Bi 1 Bi 2 Bi 3 Bi 4 Bi 5 Bi 6 Bi 7

: Tng quan v CAM (Milling).....................................................................................1 : Tng quan v trung tm gia cng phay CNC v dng c ct...................................31 : LP TRNH GIA CNG CNC ...............................................................................53 : Gia cng mt s chi tit in hnh..........................................................................133 Phng php gia cng b mt 3D: Gia cng th......................................................134 Phng php gia cng b mt 3D: Gia cng bn tinh v tinh..................................168 : Thc hnh gia cng mt s chi tit in hnh........................................................169

Bi 1 : Tng quan v CAM (Milling).

Mc ch:
Kt thc phn CAD cc bn bc vo hc CAM da trn phn mm Mastercam. Bi u tin chng ta s tm hiu mt ci nhn khi qut v nn tng nht chng ta c mt h thng v CAM. iu ny quan trng v CAM l mt phn lin quan n lm vic thc t khi cc bn lm vng kin thc c bn th vic tm hiu phn mm ch l cng c v thao tc to to ra quy trnh lm vic m thi. Nhng ni dung m sau bi hc ny cc bn cn lm vng:
Tng quan v CAM. ng dng ca CAM trong cng nghip. Quy trnh thc hin CAM. Gii thiu v cc loi phn mm CAM . Gii thiu v cc loi my CNC & cc phng php gia cng CAM. La chn my CNC v Post Processor i km. Cc tin ch h tr lp trnh trn Mastercam X. Video demo.

1.1 Tng quan v CAM.

Tham kho phn gii thiu trong bi 1 ca phn CAD vi Mastercam.

1.2 ng dng ca CAM trong cng nghip.

Tham kho phn gii thiu trong bi 1 ca phn CAD vi Mastercam.

1.3 Quy trnh thc hin CAM.

Quy trnh thc hin CAM

Trn y l s ca m hnh CAM: m hnh, hnh hc c to lp t CAD l c s d liu Cho CAM. Cc CAM khc nhau i hi cc d liu CAD khc nhau truy nhp ti cc d liu hnh hc ca CAD, vi cc thut ton giao din ca phn mm chun b cc qu trnh cng ngh : phn tch chi ph, c tnh ca nguyn vt liu, my mc v dao c qu trnh tip theo l lp chng trnh gia cng NC dng tnh nng m phng ca phn mm CAM m phng qu trnh

gia cng ng chy dao kim tra v ti u ho ng chy dao . Vic tip theo l xut code chng trnh *NC truyn xung cc my CNC thc hin gia cng sn phm.

1.4 Gii thiu v cc loi phn mm CAM .

i a s cc phn h tr k s v nh sn xut trn th trng u l cc phn mm tch hp CAD v CAM. V vy, khi gii thiu v phn mm s gii thiu c chc nng CAD v CAE nu c ca n. Sau y l cc phn mm ni ting v mnh m nht trong lnh vc CAD/CAM. Catia

Phn mm CATIA l h thng CAD/CAM/CAE 3D hon chnh v mnh m nht hin nay, do hng Dassault Systems pht trin, phin bn mi nht hin nay l CATIA V5R17 , l tiu chun ca th gii khi gii quyt hng lot cc bi ton ln trong nhiu lnh vc khc nhau nh: xy dng, c kh, t ng ha, cng nghip t, tu thy v cao hn l cng nghip hng khng. N gii quyt cng vic mt cch trit , t khu thit k m hnh CAD (Computer Aided Design), n khu sn xut da trn c s CAM (Computer Aided Manufacturing, kh nng phn tch tnh ton, ti u ha li gii da trn chc nng CAE(Computer Aid Engineering) ca phn mm CATIA. Cc Mdun chnh ca CATIA nh sau:

CATIA BASE: m bo iu kin, kim tra h thng, toiu kin thit lp mi trng, iu kin hi thoi, kim tra thc hin cc ton t c tim cn vo d liu ca cc mdun. CATIA LIBRARY: th vin ca cc phn t CAD/CAM m chng c th ha ng mt s m hnh cng ng thi. Cc i tng c th c tm kim bng cc t kha. CATIA INTERFACE: truyn cc d liu gia cc phn mm CAD khc nhau bng IGES. CATIA DRAFTING: cha hm s to phn t 2D, ghi kch thc, t mt ct, m t cu ch. CATIA 3D DESIGN: kin to, m hnh ha, phn tch v biu din phn 2D v 3D k c b mt.

CATIA SOLIDS GEOMETRY: m hnh ha th tch to hnh, hiu chnh v phn tch vt th. N cho php cc ton t logic gia cc vt th (hp, giao, tr). vt th c to t cc i tng n gin bng vic dch chuyn hoc quay Profile. CATIA KINEMATICS: gip xc nh cu trc ng hc ca c cu, m phng v phn tch chuyn ng, xc nh vn tc v gia tc ca cc chi tit c cu, ng chuyn ng v gii quyt cc bi ton va chm. CATIA IMAGE DESIGN: To s biu din thc vi phn khut hon ton, xc nh iu kin chiu sng v cc thng s b mt ca i tng. CATIA FINITE ELEMENT MODELLER: m hnh tng th m t tnh cht vt l v vt liu, iu kin bin v ti trng i tng. NC - LATHE: to chng trnh cha phn nguyn cng tin di dng u ra APT hoc CL-File.

CATIA NC - MILL: to chng trnh cha phn nguyn cng phay.

CATIA ROBOTIC: thit k v m phng robot vi cc lnh chun, nh ngha cu trc robot, c trng hnh hc, ng hc, ng b ha nhiu robot. CATIA BUILDING DESIGN AND FACILITIES LAYOUT: to thit k cc bn v xy dng, sp t cc i tng v nh ngha mi quan h gia chng. CATIA SHEMATICS: cng c sp t v tr nhng phn t c bn, v cc s , thit lp cc lin kt logic gia cc phn t v iu khin chng. CATIA PIPING AND TUBING: thit k nhng tuyn ng dn phc tp, ton t logic vi vt th, thm d va chm CATIA STRUCTURAL DESIGN AND STEELWAK: cng c t hp cho kin trc. CATIA GRAPHIC INTENSIVE INTERFACE: cng c lp trnh m rng nhng hm s mi v tip cn m vo mi trng CATIA.

Hn th na CATIA cn rt nhiu Mdun h tr thit k v gia cng khun mu , thit k kim loi tm, x l cc qu trnh gia cng khng phoi, h tr lp trnh iu khin, thit k bo mch.
Unigraphics NX

- y l phn mm ni ting ca hng UGS. L mt b phn mm ln snh ngang vi Catia ca Dassault systemn dn u trong th gii 3C. Ni chung l ch thua Catia mt cht thi, khng ng k. N tch hp qu nhiu modul nh thit k c kh, thit k khun, in-in t, my bay, gia cng khun, gia cng chi tit., phn tch kt cu vi modul Nastrans, bn cnh , ging nh CATIA, UNIGRAPHICS cng h tr cho ng tu, nhng ng nhm ln, v n ch h tr m phng chi tit thi ch khng th so vi cc chng trnh chuyn dng nh autoship, maxsurf, ship constructor.......khc vi solidworks, UNI thin v thit k surface hn l thit k solid ( lm cho vic thit k v thao tc ca unigraphics phc tp hn). V chc nng CAD th UNI cng khng c g c bit so vi cc phn khc, v hin nay, hu ht cc phn mm u c chung mt cch thit k l thit k tham s, ch hn nhau cch b tr cc toolbar v tnh khoa hc , d dng. im ny th c catia, unigrphics u thua xa solidworks v inventor - v chc nng CAM: unigraphics v catia t ra vt tri so vi Pro E ca hng PTC, n rt mnh. Cc bn c th tham kho cc din n Cad Cam kim chng. - chc nng CAE: UNI c mt modul phn tch kh mnh l nastran, c th phn tch c rt nhiu bi ton, tuy nhin, c v nh n khng c thn thin lm, hn na n ngn ti nguyn my qa nhiu, trong phn help ca unigraphics NX4 th thy rng nh sn xut cnh bo l ch c th chy modul ny tt trn cu hnh my Core2duo, ram 2GB, VGA ti thiu l 256 v n khng chy c trn cc h iu hnh 64bit, thy rng: unigraphics c rt nhiu u im trong thit k v Gia cng, ch c iu, chy c n th phi c my tnh cu hnh

rt mnh, khng ph hp lm vi sinh vin. Nhng cng rt ng cho ta tham kho, c bit vi sinh vin ngnh ch to.

Pro Engineer Mt trong nhng phn mm c c nhng tnh nng trn nh Catia,

Unigraphics NX, I-deas, Pro/Engineer Wildfire.y l bn phn mm c nh gi l rt mnh v rt ni ting trong lnh vc CAD/CAM/CNC. Ty vo th mnh ca mi phn mm m chng c nhng ng dng chuyn bit: Catia, Unigraphics NX phc v trit cho ngnh cng nghip hng khng, t, tu thy. Pro/Engineer phc v rt tt cho ngnh c kh khun mu (thit k v gia cng) nh khun dp, khun rn, khun nha. Pro/E c mt li th l gi r nn chim lnh cc th trng hng trung v cao.

Hin nay, s ngi s dng Pro/E trn th gii rt nhiu, k c Vit Nam (chim trn 75%) nn chng ta s c c hi hc hi, trao i ln nhau nhng vn lin quan n CAD/CAM vi th gii bn ngoi. Do vy, vic chn hc Pro/E l mt hng i tt cho chng ta trc khi vo ngh v cng l cch duy nht chng ta nm bt, ui kp trnh cng ngh ca th gii

Pro/E l phn mm ca hng Prametric Technology, Corp. Mt phn mm thit k theo tham s, c nhiu tnh nng rt mnh trong lnh vc CAD/CAM/CAE, n mang li cho chng ta cc kh nng nh: M hnh ha trc tip vt th rn To cc module bng cc khi nim v phn t thit k. Thit k thng s. S dng c s d liu thng nht. C kh nng m phng ng hc, ng lc hc kt cu c kh.

(Pro/Engineer Wildfire 3.0). Phn mm Pro/Engineer c cc module sau: Pro/ASSEMBLY: to iu kin thit lp d dng chi tit vo h thng

v di h thng. N h tr cho phn lp rp v lp rp nhm, gii quyt tnh hung xung t, thit k thay i

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 Pro/DETAIL: module to trc tip m hnh 3D ca cc bn v thit k chun cho phn xng v ch to trong m bo lin kt 2 pha gia cc bn v v module 3D. Pro/SHEETMETAL: module h tr thit k nhng chi tit c dng tm, v, v h tr cho vic to lp cc chi tit pht trin k c chun b cho chng trnh NC cho sn xut.

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Pro/SURFACE: module h tr v, to cc mt t do (Free Form), x l cc mt cong v b mt phc tp.

Pro/MANUFACTURING: bao gm d liu NC, m phng, format d liu CL, th vin cc phn t.

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 Pro/MESH: h tr ti to mng li cho vic phn tch phn t hu hn (FEA), xc nh iu kin bin, gn lin vi ANSYS, PATRAN, NASTRAN, ABAQUS, SUPERTAB v COSMOS/M.

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 Pro/MECHANICA: M phng ng hc, kim nghim ng sut, chuyn v, bin dng tuyn tnh v phi tuyn, xc nh v d on kh nng ph hy vt liu

M phng c cu Mechanism.

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 Pro/INTERFACE: to iu kin gn vi cc h CAD khc nh: iges, dxf, vdafs, render, SLA Pro/PROJECT: xc nh iu khin d n thit k v t hp mt s i thit k v lp d n. Pro/FEATURE: m rng kh nng thit lp nhng phn t thit k bng th vin ca cc b phn, nhm, ti to cc hnh dng chun v di nhm. Pro/DESIGN: h tr thnh lp m hnh 3D, s khi, xy dng k hoch thit k v mi quan h ph thuc, gip cho s phn tch nhanh v hiu qu v sp xp phng n. Pro/LIBRARY: module cha th vin rng ln ca cc phn t trn chun (chi tit, phn t thit k tiu chun, dng c, khp ni), c th b sung hoc hiu chnh. Pro/VIEW: module to iu kin kim tra m hnh ha chi tit v h thng t mt hng quan st bt k, phng n, o nh. S dng c ci nhn nhanh tng th t c kt qu hoc mc ch phng nga.

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 Pro/DRAFT: module h tr biu din 2D, to iu kin c bn v ca cc h CAD khc v b sung module 3D v thit k thng s. Pro/NLO: module h tr cho cng vic trong mng cc b, ha hp vi cc module khc ca h. Pro/MOLD: module thit k khun.

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 Pro/DEVELOP (Pro/PROGRAM): module h tr vic lp trnh ng dng ring. Cha cc th vin ca hm s C, th vin chng trnh con ca ngn ng lp trnh FORTRAN v c bit tip cn c vi cu trc thit lp cc h thng v cu trc d liu ca h thng. Ngoi ra, Pro/E cn c Pro/CASTING, Pro/LEGACY, Pro/TOOLKIT, Pro/PiPe

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Vi nhng tnh nng gii thiu trn cho thy: Pro/Engineer l mt phn mm CAD/CAM/CAE rt mnh, c kh nng m hnh ha cc chi tit phc tp nh cc loi my xc, my o t, t, cc bin dng v tu thy kh nng lp rp ln v rt ti u trong thit k.

Cimatron

Phn mm Cimatron ca hng CIMATRON CO,.. LTD c nh gi l phn mm tch hp CAD/CAM dng cho lnh vc thit k gia cng C kh hng u ca th gii. Phn mm Cimatron do nhm chuyn gia Nht Bn v Israel hp tc xy dng t nm 1990. Cimatron l phn mm CAD/CAM m mi lin kt gia thit k v ch to gip ta c kh nng gii quyt t khu u n khu cui vic ch to ra mt sn phm cng nghip mt cch chnh xc v hiu qu. u tin Cimatron h tr cho ngi k s thit k mu sn phm. Trong qu trnh thit k, phn mm Cimatron E rt linh ng cho php ngi thc hin thit k tin hnh cc thao

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tc tht d dng v nhanh chng bng giao din ho rt trc quan, tnh nng v cng c h tr thit k rt phong ph khng thua km cc phn mm CAD ni ting nh Pro/Engineer, Solid Egde, Solid Words, Autodesk Inventor Sau khi hon chnh thit k m hnh hnh hc, sn phm thit k c th l tit nha, kim loi hoc cc chi tit gia cng dp hay un Cimatron E cung cp Modul thit k khun nh khun p nha, c p lc hay khun dp kim loi gip ngi k s thit k hon thnh xut sc c nhim v thit k khun ca mnh vi chnh xc rt cao. Cui cng, ngi k s phi thc hin cng vic ch to khun. y li l mt th mnh ca phn mm Cimatron E. Trong phn trnh ng dng NC, vi rt nhiu chu trnh gia cng phay, tin, EDM (ct dy) h tr cho qu trnh t ng lp trnh gia cng t cc b mt 2D n gin n nhng b mt 3D phc tp nht, c kh nng to ra qu o chy dao iu khin cho cc my CNC t 3 trc n my 5 trc phc tp, hin i nht. Phn mm Cimatron E p ng tt c nhng yu cu k thut ca cng vic lp trnh gia cng CNC vi phng thc lp trnh NC Guide n gin nhng rt cht ch. Cimatron E cn tr gip ngi thit k lp rp cc chi tit li vi nhau trong phn Assembly. Qua ngi thit k nhn bit mi quan h trong khng gian ca cc chi tit trong mt cm cc chi tit, mt sn phm no . cng ch l nhng kh nng nh trong nhiu kh nng mnh mng m phn mm Cimatron E mang li. Hin nay, trn th gii ni chung v ring Vit Nam th s lng my CNC ang pht trin c v s lng v xu hng cht lng ho ca cc cng ty, doanh nghip v cc c s c kh hng ngy ang tng bc i mi cng ngh gia cng nng cao chnh xc v y cht lng sn phm cao hn, bn hn, p

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hn Do vy, ngi lm vic trong lnh vc c kh phi tm c hi nm bt phn mm ny.

MasterCAM

Phn ny tham kho phn gii thiu CAD ca gio trnh.

EdgeCAM Vi EgdeCAM cc bn c th dng cc dng d dng cc cng c ca phn

mm thc hin thit k 3D nhanh chng v c th chnh sa d dng vi modul Edgecam Part Modeler. EdgeCAM h tr gia cng trn cc my phay vi vic gia cng th v gia cng tinh, m phng v hiu chnh ng chy dao t n gin n phc tp trn cc my phay 3 trc, 4 trc v 5 trc. EdgeCAM cn h tr gia cng trn my tin t hai trc v cc my milling/lathe nhiu trc. Vi y cc chi trnh gia cng hin th v m phng y qu trnh hot ng ca my cho php bn quan st pht hin ra tnh hng gy li my trong qu trnh gia cng, cng nh l hiu chnh ng chy dao sao cho ti u lm tng gi tr kinh t ca chi tit. EdgeCAM cn h tr phn khun mu v t dp, h tr y gia cng tc cao thng minh v ti u trong cc ch ct. linh hot v ti u trong vic gia cng tinh cc b mt. Vic xut m lnh G-code cho gia cng trn cc my CNC cng tng i d dng vi EdgeCAM vi modul Edgecam Code Wizard. Nhn chung, EdgeCAM l mt phn mm thit k c th la chn cho gii php sn xut ca mt doanh nghip.
SolidCAM o

SolidCAM l mt phn mm c pht trin bi cng ti CAM

dnh cho cc my CNC. c lch s pht trin 36 nm dnh cho lnh vc CAD/CAM . SolidCAM l mt trong phn mm c giao din s dng rt thn thin v d dng nht l nhng ai c kinh nghim trong vic s dng phn

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mm solidwork th cng thy SolidCAM thn thin nh th no. Vi s pht trin mnh m ca mnh SolidCAM c mng li bn hng trn 40 quc gia trn th gii.
o

Vi y cc modul h tr: 2.5D Milling 3D Milling High-Speed Machining Multi-sided Indexial 4/5 axes Milling Simultaneous 5 axes Milling Turning Turn-Mill up to 5-axes WireEDM

Solidcam tch hp vi phn mm ph bin khc nh : solidworks, Autodesk inventer, bently modeler. 1.5 Gii thiu v cc loi my CNC & cc phng php gia cng CAM.
Hin nay c nhiu loi my CNC ca cc hng ch to t loi va nh n

loi c kch thc ln gia cng nhng chi tit ln. T loi vi b iu khin t tnh nng loi c b iu khin tch hp mnh v y . Nhng v c bn ta s i gii thiu s qua v cc loi my CNC . o o 4D, 5D. o Phn loi theo chc nng th phn ra lm: my Tin CNC, Phay CNC, ct dy CNC, t dp CNC, my xung, my bo CNC. Phn loi my CNC theo trc chuyn ng to hnh th c th phn Phn loi theo iu khin c th chia ra lm loi iu khin 2D, 3D, ra lm : my CNC 3 trc, 4 trc, 5 trc.

Mt s hng ch to CNC : - Doosan Daewoo (Hn Quc): My tin CNC, my phay CNC. - Komatec (Hn Quc) : My khoan Taro, Trung tm gia cng

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- Fanuc (Nht): My c p nha bng in, my ct dy CNC, my phay CNC. - Milacron (M, Trung Quc): My c p nha bng in, my c p nha bng thy lc. - Pinnacle (i Loan): My tin CNC, my phay CNC v my phay vn nng. - Taiyu Chemical (Nht): Cht gii nhit dng cho my CNC. - Kuroda (Nht): My mi phng vn nng, mi phng, mi trn - Naga Ichi (Singapore): My mi phng..vv V mt s chng loi my ca nhiu hng my ln khc Vi cc b iu khin ph bin c cung cp bi cc hng: heidenhain, siemens, Fanuc, Misumi, HASS, ANILAM, Cc phng php gia cng CAM: Xin nu ra cc phng php gia cng thng dng cc my CNC l: - gia cng tin - gia cng phay : 2.5D, 3D, 4D, 5D - gia cng ct dy - gia cng t dp CNC - gia cng xung

Vi phn mm Mastercam c cc modul h tr cho cc phng php gia Tin: c tin th, tin tinh, tin ren, tin rnh, tin l, tin ct Phay: phay contour, pocket, drill, surface (th v tinh), h tr H tr my milling/lathe CNC. H tr gia cng tc cao To cc ng chy dao khc chm tr ln b mt

cng :
o

t.
o

cc my phay 5 trc
o o o

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o o

Modul art cam. H tr ct dy.

1.6 La chn my CNC v Post Processor i km.

Vi Mastercam bn c th la chn nhiu dng my CNC gia cng

nh Mill, lathe, and router trn mt ca s lm vic ca Mastercam,c th la chn cc nguyn cng gia cng trn nhiu my cho cng mt chi tit trong mt ca s ho ca phn mm.

Nhng my ny c nh ngha vi file c to ra c ui m rng l m cc dng: - *.MDD dnh cho my phay (milling CNC) - *.LMD dnh cho my tin (Lathe CNC) - *. RMD dnh cho my router CNC. Khi m bn la chn mt my th mt new machine group v toolpath group s c to ra v xut hin khu vc cy qun l .

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 Sau khi chn my ph hp ri nu bn mun thay i n c th lm theo cc bc sau: - Trn menu toolpath manager click vo file ca machine group mun thay i - hp thoi Machine group properties hin ra la chn tab file, click vo replace phn la chn machine-toolpath copy.

Sau truy nhp v thay i mt my no theo yu cu.

Truy cp hp thoi Control Definition Mangager thay i cc tham

s v la chn post prosessor ph hp. truy nhp ta vo settings Machine Definition manager.

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o Editting options truy nhp vo hp thoi ny ta click vo

biu tng sau hp thoi hin ra vi nhiu option la chn v thay i.

Hp thoi y nh sau:

Vic la chn post processor rt quan trng v n nh hng ti lc chng ta chn la xut file NC gia cng. Vi cc b iu khin khc nhau ca cc hng khc nhau th phi la chn b post processor sao cho ph hp. Cc post

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processor c l cc file ui *.PST vic Add processor v thay i chnh sa s thc hin theo cch sau: - Click chn v click ok. - Click vo nu mun Add vo mt post processor mi lc nu cc post processor c Add trc ri, ta la

hp thoi control definition post list edit hin ra click vo Add nu tip tc thc hin Add mt post processor mi, mun delete mt post processor add click v la chn delete. Vic la chn c th sinh ra cc biu tng: ngha l file .PST tn ti v post processor c cu hnh cho

control definition . Mastercam khng tm thy file .PST v post processor khng c

cu hnh trong hp thoi control definition manager. l thng bo file .PST tn ti v post processor c Add vo ri

nhng cha c control definition. chuyn status sang trng thi ok th ch cn save thnh file .CONTROL.3 post processor c cu hnh trong control definition nhng

Mastercam khng tm thy file .PST, status icon ny xut hin khi m bn di chuyn cng vic ca mnh v thc hin lm vic trn mt trm khc m file .PST khng c load theo cng . file .PST tn ti nhng cha c cu hnh s dng vi control

definition. La chn post processor v to ra mt control definition vi n. Bn c th s dng n sau khi ghi li control definition thnh .CONTROL file. khng nhn bit c. Mastercam cng khng nhn bit c n l

status g . Hy th save li control definition xem n c ng khng.

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Control Definition Properties:

Tolerances: mc ny bn c th chnh sa v nh ngha li dung

sai. Ti y ta c th nh ngha cc gi tr nh nht khi create cc surfaces, ,splines, lines o Communications: dng thit lp thng s giao tip gia b

iu khin v phn mm Mastercam. Cc thng s chnh cn thit lp nh hnh v di.

Files: s dng option ny ci t nhng thao tc v file trong

khi control definition to v ghi li nhng thit lp . Chng ta c th thay i mc nh ca n .DEFAULTS, hoc file th vin .OPERATIONS dnh cho mt my m ngi s dng la mun ci t theo ca mnh. To ra file template, thit lp file C-hook v Net- Hook ca chng trnh .DLL.
o

NC Dialog: dng ci t nhng tham s cho toolpath la chn NC Output: ci t tham s ny c nh hng n phn xut Absolute/incremental, Post file debug,

li mt vi tham s khng c h tr .
o

m NC code cho my CNC.

Comments in NC: vi nhng la chn ny sp xp v la chn gi tr tuyt i,tng i cho php hay khng nhng comment c to ra trong file NC.

Sequence numbers: tt c nhng thng tin

trong phn ny c ghi trc tip ti control definition. Mastercam h tr hai kiu d liu l s thc v s nguyn. Vic click hot Use decimal sequence

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numbers

ta c th nhp mt s thc tun t phn

sequence numbers c gii hn bi Number of places m bn t sn.

Spaces and end-of-block characters: gi tr

bn ci t y c c trc tip t post processor

o Miscellaneous Integer / Real Values: hp thoi ny ni vi Mastercam

rng tu chn bin s ban u m bn c th control definition.

Vi mi bin t do c nh ngha trong vic gi thng bo kch hot s xut hin .

Mt vi gi tr mc nh c trong post s xut hin mt vi tham s. Mi mt tham s kch hot bn c th nhp cc gi tr khc nhau , khi bn thc hin ghi li vo control definition hin ti, gi tr ny s c ghi vo vng nh qun l no tng ng ca post processor.

Gi tr bn nhp y mc nh thng thng s cho tt c cc nguyn cng thc hin to ra vi control definition. Bn c th thc hin ghi vi la chn Initialize toolpath operation Vi iu khin my phay/tin Mastercam s cho bn lu hai bin miscellaneous variables , mt cho nguyn cng phay v mt cho nguyn cng tin.

Control definition gm hai chc nng: - N cung cp mt post processor c th vi thng tin n cn v d liu ng chy dao ng cho mt Machine definition. y l cch b xung d liu mt file NC khi m c yu cu t b iu khin.

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- N ni cho Mastercam v b iu khin v kh nng ca b hu x l v yu cu ngi s dng khng la chn nhng thng tin m b hu x l khng h tr. o Work System: cho php bn lm vic vi h to ca h thng bng cc

lnh G-code: - G90/G91 lp trnh theo h to tuyt i tng i. - G92 xc lp gc phi ti v tr hin thi. - G54 xc lp to gc phi. - Other t chn khc. Tplane dng xc lp mt phng dao (vc t php tuyn ca mt phng l hng ca trc Z).
o Tool:

- Dng ci t thng s ban u cho b dao, s v tr ca dao trong bng b dao v v tr home cho cc my tin, my phay, my bo, v my phay/tin. Tool offsets v tr b dao trong bng b dao Tool numbers v tr dao trn i g dao trong tool magazine trn CNC machine. Home position v tr gc my.
o Linear ni suy tuyn tnh G01 o Arc ni suy cung trn G02, G03. o Rotary thc hin chuyn ng quay ca trc th 4 hoc 5 trn my CNC

nhiu trc
o Feed iu khin tc tin dao ngang F(mm/ph ) o Cutter Compensation thit lp b bn knh dao. o Machine Cycles thit lp cc chu trnh gia cng ch yu l cc chu trnh

khoan.
o Subprograms l cc chng trnh c to ra mt cch t ng.

29

Nh vy: qua phn ny bn bc u lm quen vi Mastercam X, cch thc cu hnh, ci t v la chn cc my gia cng tng ng vi b iu khin bn c , qua chun b cho cc bc tin hnh lp trnh CNC tip theo. 1.7 Video demo.

30

Bi 2 : Tng quan v trung tm gia cng phay CNC v dng c ct.

Mc ch: Hiu v lm quen vi cc loi dng c ct phc v trong qu trnh gia cng. La chn dng c ct ng cng l mt bc quyt nh n thi gian v cht lng gia cng. y l mt bi hc quan trng trc khi i vo thc hin cc bi hc v lp trnh gia cng CNC. Bi ny s cung cp cho cc bn nhng. kin thc :
Tng quan v trung tm gia cng CNC .

Dng c ct o Gii thiu v cc hng dao chuyn dng. o Cu to dao v cc b phn g kp dao ln my CNC o Gii thiu mt s cn dao v mnh li ct thng gp o Tm quan trng ca dao ct trong gia cng CNC. o Dao chuyn dng ct th. o Dao chy bn tinh - Solid cut 3 <Dao phay ngn> - Dao R tip nh - Dao cu o Dao ct tinh, dao ct ch s dng mt ln. o Dao dng trong gia cng cao tc. o Tnh ton v la chn dng c ct . o Qun l cc thng s hnh hc ca dao trong bng dao trn my CNC. o Mt s a im cung cp dao ct CNC thng thng trong sn xut n chic, sn xut th nghim. V d.

31

2.1 Tng quan v trung tm gia cng CNC. 2.2 Gii thiu v cc hng dao chuyn dng. Vic la chn hng dao cung cp cc loi dao cng l mt vn khi lm thc t v cn cn c vo tnh kinh t cng nh l loi sn phm mnh ang gia cng l loi no. Hn na vic chn la dao xem c cung cp Vit Nam hay khng c d mua hay khng. Sau y xin gii thiu mt vi hng dao hay dng Vit Nam cho cc my CNC. Trong qu trnh la chn dao bn c cng ln hiu v vt liu dng c ct : Li ct v cn dao.

Hng dao Seco.

o y l mt loi dao c dng kh ph bin Vit Nam v c nhiu nh cung cp dao ca hng ny. Dao seco vi gi c phi chng i km l cht lng l mt la chn tt cho ngi s dng. Hng cn cung cp c phn mm tnh ton thng s cng ngh cho dao. Hng dao Kuroda
o Kuroda c thnh lp t Kuroda Gauge Manufacturing vo nm 1925 ,

l mt trong nhng hng sn xut i u trong lnh vc sn xut thit b ct gt. Cc dao c ca hng c chinh xc cao,cht lng v bn. Dao ca hng cng c cung cp vit nam. Hng dao Tungaloy
o c khi u t nm 1929 n nay hng l mt hng dao c ln sn

xut v cung cp dao c cho ngnh cng nghip sn xut nht bn v nhiu nc trn th gii. Va ri hng cng tham ra trin lm hi tr quc t MTA 2008. Hin nay dao c ca hng cng c cung cp vit nam.

32

o L mt tp on sn xut dao c vi nhiu chi nhnh sn xut nhiu ni

trn th gii nh: Hanta Co.,Ltd. Tungaloy Logistics & Technology Co.,Ltd. Tungaloy America, Inc. Tungaloy De Mexico S.A. Tungaloy Europe GmbH Tungaloy Cutting Tool (Thailand) Co.,Ltd. Tungaloy Cutting Tool (Shanghai) Co.,Ltd. Tungaloy Friction Material Vietnam Ltd. Hng dao Sutton Tools
o L mt hng dao c thnh lp vo nm 1917 thnh ph Melbourne/

Australian chuyn sn xut v cung cp cc loi dao c cho cc my CNC v cng c. Sutton Tools sn xut dao c theo cc tiu chun ISO, DIN, JIS. V cn rt nhiu hng dao khc chng ta c th lit k di y: Hng dao Taegutec Hng dao Sodick. Hng dao WIDIN Hng dao BIG Kaiser Precision Dao c ca hng NACHI Dao c ca hng MITSUBISHI Dao c ca hng HITACHI. Hng dao Sandvik Coromat Hng dao Sumitomo Electric Hardmetal Hng dao NTK Hng dao Guehring Hng dao Iscar ..

2.3 Cu to dao v cc b phn g kp dao ln my CNC.

Cu to ca dao dnh cho my phay CNC.

33

Hnh v di l bng cc loi dao s dng trn my phay phn mm Mastercam

Hnh v tht ca dao

34

Dao cu

Dao phay ngn:

Tool size parameters (tham s ca dao):

- Diameter: cho ng knh dao ct.

35

- Corner Radius (tham s ny c hoc khng vi dao khc): cho bn knh gc ca dao ct. - Arbor Diameter: cho ng knh cn dao. - Flute: chiu di lm vic ca dng c. - Shoulder: cho chiu di ca c phn ct ca dao ct. - Over rall: cho chiu di t u dao n i dao. - Taper angle: gc cn.

Holder size parameters (tham s kch thc vng kp): - Holder diameter: cho ng knh vng kp. - Holder: cho chiu di t mp ti mt cui ca vng kp. - Tool number: ch ra s th t ca dao xc nh dng c ny. Cc b phn g kp dao ln my CNC. Cc b phn g kp dao ln my CNC l b phn m dao phay lp ln v lp vo Toolhoder ca my CNC, chng bao gm:

36

- o trung gian (collet - ng kp). - u chp dao ( gi collet c nh v kp cht dao). - B phn lp trung gian ko di chiu di dao gia cng v d cc dao c ng knh nh nh cu D2, D1 - B phn Toolholder l b phn lp ln spindle ca my n c cc u BT30, BT40, BT50 (trong 30, 40, 50 l cc gc cn ca Toolholder). y l hnh nh u BT50:

Sau y l mt s hnh nh ca u g kp dao trn my CNC 2.4 Gii thiu mt s cn dao v mnh li ct thng gp.
Cn dao l phn g lp v c inh li ct ln . Cn dao c lp vo u

kp dao trn my CNC. Trong qu trnh ct gt cn dao chu tc dng ca cc lc c hc, s bin dng cn dao nh hng ln n gc u dao do cn dao phi c yu cu sau: - phi c kh nng chu un - chu bn. Di y gii thiu mt vi hnh nh ca cn dao:

37

Cn dao doa tinh:

38

Cn dao phay mt u:

39

Mt s cn dao khc:

40

41

42

Li ct l phn tham gia vo qu trnh ct gt do vt liu li ct

o

phi chu c nhit v tn nhit nhanh, va chm, bn dai, chu c mi mn. Vt liu lm li ct: y l phn vt liu trc tip ct gt ra phi nn nh hng trc tip n nng xut v cht lng b mt gia cng v vy vt liu lm phn ct gt phi c nhng yu cu sau y:

cng: mun ct c vt liu kim loi th cng

ca dao phi c cng cao hn vt liu gia cng, thng thng kim loi gia cng c cng vo khong (200-240HB), do cng ca li ct phi tm vo khong 60HRC. Gia cng vt liu: thp cng thp chu nhit thp khng bn c hc: trong khi ct dng c ct thng phi g cn c cng >=65HRC.

chu nhng lc, xung lc ln do i hi tnh nng s dng tt cn thp c b, ak cao. Tnh chu cng nng: vt liu b nung nng thng cng gim i, tnh chu cng nng l kh nng gi cng nhit cao (khng c chuyn bin t chc) trong mt thi gian di. Tnh chu mi mn: khi vt liu dao bn c hc th dng hng ch yu l mi mn. Khi cng vt liu lm dao cao th tnh chu mi mn phi cao. Tnh cng ngh: xt v iu kin lm vic, vt liu lm dao c yu cu d ti, thm ti cao, do trng thi ngui v nng, tnh d gia cng ngoi ra cn cn thm tnh dn nhit cao, chng va p v gi thnh thp. o Nhng vt liu lm dao gm c: Thp cc bon dng c. Thp hp kim dng c. Thp gi.

43

Hp kim cng.

Sau y l hnh dng cc chip ct dng cho dao phay: - li ct cho dao phay mt u:

44

Bng thng s hnh hc:

- li ct cho dao phay cnh:

45

46

- li ct cho dao phay hc:

47

- li ct cho dao phay ct rnh:

48

Dao ct chamfer:

49

Loi li ct di y thc hin phay ren:

Loi li ct rnh khc:

50

2.5 Tm quan trng ca dao ct trong gia cng CNC.

Dng c ct hay cn gi l dao l b phn h thng cng ngh c nhim v trc tip tc phi hnh thnh b mt gia cng . Chnh v th m: dng c ct c nh hng rt ln n qu trnh ct gt. N khng nhng tc ng trc tip ti cht lng b mt chi tit m cn chi phi khng nh ti vn nng xut v gi thnh sn phm. Chnh v th m hiu bit v dng c ct nhm s dng chng mt cch hp l l mt trong nhng trng tm nghin cu ct gt kim loi. Trong thc t v b mt gia cng l mun hnh mun v, do dao phc v gia cng cng rt a dng. thun tin cho cng tc nghin cu tu theo yu cu s dng m phn ra lm cc nhm dao khc nhau. Chng ta c th v d nhng tnh hung sau thy tm quan trng ca dao ct: - dao m c s rng t v c gc nghing ca ng xon ln nn dao cho php thot phoi mt cch d dng khi gia cng cc l hoc rnh khng thng sut. Trnh trng hp b mit phoi ln b mt lm nh hng ti b mt gia cng. -

51

2.6 Dao chuyn dng ct th. 2.7 Dao chy bn tinh 2.8 Dao ct tinh, dao ct ch s dng mt ln. 2.9 Dao dng trong gia cng cao tc. 2.10 Tnh ton v la chn dng c ct 2.11 Qun l thng s hnh hc ca dao trong bng dao trn my CNC. 2.12 Mt s a im cung cp dao ct CNC thng thng trong sn xut n chic v sn xut th nghim. 2.13 V d.

52

Bi 3 : LP TRNH GIA CNG CNC

Mc ch: Vi bi hc ny cc bn s c thao tc trn phn mm Mastercam vi chc nng to cc ng chy dao ca n vi my phay. By gi cc bn phi tn dng kin thc v k nng CAD, nhng hiu bit v dao cng thm kinh nghim thc t ca gio vin hng dn cc bn s thc hin nhng d n u tin ca mnh. Sau khi kt thc bi hc ny cc bn phi nm c nhng ni dung sau:

Cc phng php gia cng CNC (2.5D; 3D; 4&5D) Gii thiu cc bc gia cng mt chi tit in hnh. Cc bc thit lp mt chng trnh gia cng trn phn mm. Lp trnh gia cng. - La chn phng n n dao. - Thit lp thng s cng ngh. Xut chng trnh gia cng. Cc phng php gia cng 2.5D.

o Phay phng. o Phay hc .

o Phay bin dng ng (contour) Phng php b dao khi gia cng

o Cc chu trnh khoan. V d v thc hnh Tho lun nhm.

3.1 Gii thiu cc phng php gia cng CNC (2.5D, 3D, 4D&5D).
Mc ch: Vic ny cng nh khi chng ta lm bt v tm hiu v my CNC, bit c c nhng phng php gia cng no trong thc t v cn c iu kin thc t chng ta c nhng loi my no p ng c nhng mc gia cng no. Cng thm cn c vo hnh dng ca chi tit v la chn cc phng php gia cng cho ph hp. V trong bi hc

53

ny chng ta ch hc cc cch thc setup v cch la chn nhng ng chy dao trn my phay CNC. Vi mastercam cung cp 3 modul ng chy dao to ng chy dao to ng chy dao: modul 2.5D, modul 3D v modul nhiu trc . Ta dng modul 2.5D to cc ng chy dao 2.5D, cho gia cng phi c mt phng dng 2.5D. Ta s dng modul 3D to ng chy dao 3D cho nhiu loi mt 3D khc nhau v cho modul nhiu trc (4D&5D) cho gia cng cc phn phc tp. Vi modul 2.5D chng ta c cc ng chy dao: o Contour o Pocket o Drill o Face o

????????????????????????????

3.2 Gii thiu cc bc gia cng mt chi tit in hnh.

Mc ch phn ny l cho hc vin mt ci nhn v cch thc t duy khi thc hin cc bc cng ngh trn phn mm Mastercam. Cc thc hin chung nh sau: M chi tit gia cng. La chn kiu my v h iu khin. Thit lp phi, gc phi, g, mm cp, chng tm, luynt To ng chy dao. Kim tra v m phng gia cng. Chuyn i sang m gia cng (G-code). Chnh sa d liu file NC c to (nu cn).

3.3 Cc bc thit lp gia cng trn phn mm. Tham kho trn phn la chn my v processor trn bi 1.

54

 M v nhp tp lm vic.

- M mt tp chun Mastercam. + T menu Mastercan file Open + Trong hp thoi Open , la chn kiu tp chun ca Mastercam. + Chn Open - Nhp mt tp Cad khc. + T menu Mastercam fileopen. + Trong hp thoi Open, chn dng file CAD c i tp mun nhp vo. + Thit t cc tham s nhp trong mc Options + Chn OK - Trn cc tp vi nhau. + T menu Mastercam filefile Merge/Pattern. + Trong hp thoi c m, la chn kiu file, V chn tp cn nhp. + S dng ty chn trn thanh trng thi Merge/Pattern la chn mt im c s cho v tr t d liu, v nh ngha t l, gc quay, trc i xng (x,y hoc z)

+ Chn Apply. + n ESC kt thc lnh.

Thit t thuc tnh my.

- Trn cy qun l Toolpath manager bn c th hin th cc kiu thuc tnh my bng cch ko dn cc mc thuc tnh.

55

- Th Files. S dng th file ny xem v nh ngha cc tn tp v cc d liu ng dng c dng cho cc thao tc trong nhm my la chn. Hp thoi Machine Group Properties c hin th nh di y.

56

- Th Tool Setting. S dng th ny iu khin file NC, b dao, tc chy dao, tc trc chnh, lm mt, v cc tham s ng dng c khc, bao gm c vt liu la chn.

- Th Stock setup.

57

Th ny cung cp cho bn cc phng php nh ngha phi. Bn thc hin thit lp kch thc

- Th Safety Zone. Th ny cho php ta thit lp vng an ton ca my.

58

- Cn cc cch thit lp ng chy dao ta s trnh by di y. 3.4 Lp trnh gia cng. La chn phng n n dao.
Thit lp thng s cng ngh.

LP TRNH PHAY: CC PHNG PHP GIA CNG 2.5D.

3.5. Contour v Cc lnh h tr to ng chy dao.
ng contour l mt ng cong ph hp ca cc i tng hnh hc lin kt to ln profin cho qu trnh gia cng. Li ch ca vic xc nh ng cong l cho php cc lin kt c lin tc, t bng to thnh cc i tng n. Cc profin v cc hp ct c s dng trong di chuyn dng c trong qu trnh ct.

Trong qu trnh xc nh chi cc phng php cng ngh cho chi tit gia cng chng ta phi nhn nh u l bin dng cn la chn ng chy dao contour. ng chy dao contour to ra cc ng chy dao dc theo cc i tng lin kt contour. Gia cng thc hin c th bn trong hay bn ngoi bin dng.

3.5.1 ng chy dao contour c bn. Trit l ca gio trnh: Hc vin s tip cn gio trnh v hc cch s dng phn mm Mastercam theo cc v d. Tc l vi mi bi hc gio trnh s a ra v d v thc hin gii quyt vn trn v d . y l cch tip cn trc quan v trnh t theo vn no mi. Cch tip cn vn m bo mt quy trnh CAM y c th t. Ta thc hnh vi VD hnh v 2D nh di y.

59

Kt thc bi hc ny hc vin s lm bt c cc k nng sau: + Thit lp v To mt ng dng c contour. + La chn dao v thit t cc tham s dng c. + S dng Lnh Backplot quan st kim tra ng dng c + Hiu chnh ng chy dao v rebuile li. + La chn post processor v xut file *NC gia cng.
1. T menu chnh la chn Toolpaths la chn

2. La chn ng Contour Enter.

60

3. Menu trng thi lnh xut hin.

4. La chn dao. Kch chut phi vo khong trng nh hnh di y.

61

La chn Tool manager La chn dao c thng s nh hnh di y.

chn Ok kt thc la chn.

Nhp cc tham s ng hc cho dao: + Tc tin dao (speed rate): 300 + Tc quay trc chnh (Spindle speed): 1200 + Tc xung dao (Plunge rate): 150 + Tc rt dao (Retract rate): 150. + cc thng s khc nhp tng t nh hnh di y:

62

5. Nhp cc tham s ng dng c. La chn th contour Parameters Nhp gi tr Retract 10 (chiu cao rt dao sau mi ln i dao) Nhp gi tr Feed plane 2 ( Mt phng bt u thc hin gia cng). Nhp gi tr Depth -10 (Chiu su gia cng). Cc thng s khc c nhp tng t, kt qu nhp cc gi tr c hin th

nh hnh v di y.

63

Chn OK pht sinh ng dng c, n s c thy nh hnh di y.

6. Quan st kim tra ng dng c.

-

La chn cng c lnh Backplot

, khi thanh trng thi lnh c m ra

nh hnh di y.

64

Cc cng c lnh trn cho php bn iu khin quan st ng i ca dao

trong tin trnh.

7- Bin tp li ng dng c. - n ESC thot khi lnh, la chn biu tng Paramaters

65

La chn hp kim Lead in/out . Trong hp kim ny cho php bn nh r

vo dao v ra dao theo ng thng hay cung trn. Trong VD ny chng ta nhp cc gi tr nh hnh di y.

Chn OK chp nhn. Khi bn quay li menu qun l Operations manager, bn s thy du X mu

nh hnh di y, ngha l ng chy dao ca bn cha b thay i. La chn Regen Path pht sinh li ng chy dao.

66

Sau khi pht sinh li ng chy dao. Th ng dng c ca bn s c

thy nh hnh di y.

8- To file chng trnh gia cng NC. - T menu chnh la chn Machine typeControl definition. Khi mt hp thoi c m ra nh hnh di y.

67

- La chn ty chn post processors. Khi y hp thoi mi c m ra nh hnh di y.

- La chn Add files v chn tp c dng ui *.pst ph hp vi my gia cng. - Chn OK, ng hp thoi ny li. V quay tr v hp thoi ban u

68

- Ko menu s xung vng ty chn post processors v chn file nh dng m my gia cng.

- Chn OK. ng hp thoi - La chn Post hp thoi Post processing c m ra.

- Ta la cc ty chn nh di y.

69

Chn OK khi file NC s c t ng pht sinh nh hnh di y.

70

3.5.2 To nguyn cng phay th v phay tinh. Vi mc ny hc vin s hc c nhng k nng sau y: + Copy nguyn cng. + To nguyn cng phay th. + To nguyn cng phay tinh. + Thay i dao v tc chy dao. aCopy nguyn cng.

- Kch chut phi vo nguyn cng Contour 2D nh hnh v v la chn Copy.

71

Kch chut phi v chn paste, khi mt nguyn cng mi c to ra nh

hnh di y.

Kch chut vo tn nguyn cng v i tn nguyn cng 1 l rough v

nguyn cng 2 l finish nh hnh di y.

72

b-

Thit t tham s phay th.

- La chn biu tng Paramaters nguyn cng 1. - La chn Toolpath Paramaters - Kch chut phi v la chn Tool manager - La chn dao 25 mm HSS flat endmill ri chn OK. - La chn th contour paramaters - lt phay th ny ta t gi tr lng d l 1 (XY stockto leave) . Cc thng s khc c t nh hnh di y.

- La chn hp kim Multi Passes v la chn Keep tool down , cc thng s khc c xc nh nh di y.

73

- Chn OK - Chn Lead in/out. - Nhp gi tr Overlap l 5, ngha l cc cung vo dao v ra dao s m rng ra mt khong l 5. - Thay i Entry Arc-Radius % l 50. - La chn nt sao chp kt qu thit t.

- Chn OK chp nhn.

74

c-

Thit t tham s phay tinh. La chn biu tng Paramaters nguyn cng 2. La chn th Tool paramaters. Nhp gi tr 20 cho Feed rate (tc tin dao). Chn th Contour Paramaters. La chn Lead in\out. Nhp gi tr 5 cho Overlap , v chc chn cc gi tr c nhp nh di

y.

Chn OK chp nhn. Chn Select All Chn Regent Path . . Khi ng dng c s c pht sinh li, v c

thy nh di y.

75

3.5.3 To nguyn cng vt gc theo ng contour. - Thc hin Copy nguyn cng Finish v i tn nguyn cng ny l Chamfer

Chn biu tng Paramaters Chn th Tool Paramaters.

76

La chn dao 10mm HSS Chamfer trong th vin. La chn th Contour Paramaters . Ko s mc Contour type, V la chn 2D Chamfer.

La chn nt Chamfer. Nhp cc gi tr nh hnh di y.

Chon OK quay li hp thoi Contour Paramaters.

77

Nhp gi tr 0 cho Depth (chiu su ct), v chon Incremental (tng i).

Cc thng s khc c thit lp nh cc thng s di y.

Chn OK kt thc. Chn Regent Path pht sinh li ng dng c. La chn chc nng Verify m phng qu trnh gia cng.

78

3.5.4 i xng ng dng c. - T menu lnh chn Tool path Transform. - La chn Tool paph Group 1. - La chn Type Mirror. (i xng) - Chn Creat new operations geometry (Copy hnh hc). Cc thng s cn li chn tng t nh hnh di y.

79

Chn th Mirror. Kch chn Reverse Tool path (Ngha l ng dng c c to cng i

xng qua trc la chn). Cc thng s khc nh hnh di y.

Chn Ok. Khi ng dng c pht sinh c thy nh hnh di y.

80

3.5.5 Ct cc khe rnh. To hnh 2D nh di y.

Mc ny ta s hc k nng:

+ Ct bn trong mt ng cong kn

81

+ Thm i tng hnh hc cho mt nguyn cng to. a- To ng dng c. T menu chnh chn Tool path Contour. Chn bin dng kn nh hnh di y.

Chn OK. Kch chut phi chn dao t th vin (chn dao 10 mm HSS flat endmill) La chn th Contour Paramater (Chi tit c dy l 12 v bn s ct

mt lng l 3mm). Cc tham s c nhp vo nh hnh di y.

82

La chn hp kim Lead in\out . Nhp gi tr 0 cho EntryLine-length Nhp gi tr 12 cho Entry Arc- Radius. Chn xc nh thng s ra dao tng t nh vo dao.

Nhp gi tr 5 cho Overlap. Cc gi tr khc c nhp nh hnh bn di

83

Chn OK . Khi y ng dng c c pht sinh nh di y.

b- Thm i tng hnh hc vo nguyn cng to.

-

Trong Menu qun l nguyn cng. Chn biu tng Geometry

84

Kch chut phi vo chain v chn Add Chain.

La chn i tng hnh hc nh hnh di y.

85

Enter Hp thoi Chain manager c hin th nh di y.

Chn OK v chn Regen path . khi ng dng c c pht sinh thm

cho nguyn cng c thy nh hnh di y.

3.5.6 Sao chp xoay ng dng c. - mc ny bn s hc k nng dch chuyn v xoay ng dng c. a- To ng dng c. -

M file Rotation-mm.mc9. T menu chnh chn Tool path Contour.

86

La chn i tng hnh hc nh di y.

Chn OK. Chn Dao 6 mm HSS endmill t th vin. La chn th Contour Paramaters. Nhp gi tr -6 cho chiu su ct Depth. Cc thng s khc c c nhp

c gi tr nh di y.

87

Chn hp kim Multi Passes. Nhp cc gi tr cho hp ny nh hnh di

y.

La chn mc thng s vo v ra dao Lead in\out v nhp cc gi tr nh

hnh di y.

88

Chn OK pht sinh ng chay dao. V ng chy dao pht sinh s

c thy nh hnh di y.

b- Sao chp bng cch xoay ng dng c. - T menu chnh chn Tool path Transform. - Chn Type-Rotate. - Chn Method- Coordinate. C ngha rng cc ng dng c s c pht sinh tnh ton trong mt mt phng tng t. Cc thng s khc c xc nh nh di y.

89

La chn th Rotate. Chn Oirgin (gc ta ) im dng quay (chn Point cho bn la chn

mt im lm gc quay)
-

Nhp gi tr 29 cho Numberof steps ( s i tng c to) Nhp gi tr 12 cho Start Angle ( gc bt u quay), v nhp gi tr 12 cho

Rotate Angle (bi v 360:30=12)

90

Chn OK. Khi y ng chy dao pht sinh c thy nh hnh di y.

91

3.6 To ng gia cng khoan. - M file gasket-mm.mc9.

a- Chn cc l cho nguyn cng khoan.

-

T menu chnh la chn Tool

pathDrill.
-

La chn ty chn Sorting, la chn

phng php dch dao point to point, nh hnh di y.

92

Chn OK. La chn Mask on Arc. ( ty chn ny cho

php ta la chn i tng c cng kch thc). La chn l kch thc 6 mm (ngha l ch

chn cc l c kch thc 6 mm) Enter. -

La chn th t cc l khoan. Enter. La chn im bt u khoan Enter. Chn dao. Kch chut phi v chn dao t th vin dao. Chn nt ty chn Filter. Chn None. Chn nt Dill, (Ngha l khi quay tr v th

vin dao ta ch c dao khoan c hin th).

93

Chn OK. La chn dao 6 mm HSS Drill v chn OK.

b- La chn cc tham s khoan.

-

Chn th Simple drill-no peck Nhp gi tr -6 cho gi tr chiu su Depth, cc gi tr khc cng c xc

nh nh hnh di y.

94

Trong la chn ty chn Cycle cho ta la chn cc kiu khoan Kiu khoan khng rt dao/doa ngc li. Thi gian ngng i chiu quay. Chia lm nhiu ln khoan su Lng khoan su u tin. Lng n su tip theo. Khong an ton. Khoan b phoi. Lng rt dao v Tar Doa

+ Drill/Counterbore: + Dwell: + Peck drill: + 1 st peck: + Subsequent peck: + Peck clearance: + Chip break: + Retract amount: + Tap: + Bore:
-

La chn hp kim Tip comp.

95

Nhp cc gi tr vo hp ny nh di y.

Chn OK. Chn OK. pht sinh ng chy dao. Chn ch nhn Gview Isometric. Khi ng chy dao quan st c

s nh hnh di y.

c- Khoan cc l nm cc b mt khc nhau.

-

M file tab-mm.mc9.

96

T menu chnh chn Tool path chn Drill. La chn ty chn Sorting v chn kiu dch dao Point to Point . La chn cc l khoan, v kt qu c thy nh hnh di y.

- La chn mi khoan 5mm HSS

97

- La chn th Sinple drill- no peck. Trong th ny la chn cc thng s nh hnh di y. + Nhp gi tr 6 cho Clearace (Mt phng rt dao v khi kt thc gia cng), v chn ty chn Absolute (theo ta tit i) + Nhp gi tr 2 cho Retract (lng rt dao gia cc ln n dao) v chn ty chn Incremental (theo ta tng i) + Nhp gi tr 0 cho Top of stock (b mt phi), v chn ty chn Incremental + Nhp gi tr -2 cho Depth (chiu su ct). Chn ty chn Incremental.

La chn hp kim Tip comp, v nhp cc thng s nh hnh bn di.

98

Chn OK. V kt thc qu trnh thit lp cc thng s. Khi ng chy dao khoan s c pht sinh nh hnh di y.

3.7 VD gia cng 2D. M file mounting plate-mm.mc9.

99

a- Gia cng bin dng ngoi. T menu chnh chn Tool path, contour La chn ng bao ngoi nh di y.

Enter. Chn dao 20 mm HSS endmill OK Chn th Contour paramaters La chn hp kim Multi passes v nhp cc thng s nh di y.

100

La chn hp kim Depth cut. Nhp gi tr lng n su ln nht Max rough step l 10, cc gi tr khc c xc nh nh hnh di y.

La chn hp kim Lead in\out , nhp cc tham s cho bng ny nh hnh di y.

101

Chn OK. Cc tham s trong th Contour paramaters nh hnh di y.

102

La chn OK pht sinh ng chay dao.

b- Lm sch gc ln ngoi.
-

La chn Tool path Contour. La chn bin dng ngoi.

103

La chn dao 5 mm HSS endmill. La chn th Contour paramaters, La chn Remachining t menu s contour type Nhp gi tr -25 cho Depth v chn ty chn Absolute B la chn ty chn Multi passes. Bi v nguyn cng ny ta ch cn phay mt lt.

La chn hp kim Lead in\out, nhp cc tham s cho hp ny nh hnh di y.

104

Nhp cc tham s khc ca th Contour paramaters nh hnh di y.

Chn OK. Khi ng chy dao c pht sinh cho nguyn cng ny nh di y.

c- Gia cng l v rnh. T menu chnh la chn Tool pathCircle pathCircmill tool path. La chn ng trn nh hnh di.

105

Chn dao 32 mm HSS flat endmill t th vin dao La chn th Circmill Paramater Nhp gi tr -25 cho Depth. Nhp gi tr 3 cho Overlap. La chn hp kim Depth cut , nhp gi tr 5 cho Max. rough step, La chn Keep down tool, cc tham s khc c thit lp nh di y.

La chn hp kim Roughing (phay th) , b la chn helical entry, cc tham s c xc nh nh hp di y.

106

Nhp cc tham s khc nh di y.

Chn OK pht sinh ng chy dao.

107

d- Doa l: T menu chnhTool pathCircle path Helix bore Chn ng trn nh hnh di y.

Chn dao 32 mm flat endmill Nhp gi tri -25 cho gi tr Depth La chn Start at Center Nhp gi tr 3 cho Overlap, cc tham s khc nhp nh hnh di y.

108

Chn th Rough/Finish Paramaters. Nhp gi tr 2 cho Rought Pitck. Nhp gi tr 2 cho Number of rough Pasess v 5 cho Rough pass stepover.

La chn ty chn Finish. Nhp gi tr 1 cho Finish stepover. Cc gi tr ca bn nhp nh hnh di y.

109

Chn OK pht sinh ng chy dao.

e- Phay rnh. - La chn Tool path Circle pathSlot mill

110

- La chn dao 32 mm flat endmill. - La chn th Slot Paramaters. Nhp gi tr -25 cho Depth, nhp gi tr 3 cho Overlap, cc thng s khc c thit lp nh di y.

111

La chn th Rough/Finish Paramater, Nhp gi tr 3 cho Plunge Angle, nhp gi tr 1 cho Finishing passes-Number, Nhp gi tr 1 cho Spacing, Cc tham s khc c thit lp nh hnh di y.

Chn OK pht sinh ng chy dao.

112

f- S dng auto Drill to cc nguyn cng khoan. mc ny ta s hc cc k nng :

+ S dng auto Drill to nguyn cng khoan ly du, khoan ban u, ta r, vt gc. 1/ la chn cc l D12 cho nguyn cng u. T menu chnh la chn Tool pathCircle pathauto Drill. La chn ty chn Sorting.

La chn ng chn 12

113

114

. Nhp cc gi tr li nh hnh di y.

Chn th Depth, Group and library. Trong mc Drill group and type, nhp vo tn 12mm thru holes (ngha

rng y l tn nhm nguyn cng)

-

Nhp gi tr -25 cho Depth (chiu su khoan) Cc tham s khc c xc lp nh di y.

115

chn the Pre- Drilling, nhp cc gi tr cho th ny nh hnh di y. (Cc

thng s ca th ny ng dng cho bc khoan ph)

116

Chn OK pht sinh ng dng c. Khi y ng dng c c pht sinh

v trn cy qun l Tool path manager s t ng pht sinh cc nguyn cng khoan nh hnh di y.

3/ La chn l 10 cho nguyn cng th 2. - T menu chnh chn Tool pathCircle pathAuto drill. - La chn ty chn Sortting v chn kiu i dao.

117

- La chn Mask on arc. V la chn i tng 10 nh di y.

Thit t tham s cho nguyn cng ny. nguyn cng ny chng ta thc hin cc bc khoan nh di y + Khoan ly giu

118

+ Khoan ph su xung 2mm + Ta r ren phi + Vt mp

-

T ty chn Finish tool type ko s xung, chn Tap HR Fine Nhp gi tr 20 cho Default spot drill diameter Trong vng ty chn Chamfering with the spot drill la chn Make

separate operation, v nhp gi tr 2 cho Chamfer size.

-

La chn hp kim Home pos. nhp cc thng s cho hp ny nh di

y. (V tr tr v ca dao khi kt thc gia cng)

Chn OK v cc thng s khi y trong th Tool paramaters c thit lp

nh hnh di y.

119

Chn th Depth, Group and library Trong ty chn Drill group and type, ta nh vo dng ch 10 mm drill

and tapped. Cc tham s cn li trong th ny ta thit lp nh hnh di y.

120

Chn th Pre-Drilling. Nhp gi tr 2 cho Pre-drilldiameter increment,

cc tham s lhc c thit lp nh hnh di y.

Chn OK pht sinh ng chy dao. Khi y trong nguyn cng khoan s

t ng pht sinh cc bc khoan nh hnh di y.

121

3.8 Gia cng hc. - M file facing-mm.mc9.

122

 To bin dng phi. + la chn th Stock setup.

+ Nhp 90 cho gi tr kch thc y ca m hnh phi + Nhp 120 cho gi tr kch thc X + Nhp gi tr 15 cho kch thc Z + Nhp gi tr 3 cho Stock Origin-Z , (c ngha rng b mt phi nm v tr ta z l 3) + Cc tham s ca khc c thit lp nh hnh di y.

123

+ Chn OK , khi y bin dng phi bao chi tit c hin th nh di y.

124

 Gia cng hc.

-

T menu chnh chn Tool path Pocket. La chn bin dng. La chn dao 25 mm HSS flat endmillchn OK Chn th Pocketing paramaters, nhp gi tr -8 cho chiu su Depth, cc

tham s khc xc nh nh di y.

La chn th Roughing/Finishing paramaters. V thit t cc tham s

nh di y.

125

Chn nt ty chn Entry-helix. La chn th Helix, v thit t cc tham s

nh di y.

126

La chn nt Lead in/out, nhp cc gi tr cho bng ny nh hnh di y.

Chn OK Mastercam pht sinh ng chy dao.

127

La chn cng c Backplotting m phng kim tra ng chy dao.

To ng chy dao ct lng phi cha gia cng c.

-

T menu chnh chn Tool path Pocket. La chn bin dng Chn Dao phay 10 mm HSS flat endmill Chn th Pocketing Paramaters, Nhp gi tr -8 cho gi tr Depth. La chn kiu phay Remachining t menu s Pocket type.

128

Ta thit lp cc gi tr cho th ny nh di y.

Chn nt Remachining v thit lp tham s cho hp thoi ny nh di

y.

OK.

129

Chn th Rough/finish paramaters, ta nhp cc gi tr cho th ny nh

hnh di y.

La chn Lead in/out, nhp cc thng s cho th ny nh hnh di y.

130

Chn Ok pht sinh ng chy dao. Khi y ng chy dao c pht

sinh c thy nh di y.

131

Bi 4 : Gia cng mt s chi tit in hnh.

1. Tng hp kin thc v gia cng 2.5D. 2. V d 1: Quy trnh gia cng sn phm mu . 3. V d 2 : Quy trnh gia cng mt s c cu ca robot DKS

132

Bi 5 Phng php gia cng b mt 3D: Gia cng th

Mc ch: Bi ton t ra l khi bn thc hin phay mt chi tit nh cnh qut ca nm thu lc chng hn th vi nhng ng chy dao 2.5D khng th thc hin c. Vy khi phi s dng nhng ng chy dao nh th no khi trong trng hp ny v trong mt tnh hung khc khi gia cng mt chi tit m bin dng l mt b mt cong . iu ny hon ton c th gii quyt khi bn thc hin vi ng chy giao gia cng b mt. Mc ch ca bi hc l cho bn nhng k nng phn tch vn v s dng cng c trn phn mm Mastercam X lm nhng cng vic nh th Nhng k nng bn hc c: Quy trnh gia cng v phng n la chn dng c ct Mt s phng php gia cng th b mt 3D . ng dng : Gia cng khun mu Gii thiu v Gia cng tc cao V d v thc hnh Tng kt bi v gii p thc mc 5.1 Quy trnh gia cng v phng n la chn dng c ct. 5.2 Mt s phng php gia cng th b mt 3D.
Phay th l qu trnh s bc i mt lng ln vt liu trn b mt chi tit trong thi gian ngn m khng cn t chnh xc cao. Trong phn ny phn setup chng ta s khng cp n v c thng s ging mt vi phn trc y chng ta cng khng ni n. Ngi c se phi nh nhng tham s thit lp.

5.2.1 Thng s chung ca chu trnh surface

Gi tr tuyt i (Absolute) v tng i (Incremental).

133

Hu ht cc thng s Clearance (mt phng an ton), Retract (mt phng li dao), Feed plan (mt phng ct gt), Top of stock (mt trn ca phi), Depth (chiu su ct) u c th c nhp bng gi tr tng i hoc tuyt i.

*Absolute: gi tr tuyt i lun c tnh t gc to (0,0,0). Nu ta chn cc i tng hnh hc to cc ng chy dao th cc ng chy dao ny s su tuyt i, bt k i tng hnh hc ta chn cao no. * Increamental: khi ta nhp gi tr tng i th Depth v Top of Stock s lin quan n v tr ca i tng hnh hc cn Clearancen, Retract v Feed plan s ph thuc vo Top of Stock. Nu ta chn cc i tng hnh hc to cc ng chy dao th cc ng chy dao ny s sau ca i tng hnh hc ta chn. Ch : trong cc chu trnh Multiaxis th Clearance, Retract v feed plane c t ng gi tr tng i. Tp tin Regen

134

Tp tin Regen c s dng tng tc khi cp nht thng s cho cc chu trnh Surface phc tp. Ta c th t li tn v ng dn cho tp tin Regen lin quan n mi chu trnh Surface. - Trc tin ta rt Regen bt k chu trnh Surface no. - Nhp tn v ch ng dn lu tp tin Regen cho chu trnh Surface. - Chn Ok.

trang Surface parameters ca

vo dao (Plunge Thit lp cc ng), ra (retract) dao: Hp thoi Direction cho ta cc tu chn to cc ng vo, ra dao cho cc chu trnh Surface. Thng s Plunge cho php ta thit lp chuyn ng vo dao thng s Retract cho php ta thit lp chuyn ng ra dao. - trang Surface parameters ca bt k chu trnh Surface no nh du chn v click vo node - Thit lp cc gi tr Direction.

Ch : -Ta c th chn node Vector nhp gi tr theo 3 phng X, Y, Z.

135

- Ta cng c th chn node Line tr v mn hnh ho chn ng thng cho chuyn ng vo hoc ra dao. ng bin gii hn vng chy dao (Tool containtment boundaries) ng bin gii hn vng chy dao l mt chui (Line, arc) kn, dng gii hn vng gia cng trong mt chu trnh. S dng ng gii hn vng chy dao m bo rng dao ct trong mt vng nht nh. ng gii hn vng chy dao ny c th lm bt k cao Z no so vi chi tit. V d:

Drive v check surfaces Drive Surface l nhng vng c gia cng trn chi tit. Check Surfaces bo v nhng vng trn chi tit t s chuyn ng ca dng c ct. to mt chu trnh Surface th ta phi chn t nht mt Drive Surface. Trong khi th Check Surfaces khng nht thit phi c chn, chng ch gii gin chuyn ng ca dng c ct, m bo mt chng trnh chnh xc hn. V d:

136

Trong hnh v d trn, 3 mt phng to nn mt mt y v 2 vch. Mt y c chn lm Drive Surface (Vng gia cng) cn 2 mt kia c chn lm Check Surface. Khi , dng c ct s ct dc theo mt y v trnh chm vo 2 mt vch.

Lc chu trnh (Filtering toolpaths): Khi ta lc mt chu trnh, Mastercam s thay i ng chy dao trong mt dng sai nht nh thnh nhng chuyn ng thng

Ta cng c th thay th nhng chuyn ng thng thnh nhng chuyn ng theo cung trn vi bn knh trong gii hn t nh n ln nht (do ta thit lp). * Phng php chn Filter toolpaths: - click phi trn hp thoi Operation Manager chn Option/Filter lc chu trnh nhng tp tin hin hnh. - Chn Main menu/NC utils lc bt c tp tin NCI no. Phng php ny s to ra tp tin ASCII NCI.

137

- Thay th nhng chuyn ng thnh chuyn ng theo cung trn: khi ta lc chu trnh theo phng php ny, ta phi ch ra bn knh ca cung trn ln nht hoc nh nht c th. Tu thuc vo hnh dng hnh hc v dung sai cc cung trn c to ra c bn knh ln s lm cho chu trnh ngn gn hn, trong khi cung trn c to ra c bn knh ln s lm cho chu trnh phc tp hn.

Nh vy, gii thiu tham s c bn ca vic to nhng chu trnh phay Surface. By gi chng ta s i vo cc chu trnh phay th c th. Cc thc to mi chu trnh v c bn khng c g, nhng vic thu hiu nhng tham s trong mi mt chu trnh l iu rt quan trng. N nh hng ti thi gian gia cng, cht lng ca mt sn phm phay th chun b phay tinh

138

5.2.2 Gia vi ng chy dao song song (Rough Parallel) y l chu trnh thng s dng ph tho cc b mt li (boss) hoc lm (cavity) n gin. Cc ng chy dao c to ra s song song nhau vi Z l trc thu 3 c iu khin c lp. Trnh t to ra mt chu trnh rough parallel: -

Chn Main menu/ Toolpaths/ Surface/ rough parallel. Chn dng chi tit li, lm hoc khng xc nh (unspecified) t Part Chn cc b mt cn c gia cng. Nhp cc thng s cho chu trnh ri chn Ok. Click phi/ Toolpaths / Surface rough / parallel.

shape menu.

Ghi ch: ta c th to chu trnh rough parallel t hp thoi Operation manager:

139

Total tolerance: l dung sai tng ch c chu trnh surface, n kt hp Maximun stepdown: thit lp khong cch ln nht gia hai lp ct k

gia Arc filter tolerance v Cut tolerance theo mt filter ratio no . nhau theo phng Z trong chu trnh Surface.

Maximum stepover: thit lp khong cch ln nht gia 2 lt ct theo

phng XY trong chi trnh Surface. Khong cch ny nh th chu trnh cng chnh xc nhng chng trnh cng di hn v tn nhiu thi gian tnh ton hn.

140

Approx. scallop height on flat floor: tnh ton khong dch dao

ngang sao cho to c chiu cao nhp nh (Scallop) ng theo chiu cao theo yu cu trn phng. n v mm.

Approx. scallop height at 45 Degrees: Tnh ton khong dch dao

ngang sao cho to c chiu cao nhp nh (Scallop) ng chiu cao theo yu cu trn mt phng nghing 45 .

Machining angle: thit lp hng ct theo chu trnh t 0 n 360 so Cuttinh method: trong chu trnh phay Parallel c th chn mt trong hai Ct mt pha (one way): theo phng php ny, sau mt lt ct,

vi trc X ca Cplane. kiu chy dao sau:

dng c ct s rt dao ln mt phng an ton v li dao nhanh v im u bt u lt ct tip theo. Tt c cc lt ct u cng mt pha. Ct theo hai pha (Zigzag): theo phng php ny, dng c ct s di chuyn ti lui dc theo chi tit.

141

Plunge control: y l thng s xc nh cch dao chuyn ng theo

phng Z trong chu trnh ct b. N c s dng ngn chn dng c ct chy khng t nhng lt ct trc . Thng s ny c tc dng i vi dng chi tit lm . Ta c th chn dng c ct ln xung dc theo chi tit, dng c ct ch xung t mt pha hoc t hai pha.

Allow Multiple Plunges Along Cut: c tnh ny s bo cho h Cut From One Side: c tnh ny s hng dn h thng ct dc

thng ct dc chi tit.

theo mt bn ca chi tit. Nu thit lp phng php ct l Zig-zag th h thng s ct dc theo tng ng bt u t mi bn, iu ny s lm cho c hai bn u b ct. Nu thit lp phng pho ct oneway th h thng ch ct mt bn.

Cut From Both Side: c tnh ny s ct dc theo c hai bn ca

chi tit. Nu thit lp phng php ct zig zag th h thng s ct dc theo tng ng ct bt u t mt bn v chuyn sang ct bn i din, nu thit lp phng php ct theo oneway th h thng s ct dc theo ton b mt bn sau mi chuyn sang ct ton b bn cn li. Ghi ch: +Cut From One Side, Cut From Both Side dao ch thay i chiu su ct Z mt ln v dc theo chiu ct. p dng cho b mt li 1 o. + Allow Multiple Plunges Along Cut : dao ln xung theo phng Z nhiu ln. p dng cho b mt li nhiu o.
-

Cut depths: Phng php ny xc nh chiu su ct ti thiu v ti a

(tng i v tuyt i) cho cc lt ct dc theo phng Z trong cc chu trnh phay b mt (Surface). Cc chiu su ny c lin quan n nh v y ca chi tit.

142

Absolute: Thit lp chiu su nh nht. Tt c cc lt ct trong chu Minimum depth: chiu su nh nht m dng c ct c th vn Maximum depth: Chiu su ln nht m dng c ct c th

trnh s nm gia hai gi tr ny. ti

xung.

Selectet depths: tr v mn hnh ho chn chiu su nh

nht v chiu su ln nht.

143

Incremental: t cc lt ct cc cao tng i so vi b mt chi Adjustment to top cut: thit lp khong cch gia cc chiu su

tit. MasterCAM s t tnh ton chiu su ti thiu v chiu su ti a cho chu trnh.

nh nht m Mastercam tnh ton c v lt ct u tin. Mt s dng s cho iu chnh xung v m s cho iu chnh ln. Adjustment to other cuts: thit lp khong cch gia chiu su ln nht m Mastercam tnh ton c v cc lt ct trong chu trnh. Mt s dng s cho iu chnh theo chiu dng v s m s cho iu chnh theo chiu m.

Gap settings: Thng s ny iu khin vic li dao hay gi nguyn

chuyn ng khi c khe h trong chuyn ng chy dao. Khe h c th sinh ra gia hai lt ct, gia drive v check surfaces, gia 2 drive surfaces. V d:

144

Hnh v trn , khe h sinh ra gia Drive surfaces. Khe h nh hn khong thit lp th dao s li v mt phng an ton ri, qua khi xe h ri xung dao li. Chn nt Gap settings thit lp cc thng s: Distance: Thit lp khe h nh nht gia cc chuyn ng chy dao (gi tr tuyt i). % of stepover: khe h nh nht c xc nh bng gi tr % ca khong dch dao ngang ln nht.

145

Advanced settings: thng s ny thit lp chuyn ng ca dao trn cc

cnh ca b mt (Surface), khi rn (solid) v s chnh xc (dung sai) ca chuyn ng chy dao trn nhng gc nhn. Mastercam cung cp 3 phng php thit lp chuyn ng chy dao bo trn trn cc cnh trong chu trnh phay b mt (Surface toolpath):

Automatically (base on geometry): thit lp vic chuyn ng chy dao bo trn trn cc cnh ph thuc vo s c mt hay khng c mt ca ng gii hn chy dao (tool containment boundary). Nu ta c nh ngha ng gii hn chy dao th dao s bo trn nhng cnh gia cc b mt v cc cnh ngoi cng ca chi tit. Nu ta khng nh ngha ng gii hn chy dao th dao ch bo trn cc cnh gia cc b mt ca chi tit.

146

 Only between surfaces (solid faces): dao ch bo trn cc cnh gia cc b mt ca chi tit Over all edges: dao s bo trn nhng cnh gia cc b mt v cc cnh ngoi cng ca chi tit.

Sharp corner tolerance: thng s ny thit lp chnh xc ca nhng gc gia cc b mt v ca nhng cnh ngoi cng ca chi tit:

Distance: chia chuyn ng bo trn ca dao thnh nhng gi tr c xc nh bng gi tr do ta nhp. Mt dung sai cht (gi tr nhp vo nh hn) s to thnh nhng gc sc hn vi tng nhiu hn. Mt dung sai lng (gi tr nhp vo ln hn % of cut tolerance: chia chuyn ng bo trn ca dao thnh nhng gi tr c xc nh bng gi tr phn trm ca dung sai ct gt (cut tolerance). Khi ta thay i dung sai ct gt ra nhng gc sc hn vi tng nhiu hn. Mt dung sai (s nhp vo b) s to ra nhng gc sc hn vi tng nhiu hn. Mt dung sai nh (gi tr nhp vo ln hn) s to nhng gc trn vi tng t hn.

Skip hidden face test for solid body: nhng mt b che khut s khng c gia cng trong nhng chu trnh 3 trc. Chn tnh nng ny i vi chi tit c nhiu b mt, nh vy th thi gian tnh ton s gim li.

147

 Check for internal sharp corner: nhng b mt vi cc nh bn trong c th dn n ng dao. i khi lm vic chuyn d liu, cc b mt c a vo MasterCAM c th cha cc nh nhn. Mastercam s thng bo khi n bt gp mt nh nhn v nhc ta nn hiu chnh li chi tit.

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5.2.3 Radial rough toolpaths.

y l chu trnh s dng ch yu cho nhng chi tit trn, cc ng chy dao c sinh ra s xoay quanh mt tm. o o menu. o o Chn cc b mt cn c gia cng. Nhp cc thng s cho chu trnh ri chn OK. Trnh t to mt chu trnh rough radial: Chn Main menu / Toolpaths / surface / Rough / Radial. Chn dng chi tit li, lm, hoc khng xc nh t parth shape

Ghi ch: ta c th to chu trnh rough parallel t hp thoi Operation Manager : click phi / Toolpaths / Surface rough / Radial:

Gii thch cc thng s c bn ca chu trnh khi thit lp ng chy dao:

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- max. angle increment: thit lp gc tng ln nht gia cc lt ct. Kt qu ca gc tng c th nh hn gi tr thit lp v h thng s chia chu trnh ra theo nhng s nguyn. - start offset distance: thit lp khong gia cc ng chy dao so vi tm ca chu trnh Radial (im tm ny do ta ch ra). - start angle: thit lp gc m chu trnh bt u. - sweep angle: thit lp gc (0-360) m chu trnh s qut qua, bt u t start angle. Nu ta nhp vo s m h thng s to ra ng chy dao ngc chiu kim ng h. - start point: + start inside: bt u chu trnh t tm v ct v pha ng bin ngoi. + start outside: bt u chu trnh t bin dng ngoi v ct v pha tm ca chu trnh.

Ch : cc thng s cn li c trnh by t cc chu trnh trc nn ngi vit khng trnh by li. V d: ca chu trnh Rough Radial:

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5.2.4 Project rough toolpaths

Chu trnh ny cho php ta chiu nhng ng thng hoc cong (curves), im hoc cc file NCI khc ln nhng b mt do ta ch ra. Chu trnh ny c th dng iu khc, chm, tr o o o o Trnh t to mt chu trnh rough project: Chn Main menu / Toolpaths / Surface / Rough / Project. Chn bin dng chi tit li (boss), lm (cavity) hoc khng xc nh Chn cc b mt cn c gia cng. Nhp thng s cho chu trnh ri chn ok.

(unspecified) t part shape menu.

Ghi ch: ta c th to chu trnh rough parallel t hp thoi Operation manager: click phi / toolpaths / surface rough / project:

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 o o

cc thng s c bn ca chu trnh: NCI: chiu mt chu trnh ln nhng b mt do ta chn. Chu Curves: chiu mt hoc mt tp hp ng (curves) ln nhng trnh ny phi c to trong cng mt file vi chu trnh Project. b mt do ta chn. H thng s nhc ta chn Curves sau khi nhp cc thng s. o
o

Points: Chiu mt hoc mt tp hp im (points) ln nhng Retract between cuts: thng s ny khi c chn s cho php

b mt do ta chn. H thng s nhc ta chn im sau khi nhp thng s. nhc dao ln gia cc lt ct. Khi khng c chn th dao s gi nguyn v tr gia cc lt ct.

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V d :

5.2.5 Flowline rough toolpaths

Chu trnh ny c kh nng qun l tht chnh xc nhp nh b mt cn li trn chi tit sau gia cng. Chc nng Flowline ch to c ng chy dao cho mt b mt n xc nh. Trnh t to mt chu trnh rough Flowline. o Chn Main menu / Toolpaths / Surface / Rough / Flowline o o o Chn bin dng chi tit li (boss), lm (cavity) hoc khng xc nh Chn cc b mt cn c gia cng. Nhp thng s cho chu trnh ri chn ok. (unspecified) t part shape menu.

Ghi ch: ta c th to chu trnh rough parallel t hp thoi Operation manager: click phi / toolpaths / surface rough / project.

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Cc thng s c bn ca chu trnh. Check flowline motion for gouge: iu chnh ng chy dao khi sp gp phi mt khe h. Thng s ny s gn cho nhng chuyn ng chy dao ln hn hoc nh hn dung sai ct (cut tolerance). Nu chuyn ng chy dao ln hn th dao s nhc ln trnh khe h. o Stepover control: ta c th thit lp gi tr dch sao ngang bng gi tr tuyt i nu nhp gi tr vo Distance. Tuy nhin ta c th nhp vo cao ca nhp nh b mt ( callop height) sau MasterCAM s t ng tnh ra gi tr dch dao ngang. Ghi ch: thng s ny c th thit lp cho chu trnh Flowline 5-axis

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- cutting method: trong chu trnh phay rough Flowline ta c th chn mt trong hai kiu sau: + ct theo mt pha (one way): theo phng php ny, sau mt lt ct, dng c ct s rt ln mt phng an ton v li dao nhanh v im u bt u lt ct tip theo. Tt c cc lt ct u cng pha. + ct theo pha (zigzag): theo phng php ny, dng c ct s di chuyn ti lui dc chi tit.

Cc thng s cn li c gii thch cc phn trc.

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5.2.6 Contour rough toolpaths Chu trnh ny thc hin cc lt ct ti nhng cao Z khng i.
o o o o o Trnh t to mt chu trnh rough Flowline. Chn Main menu / Toolpaths / Surface / Rough / contour Chn bin dng chi tit li (boss), lm (cavity) hoc khng xc nh Chn cc b mt cn c gia cng. Nhp thng s cho chu trnh ri chn ok. Chn ng gii hn vng chy dao (nu c) v chn done.

(unspecified) t part shape menu.

Cc thng s c bn ca chu trnh. Entry / exit arc / line: thit lp cc thng s v ng ra vo dao.

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Allow arc/line outside boundary: cho php chuyn ng ra vo dao

ngoi ng gii hn chy dao ng chy dao mn v cht lng b mt cng tt hn. o Prompt for starting point: h thng s yu cu ta ch ra mt im sau khi nhp xong cc thng s ca chu trnh. Cc ng chy dao s bt u gn im ny nht v tnh ton lin quan n hng ct to ra cc ng chy dao. o o o o Optimize cut order: ti mt to Z, h thng s tnh ton v to ra Order cut bottom to top: chu trnh s bt u ct t di ln. Transition: thng s ny thit lp cch chuyn dao gia hai lp ct High speed: to ra mt vng chy dao xon c khi khong cch hai tt c ng chy dao c th trc khi thay i to Z (ct t trn xung).

k tip theo phng Z. lt ct nh hn gi tr loop length do ta nhp vo hoc to ra mt ng spline khi khong cch gia hai lt ct ln hn gi tr loop length. o o setting. o Follow surface: di chuyn dc theo b mt ca surface khi khong cch gia hai lt ct nh hn gi tr trong gap settting. Thit lp ng xon c khi vo dao: Broken: di chuyn dao ln xung khi khong cch gia hai lt ct Ramp: di chuyn dao xung theo mt gc theo phng Z t im nh hn gi tr trong gap setting. ny ti im khc khi khong cch gia hai lt ct nh hn gi tr trong gap

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Hng ng xon c s c tnh ton cng chiu vi hng ca ng chy dao:

Thm bt ng chy dao trn mt nghing (shallow parameter): Mastercam cho php ta thm hoc bt cc ng chy dao t mt

nghing (shallow) trong chu trnh Rough contour v finish contour.

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o o

Minimum stepdown : thng s ny xc lp khong cch nh nht Limiting angle: thit lp gc m gc ny s nh ngha cc mt

gia hai lt ct thm vo trn mt nghing ca chi tit. phng nghing trn chi tit. Gi tr thng dng 45 . Mastercam s thm hoc bt nhng lt ct trong nhng khu vc c gi tr trong dy 0 n 45 . o Limiting stepover: . c s dng nh l khong cch dch dao ngang ln nht

khi b i nhng ng chy dao trn mt phng nghing. Nu nhng lt ct k nhau nh hn gi tr limiting stepover th mt trong nhng ng chy dao s b b i. c s dng nh l khong cch dch dao ngang nh nht khi thm vo nhng ng chy dao trn mt phng nghing. Nu nhng lt ct k nhau ln hn gi tr Limiting stepover th s c nhng ng chy dao to ra thm nhng ng chy dao ban u. V d:

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Thm ng chy dao trn mt phng: Mastercam c tu chn Shallow, tuy nhin thng s ny ch cho php thm ng chy dao trn nhng mt nghing vi Z thay i. to nhng ng chy dao trn mt phng (cng nh mt phng nghing) ta s s dng tu chn Flats. Hnh nh di y s cho thy hiu qu ca vic s dng tu chn Flat:

Trong hnh ny, tu chn Flats tt, ta d dng nhn thy rng vng phng gia chi tit khng c gia cng.

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Vi tu chn Flats, Mastercam s to ra nhng lt ct ph hon tt vng mt phng. o S dng cc ng curve nh l ng gii hn tm dao: i vi nhng chi tit n gin, s dng chu trnh rough contour

v finish contour ta c th qun l chiu su ct Z bng hng s bng cch s dng ng curve. t l nhng ng dc theo chi tit v c chn nh l ng gii hn vng chy dao. ng curve ny phi nm trong mt phng vung gc mt phng Cplane.

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To nn ng curve trc khi to chu trnh rough (finish) contour.

Chn contain Y trn menu surface / solid / cad hoc chn node tool containment trn trang surface parameter khi ta nhp cc thng s cho chu trnh. Chn ng curve ging nh chn ng gii hn vng chy dao (tool containment boundaries). Hnh v di y s cho thy s khc bit gia chn ng curve nh l gii hn tm dao:

5.2.7 Resmill toolpaths

y l chu trnh phay th c s dng tho b lp vt liu cn li trn phi ca cc chu trnh trc li trn thng s ca dao th. Chu trnh restmill g b phi cn li nhng ni m dao khng th vo c.

To ng chy dao Restmill.

- La chn Tool path Surface roughRestmill toolpath. - La chn cc b mt.

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- La chn ng bao gii hn vng gia cng.

- Chn OK. - Chn th Toolpath Paramaters ,la chn dao 6 mm HSS flat endmill t th vin dao. - La chn th Surface paramaters, v nhp cc gi tr cho bng ny nh hnh di y.

La chn th Restmill paramaters, v nhp cc gi tr cho bng ny nh

hnh di y.

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La chn th Restmaterials paramaters. V nhp cc gi r cho bng ny

nh hnh di y.

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Chn OK. Khi y ng chy dao pht sinh c thy nh hnh di y.

La chn cng c verify m phng qu trnh gia cng.

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5.3 ng dng gia cng khun mu 5.4 Gii thiu v gia cng tc cao. 5.5 V d v thc hnh.

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Bi 6 Phng php gia cng b mt 3D: Gia cng bn tinh v tinh

Cc phng n gia cng bn tinh. Cc phng n gia cng tinh. Hiu chnh v ti u ng chy dao. - Mt s li va chm thng gp trong gia cng. - Hiu chnh v ti u ha ch ct. - Hiu chnh v ti u ha thi gian gia cng. V d v thc hnh Tng kt bi v gii p thc mc

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Bi 7 : Thc hnh gia cng mt s chi tit in hnh

Thit k quy trnh gia cng mt chi tit in hnh: mu 1 (2.5D) ; mu 2 (3D Solid) & mu 3 (3D Surfaces) Phn tch phng n gia cng mu Thit k chng trnh gia cng mu Tng kt ni dung v gii p thc mc

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