc phin bn trc ca Cimatron
cng rt kh dng. Bt u t phin bn 12, giao din ca Cimatron cng c ci
tin mt cch tch cc theo chun Windows.
- SolidWork v AutoDesk l hai hng sn xut phn mm ni ting th gii,
sm cho ra cc phin bn Windows:
+ SolidWork l sn phm ca hng cng tn (SolidWork Corp). u
im ln nht ca n l giao din rt thn thin, cc phn tr gip y v gi c
phi chng. Nhc im ca SolidWord l chc nng v (Draft) v m hnh ho b
mt hn ch, khi chy tn nhiu tim nng ca my tnh. Phi n bn mi nht ca
hng l SolidWork 2008.
+ AutoDesk c 2 sn phm thit k c kh chuyn dng l
Mechanical Desktop (MDT) v Inventor.
Mechanical Desktop (MDT) chy trn nn AutoCad nn mi giao din tng
t ca AutoCad, c ngi s dng hoan nghnh khi h mun chuyn t mi
trng CAD truyn thng sang m hnh ho 3D.
Inventor chy c lp, s dng cng ngh tin tin. Ngoi cng ngh tham
s, hng i tng nh cc phn mm khc, Inventor ln u trnh din cng ngh
thit k thch nghi. Chc nng qun l theo Project cho php thit k v qun l cc
c lp rp ln. Giao din ngi dng ca Inventor rt hon chnh, thn thin, tin
dng v hp dn. H thng thanh cng c ca Inventor c thit k gn, thng
minh, cho php ngi dng gim thiu v s ln bm chut. Bn cnh Inventor
c h thng tr gip kh y , phc v tt cho mi lp ngi dng. Bn thn
MDT v Inventor l phm mm CAD/CAE ch c chc nng thit k thng thng:
m hnh ho Solid v b mt, phn t hu hn, th vin c kh, tnh cc b
truyn, Cc chc nng c bit khc, nh khun, CAM, c tch hp t cc nh
- 39 -
pht trin th 3 (MAI). u im ln nht ca cc phm mm ny l d s dng,
giao din ngi dng thn thin. Gi c ca chng thuc loi thp.
Giao din ngi dng l mt ch tiu ht sc quan trng, v c mt thc t l
nhiu nh thit k gii li khng gii v my tnh. Hn na, giao din tt cho php
tng nng sut thit k n 200%. MDT, Invent or v SolidWork to ra mi trng
lm vic thoi mi cho ngi dng nh cc h thng giao din nhiu knh, t thanh
v hp cng c n menu chun v g phm, phm g tt, H thng nh vy p
ng tt cho c ngi dng chuyn v khng chuyn.
2. Khi qut v h thng CAD/CAM/CNC ph bin ti Vit Nam:
Nh vy ta i tng quan v cc h thng CAD/CAM c mt ti Vit Nam,
y cha phi l danh sch hon thi n nhng cng th hin kh r s a dng ca
h thng. S a dng v pht trin su rng ca cc h thng CAD/CAM ti cc c
s sn xut ti nc ta h tr mnh m cho cc h thng my iu khin s
CNC. Cc c s sn xut v ang trang b cho mnh nhng trung tm gia cng v
nhng u vit ca n. Tuy vy mt thc trng chung l gi thnh ca cc phn
mn CAD/CAM v h thng my gia cng i u khin s thng c chi ph rt cao,
nn cc c s sn xut ch thng nhp v nhng h thng my qua s dng.
Nhng my ny thng khng chc nng, gy sai s, v khng th t nng sut
yu cu.
- 40 -
CHNG 3
THIT K V CH TO B KHUN C P
LC CHO CHI TIT UI MANG C.
I. TM HIU V KIM TRA TNH HP L CA CHI TIT
UI MANG C .
1. Kim tra tnh hp l ca chi tit ui mang c .
Tm hiu chi tit ui mang c:
Tn chnh xc : CHAIN CASE COVER
Vt liu ch to: ADC12
S lc v vt liu hp kim gc nhm ADC12 hay ng hn l ADC12* l
hp kim nhm chuyn dng dng c vi khun kim loi Die Casting . ADC12*
ty theo thnh phn ha hc ( Cu ) s c chia lm 2 loi (theo quy cch JIS ca
Nht) l ADC12-F v ADC12Z-F .
Do c thnh phn Cu nn c tnh v co gin trong khi c v gia cng rt tt.
1) Thnh phn ha hc ca ADC12* nh sau :
Thnh phn Si chim t 9.6 n 12%
Fe------------1.3%
Cu------------1.5 n 3.5%
Mn------------0.5%
Mg------------0.3%
Zn------------ 1%
Ni-------------0.5%
Sn -----------0.3%
2) Tnh cht vt l :
Mt : 2.7 mg/m3
Nhit nng chy: 580
0
C tr ln.
Nhit kt tinh : 515
0
T nhit (20
0
C) : 963(J/kg.C)
H s truyn nhit (20
0
C) : 92 (W/(m.C)
- 41 -
3) Tnh cht c kh : (tiu chun nhit phng 25 C)
ko tiu chun : 195 - 295 N/mm
2
ko ti a : 295 N/mm
2
H s chu lc khi thit k: 185 N/mm
2
H s gin khi ko theo phng thng : 2%
H s va p sharubi : 81 kj/m
2
H s mi vt liu ti a khi thit k : 140 N /mm
2
H s n hi khi thit k : 26.5 kN/mm
2
(Thng s thc nghim ca JIS da theo ASTM ti u chun khun st vi mu
th thc nghim theo quy cch mu vt liu F. mi vt liu c o vi
my c tay n quay MAKINO vi s ln quay un 500 triu ln, s l ng
mu th thc nghim ly thng s : 18 mu. Tham kho theo t i liu ca
Honda Casting v JIS) .
Tnh cht c kh ca vt liu trong trng thi nhit cao v thp ( thc
nghim duy tr lin tc trong 10000h nh sau ):
Nhit ch to ( C)
Lc ko ti a (N/mm2) --------- co gin (%)
150------------------ 261 ..........................2
205 ----------------- 178 --------------------6
260------------------ 96 ------------------ 25
315----------------- 48 -------------------45
370----------------- 31 ------------------ 45
Bn v k thut.( xem ph 1)
Kh nng ng dng cng ngh c p lc cao cho chi tit ui mang c
Cn c vo hnh dng hnh hc, c im lm vic ca chi tit ta thy rng kh
nng p dng cng ngh c p lc cho chi tit ui mang c ta thy l hon ton c
c s. Phng n ny c mt s u im nh sau:
Cho php c c hnh dng phc tp ca chi tit
Gim c lng d gia cng v thi gian gia cng c bn.
m bo tnh thm m ca chi tit.
m bo c tnh cho chi tit.
- 42 -
II. XY DNG M HNH CHI TIT TRN PHN MM
Pro/wildfire.
Khi ng Pro/Wildfire bng cch nhp vo biu tng trn mn hnh
Desktop, hoc c th thc hin theo ng dn sau: Start / programs / PTC / Pro
Engineer / Pro Engineer. Giao din ca chng trnh nh hnh 3.1
- Chn New t Menu File hp thoi New xut hin vi vic chn trc Part
Solid. Ti Name: duoimangca. Sau la chn Use default template bng cch
kch chut vo u dng. Trong Option ca Template chn mmns_part_solid.
- Mi trng lm vic ca Pro/Wildfire 4.0 nh hnh 3.2.
Xy dng ng curve l ng dn cho bin dng knh ln c thc hin
nh sau: Nhp chut vo biu tng (sketch) trn thanh cng c Datum. Chn
Top l mt phng v phc tho ( Sketch plane) nhp vo biu tng Sketch chp
nhn hng nhn mc nh.
- Trn mi trng Sketch ta s dng lnh Line bng cch Click vo biu tng
trn thanh Sketch tools xy dng thit din nh (hnh 3.3). thay i kch
thc ta Click 2 chut vo kch thc cn chnh sa v nhp gi tr. Hoc c th
Hnh 3.1: Giao din ca chng
trnh Pro/Wildfire
Hnh 3.2: Mi trng lm vi c
ca Pro/Wildfire
- 43 -
nhp vo biu tng Modify Dimesion trn thanh cng c Sketch. Kt thc
lnh v sketch ta kch vo biu tng ( true).
- To mt phng DTM 1 cch mt phng Right mt khong bng 45, c thc
hin nh sau: Kch chut vo biu tng (datum plane) hoc thc hin theo
ng dn Main menu / Insert / Model Datum / Plane. Click v o mt phng Right,
nhp gi tr 45mm l khong cch offset gia Datum 1 vi mt Righ t. Nhn OK
hon tt. Nh hnh 3.4 di.
S dng cng c Sketch xy dng bi n dng nh hnh di bng cch kch
vo biu tng (sketch) trn thanh cng c. Chn mt phng v phc (Sketch
plane) l DTM 1, nhp chut gia bt u xy dng thit din. S dng cng c
line v arc xy dng thit din nh hnh 3.5. Kt thc ta kch vo biu tng
( true).
- S dng cng c Sketch xy dng tit din cong bng cch kch v o biu
tng (sketch) trn thanh cng c. Chn mt phng v phc (Sketch plane) l
Font, nhp chut gia bt u xy dng thit din. S dng cng c Line xy
dng thit din nh hnh 3.6. Kt thc ta kch vo biu tng ( true).
Hnh 3.3:Xy dng Sketch
Hnh 3.4: To mt DTM1
- 44 -
Hnh 3.5 Hnh 3.6
Thng qua cc cng c to Sketch ta c m hnh khung dy nh hnh 3.7
di, m hnh khung dy ny c s dng to b mt cho chi tit bng lnh
Blend boundary.
Hnh 3.7: M hnh khung dy.
Nhp chut vo biu tng Boundary Blend Tool khai bo cc thng s
nh hnh. Kt thc ta kch vo biu tng ( true).
Hnh 3.8: Dng mt bao cho m
hnh khung dy.
Hnh 3.9: Xy dng thit din
ph mt u
- 45 -
Chn DMT1 l mt phng v phc, ta kch vo biu tng Sketch (sketch)
trn thanh cng c, s dng lnh Line v xy dng m h nh nh hnh 3.9 di.
Kt thc ta kch vo biu tng ( true).
Kch vo biu tng Fill Tool ph mt ln tit din va to
Tng t ta cng ph mt bn cn li v mt y, bng cch xy dng bng
lnh Sketch v lnh Fill Tool, ta c kt qu nh hai hnh 3.10
Ta kt hp cc mt va to bng lnh Merge bng cch kch vo biu
tng .Gi phm Ctrl click chut vo hai b mt gn nhau sau click vo biu
tng (Merge tool) hoc thc hin theo ng dn Main menu / Edits / Merge
nhp vo biu tng OK khi kt thc.
Hnh 3.11: Lin kt cc mt va ph.
Hnh 3.10: Ph mt cho cc thit din va to
- 46 -
To mt phng DTM 3 cch mt phng Top mt khong bng 43, c th
hin nh sau: Kch chut vo biu tng (datum plane) hoc thc hin theo
ng dn Main menu / Insert / Model Datum / Plane. Click vo mt phng Top,
nhp gi tr 43 l khong cch offset gia DTM 3 vi mt Top. Nhn OK ho n
tt.
To Sketch t mt DTM 3 bng cch click v o biu tng (sketch) trn
thanh cng c ta xy dng c tit din nh hnh.
S dng lnh Line v cng c chnh sa kch thc Modify Dimesion
trn thanh cng c Sketch. Kt thc lnh v sketch ta kch vo biu tng
( true).
S dng lnh Extrude nng thit din va to bng cch click chut v o
biu tng Extrude v khai bo cc thng s nh hnh 3.12
Hnh 3.12: Xy dng m thit din, khi n cho phn li.
To phn ht lng cho b mt trn ca chi tit bng cch s dng lnh Draft
c thc hin nh sau: kch chut vo biu tng (Draft Tool) hoc thc hin
theo ng dn: Main menu / Insert / draft. Khai bo cc thng s nh hnh 3.13a.
Kt thc nhn OK.
- 47 -
Tng t ta thc hin ht l ng cho hai mt bn, cc thng s c khai bo
nh hnh 3.13b di.
(a) (b)
Hnh 3.13: To ht lng cho phn li.
Thc hin bo cc mt bn ca chi tit bng cch s dng lnh Round, c thc
hin nh sau: Kch chut vo biu tng (Round Tool), chn bn knh gc bo l
25, sau kch chut vo cc cnh cn bo ta s c kt qu nh hnh 3.14a sau:
Vt mp cho cc cnh bng cch s dng lnh Chamfer, c thc hin nh sau:
Kch chut vo biu tng (Chamfer Tool) hoc thc hin theo ng dn: vo
Main menu / Insert / Chamfer / Edge chamfer. Ch n cnh cn vt mp v khai bo
cc thng s nh hnh 3.14b. Kt thc lnh v sketch ta kch vo biu tng ( true).
(a) (b)
Hnh 3.14: Bo gc cho phn li.
- 48 -
- Dng lnh sweep to g li cho chi tit, c thc hin nh sau: Main
menu / insert / sweep / protrusion . khai bo ng dn cho php ta ko tit din
(trajectory ) ta chn Sketch traj sau chn mt v phc tho (Sketch plane) l mt
Top xy dng ng dn nh hnh 3.15. Ta chn Done tip tc khai bo cc
thng s cn li.
- Trong la chn attributes ta chn No inn Fcs (dnh cho thit din kn v ng
dn kn). Nhn Done khi kt thc.
- Xy dng thit din cho php qut hnh (section). S dng lnh Line v cng
c thay i kch thc (modify dimensions) xy dng thit din nh hnh 3.16 .
Nhp vo biu tng ( true) khi kt thc.
Hnh 3.15: To ng dn Sweep Hnh 3.16: To Thit din Sweep.
To v mng cho khi bng cch s dng lnh shell, thc hin nh sau: nhp
chut vo biu tng (Shell Tool) v khai bo cc thng s nh hnh 3.17.
Nhp vo biu tng ( true) khi kt thc.
- 49 -
Hnh 3.17: To ht lng cho phn li.
To mt phng DTM 4 bng cch offset t mt phng Top mt khong 18. Thc
hin nh sau: chn mt Top lm mt phng gc, click vo biu tng (Datum
plane) trn thanh cng c, nhp gi tr offset l 13. Nhp vo biu tng OK khi kt
thc.
To khi n t mt phng DTM 4 bng cch click vo biu tng Sketch. Xy
dng thit din sau s dng lnh Extrude nng thit din va to bng
cch click chut vo biu tng Extrude.Chn chc nng nng ti mt v khai bo
cc thng s nh hnh 3.18
- 50 -
Hnh 3.18
T mt phng DTM 3 to thit din nh hnh 3.19 , s dng cc cng c Line v
Circle. Nhp vo biu tng ( true) khi kt thc.
Hnh 3.19: To thit din trn Hnh 3.20: To khi n.
mi trng Sketch
Nng tit din va to bng chc nng Cut Extrude khai bo thng s nh hnh
3.21. Hng mi tn th hin hng ly vt liu. Nhp vo biu tng ( true)
khi kt thc.
- 51 -
To mt phng DTM 5 bng cch Offset t mt phng DTM 4 mt khong bng
4, thc hin nh sau: Nhp vo biu tng (Datum plane), chn mt gc l
DTM 4, nhp g tr offset l bng 4.
T mt DTM 4 ta to thit din nh hnh 3.21a bng cch kch chut vo biu
tng (sketch), Sau nng thit din va to, s dng cng c Extrude, thc
hin nh sau: Click vo bi u tng ( Extrude Tool ) chn ch nng ti mt
cong. Nhp vo biu tng ( true) khi kt thc.
(a) (b)
Hnh 3.21
Chn mt Top xy dng tit din nh hnh 3.12a. Sau s dng lnh Extrude
nng tit din va to, thc hin nh sau: Nhp vo biu tng ( Extrude Tool
) trn thanh cng c hoc thc hin theo ng dn: Main menu / insert / Extrude.
Kch chut chn thit din va to s dng chc nng nng ti m t y. Nhp vo
biu tng ( true) khi kt thc. Ta c kt qu nh hnh 3.22.
- 52 -
(a) (b)
Hnh 3.22: To khi n cho mt bn.
Chon Top l mt phng v phc ta dng thit din nh hnh 3.23 di bng
cch click vo biu tng ( sketch), s dng lnh Line v Fillet. S dng lnh
Extrude nng tit din va to bng cch click vo biu tng ( Extrude
Tool ) trn thanh cng c hoc thc hin theo ng dn: Main menu / insert /
Extrude . Nhp vo biu tng ( true) khi kt thc ta c nh hnh Hnh
3.23b
(a) (b)
Hnh 3.23.
- 53 -
xy dng b mt lp rp cho chi tit ta s dng lnh Cut extrude, thit din ct
c v t mt Front, khai bo cc thng s nh hnh 3.24, hng mi tn ch
hng ly vt liu. Nhp vo biu tng ( true) khi kt thc.
Hnh 3.24 Hnh 3.25
Thc hin tng t vi mt lp rp cn li, thit din cng c to t mt
Front, cc thng s c khai bo nh hnh 3.25. Nhp vo biu tng ( true)
khi kt thc.
to gn cho chi tit ta s dng lnh Extrude, thit din c xy dng trn b
mt chi tit va c ct. Cc thng s c xy dng nh hnh.Ta c kt qu
nh hnh 3.26.
Hnh 3.26: To gn Hnh 3.27. To gc ht lng
- 54 -
to gc thot khun cho cc gn ta s dng lnh Draft bng cch click vo
biu tng (Draft tool) hoc thc hin theo ng dn: Main menu / Insert /
Draft.
Khai bo cc thng s nh hnh 3.27. Nhp vo biu tng ( true) khi kt
thc.
Thc hin tng t i vi gn bn kia ta cng c kt qu nh hnh 3.28
Hnh 3.28:To gn cho chi tit.
Trn mt DTM 5 ta to tit din nh hnh 3.29a bng cc cng c Sketch. S dng
lnh Extrude nng tit din va to vi b mt y, khai bo cc thng s nh
hnh 3.29b
(a) (b)
Hnh 3.29.
- 55 -
to gc thot khun cho khi va nng ta s dng lnh Draft, cc thng s
c khai bo nh hnh 3.30. Nhp vo biu tng ( true) khi kt thc.
Hnh 3.30: To gc thot khun.
Ct ng hnh dng gn c chi tit ui mang c, thit din c xy dng trn
b mt ca gn, cc thng s ct c khai bo nh hnh 3.31,,hnh 3.32.
hnh 3.31 hnh 3.32.
to im t cho kim y ta s dng cc lnh Extrude, cc thng s c khai
bo nh hnh 3.33, hnh 3.34.
- 56 -
Hnh 3.33 Hnh 3.34
Ct ng bin dng mt u chi tit s dng lnh Cut Extrude, thit din c
dng trn mt phng Top thng qua cc cng c Sketch. Ta c nh hnh hnh
3.35
Hnh 3.35: Ct ng bin dng mt u.
Nh vy ta hon tt qu trnh xy dng chi tit ui mang c tr n mi trng
ha nh hnh 3.36
- 57 -
Hnh 3.36: Chi tit ui mang c.
2. Thit k b khun da trn phn mm Pro/Wildfire.
Cc chi tit c sn xut bng cng ngh c p lc th ng c cht lng b
mt tng i tt, c tnh m bo v cho php gim ng k cc cng on gia
cng sau c. Cn c vo c im ca chi tit ui mang c ta c th xy dng kt
cu phi c t tn: phankhuon nh sau:
Hnh 3.37: Phi c ca chi tit dui mang c
- 58 -
Do hnh dng tng i phc tp nn vic phn khun i hi phi b tr b
mt phn khun vic tch khun v gia cng cc t m khun l d dng nht.
Phn thit k mt phn khun ny em xin php c gii thiu s b cc giai on
v hu ht thit din c to dng t trc nn chng ta ch cn s dng li
nhng gi liu ny. Nh vy ta c th to b mt phn khun thng qua cc giai
on sau:
Ta tin hnh ph mt cho hai mt bn ca chi tit ui mang c. Ph mt cho
hai mt ny ta ch vic nng thit din ti mp tng ng s dng lnh Extrude. Cc
thng s c khai bo nh hnh 3.38.
Hnh 3.38: Pht trin cc mt bn ca chi tit
Coppy b mt bn di ca chi tit, thc hin nh sau: Click vo mt mt
di ca chi tit, sau dng phm nng Ctrl + C v Ctrl + V sau ln lt chn
tt c cc mt di ca chi tit sao chp v dn nhng mt ti v tr c.
- 59 -
Hnh 3.39: Coppy mt dy ca chi tit.
Ln lt khp kn hai u ca chi tit bng cc mt n s dng lnh
Extrude vi thit din c to theo bin dng ca chi tit. Ta c nh hnh 3.40a
sau:
(a) (b)
Hnh 3.40: Ph mt u v lin kt mt u cho chi tit
Ta tin hnh lin kt mt va to vi mt coppy t b mt d i ca chi tit,
s dng chc nng Merge surface. Ta thc hin nh sau: Click chut v gi phm
Ctrl chn hai mt cn li n kt, sau nhp vo biu tng (Merge tool)
- 60 -
hoc thc hin theo ng dn Main menu / Edits / Merge, nhp vo biu tng OK
khi kt thc. Ta c mt nh hnh 3.40b t tn l Merge 1 sau:
- Tng t ta tin hnh khp kn u cn li ta c nh hnh 3.41a
- Lin kt mt va to vi mt Merge 1 ta c Merge 2 nh hnh 3.41b.
(a) (b)
Hnh 3.41: Ph v lin kt mt u cn li
- Ta lin kt cc mt bn tri trn vi mt Merge 2 ta c Merge 3 v
Merge 4 nh hnh 3.42.
Hnh 3.42: Lin kt cc mt bn
- Ta chn b mt Top, sau chn biu t ng (sketch) trn thanh cng
c ta xy dng c tit din v s dng lnh Extrude nng thit din va to l n
60 thc hin nh sau: chn thit din va to, click chut v o biu tng
- 61 -
(Extrude) trn thanh cng c hoc thc hin theo ng dn Main menu / insert /
Extrude. Khai bo cc thng s cn li nh hnh 3.43.
Hnh 3.43: To khi mt s dng lnh Extrude
- Nhn bn mt phng va nng thnh hai bng cch s dng cp phm
nng Ctrl + C, Ctrl + V.
- Ta tin hnh to phn Elip cho vt mu thc hin nh sau: Chn mt mt
va nhn bn sau click vo biu tng (Solidify) trn thanh cng c hoc
thc hin theo ng dn Main menu / Edit / Solidify. Khai bo cc thng s c n
li nh hnh3.44. Hng mi tn ch hng ly vt liu.
- Click chut vo mt trn ca chi tit, thc hin coppy mt tr n ca chi
tit s dng cp phm nng Ctrl + C, Ctrl + V. Kt thc nhn biu t ng
(true).
- 62 -
Hnh 3.44: Ct ng bin dng Hnh 3.45:Coppy mt trn ca chi tit
Pht trin mt va to theo pha mt khng li ca chi tit. Mc ch chng
ta cn xy dng mt trn cho chi tit l ct to vng Elip cho chi ti t. Thc hin
nh sau: Click chut chn cnh bin ngoi ca mt va Coppy sau click vo bi u
tng (Extend tool) trn thanh cng c hoc thc hin theo ng dn Main
menu / Edit/ Extend. Kt thc nhp vo biu tng (true).
Hnh 3.46: Pht trin mt trn. Hnh 3.47:Lin kt mt trn v mt nng
Ta tin hnh lin kt mt va pht trin vi mt nng s dng chc nng
Merge surface. Ta thc hin nh sau: Click chut v gi phm Ctrl chn hai mt
cn lin kt, sau nhp vo biu tng (Merge tool) hoc thc hin theo
ng dn Main menu / Edits / Merge, nhp vo biu tng OK khi kt thc. Ta
c mt nh hnh 3.47 t tn l Merge 5.
- 63 -
Tip tc lin kt Merge 4 vi Merge 5. Khai bo cc thng s nh hnh 3.48
ta thu c mt phn khun nh sau:
Hnh 3.48: Lin cc mt to mt phn khun.
Nh vy ta hon thnh cc bc to mt phn khun. Mt phn khun ca
chi tit ui mang c c xy dng thng qua s tri v khp kn ca cc mt bn.
Phn tip theo chng ta tin hnh tch khun cho chi ti t ui mang c. Cc bc
tin hnh nh sau:
- Khi ng modun thc hin nh sau: Click chut vo biu tng
(Create a New object) chn modun Menufacturing/ Mold cavity. Nhp t n
tachkhuon vo dng name v s dng template l : mmns_mfg_mold. Mn hnh
ha ca modun nh sau:
- 64 -
Hnh 3.49:Mi trng lm vic Hnh3.50: a chi tit lm
ca chi tit i t ng tham kho
- a chi tit vo modun - i tng tham kho cho qu tr nh tch khun,
thc hin nh sau: Click vo bi u tng (select part) trn thanh cng c sau
ch dn ti file phankhuon.part nhp Ok hon tt
- co ngt cho vt liu nhm vo khong 0.005 0.007 ta thc hin khai
bo nh sau: Click chut vo biu tng (specify shrinkage by scan for part) .
cc thng s khai bo nh hnh 3.51.
- To phi cho qu trnh tch khun, thc hin nh sau: Click vo bi u
tng (Create a workpiece). Phn mm Pro/wildfire cho php to phi t ng
bng cch offset t b mt chi tit v c tnh ton thng qua gc ta O ca
chng trnh. Cc thng s hnh hc ca khun c khai bo nh hnh 3.52.
Hnh 3.51 : Khai bo co rt. Hnh 3.52:To phi tch khun
- 65 -
Nh vy ta to xong phi cho qu tr nh tch khun, kt cu khun ny
c chn theo cc t i liu chuyn ngnh v kinh nghi m nn cn c b xung
tnh bn cho kt cu. Phn ny em xin c trnh by sau.
Hnh 3.53:M hnh khi phi tch khun.
Sau khi to phi xong chng ta tin hnh tch th tch cc tm khun thc
hin nh sau: Click vo bi u tng (Split into a new mold volume ) trn thanh
cng c, chn kiu tch thnh hai vng th tch v tch trn ton b phi c to
nh hnh 3.54. Nhp chut chn b mt phn khun, khi kt thc n OK.
Hnh 3.54: Tch th tch cc tm khun
- 66 -
Nh vy khi tch khun ta c b khun gm 2 na khun m v khun
dng nh hnh 3.55 v hnh 3.56
Hnh 3.55: Th tch khun m.
Hnh 3.56: :Th tch tm khun dng
Chng ta cn to 2 tm khun trn bng cch ly t khi th tch ban u thc
hin nh sau: Click vo bi u tng (create cavity insert part from mold
volume) trn thanh cng c. Chn hai i t ng sau nhn OK, kim tra tr n
thanh cng c ta thy to thm hai file khuonam v khuonduong.
- 67 -
Hnh 3.57:Tch th cc tm khun.
- m khun ta thc hin nh sau: Click vo bi u tng (Open
Mold) trn thanh cng c, chn Define step sau chn Define move, chn tm
khun m v khai bo gi tr 200 ta c nh hnh 3.57 sau:
Hnh 3.58 : M phng tho lp khun.
- 68 -
- Ta chn gc kim tra thot khun ti uu cho hai tm khun l 3
0
. Ta
thy kh nng thot khun ca 2 tm khun l chp nhn c. Kt qu th hin
trn mi trng ha.
Hnh 3.59: Kim tra gc thot khun cho tm khun m
Hnh 3.60 : Kim tra gc thot khun cho tm khun d ng.
- 69 -
- Vi sn phn c th ta kim tra vi gc thot khun l 3
0
, vi iu kin
ny chi tit c kh nng thot khun t ng i tt.
Hnh 3.61 : Kim tra gc thot khun cho vt c.
ngha ca vic kim tra gc thot khun l xc nh kh nng thot khun,
trn c s b tr h thng y vt c.
III. LP TRNH GIA CNG CC TM KHUN TRN PHN
MMPro/Wildfire.
1. Lp trnh gia cng tm khun m.
lp trnh gia cng tm khun m trn my CNC ta s dng phn mm
pro/Wildfire vi modul Manufacturing. Ta thc hin theo cc giai on sau:
a. Chun b file gia cng.
- Khi ng Pro/Wildfire bng cch nhp vo biu tng trn mn hnh
Desktop, hoc c th thc hin theo ng dn sau: Start / programs / PTC / Pro
Engineer / Pro Engineer.
- Chun b file gia cng : thit lp h trc ta ct, to gc ta nh
hnh:
- 70 -
Hnh 3.62 : Tm khun m.
Mt vn khi gia cng tm khun m l vic gia cng cc rnh gp rt
nhiu kh khn, v vy c th gia cng c ta cn thc hin cng on tch th
tch khi trn thnh nhiu tm v sau ghp li vi nhau. Di y l m hnh
ha ca cc vng th tch tm khun m .
Hnh 3.63: Vng th tch th 1.
Lu m hnh trn vi tn khuonam1.part
- 71 -
- Vng th tch th 2:
Hnh 3.64 : Vng th tch th 2.
Lu li th tch 2 di dng File khuonam2.part
- Vng th tch th 3:
Hnh 3.65:Vng th tch th 3
- 72 -
- Vng th tch th 4 :
Hnh 3.66: Vng th tch th 4
Nh vy ta hon tt qu trnh tch th tch tm khun m, by gi chng
ta bt u lp trnh gia cng cc th tch trn.
b. Lp trnh gia cng cc phn th tch khun m..
T menu iu khin chng ta nhp vo biu tng New trn thanh cng c
thc hin theo ng dn sau: file / new / menufacturing / NC Assemby. G tn
gc_khuonam1.
Hnh 3.67: a chi tit vo lm i tng tham kho.
- 73 -
Gia cng phn th tch 1:
- a chi tit na trn lm i tng tham kho bng cch click biu t ng
(assembly a reference model) trn thanh cng c . Ch dn ti file khuonam1.part
Xy dng phi m phng qu tr nh gia cng bng cch kch vo biu tng
(create a auto workpiece). Phn mn s to khi phi da trn khch thc thc
t ca chi tit gia cng. (hnh 3.68)
Hnh 3.68: To phi m phng qu trnh gia cng.
- Khai bo cc thng s my cng c, gc ta lp tr nh, mt an ton thc
hin nh sau: menu manager / mfg setup tip tc khai bo cc thng s nh ch dn
trn hnh 3.69. Nhp chut vo OK kt thc cu lnh.
Hnh 3.69:Ci t my, gc ta , mt an ton.
- 74 -
Phay th:
Khai bo ch gia cng thc hin theo ng dn sau: menufacture /
machining / NC Sequence/ volume -3D / Done. Sau phn mm yu cu khai bo
mt s thng s bt buc bao gm: Dng c ct (Tool), ch ct (parametter), Th
tch phi b ly i (volume). Ta tin hnh khai bo cc thng s nh sau:
- Khai bo dng c ct: S dng dao phay ngn ng knh 12 (mm) gia
cng th.
Hnh 3.70 : Khai bo dng c ct
- Khai bo ch gia cng: Vic tnh ton ch gia cng cho chi tit c xc
nh thng qua phn mm ca hng Seco. Cc thng s cn thit cho qu trnh gia
cng c khai bo nh hnh.
Hnh 3.71 : Khai bo ch gia cng
- Khai bo th tch vt liu b ct i:
- 75 -
C nhiu cch khai bo l ng vt liu b ly i, To volume thng kiu
thun nht, Garther, window. Trong to th tch theo kiu Window l phng
php to th tch phay rt nhanh v c th ng dng cho nhiu tr ng hp khc
nhau. Ta s khai bo th tch theo kiu Window, cng vic thc hin nh sau: Click
chut vo biu tng (Mill volume tool) ti p tc thc hin nh hnh
Hnh 3.72: Khai bo Mill Window.
Nh vy ta khai bo cc thng s cn thit cho qu trnh gia cng, ta kim tra
ng chy dao nh sau: Play Path / Screen play. Nh n biu tng Play bt u
qu trnh m phng.
- 76 -
Hnh 3.73: M phng ng chy dao.
- Tip tc chn NC Check kim tra h nh dng bin dng va gia cng
thng qua s tr gip ca phn mm Verycut ta c m hnh nh sau:
Hnh 3.74: M phng qu trnh gia cng.
- 77 -
Gia cng tinh b mt.
gia cng tinh b mt ta s dng kiu gia cng b mt (mill surface),
thc hin theo ng dn sau: : menufacture / machining / NC Sequence/ Surface
mill-3D / Done. Cc thng s cn thit cho qu trnh gia cng c khai bo nh
sau:
Khai bo dng c ct, ch ct .
Dng c gia cng tinh l dao cu c ng knh 6(mm). Ci t dng c
ct nh hnh:
Hnh 3.75: Khai bo dng c ct.
Ch ct c khai bo nh hnh :
Hnh 3.76:Khai bo ch ct.
- 78 -
Khai bo v mt gia cng tinh.
Sau khi ci t dng c ct v cc thng s cn thit cho qu trnh gia cng
ta cn khai bo b mt gia cng tinh cho qu tr nh gia cng. Thc hin nh sau:
surface pick / Model / Done / ln lt chn cc b mt cn gia cng tinh nh hnh:
Hnh 3.77:Chn mt gia cng tinh Hnh 3.78:Hng chy dao.
Tip tc nhn chut gia khai bo cch chy dao cho qu tr nh gia cng
mt. Ta s dng la chn cho php dao chy dc theo bi n dng ca b mt gia
cng nh trn hnh 3.78. Hng mi tn th hin hng chy dao khi gia cng. Khi
hon tt ta tin hnh m phng thng qua phn Play path
M phng qu trnh gia cng.
m phng ng chy dao ta thc hin theo ng dn sau: play path /
Play ta c kt qu nh hnh sau:
- 79 -
Hnh 3.79: M phng ng chy dao khi gia cng tinh
M phng qu trnh n dao s dng chc nng NC Check ta c kt qu
nh sau:
Hnh 3.80: M phng ng chy dao khi gia cng tinh
- 80 -
Nh vy ta hon thnh xong chng trnh gia cng phn th tch
khuonam1, xut sang chng trnh gia cng ta thc hin nh sau:
- Tng hp cc file gia cng thc hin nh sau: CL data / our put /
select set / gc_khuonam1 / file / ok / done return / post proce / Done / UNCXO1.
p01 . Nh vy file gia cng c to theo h iu khin Fanuc 16 M trong th mc
lm vic di y l phn trch ca file.
%
N5 T1 M06
N10 S2500 M03
N15 G1 X21.04 Y2.17 Z2. F2500.
N20 Z.5
N25 Z-.3 F20.
N30 Y-2.17 F250.
N35 X25.38
N40 Y2.17
N45 X13.04
N50 Y-10.17

N2500 Y1.752 Z-10.397
N2505 Y-4.509 Z-10.432
N2510 X63.719 Y-3.97 Z-10.434
N2515 Y1.752 Z-10.404
N2520 Y7.473 Z-10.434
N2525 X63.599 Y6.875 Z-10.435
N2530 Y1.752 Z-10.411
N2535 Y-3.372 Z-10.435
N2540 X63.48 Y-2.69 Z-10.436
N2545 Y3.232 Z-10.42
N2550 Y6.193 Z-10.436
N2555 X63.361 Y5.382 Z-10.437
- 81 -
N2560 Y-.669 Z-10.431
N2565 Y-1.879 Z-10.437
N2570 X63.241 Y-.871 Z-10.439
N2575 Y4.364
N2580 Z2 F1000.
N2585 M09
N2590 M05
N2595 M030
%
Gia cng phn th tch cn li thc hin tng t nh gia cng phn th tch
th nht, em xin php c trnh by vn tt qu trnh gia cng cc vng th tch
cn li.
Gia cng vng th tch khuonam2.
Khi ng modun menufacturing t t n mi cho trng trnh l :
gc_khuonam2.
- a vng th tch 2 vo lm i tng tham kho cho qu tr nh gia cng.
- To phi m phng qu tr nh gia cng: phi c kch t hc 65x65x60
Hnh 3 .81: To phi m phng qu trnh gia cng.
- Xc nh gc ta lp trnh v b mt an ton.
- 82 -
Gc ta c xc nh l giao im ca 3 mt DTM1, DTM2 v mt
trn ca phi.
Mt an ton c xc nh bng cch nng mt OXY theo phng z mt
khong 2(mm).
Xy ng phng n phay th: Chn phng n phay th theo ki u Volume,
th tch phay xc nh theo kiu Window.
Hnh 3 .82: Cc thng s cn thit cho qu trnh gia cng
Cc thng s cn thit cho qu trnh gia cng bao gm:
+ Dng c ct: dao phay ngn ng knh 5(mm)
- 83 -
Hnh 3 .83: Khai bo dng c ct.
+ Khai bo ch ct: Ch ct c khai bo nh hnh
Hnh 3 .84: Khai bo ch ct.
- 84 -
To phi theo kiu Window:
M phng ng chy dao vi Screen play
Hnh 3 .86: M phng ng chy dao gia cng.
- 85 -
- M phng quy trnh ct kim loi vi NC check:
Hnh 3 .87: M phng qu trnh gia cng th,
Gia cng tinh b mt khi 2.
Chn ch gia cng tinh l Mill surface, cc thng s cn thit cho qu
trnh ct c lit k nh hnh:
Hnh 3 .88: Cc thng s cn khai bo.
- 86 -
- Dng c ct : Dao cu ng knh 4 (mm)
Hnh 3 .89: Khai bo dng c ct khi gia cng tinh
- Ch ct c khai bo nh sau:
Hnh 3 .90: Khai bo ch ct khi gia cng tinh.
- 87 -
- Khai bo b mt gia cng.
Hnh 3 .91: Chn mt gia cng tinh
- M phng ng chy dao vi Screen play ta c kt qu nh hnh
Hnh 3 .92: M phng ng chy dao khi gia cng ti nh.
- 88 -
- M phng qa trnh ct kim loi vi NC check:
Hnh 3 .93: M phng qu trnh gia cng tinh.
- Xut sang m lnh G-code ta file gia cng gc_khuon2.tap.
Nh vy ta hon tt qu trnh gia cng phn th tch th 2 ca khun m.
Ta tin hnh gia cng cc vng th tch cn li.
gc_khuonam2.
- To phi m phng qu tr nh gia cng: phi c kch thc 45x65x60
- 89 -
- Xc nh gc ta lp trnh v mt an ton.
Hnh 3 .95: Xc nh gc ta cho qu tr nh gia cng.
Gc ta c xc nh l giao im ca 3 mt DTM1 DTM2 v mt trn
ca phi.
khong 2(mm).
Xy ng phng n phay th: Chn phng n phay th theo kiu
Volume, th tch phay xc nh theo kiu Window.
- 90 -
Hnh 3 .96: Cc thng s cn thit cho qu trnh gia cng.
Hnh 3 .97: Khai bo dng c ct khi gia cng th
- 91 -
+ Khai bo ch ct:
Hnh 3 .98 : Khai bo ch ct th.
To phi theo kiu Window:
Hnh 3 .99: To phi theo kiu Window.
- 92 -
Hnh 3 .100: m phng ng chy dao.
- M phng qu trnh ct kim loi vi NC check:
Hnh 3 .101: M phng qu trnh gia cng.
- 93 -
Gia cng tinh b mt khi 3.
Chn ch gia cng tinh l Mill surface, cc thng s cn thit cho qu
trnh ct c lit k nh hnh:
Hnh 3 .102: Cc thng s cn thit cho qu trnh gia cng.
- Dng c ct : Dao cu ng knh 4 (mm)
Hnh 3 .103: Khai bo dng c ct tinh
- 94 -
- Ch ct c khai bo nh sau:
Hnh 3 .104: Khai bo ch ct khi gia cng tinh
- Khai bo b mt gia cng.
Hnh 3 .105: Chn mt gia cng tinh.
- 95 -
- M phng ng chy dao vi Screen play ta c kt qu nh hnh
Hnh 3 .106: M phng ng chy dao.
- M phng qa trnh ct kim loi vi NC check:
- 96 -
- Xut sang m lnh G-code ta file gia cng gc_khuonam3.tap.
gc_khuonam2.
- To phi m phng qu tr nh gia cng: phi l hnh tr c kch thc 30
x 60
- Xc nh gc ta lp trnh v mt an ton.
Gc ta c xc nh l giao im ca 3 mt DTM1 DTM2 v mt
trn ca phi.
khong 2(mm).
Xy ng phng n phay th: Chn phng n phay th theo kiu
Volume.
- 97 -
Hnh 3 .109: Cc thng s cn thit cho qu trnh gia cng
Hnh 3 .110: Khai bo dng c ct khi ct th
+ Khai bo ch ct:
- 98 -
Hnh 3 .111: Khai bo ch ct cho qu trnh gia cng th.
To phi theo kiu Volume, s dng cc cng c Trim, offset volume xy
dng th tch g b nh hnh
- 99 -
Hnh 3 .112: M phng ng chy dao khi gia cng th.
Hnh 3 .113: M phng qu trnh gia cng th.
- Xut sang m lnh G-code ta file gia cng gc_khuonam3.tap.
- 100 -
2. Lp trnh gia cng khun dng.
Khi ng modun menufacturing t t n mi cho chng trnh l :
gc_khuonduong.
- a tm khun dng vo lm i tng tham kho cho qu tr nh gia
cng, thc hin nh sau: Click chut vo biu tng (assemble a reference
model) dn ti file khuonduong.part nhn OK hon tt.
To phi m phng qu tr nh gia cng Xy dng phi m phng qu tr nh
gia cng bng cch kch vo biu tng (create a auto workpiece). Phn mm
s to khi phi da tr n kch thc thc t ca chi tit gia cng. Phi c to ra
c kch thc 200x200x80, cc thng s khai bo nh hnh, nhn True hon tt.
- Khai bo cc thng s my cng c, gc ta lp tr nh, mt an ton
thc hin nh sau: menu manager / mfg setup tip tc khai bo cc thng s nh ch
dn trn hnh 3.115. Nhp chut vo OK kt thc cu lnh.
- 101 -
Hnh 3 .115: Khai bo my , gc ta my, mt an ton
Gc ta c xc nh l giao im ca 3 mt DTM1, DTM2 v mt trn
ca phi.
khong 2(mm).
Xy ng phng n phay th: Chn phng n phay th theo ki u
Volume
Hnh 3 .116: Cc thng s cn thit cho qu trnh gia cng khun dng
- 102 -
thc hin phay theo kiu Volume ta cn khai bo th tch vt liu ly i,
thc hin nh sau:
+ To thit din nh hnh 3.117 trn mt phng DTM1 bng cng c
Sketch. S dng chc nng offset edge.
Hnh 3 .117: To thit din n.
+ Click vo biu tng (Mill volume tool) trn thanh cng c khai
bo to phi volume cho qu tr nh gia cng. Sau Click vo biu tng
(extrude tool) to khi n cho thit din va to, cc thng s khai bo nh hnh
Hnh 3 .118: To th tch vt liu ct b.
- 103 -
to ng th tch cn phay ta s dng thm cc chc nng Trim, Offset
th tch hon thin th tch cn phay. Ta thu c th tch phay i nh sau:
Nh vy ta xy dng xong th tch vt liu ly i trong qu tr nh gia
cng.Tip tc khai bo cc thng s cn thit cho qu tr nh gia cng bao gm:
+ Dng c ct: dao phay ngn ng knh 12 (mm) khai bo nh hnh
Hnh 3 .119: Khai bo dng c ct khi gia cng khun dng
+ Khai bo ch ct: Ch ct c khai bo nh hnh
Hnh 3 .120: Khai bo ch ct khi gia cng khun dng.
+ Chn vng phi va to
- M phng ng chy dao vi Screen play
- 104 -
Hnh 3 .121: M phng ng chy dao.
Hnh 3 .122: M phng qu trnh gia cng th khun dng.
- 105 -
Phay bn tinh cho na khun dng.
Khi phay th tch trn ta s dng dao phay ngn ng knh 12 (mm) nn
mt s v tr chng ta khng c gia cng, trong nguyn cng ny chng ta s
dng dao c ng knh nh hn gia cng ht nhng phn tr n .
- Trong phn Mechining ta chn my nguyn cng mi vi phng n l
Local Mill. Trong model Local Mill l a chn phng n Preview NV secquence -
gia cng phn vt liu m nguyn cng trc cha gia cng ht. Chn Done chp
nhn.
- Chn nguyn cng trc l Volume mill.
- Tip theo khai bo cc thng s cn thit cho qu trnh gia cng.
Hnh 3 .123: Cc thng s cn thit cho qu t nh gia cng
- Khai bo dng c ct: Dng c ct c khai bo nh hnh
- 106 -
Hnh 3.124: Khai bo dng c ct
- Khai bo ch ct cho qu trnh gia cng: ch ct c khai bo nh hnh
Hnh 3 .125: Khai bo ch gia cng.
- M phng ng chy dao vi Screen play
- 107 -
Hnh 3 .126: m phng ng chy dao qu trnh gia cng.
- M phng qu trnh gia cng vi NC Check
Hnh 3 .127: M phng qu trnh gia cng.
Gia cng tinh b mt khun dng .
- 108 -
gia cng b mt khun dng ta s dng Surface Mill. Cc thng s cn
thit cho qu trnh gia cng mt khun c lit k nh hnh.
Hnh 3 .128: Cc thng s cn thit cho qu trnh gia cng tinh.
Khai bo nhng thng s bt buc cho qu trnh gia cng bao gm:
- Dng c ct: Dao cu c ng knh l 6(mm), c khai bo nh hnh
Hnh 3 .129: Khai bo dng c ct.
- Ch gia cng: Ch gia cng c khai bo nh sau:
- 109 -
Hnh 3 .130: Khai bo ch gia cng tinh.
- B mt gia cng: B mt gia cng c lit k nh hnh
Hnh 3 .131: Khai bo b mt gia cng tinh tm khun dng.
- 110 -
- Xc nh hng chuyn ng ca dng c ct . Hng mi tn th hin hng
dch chuyn ca dao.
Hnh 3 .132: Chy dao theo cc ng ISOline.
- Sau khi khai bo hon tt chng ta bt u m phng ng chy dao
s dng Screen play.
Hnh 3 .133: M phng ng chy dao khi gia cng tinh gia cng.
- 111 -
- M phng qu trnh ly vt liu s dng NC check ta c nh hnh
- Tng hp 3 nguyn cng v lu li di dng file gc_khuonduong.ncl
- Xut sang m ln G-code thc hin nh sau: CL data / our put / select set /
gc_khuonam1 / file / ok / done return / post proce / Done / UNCXO1. p01 .
Nh vy file gia cng c to theo h iu khin Fanuc 16 M trong th mc
lm vic di y l phn trch ca file.
%
N5 T1 M06
N10 S2500 M03
N15 G1 X-34. Y9.289 Z2. F2500.
N20 Z.5
N25 Z-.3 F20.
N30 Y-.605 F250.
N35 G2 X-21.928 Y2.305 I24.26 J-74.132 F150.
N40 G1 X-21.928 Y2.305 Z-.3
N45 X-16.072 Y.999 F250.
N50 X-13.732 Y1.158
- 112 -
N55 X-15.938 Y1.954
N60 X-21.928 Y2.305
N65 G2 X-34. Y9.289 I32.866 J70.738 F150.
N70 G1 X-34. Y9.289 Z-.3
N75 X-42. F250.
.
N9905 Y-14.848
N9910 X4.169 Y-14.507 Z-43.514
N9915 Y8.012
N9920 X4.409 Y7.721 Z-43.508
N9925 Y-14.165
N9930 X4.649 Y-13.824 Z-43.502
N9935 Y7.43
N9940 X4.888 Y7.138 Z-43.496
N9965 Y-12.801
N9970 X5.608 Y-12.459 Z-43.477
N9975 Y6.264
N9980 M05
N130 M030
%
Nh vy ta hon thnh giai on lp trnh gia cng cc tm khun. Sau
khi gia cng cc phn th tch ca tm khun m c ghp li vi nhau v c
ghp vo vi vy khun. B khun sau cng on l m ngui l giai on , sn,
ph cc lp Nenhm gia tng cng, bn nhit, nhm m bo thi gian l m
vic lu di . Nu cha c s dng ngay cn c phng n bo tr hp l. Trong
phm vi nghin ca ti khng bao hm ni dung ny.
3. La chn cc thng s my.
Cn c vo kch thc ca cc tm khun ta la chn s b my c p lc
vi l loi my c lc ng khun l 250 tn vi mt s kch thc c bn nh hnh
- 113 -
ng knh Piston p l 60(mmm).
C cu khun c xy dng nh sau:
Hnh 3.135: M hnh cc t m khun trn my 250T
- 114 -
IV. TNH TON KT CU KHUN.
1. Xc nh p lc p.
- Xc nh p lc p: p lc p ca vt c c tnh ton theo my c th.
Vi phng n s dng my c p lc nh trn ta c th xc nh p lc ln nht
ca pittng p ln kim loi lng. p sut p p ph thuc vo t l gia 2 ng
knh, xilanh dn ng D
u
v pittng p D
n
(hnh 3.135). p lc p c xc nh
theo cng thc 2.21 [1, trang 81].
2
|
.
|
\
|
=
n
u
a
D
D
p p (3.1)
Trong :
D
u
- ng knh xilanh dn ng D
u
= 220(mm)
D
n
- ng knh pittng p D
n
= 60 (mm)
P
a
- p sut bnh cha P
a
= 7(Mpa)
Thay gi tr ta c :
2
60
220
7
|
|
.
|
\
|
= p = 94,11 (MPa)
Hnh 3.136: M hnh cc tm khun c p lc khi t trn my 250t
- 115 -
2. Tnh ton lc kha khun.
Lc kha khun p
k
c gi tr cc i ti thi im kt thc qu tr nh in y, tc
l thi im xut hin thy kch v lc kha khun phi c duy tr cho n tn
khi xut hin lp v vt c ng c. iu ny m bo cho khun c ng
cht hon ton trong sut giai on p. Lc kha khun, khi khng c hin t ng va
p thy lc (hay cn gi l lc kha tnh) ca c cu kiu cnh tay n (hnh
3.135), tnh theo cng thc:
|
.
|
\
|
+ =
u
a
e
D
D
p K p
n
u
k
1 . (3.2)
Trong :
K h s tn tht ly K=0,8 0,9;
p
= p
no
F (F l tng din tch hnh chiu vt c xc nh trn
phn mm Pro/Wildfire, h thng rt v cc b phn khc ln mt
phn khun, F = 0,0399 (m
2
)
p
no
p lc p, tnh theo cng thc (2.21)
e khong cch t trc c cu kp khun n im t lc p,
vi e = 0,07(m)
a khong cch t trc tay n n trc c cu kp,
a = 0,285(m)
D
u
v D
n
ng knh xilanh thy lc v xi lanh p.
Thay s ta c:
) ( 6 , 343
285 . 0
07 . 0
1
60
220
. 0399 , 0 . 11 , 94 . 8 , 0 MPa p
k
= |
.
|
\
|
+ =
- 116 -
3. Lc tch chi tit:
Lc tch khun ph thuc vo lc cn thit tch vt c ra khi rut. Nu
b qua hin tng chnh lch nhit gia vt c v khun th lc khun c
th tnh nh sau:
P
d
=f.p.F (3.3)
Trong :
f -h s ma st gia vt c v rut.
p - p sut lc ca kim loi c l n rut ,Mpa;
F- din tch b mt tip xc rut vt c, m
2
.
Ta c gi tr ca f, p c xc nh theo bng 2.6 [1.trang 84] p dng vi vt liu
c l hp kim nhm.
f = 0,35 ; p = 27,5
Din tch b mt tip xc c xc nh thng qua tr gip ca phn mm
Pro/Wildfire F = 0,0252267(m
2
)
Thay gi tr vo cng thc ta c:
P
d
= 0,35.27,5.0,0252267.1000.981
= 238193,65( N )
= 0.238193 (t n)
4. Tnh ton h thng rt:
Tc np v tc p:
Tc chy ca kim loi trong rnh dn v
n
gi l tc np v tc chy ca
kim lai trong bung p v
e
gi l tc p. y l hai thng s quan trng, mang
tnh quyt nh n cc iu kin thy ng v iu kin nhit ca qu tr nh in
y khun p lc.Gi tr tc np v tc p c lin quan ln nhau theo phng
trnh dng lin tc:
- 117 -
v
n
.f
n
= v
c
.f
c
(3.4)
Trong : f
c
v f
c
l din tch thit din ngang ca r nh dn v bung p,m
2
.
Cn c theo bng 2.7 [1,trang85] ta chn tc np i vi vt c nhm, chiu
dy l 3(mm) l v
n
= 30 (m/s). Nh vy thay cc gi tr vo ta c:
) ( 98 . 47
30 .
2 , 45 . 30
2
s m
fn
f v
v
c c
n
= = =
Thi gian in y khun:

Gi tr thi gian in y tnh theo cng thc 2.30 [1, trang 86] ph thuc vo ch
ma st dng chy in y hc khun. i vi ch in y ri Phn tn
tun t, thi gian in y tnh theo cng thc:
t
d
= t
b
+ t
p
+t
l
(3.5)
Trong :
t
p
v t
l
khong thi gian kim loi chuyn ng phn tn v chuyn ng ri trong
hc khun, (s).
t
b
- khong thi gian bay t do ca dng kim loi trc khi to dng phn tn ti ch
va p vi vt chng ngi xc nh theo cng thc:
t
b
= (L
b
+
vd
+
r
)/v
n
, (s)
Trong :
L
b
l chiu di dng kim loi bay t do 0.196 (m)

vd
l chiu dy trung bnh ca chi tit
vd
= 0.003(m)

r
l chiu dy rnh dn theo thit k h
r
= 0.003 (m)
Thay gi tr ta c:
- 118 -
) ( 0042 . 0
98 , 47
003 . 0 003 . 0 196 , 0
s t
b
=
+ +
=
Gi tr thi gian in y t
d
m trong khong thi gian cc dng ring bit
kt hp li vi nhau tr c khi ng c c tnh ton xut pht t iu kin: nhit
kim loi lng trc khi in y song khng c thp hn nhit ng c th
thi gian in y trong chuyn ng phn tn:
]
]
]
]
]
|
|
.
|
\
|
+
|
|
.
|
\
|
=
3
2
3
1
3
ln . ln .
k kt
k i
k l
k r
vd p
T T
T T
K
T T
T T
K t (3.6)
Thi gian trong giai on chy ri :
]
]
]
]
|
.
|
\
|
+
|
.
|
\
|
=
2
4
2
3
2
1
ln ln .
k d
k kt
k kt
k r
vd
T T
T T
K
T T
T T
K t (3.7)
Trong : K
1,
K
2,
K
3,
K
4
h s trn bng 2.8.
T
kt
- nhit kt tinh ca kim loi ADC12 l 515
0
C.
T
r
- nhit rt kim loi lng khong 680
0
C.
T
l
- nhit ng lng vo khong 650
0
C.
T
k
- nhit khun vo khong 200
0
C.
T
d
- nhit ng c hon ton 380
0
C
Vi K
1
= 0.179, K
2
= 0.25
,
K
3
= 0.013, K
4
= 0.015
Thay gi tr ta c :
) ( 0857 . 0
200 515
200 650
ln . 25 , 0
200 650
200 680
ln 179 , 0 . 3
3 3
3
s t
p
=
]
]
]
]
|
.
|
\
|
+ |
.
|
\
|
=
- 119 -
) ( 0213 . 0
200 380
200 515
ln 015 . 0
200 515
200 680
ln 013 . 0 . 3
2 2
2
1
s t =
]
]
]
]
|
.
|
\
|
+
|
.
|
\
|
=
T cng thc 3.5 ta c th xc nh c thi gian in y khun nh sau:
t
d
= t
b
+ t
p
+t
l
= 0,0042 + 0,0857 + 0,0213 = 0.113(s)
Thi gian p tnh
Khi tnh ton thi gian p , ngi ta gi thit rng , nhit kim loi ti thi
im kt thc qu trnh in y khun coi bng nhit kt tinh T
kt
. Thi gian p
tnh c xc nh theo cng thc 3.7 [1,trang 88]
]
]
]
]
|
|
.
|
\
|
|
|
.
|
\
|
=
2 2
k kt
vd
rd kt
rd
c
T T T T
K t

(3.7)
Trong : K h s ph thuc hp kim c, K = 289.
T
rd
Nhit nung s b ca rnh dn T
rd
= 250
o
C.
rd
- chiu dy rnh dn 3 (mm)
Thay s ta c :
) ( 01 . 0
200 515
3
250 515
003 , 0
289
2 2
s t
c
=
]
]
]
]
|
.
|
\
|
|
.
|
\
|
=
Thit k h thng rt
Do c im kt tinh ca kim loi c p lc cao l khng th to iu kin ng
c c hng, do phi to iu kin cho vt c ng c ng thi. Mt khc,
kim loi in y khun trong mt khong thi gian v c ng ngn, bi vy thit k
h thng rt cn phi tun th mt s iu c bn sau y:
- Qung ng chuyn ng ca kim loi lng trong khun l ngn nht c
th c.
- 120 -
- Din tch rnh dn thu hp dn t bung p ti hc khun. H thng rt
thu hp dn c tc dng l m gim s cun kh vo vt c, ng thi lm
tng tc ng in y.
im khc bit gia hai h thng rt ca hai kiu bung p ngui kiu thng
ng v kiu ngang ny l: trong bung p ngui nm ngang, h thng rt khng c
phn ni trung gian t bung p n r nh dn. Khi , ng i ca kim loi lng
s ngn hn, trnh c hin tng ngui sm ca kim loi trong bung p.
Ph thuc vo v tr tng quan gia cc ng dn, knh dn trong h thng p
i vi vt c, c th phn h thng rt thnh ba kiu: rt trc tip, rt pha trong
v rt ngoi, trong h thng rt trc tip, khng c knh dn trung gian, din tch
knh np trong my bung p thng ng tnh bng din tch thit din ngang ca
ng dn (hnh 3.137); trong bung p ngang, din tch knh np tnh bng din tch
bung p (hnh 3.138). Khi vt c c l hng trc, ng dn kt thc cui r nh
dn b tr xung quanh ci ngt dng (hnh 2.17c).
Hnh 3.137: H thng rt kiu rt ngoi
- 121 -
Hinh 3.138: H thng rt cho vt c c cu to v hnh dng khc nhau
H thng p bn trong c s dng i vi vt c c l tm kch th c ln
cho php cc knh dn v rnh dn . H thng rt kiu ny thng p dng cho
khun c thic, lm gim ng k kch thc khun p.
H thng rt ngoi c p dng ph bin nht. y l bin php c th p mt
ln vo nhiu hc khun. lm c vic , trong h thng rt , ngi ta cn b
tr thm mt tch kim loi va c tc dng phn phi kim loi lng, va duy tr
nhit n nh rnh dn.
Tnh ton rnh dn
Rnh dn l thnh phn c bn nht ca h thng rt . Din tch thit din ngang
ca rnh dn quyt nh tc np kim loi . Chiu d y rnh dn quyt nh ng
hc qu trnh in y v kh nng p trong bung p. Hin nay, cn mt phng
php tnh din tch rnh dn thng qua cc h s. Trong phng php ny , ngi ta
coi tc np
n
v l tch ca cc h s v tc trung bnh:
tb n
v K K v
2 1
= . Trong
tb
v l tc trung bnh ca dng np v ly bng 15 m/s.
1
K v
2
K cc h s tnh
n kiu dng vt c v p sut p. Thi gian in y
tb dd
t K K t
4 3
= vi
tb
t l thi
gian in y trung bnh, ly bng 0.06 giy.
3
K v
4
K l cc h s tnh n loi
- 122 -
hp kim v chiu dy trung bnh ca vt c. Vi cch t cc h s nh vy, din
tch rnh dn tnh theo cng thc 2.36 [1, trang 92].
M
p v
d
K K K K
m m
f
4 3 2 1
) ( 12 , 1 +
= (2.36)
Trong :
m
vd
: l khi lng vt c.
m
p
: l khi lng ca vu.
M
: khi lng ring ca vt c
Cc gi tr h s
1
K ;
2
K ;
3
K ;
4
K i vi c hp kim nhm, khi l ng
nh hn 2 kg; khi lng tnh theo gam v khi lng ring p tnh theo g/
3
cm cho
bng 2.11 [1, trang92]. Nh vy ta c th suy ra:
4 3 2 1
. 12 , 1
K K K K
V
f
d
=
V: l th tch vt c c xc nh qua tr gip ca phn mm
Pro/Wildfire l 9,0803777.10
4
(mm
3
) = 0,90803777(cm
3
).
1
K = 2;
2
K = 1,5 ;
3
K = 0.75;
4
K = 1
Thay gi tr ta c:
) ( 452 . 0
1 . 75 , 0 . 5 , 1 . 2
90803777 , 0 . 12 , 1
2
cm f
d
= = = 45,2(mm
2
)
m bo nguyn tc tht dng ca h thng rt, ngi ta s dng din
tch thit din ngang ca knh dn ph c gi tr
d dp
f f ) 5 , 1 2 , 1 ( . Chiu cao knh dn
ph xc nh bng cng thc thc nghim:
d dp
f h 77 , 0 =
Thay gi tr f
d
= 45.2(mm
2
) ta c:
) ( 176 , 5 2 , 45 77 , 0 mm h
dp
= =
5. Tnh h thng thot hi:
H thng thot hi thng c thit k c dng rnh vung gc. Cn c theo
bng 2.12 [1, trang 93] ta chn c hiu dy
h
ca rnh thot hi l 0,12(mm). Kh
trong hc khun c p lc c th thot qua r nh thot hi, qua h thng y, qua
mt phn khun. Vic b tr h thng thot hi ph thuc vo hnh dng ca chi tit c.
- 123 -
CHNG 4
TNG KT V XUT KIN
Nh vy ta hon tt cc ni dung cn nghi n cu trong phm vi t i tt
nghip. Thng qua qu trnh thc hin ti em bit thm v cng ngh vt liu
v ng dng cc phn mn CAD/CAM/CAE khi thit k khun mu. Thit k v
ch to b khun c p lc cho hp kim nhm l ni dung tm hiu rt rng bao
gm c v hin tng vt liu trong khun v thit k ch to khun. Sau 3 thng
thc hin ti em xin xut mt s vn sau:
Cng ngh c trong khun kim loi ni chung v cng ngh vt liu ni
ring l lnh vc rt quan trng c ngha thc tin cao cn c nghin cu v o
to chuyn ngnh ring.
Tip tc nghin cu phn mm Pro/E thng qua vic thit k khun cho
nhng dng chi tit khc nhau v c yu cu k thut cao hn, p dng vi loi
khun phc tp sn xut trong cng nghip.
Ngoi vic nghin cu chc nng CAD/CAM ta nn u t vo vic nghin
cu chc nng CAE trong thit k khu n mu n gim ti a thi gian tnh ton
bn, kt cu khun, dng chy kim loi lng trong hc khun, thi gian cn thit
in y khun y l mt ni dung rt quan trng v n c th cho chng ta tc
ng su vo cc hin tng ca khun.
Trong qu trnh nghin cu v hon thnh ti ny nh s gip nhit
tnh ca cc Thy gio trong khoa, cc anh Xng c kh K thut s L Huy, cc
bn hc trong khoa. c bit l s ch dn gip tn t nh v y trch nhim ca
thy hng dn L Ngc Sn. Em xin chn thnh cm n.
- 124 -
TI LIU THAM KHO
1. Nguyn Hu Dng
Cc phng php c c bit.
NXB Khoa hc v k thut, H Ni, 2006.
2. Nguyn Ngc H
Cc phng php v cng ngh c c Bit.
NXB i hc Quc Gia TP. HCM, 2006
3. Trn Tng Thy Phng Hoa.
Lp trnh gia cng khun vi Pro/Engineer WildFire 2.
Giao Thng Vn Ti, 2005
4. Hong Dng Quang Huy Tng Thy
Gia cng trn my CNC vi Pro/Engineer WildFire.
Giao Thng Vn Ti, 2005
5. Khoa cng ngh vt liu i hc Bch khoa Nng
Gio trnh Vt Liu K Thut
6. B mn my v Robot Hc Vin K Thut Qun S.
Hng dn s dng Pro/Engineer 2000i
7. Tm kim trn google: Heigh pressure Die Casting.
- 125 -
MC LC
CHNG 1: TNG QUAN V CNG NGH C P LC ..................... - 1 -
I. LCH SHNH THNH V PHT TRINCA NGNH C P LC......- 1 -
1. Trn th gii. .............................................................................................................- 1 -
2. Ti Vit Nam. ............................................................................................................- 4 -
II. TM HIU CHUNG V CNG NGH C P LC CAO. ............................. - 4 -
1. Th no l c p lc cao. ......................................................................................... - 4 -
2. Quy trnh c p lc cao. .......................................................................................... - 5 -
3. Thy ng hc qu trnh in y khun................................................................. - 9 -
4. Khun c p lc cao. ............................................................................................ - 16 -
5. Thit b c p lc cao............................................................................................. - 17 -
6. Khuyt tt c v cc bin php phng nga........................................................- 21 -
7. Lnh vc ng dng c p lc cao. .......................................................................- 22 -
CHNG 2: TNG QUAN V CNG NGH CAD/CAM/CNC V NG
DNG................................. ................................ ................................ .............. - 24 -
I. TNG QUAN V CNG NGH CAD\CAM\CNC. .........................................- 24 -
1. Cc chc nng c bn ca h thng CAD\CAM....................................................- 24 -
2. Chc nng c bn ca h thng iu khin s. ......................................................- 31 -
II. THC TRNG VIC NG DNG H THNG CAD/CAM/CNC TI VIT
NAM. .......................................................................................................................... - 37 -
1. Khi qut v h thng CAD/CAM/CNC c mt ti Vit Nam. ............................ - 37 -
2. Khi qut v h thng CAD/CAM/CNC ph bin ti Vit Nam: .......................... - 39 -
CHNG 3: THIT K V CH TO B KHUN C P LC CHO
CHI TIT UI MANG C. ................................ ................................ ......... - 40 -
I. TM HIU V KIM TRA TNH HP L CA CHI TIT UI MANG C .- 40 -
1. Kim tra tnh hp l ca chi tit ui mang c. ......................................................- 40 -
II. XY DNG M HNH CHI TIT TRN PHN MM Pro/wildfire.................- 42 -
- 126 -
2. Thit k b khun da trn phn mm Pro/Wildfire. .............................................- 57 -
III. LP TRNH GIA CNG CC TM KHUN TRN PHN MM
Pro/Wildfire.................................................................................................................- 69 -
1. Lp trnh gia cng tm khun m. ..........................................................................- 69 -
2. Lp trnh gia cng khun dng. ..........................................................................- 100 -
3. La chn cc thng s my. ..................................................................................- 112 -
IV. TNH TON KT CU KHUN...................................................................- 114 -
1. Xc nh p lc p. .............................................................................................. - 114 -
2. Tnh ton lc kha khun. ...................................................................................- 115 -
3. Lc tch chi tit: .................................................................................................- 116 -
4. Tnh ton h thng rt: ........................................................................................- 116 -
CHNG 4: TNG KT V XUT KIN ................................ ..... - 123 -
TI LIU THAM KHO................................ ................................ ............. - 124 -

Tong Quan Cong Nghe Duc AP Luc

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Tong Quan Cong Nghe Duc AP Luc

Uploaded by

Copyright:

Available Formats

- 1 -

Thi gian in y khun:

You might also like