B mn c in t & CTM c bit

Phn III: CAM trong Pro/ ENGINEER Chng 1: lm quen vi Pro/NC

Pro/NC l mt modul ca to ra cc d liu cn thit iu khin my CNC gia cng mt chi tit ca Pro/E. Nhim v ca n l: - Xut pht t m hnh thit k v cc d liu cng ngh, tnh ton qu o ca dao, xut ra file di dng ASCII (CL Data file). Ngn ng dng trong File ny c dng ngn ng APT, cha th dng iu khin my CNC. - M phng kim tra qu trnh ct trn mn hnh (NC Check). - Cho php sa cha file ng chuyn dao. - Dng Post-prossesor thch hp (modul tu chn) to ra chng trnh iu khin my (Machine Control Data - MCD File). File MCD thng c gi l chng trnh NC. Cu trc v ngn ng dng trong chng trnh NC phi tng tch vi b iu khin lp trn my. Tu theo yu cu ca khch hng, PTC c th cung cp cc modul sau: - Pro/NC-MILL: Phay 2,5 hoc 3 trc, gia cng l. - Pro/NC-TURN: Tin 2 trc hoc 4 trc v khoan tm. - Pro/NC-WEDM: Ct dy t 2 n 4 trc. - Pro/NC-ADVANCE: Phay 2,5 n 5 trc, tin 2 n 4 trc, phay tin trn trung tm phay/tin, ct dy 2 n 4 trc. 1.1. Cc khi nim 1.1.1. Cc khi nim v qu trnh gia cng Machining Process (Qu trnh gia cng): Qu trnh gia cng l qu trnh trc tip bin i phi (Workpice) thnh chi tit my (Part). Trong ti liu ny, qu trnh gia cng l qu trnh ct gt. Operation (Nguyn cng): Mt phn c bn ca qu trnh gia cng. Nguyn cng c thc hin trn mt thit b (Workcell), mt phi vi mt h to xc nh. NC Sequence (Bc): Mt phn ca nguyn cng, thc hin ct gt trn mt b mt hay mt t hp cc b mt vi mt dao v mt b thng s cng ngh xc nh. Tool Path (ng chuyn dao): l ng hnh hc m t qu o ca dao trn m hnh gia cng. Nh ng chuyn dao, c th kim tra bng hnh hc qu trnh ct. cng l c s hnh thnh CL Data File.

B mn c in t & CTM c bit

1.1.2. Cc thnh phn ca m hnh gia cng

Design Model (M hnh thit k): l chi tit thit k, sn phm nhn c sau gia cng, c dng lm c s hnh thnh cc nguyn cng. Cc Feature, mt, cnh ca m hnh thit k c chn sinh ra ng chy dao. Gia Design Model v phi c mi lin kt. Cc thay i t chi tit c th cp nht vo cc nguyn cng. Part, Assembly, Sheermetal part c th c dng lm Design Model. Hnh 1: M hnh thit k Hnh 1 minh ho m hnh thn van, c dng lm Design Model. Trn thn van c cc l khoan 1 v cc b mt cn phay 2. Workpice (Phi): l phi ban u, s c gia cng. Vic nh ngha phi l khng bt buc, nhng to cc thun li cho cc bc sau, nh m phng gia cng hoc kho st phn vt liu b ct. Phi c th c biu hin di dng thanh hay vt c. N c th c d dng to ra t Design Model bng cch thay i kch thc to lng d gia cng, hoc xo, n (Delete/Suppres) cc Feature. Hnh 2 minh ho phi c thn van, c thit lp t m hnh chi tit bng cch cho n cc l (ti v tr 1), tng (v tr 2) hoc gim kch thc (v tr 3). Hnh 1: Phi gia cng M hnh gia cng (Manufacturing Model): M hnh gia cng gm chi tit (cn c gi l "Reference Part") v mt phi lp ghp vi nhau. M hnh gia cng cho php th hin lng d gia cng v m phng gia cng. Thng th sau khi c gia cng, phi s trng kht vi chi tit. Hnh 3 minh ho m hnh gia cng thn van. M hnh gm c chi tit (mu en) v phi (mu xanh). Nu khng quan tm n lng d gia cng th bn khng cn nh ngha phi. Khi m hnh gia cng ch gm c chi tit.

B mn c in t & CTM c bit Nu mun, bn c th lp thm vo m hnh gia cng cc ph kin khc, nh c cu kp hay bn quay. Tuy nhin, chng s khng nh hng g n qu trnh gia cng. Sau khi thit lp m hnh gia cng, cc file sau s c to ra: - Tin trnh gia cng (.mfg) - Cm lp gia cng (.asm) - Design Model (.prt) - Phi (.prt). Cn phn bit 2 loi m hnh gia cng, l Part Machining v Assembly Hnh 2: M hnh gia cng Machining. Gia chng c s khc nhau v th tc gia cng. t cu hnh cho Pro/NC Qu trnh gia cng Operations Workcells Fixtures H to Tin trnh gia cng Mt hi dao Xut, nhp d liu gia cng Xc lp thng s dao Thng s cng ngh Gia cng Phay

B mn c in t & CTM c bit

Chng 2: Mt s bi tp thc hnh

Bi tp 1: Lp trnh gia cng chi tit c bin dng, hc v l (hnh 4)

Hnh 4: Bn v chi tit Trong Pro/E, gia cng Manufacture l mt chc nng quan trng, cho php to ra, kim tra (m phng), sa i d liu v ng chy dao gia cng. D liu ny c th c ghi ra file. Nu c modul hu x l (Post-Processor) thch hp, t d liu ng chy dao c th to ra chng trnh NC iu khin my gia cng. Trc khi thc hin bi thc hnh, cn phi hiu mt s khi nim thng dng trong Pro/E.

1. Mt s khi nim
1.1. Qu trnh gia cng (Machining Process)
Qu trnh thc hin cc thao tc cng ngh cn thit bin phi ban u thnh chi tit. Qu trnh gia cng gm qu trnh cng ngh, trong c s trc tip tng tc gia dao v phi thay i kch thc, hnh dng, tnh cht c l ca i tng v qu trnh khng cng ngh, nh o, vn chuyn,... i tng.

1.2. Nguyn cng (Operation)

Mt phn ca qu trnh cng ngh, c c trung bi mt my (v d my phay 3 trc hay my tin), mt chi tit, mt phi v mt h trc to xc nh.

1.3. Bc gia cng (NC Sequence)

Mt phn ca nguyn cng, c c trng bi mt hay mt nhm b mt gia cng (cc feature), mt dao v mt ch cng ngh xc nh. Mt bc gn lin vi mt ng chy dao. 4

B mn c in t & CTM c bit

1.4. ng chy dao (Tool Path)

L ng biu din qu o di chuyn ca dao trong qu trnh gia cng. Trong Pro/E, ng chy dao c biu din bng mt ng mu v mi tn ch hng di chuyn ca dao.

1.5. Cc yu t ca qu trnh gia cng

Trong Pro/E, cc yu t vt cht ca qu trnh gia cng c th hin di dng cc m hnh v thng c lu thnh cc file. Trong trng hp ny, c th hiu yu t l m hnh hay l file. Pro/E dng cc file sau: Ref.Model.prt (Design Model) = M hnh cui cng phi hon thnh (kt qu gia cng). Ta c th gi tt l chi tit. Workpiece (Stock) = Phi ban u gia cng nhn c Ref.Model. Manufacture.asm = M hnh lp rp (Assembly) ca phi v chi tit. Phi v chi tit c th c lu thnh 2 file ring bit hoc c to trong cng mt file Manuacture.Mfg. Manufacture.Mfg = File cha m hnh lp Manufacture.asm v cc d liu cng ngh.

1.6. Nhim v ca bi thc hnh

To mt phi bao quanh mt chi tit (Ref.Model) cho trc. To h to phi. Gia cng mt profile. Gia cng mt hc. Khoan mt lot l. File m hnh chi tit gia cng: Bai1.prt.

2. Trnh t thc hin

2.1. To m hnh gia cng
M hnh gia cng cha chi tit, phi c lp vi nhau v cc thng s cng ngh lin quan. Bt u to m hnh gia cng bng cch chn menu New t menu File v chn Manufacture NC Assembly nh trong hnh 5. G vo tn file, v d Bai1. Pro/E s to ra file Bai1.Mfg trng, sn sng nhn cc thng tin hnh hc v cng ngh gia cng. Thng tin u tin phi a vo l m hnh chi tit gia cng. l file m hnh chi tit dng *.PRT. File m hnh dng cho bi thc

B mn c in t & CTM c bit hnh ny l Bai1.Prt. T Menu Manager chn MFG Model Assemble REF.Model. Trong danh sch file hin ra, chn Bail.prt. Chn Done/Return. M hnh chi tit xut hin nh trong hnh 6. Thng tin k tip c a vo m hnh gia cng l phi (Workpiece). Hnh 6: M hnh chi tit (Ref.model, Design model) V bn cht, phi cng l mt chi tit nhng cha d liu hnh hc ban u. Tri qua qu trnh gia cng, cc lp vt liu ca phi s c ht i hnh thnh chi tit. D liu phi c th c cha trong file .Prt c lp hoc c to ngay trong file m hnh gia cng. Trong bi ny ta dng phng php th hai. T Menu Manager chn MFG Model Create Workpeace. Pro/E nhc nhp tn phi. Hy g Bai1-W lm tn phi. Menu Feature quen thuc to m hnh chi tit xut hin. Chn Solid Prostrusion Extrude Solid Done. M bng nhp Extrude, chn Placement, Define Pro/E nhc chn Sketch Plane. Chn mt y ca m hnh, Flip i chiu mi tn, chn OK. Chn LEFT, chn mt trong cc mt bn ca m hnh. T thanh cng c Sketcher, chn ( hoc t Hnh 7: To Sketch c s ca phi menu Sketcher, Edge, Use) v chn ln lt tt c cc cnh bin ca ch nht (hnh 7). S dng tu chn "Edge use", kch thc y ca phi s trng kht vi y ca chi tit. Sau khi chn tt c cc cnh y ca chi tit, lm thnh chu vi khp kn, chn trn thanh cng c Sketcher. Quay li bng nhp tham s Extrude, biu tng xc nh khong ko, nhp gi tr 50 vo trong hp text . Khi hp biu din phi xut hin vi mu xanh l cy (hnh 8). Ta to ra c m hnh lp rp chi tit lng phi. 6 Hnh 5: Hp thoi New, to file

B mn c in t & CTM c bit Trong bc tip theo chng ta s hoch nh tin trnh cng ngh. Chi tit ny s c gia cng bng 1 nguyn cng. l nguyn cng Phay, c thc hin trn my phay ng CNC 3 trc. Nguyn cng s gm 4 bc: 1. Phay bin dng ngoi to hnh khi ch "D" pha trn. Vy NC Sequence u tin ly Hnh 8: M hnh lp chi tit lng phi tn l Profile. 2. Phay hc ch nht. t tn NC Sequence l Pocket. 3. Khoan 6 l 10. t tn NC Sequence l Drill1. 4. Khoan l 15. t tn NC Sequence l Drill2. Cc thng s cng ngh chnh c cho trong bng sau. Cc quan h sau c s dng: Tc ct: S =
1000 v D ( v / ph )

Lng chy dao: Sz Z S (mm/ph). Lng chy dao rng Sz ly cho thp khng hp kim l 0.06 mm/r. TT Tn bc Dao v S (v/ph) F (mm/ph) (m/ph) 1 Profile Ngn u bng 150 1500 360 D30, 4 rng 2 Pocket Ngn u bng D10, 2 rng Rut g D10 Rut g D15 150 4500 540

3 4

Drill1 Drill2

100 100

3000 2000

150 100

2.2. To nguyn cng

Trong bc ny chng ta phi chn my gia cng, xc nh to gc phi, mt phng thot dao. Qu trnh gia cng ch qua mt nguyn cng. V vy chng ta ch phi thc hin bc ny mt ln. Trong Menu Manager chn Mfg Setup m hp thoi Operation Setup chn my, xc nh gc to ca phi v mt phng thot dao: 1. Operation Name: t tn nguyn cng. G PHAY1. 2. NC Machine: Xc nh loi my gia cng. Loi my cn dng l my phay 3 trc. Chn Mill 3 Axis v nhp cc tham s v my, b iu khin, dao c 7

B mn c in t & CTM c bit trong hp thoi Machine Tool Setup. Tab Comments s dng nhp li m t nguyn cng, v d "Bai thuc hanh so 1" trong hp thoi va hin ra. Sau chn OK. 3. Mach Zero: nh ngha h to phi (thng gi l im Zero phi). Phi ch nh gc to v phng cc trc X, Y, Z. Hin ti cha c h to no trong m hnh gia cng nn cn phi to mt h to mi.

Hnh 9: Hp thoi Operation Setup Chn nt sau chn Create chn phi ( gn h to ). M hp thoi COORDINATE SYSTEM. Vi mong mun cc trc to hng theo 3 cnh khi hp ca phi, chng ta chn 3 mt phng k nhau ca phi. Sau khi chn, 3 mi tn xut hin gc phi. Trc z hng ln trn hai trc x v y hng vo trong phi, nu cn s dng nt Flip trong tab Orientation chn hng ph hp.

Hnh 10: Cc mi tn biu din h to phi 8

B mn c in t & CTM c bit Phng cc trc to phi phi ng vi h trc to trn my, nu khng th khi gia cng s b sai kch thc. c bit, chiu dng ca trc Z phi hng ra khi phi, nu khng th s nguy him. Dng cc lnh ni trn nh hng cc mi tn v gn trc nh trong hnh 11. Ch cn gn 2 trc. Trc cn li s t c xc nh theo quy tc bn tay phi. Sau khi xc nh xong cc trc to , menu MACH CSYS bin mt. Biu tng h to Hnh 11: H to trn phi thay th cho 3 mi tn. 4. Retract: Mt phng an ton, xc nh v tr dao trc v sau khi thc hin mt bc gia cng. Mt ny phi nm ngoi phi v cch mt phi mt khong nht nh. Trong trng Retract ti vng nh ngha mt Surface chn nt phng an ton. Trong hp thoi (hnh 12), chn Surface Along Z Axis, g khong cch theo trc Z, v d 20 vo Enter Z Depth OK. Nguyn cng PHAY1 va nh ngha xong cn rng, mi ch cha cc thng s chung, cha c lnh gia cng no. Sau bc ny chng ta phi nh ngha cc bc cng ngh gia cng cc b mt c th. Hnh 12: Hp thoi Retract Selection kt thc nh ngha nguyn cng, chn OK Done/Return.

2.3. To cc bc (NC Sequences)

1. Phay bin dng (Profiling) Trong bc ny chng ta s lp trnh phay theo bin dng ngoi ca khi hnh ch "D".

B mn c in t & CTM c bit Phng php ny dng phay th hoc phay tinh mt b mt thng ng hoc xin. Mt ng chy dao theo Profile s c to ra, c b bn knh dao m bo kch thc yu cu. Trong Menu Manager, chn Machining NC Sequence Machining Profile, 3 Axis Done. Trong hp thoi (hnh 13-a), nh du cc Name, Comments, Tool, Parameters v Surface, sau chn Done. Nhp cc thng tin theo yu cu to ra NC Sequence.

(a) (b) Hnh 13: Hp thoi chn NC Sequence (a) v nh ngha dao (b) 1. Name: G "Profile" t tn cho NC Sequence <CR>. 2. Comments: G li ch gii, v d "Phay mat ngoai", xong bm OK. 3. Tool: nh ngha thng s dao bng cch in cc gi tr vo hp thoi va xut hin nh hnh sau (hnh 13-b). Chn trang Geometry, g 4 vo Number of teech (s rng dao). chn Apply. Quan st s thay i hnh hc ca dao. Sau khi nh ngha dao xong, chn OK. 4. Parameters: Chn Set trong Menu Manager m hp thoi Param tree (hnh 14). Xc nh cc thng s cng ngh v in vo bng ca hp thoi. ngha ca cc thng s nh sau: 10

B mn c in t & CTM c bit CUT_FEED: Lng chy dao, nhp 360 (mm/ph) STEP_DEPTH: Chiu su mt lp ct, nhp 5 (mm) PROF_STOCK_ALLOW: Lng d li theo Profile, thng l gia cng tinh. Nhp 0 (khng gia cng tinh). CHK_SRF_STOCK_ALLOW: Lng d trn b mt kim sot va chm. Nu khng t ch kim sot va chm th khng nhp gi tr ny. WALL_SCALLOP_HGT: Chiu su lp ct khi gia cng khi (Volume Milling). Khi khng dng ch ny, gi tr mc nh (0). SPINDLE_SPEED: Tc trc chnh, nhp 1500 (vng/ph). COOLANT_OPTION: Ch ti trn ngui, nhp OFF (khng ti). CLEAR_DIST: Khong cch an ton (so vi mt phng an ton).

Hnh 14: Hp thoi nhp thng s cng ngh Sau khi nhp xong cc thng s, chn menu File Save trong hp thoi. Nhp tn file tham s, chn OK. Sau chn File => Exit kt thc nhp tham s. 5. Surfaces: Xc nh b mt (Profile) gia cng. Chn Model Done Add, Surface, chn chnh xc cc b mt cn gia cng (hnh 15). Sau khi chn ht cc cung ca Profile, kt thc bng lnh Done Done/Return.

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B mn c in t & CTM c bit Chn cc b mt hnh thnh Profile cn gia cng

Hnh 3: Chn cc b mt gia cng kim tra kt qu, chn Play Path Screen Play M hp thoi PLAY PATH. Sau mt lt ch tnh ton, ta s nhn thy dao chy v ng qu o dao c v ra di dng khung dy. m phng di dng Solid, chn NC Check Run. Trong hnh 16 l kt qu Play Path v NC Check bc gia cng Profile.

Hnh 16: Kt qu gia cng Profile Nu chp nhn kt qu th chn Done/Return Done Sequ nhn NC Sequence va to v kt thc. 2 Phay hc (Pocketing) Phay hc dng phay tinh mt hc sau khi phay th vi Volume Milling hoc phay tinh mt hc c sn. B mt phay hc phi cho php chy dao lin tc. Bc ny nhm phay hc ch nht trn nh chi tit nh ch ra trong m hnh. Chn Maching NC Sequence New Sequence Machining Poketing Done. T Menu Manager, nh chon cc Name, Comments, Tool, Parameters, Surfaces. Cui cng chn Done. 1. Name: G tn bc "Pocketing". 2. Comments: G ch gii "Phay hoc chu nhat" OK. 12

B mn c in t & CTM c bit 3. Tool: nh ngha dao mi, trong hp thoi nh hnh 13-b, chn menu File New. Nhp thng s dao tng t nh dao trc, ch khc tn dao (Tool_ID) l 10FLAT, ng knh dao (Cutter_Diam) l 10, g 2 vo Number of teech (s rng dao), chn Apply. Xong chn OK kt thc nh ngha dao. 4. Parameters: Chn Set t Menu Manager, hp thoi Param Tree xut hin vi danh mc cc thng s cn nhp cho Pocketing (hnh 17). Xc nh cc thng s cng ngh v in vo bng ca hp thoi. ngha ca cc thng thng s mi gp nh sau: BOTTOM_SCALLO P_HGT: Chiu su lp ct y khi gia cng khi (Volume Milling). Hnh 17: Hp thoi nhp thng s phay hc SCAN_TYPE: Kiu ct. Vi phay hc, c th chn cc kiu nh hnh 18. 1. TYPE_1: Ct thng. Gp o th nhc dao qua. 2. TYPE_SPIRAL: Ct theo ng xon c. Gp o th chy vng quanh. 3. TYPE_2: Ct thng. Gp o th chy vng quanh. 4. TYPE_3: Ct lin tc theo tng vng. Ht mt vng th nhc dao sang vng khc. Gp o th chy vng quanh. 5. TYPE_ONE_DIR: Ch ct theo 1 chiu. n cui ng th nhc dao, chy v pha u v ct tip nh ng trc. Hnh 18: Cc kiu ct 6. TYPE_1_CONNECT: Ct mt chiu. Ht mt ng th nhc dao, chy nhanh v pha u, khoan xung v ct tip ph c. Nu c ng bn cnh th ct ni trnh va chm. Khi phay hc thng chn 4 kiu u, ngha l TYPE_1, TYPE_2 TYPE_3v TYPE_SPIRAL. Sau khi in ht cc thng s chn menu File, Save trn hp thoi, sau chn File Exit ra ngoi. 13

B mn c in t & CTM c bit 5. Sufaces: Chn cc b mt hnh thnh hc, gm cc thnh v y. Xong, chn Model Done Add, ch dng Query Sel, xong chn Done Sel Done Done Return. kim tra kt qu, chn Play Path Screen Play. Sau mt lt ch tnh ton, ta s nhn thy dao chy v ng qu o dao c v ra di dng khung dy. m phng di dng Solid, chn NC Check Run. Trong hnh 19 l kt qu Play Path v NC Check bc gia cng Pocketing. Nu chp nhn kt qu th chn Done/Return Done Sequ nhn NC Sequence va to v kt thc. Hnh 19: Kt qu gia cng Profile 3. Khoan cc l 10 (Holemaking) Bc ny khoan 6 l cng ng knh 10. Trong Menu Manager chn Machining NC Sequence New Sequence Machining Holemaking Done Drill Standard Done. Trong menu bn di, nh du cc Name, Comments, Tool, Parameters, v Holes, sau chn Done. Ch thch: Vi phng php Holemaking (to l) c nhiu chu trnh gia cng khc nhau chn: + Drill (Khoan) - Standard (mc nh): Khoan thng. - Deep: Khoan su. - Break chip: C b phoi. - Web: to rnh. - Back: Vt pha sau l + Face (Kho y): C dng dao kho y l. + Bore (Doa): Doa tinh kch thc ng knh. + Countersink (Doa ming): Vt ming l. + Tap (Taro): Taro ren trong l - Fixed (Cng): Phi hp chnh xc tc trc chnh v chy dao c bc ren chnh xc. My CNC phi c kh nng nh hng trc chnh. - Floating (Bi): Cho php hiu chnh lng chy dao nh tham s FLOAT_TAP_FACTOR. + Ream (Khot): Khot tinh l bng dao khot. + Custom: Cho php to chu trnh ring cho my c th. Trong bi ny, chn chu trnh khoan tiu chun Drill Standard. Ln lt nhp cc thng tin sau: 14

B mn c in t & CTM c bit 1. Name: G tn "Drill1". 2. Comments: G ch gii, v d "Khoan cac lo D10" OK. 3. Tool: Nhp cc thng s dao nh trong hnh 20. T menu File ca hp thoi chn Done. 4. Parameters: Chn Set trong Menu Manager, xut hin hp thoi Param Tree cho khoan (Drilling) nh trong hnh 21.

Hnh 20: Nhp mi khoan Hnh 21: Thng s khoan Xc nh cc thng s cng ngh v in vo bng ca hp thoi. ngha ca cc thng thng s mi gp nh sau: BREAKOUT_DISTANCE: Khong chy qu ca mi khoan, thng dng khi khoan l thng. SCAN_TYPE: Quy nh th t khoan cc l. C mt s la chn sau (xem hnh 22). 1. TYPE_1: Chy theo chiu dng ca trc Y v chy i chy li theo trc X (hnh bn tri). 2. TYPE_SPIRAL: Vng theo Hnh 22: Cc kiu khoan chiu kim ng h (hnh gia). 3. TYPE_ONE_DIR: Theo chiu tng X, gim Y (hnh bn phi). 4. SHORTEST: H thng t xc nh th t khoan sao cho khong chy khng l ngn nht (mc nh).

15

B mn c in t & CTM c bit CLEAR_DIST: im kt thc chy dao nhanh, bt u chy dao vi tc gia cng. Gi tr mc nh l -1. CLEARANE_OFFSET: im an ton, b thm vo CLEAR_DIST. Nu nhp gi tr mc nh (-), ly im CLEAR_DIST. PULLOUT_DIST: im dng dao sau khi khoan. Gi tr mc nh (-), dng chnh im CLEAR_DIST. Xc nh cc thng s cng ngh v in vo bng ca hp thoi. ngha ca cc thng thng s mi gp nh sau: BOTTOM_SCALLOP_HGT: Chiu su lp ct y khi gia cng khi (Volume Milling). Sau khi nhp cc thng s cng ngh, trong hp thoi chn menu File Exit v Done trong Menu Manager. 5. Hole set: Chn l khoan. Pro/E cho php khoan mt tp hp l (Hole Set) trong mt bc theo cc phng php khc nhau nh trong hp thoi HoleSet (hnh 23). Hnh 23: Hp thoi chn l Phn trn ca hp thoi (Hole Selection) cho 6 phng php chn cc l khoan: 1. Axes: Cho php chn tng l nh ng tm. 2. Group: Chn mt nhm l c thit lp t trc. 3. Points: Trc tip chn v tr khoan nh im chun (Datum Point) trn m hnh hoc c to cc im chun t bng d liu. 4. Diameters: Chn cc l c cng ng knh. 5. Surfaces: Chn cc l cng nm trn mt b mt. 6. Parameters: Chn mt l theo thng s no . C th phi hp cc phng php k trn chn tp hp l. Ring phng php chn theo im khng th phi hp vi cc phng php khc. Phn di ca hp thoi (Options) a ra cc tu chn xc nh thng s tip theo ca l:

16

B mn c in t & CTM c bit 1. Depth: Xc nh chiu su ca l. Sau khi chn Depth, hp thoi Hole Set Depth xut hin (hnh 24). C th la chn 1 trong 3 tiu ch: - Blind: Ch im u v im cui ca l khoan bng cch nhp cc gi tr Z hoc chn cc b mt tng ng. - Auto: Chiu su l c xc nh t ng theo kch thc thit k, Nu c cc l trng tm nhau th chiu su ln nht c chn min l ng knh dao trng vi ng knh l. Hnh24 cho v d v trng hp va nu. - Through All: Khoan thng tt c cc phi hoc cc chi tit c chn. C th dng Delect, Select All hoc Unselect chn, thi chn cc phi hoc chi tit cn a vo tnh chiu su l. Mc Tool Depth cho php tnh chiu su l theo Tip (nh mi khoan) hoc Shoulder (phn thn) nh minh ho trong hnh 25. 2. Use Prev: Chn tp hp l c trong bc trc v c th thm, bt theo yu cu ca bc mi. 3. Auto Chamfer: Nu nh du tu chn ny th cc l c t ng vt ming. Kch thc vt tu thuc kch thc dao ang dng.

Hnh 24: Hp thoi xc nh chiu su l

Hnh 25: Tu chn chiu su Trong bi ny, chn Diameter Chn 10 trong hp thoi Select Hole

Diameter. Trong hp thoi Hole Set Depth, chn Auto v Tip OK OK. kim tra kt qu, chn Play Path Screen Play . Sau mt lt ch tnh ton, ta s nhn thy dao chy v ng qu o dao c v ra di dng khung dy. m phng di dng Solid, chn NC Check Run. Trong hnh 26 l ng chy dao c hnh thnh. Hnh 26: Th t khoan cc l 10 17

B mn c in t & CTM c bit Nu chp nhn kt qu th chn Done/Return Done Sequ nhn NC Sequence va to v kt thc. 4. Khoan l 15 Trn chi tit c 1 l 15. Th tc lp trnh khoan l ny tng t nh khoan cc l 10, ch khc trong hp thoi Select Hole Diameter, chn Diameter = 10. n y, chng ta thc hin xong 4 bc ca nguyn cng Phay1. kim tra ton b nguyn cng, trong Menu Manager chn CL Data Ouput Operation. Trong danh mc, chn Phay1. Chn cng c xut file: Play Path Screen Play Done s nhn c qu o dao gia cng. m phng, chn NC Check Run. Kt qu gia cng c th hin nh trong hnh 27.

Hnh 27: M phng gia cng nguyn cng Phay1

2.4. Ghi v s dng CL Data file

Cho n y, cc d liu mi ch c lu tr trong file m hnh gia cng. Cn phi xut d liu ny ra CL Data file c lp, t c th to ra file d liu iu khin my CNC (chng trnh NC). Mun to ra chng trnh NC, phi c Post-Processor. Phn mm Pro/E tiu chun ch c th to ra CL Data File di dng ngn ng APT. 1. Xut CL Data ra file Trong Menu Manager, chn Manufacture Machine CL Data Output Select set => Creat tn Operation hoc tn NC Sequence. M menu CREAT SET chn ton b cc nguyn cng, ri chn Done Sel. File. Trong menu Output Type, nh du CL File v Interactive Done. Trong hp thoi Save As, chn New File (g tn file, v d Bai1) OK. Kt qu, nhn c file Bai1.NCL. 2. c d liu t file Sau khi khi ng Pro/E, t menu File Open Chn tn file (Bai1.mfg) Open. M hnh gia cng xut hin trn mn hnh ho. T Menu Manager, chn CL data Operaton tn nguyn cng (Phay1) Display Done. Sau mt thi gian tnh ton, qu o dao s c v trn m hnh gia cng. Mun chy m phng, chn NC Check Run. 18

B mn c in t & CTM c bit Bi 2: Lp trnh gia cng chi tit lng khun Qua bi ny chng ta s lm quen vi mt nhim v phc tp hn, to b mt phc tp (Free-Form Surface). Mt s ni dung quen thuc t bi trc s c trnh by ngn gn hn. Nhim v ca bi thc hnh gm To m hnh gia cng t mt phi v mt chi tit cha trong 2 file c lp. To nguyn cng phay (Mill). Gia cng th lng khun (Rough). Gia cng tinh lng khun (Finish). Ghi CL Data ra fle v c d liu t file. File cha m hnh chi tit gia cng c tn l Bai2.prt. Chi tit (hnh 28) l mt na khun. Lng khun c hnh thnh t 4 mt thng ng, nhng li c cc cung v trn cnh v cc vu li. Kch thc bao ngoi ca chi tit l 100 60 30.

Hnh 28: Chi tit (na khun) v phi gia cng

1. To m hnh gia cng

Ln ny, chng ta dng k thut khc to m hnh gia cng: to phi c lp ri dng k thut lp rp lp phi vi chi tit. Phng php ny cho php nh hng chi tit theo phi.

1.1. To m hnh phi

Phi cn to ra l khi hp c kch thc 100 60 30, bng kch thc bao ngoi ca chi tit (hnh 28). Vo menu File New Part g tn Bai2-W to ra file Bai2-W.prt. Ch : - nh n v o chiu di l mm. - nh hng y phi theo mt chun DTM2 (Top), cnh di DTM3 (Front), cnh ngn bn tri DTM1 (Left).

19

B mn c in t & CTM c bit

1.2. Lp chi tit vo phi

Chn New t menu File. Trong hp thoi New, chn Manufacture NC Assembly nh trong hnh 29. G vo tn file, v d Bai2. Pro/E s to ra file Bai2.Mfg trng, sn sng nhn cc thng tin hnh hc v cng ngh gia cng. Trc ht np m hnh phi gia cng trong file Bai2-W.prt. T Menu Manager chn MFG Model Assemble Workpeace. Trong danh sch file hin ra, chn Bai2W.prt. Tip theo, np thng tin v chi tit (REF.Model). T Menu Manager chn MFG Model Assemble Ref Model. Trong danh sch file hin ra, chn Bai2.prt. Ta c m hnh chi tit lng phi nh trong hnh 30. Trong bc tip theo chng ta s hoch nh tin trnh cng ngh. Chi tit ny s c gia cng bng 1 nguyn cng. Hnh 30: M hnh lp rp (chi tit lng phi) l nguyn cng phay, t tn l Mill, c thc hin trn my phay ng CNC 3 trc. Nguyn cng gm 2 bc: 1. Phay th lng khun vi NC Sequence u tin ly tn l Rough. 2. Phay tinh lng khun vi NC Sequence th hai Finish.

Hnh 29: Hp thoi New, to file

2. Gia cng
2.1. To nguyn cng
Trong bc ny chng ta phi chn my gia cng, xc nh to gc phi, mt phng thot dao. Qu trnh gia cng ch qua mt nguyn cng. V vy chng ta ch phi thc hin bc ny mt ln. Trong Menu Manager chn Machining Operation. M hp thoi Operation setup, trong hp thoi ny ta nh ngha cc s liu sau: 1. Operation Name: t tn nguyn cng. G Mill. 20

B mn c in t & CTM c bit 2. NC Machine: Chn nt m hp thoi Machine Tool Setup xc nh loi my gia cng. Loi my cn dng l my phay 3 trc, t tn my v cc thng s v my trong hp thoi. 3. Machine zero: nh ngha h to phi hin ti cha c h to no trong m hnh gia cng nn cn phi to mt h to mi. Click vo biu tng v chn Creat to gc to , click vo 3 mt phng trn phi ri chn OK trong hp thoi COORDINATE SYSTEM.

Hnh 31: Hp thoi Operation Setup v Machine Setup Vi mong mun cc trc to hng theo 3 cnh khi hp ca phi, chng ta chn 3 mt phng k nhau ca phi. Ch cho trc X hng sang phi, Z hng ln trn (s dng tab Oriention v nt Flip chn hng cc trc) nh hnh 32.

Hnh 32: H to trn phi

21

B mn c in t & CTM c bit 5. Retract: Mt phng an ton, xc nh v tr dao trc v sau khi thc hin mt bc gia cng. Mt ny phi nm ngoi phi v cch mt phi mt khong nht nh. Trong trng Surface chn nt nh ngha mt phng antenna ton. Trong hp thoi (hnh 33), chn Surface Along Z Axis, g khong cch theo trc Z, v d 20 vo Enter Z Depth OK. kt thc nh ngha nguyn cng, chn OK Done/Return. Nguyn cng MILL va nh ngha xong cn rng, mi ch cha cc thng s chung, cha c lnh gia cng no. Sau bc ny chng ta phi nh ngha cc bc cng ngh gia cng cc b mt c th. Hnh 33: Hp thoi Retract Selection

2.2. To cc bc (NC Sequences)

1. Phay th lng khun (Roughing) Trong bc ny chng ta s lp trnh phay th lng khun vi dao phay ngn D=10, mi dao hnh chm cu bn knh R=5. V cn c bc gia cng tinh, nn chng ta s li lng d xung quan thnh l 1 mm. Trong Menu Manager, chn Machining NC Sequence Machining Rounhing, 3 Axis Done. Trong hp thoi, nh du cc Name, Comments, Tool, Parameters v Window, sau chn Done. Nhp cc thng tin theo yu cu to ra NC Sequence. 1. Name: G "Rough" t tn cho NC Sequence <CR>. 2. Comments: G li ch gii, v d "Phay tho long khuon" OK. 3. Tool: nh ngha thng s dao bng cch in cc gi tr vo hp thoi va xut hin (Hnh 34 -a). Chn trang Greometry, g 2 vo Number of teech (s rng dao), chn Apply. Quan st s thay i hnh hc ca dao. Sau khi nh ngha xong dao c chn OK kt thc nh ngha dao. 4. Parameters: Chn Set trong Menu Manager m hp thoi Param tree (Hnh 34-b). Xc nh cc thng s cng ngh v in vo bng ca hp thoi. Ch cc thng s: MAX_STEP_DEEPTH: Chiu su mt lp ct ln nht nhp gi tr 3. MIN_STEP_DEEPTH: Chiu su lp ct nh nht, nhp gi tr mc nh (-). 22

B mn c in t & CTM c bit ROUGH_STOCK_ALLOW: Lng d li theo b mt. V cn li 1 mm gia cng tinh nn nhp gi tr 1.

(a)

(b)

Hnh 34: Hp thoi nh ngha dao (a) v thng s cng ngh (b) Sau khi nhp xong cc thng s, chn menu File Exit trong hp thoi. Chn Done trong Menu Manager kt thc nhp thng s. 5. Window: nh ngha ca s. Dng Window l phng php nhanh nht ch nh khi (Volume) hoc b mt (3-Axis Conventional Surface) cn gia cng. Sau khi to mt ng bao kn (dng cng c Sketch) hoc chn mt ng bao kn c trc lm ca s, th tt c cc b mt thy c trong ca s u c chn gia cng. Hnh 35: Ca s ch nh b mt gia cng T Menu Manager, chn Create Wind, g tn Window, Chn to ca s bng cc cng c Sketcher. Trong ch Sketcher s dng cng c Edg Use chn ng bao trn ming lng khun lm ca s OK. Mt ng bao kn c hnh thnh (chiu ng bao ming khun) trn mt phng rt dao (hnh 35). Chng ta nh ngha xong cc thng s gia cng. kim tra kt qu, chn Play Path Screen Play. Sau mt lt ch tnh ton, ta s nhn thy dao chy v ng qu o dao c v ra di dng khung dy. m phng di dng Solid, 23

B mn c in t & CTM c bit chn NC Check Run. Trong hnh 36 l kt qu Play Path v NC Check bc gia cng th lng khun (Nu khi chn NC Check m phng chng trnh bo li thi ta phi vo Tools Options v thay i gi tr ca tu chn nccheck_type l nccheck).

Hnh 36: Kt qu gia cng th lng khun theo b mt Nu chp nhn kt qu th chn Done/Return Done Sequ nhn NC Sequence va to v kt thc. 2 Phay tinh lng khun (Finishing) Bc ny nhm phay tinh lng khun. Ta dng chc nng phay tinh Finishing dng dao nh hn (D=3 mm). Trong Menu Manager, chn Machining NC Sequence New Sequence Finishing, 3 Axis Done. Trong hp thoi, nh du cc Name, Comments, Tool, Parameters v Surface, sau chn Done. Nhp cc thng tin theo yu cu to ra NC Sequence. 1. Name: G "Finish" t tn cho NC Sequence <CR>. 2. Comments: G li ch gii, v d "Phay tinh long khuon", xong bm OK. 3. Tool: nh ngha thng s dao bng cch in cc gi tr vo hp thoi va xut hin. nh ngha dao chm cu mi: New 3_Ball vi ng knh 3 mm, bn knh 1,5 mm. Chn trang Geometry g 2 vo Number of teech (s rng dao), chn Apply. Chn OK kt thc nh ngha dao c. 4. Parameters: Chn Set trong Menu Manager m hp thoi Param tree. Xc nh cc thng s cng ngh v in vo bng ca hp thoi. Ch cc thng s: ROUGH_STEP_DEEPTH: Chiu su mt lp ct. Chp nhn gi tr mc nh (), cho php ct 1 ln ht chiu su. PROF_STOCK_ALLOW: Lng d li theo b mt. Nhp gi tr 0. Sau khi nhp xong cc thng s, chn menu File Exit trong hp thoi. Chn Done trong Menu Manager kt thc nhp thng s. 5. Window 24

B mn c in t & CTM c bit Dng li Window c to ra t bc trc. T Menu Manager, chn Select Wind . Ngi dng c nhc chn i tng, pick chn ca s to ra nguyn cng gia cng th. Chng ta nh ngha xong cc thng s gia cng. kim tra kt qu, chn Play Path Screen Play Done. Sau mt lt ch tnh ton, ta s nhn thy dao chy v ng qu o dao di dng khung dy. m phng Solid, chn NC Check Run. Trong hnh 37 l kt qu Play Path v NC Check gia cng tinh.

Hnh 37: Kt qu gia cng tinh lng khun theo b mt Nu chp nhn kt qu th chn Done/Return Done Sequ nhn NC Sequence va to v kt thc.

2.3. Ghi v s dng CL Data file

Cho n y, cc d liu mi ch c lu tr trong file m hnh gia cng. Cn phi xut d liu ny ra CL Data file c lp, t c th to ra file d liu iu khin my CNC (chng trnh NC). Mun to ra chng trnh NC, phi c PostProcessor. Phn mm Pro/E tiu chun ch c th to ra CL Data File di dng ngn ng APT.

25

B mn c in t & CTM c bit 1. Xut CL Data ra file Trong Menu Manager, chn Manufacture Machine CL Data Output Select One NC Quence chn mt nguyn cng. Operation hoc tn NC Sequence File. Trong menu Output Type, nh du CL File v Interactive Done. Trong hp thoi Save As, (hnh 38) g tn file (Bai2) vo dng New File OK. Kt qu, nhn c file Bai2.NCL. Hnh 38: Xut CL Data ra file 2. c d liu t file Sau khi khi ng Pro/ E t menu File Open Chn tn file (Bai2.mfg) Open. M hnh gia cng xut hin trn mn hnh ho. T Menu Manager, chn CL data Input. Trong hp thoi Open, chn tn file: Bai2.NCL Open. Tr li Menu Manager, chn Display CL nh du Tool Done/Return. Sau mt thi gian tnh ton, qu o dao s c v trn m hnh gia cng. Mun chy m phng, chn NC Check Run. Bi 3: Lp trnh gia cng chi tit lng khun c thnh vt 100 i tng gia cng trong bi ny vn l lng khun tng t nh trong bi 2. im mi trong bi ny l cc mt bn ca lng khun vt 10o so vi phng thng ng. V vy chng ta phi dng k thut khc, dng Surface Mill. Trong bi ny chng ta cng c lm quen vi k thut sp xp li th t (Reoder) cc bc trong mt nguyn cng. Nhim v ca bi thc hnh gm To m hnh gia cng t mt phi v mt chi tit cha trong 2 file c lp. To nguyn cng phay (Mill). Gia cng tinh lng khun (Finish). Gia cng th lng khun (Rough). Sp xp li cc bc (Reoder). Ghi CL Data ra fle v c d liu t file.

26

B mn c in t & CTM c bit File cha m hnh chi tit gia cng c tn l Bai3.prt. Chi tit (hnh 39) l mt na khun. Lng khun c hnh thnh t 4 mt nghing 10o so vi phng thng ng, c cc cung v trn cnh v cc vu li. Gia cng mt phng nghing l vn mu cht ca bi ny. Kch thc bao ngoi ca chi tit l 100 80 30.

Hnh 39: Chi tit na khun

1. To m hnh gia cng Ln ny, chng ta cng to m hnh gia cng t 2 file c lp: File cha m hnh gia cng Bai3.prt v file cha m hnh phi Bai3-W.prt. 1.1. To m hnh phi Phi cn to ra l khi hp c kch thc 100 80 30, bng kch thc bao ngoi ca chi tit. Vo menu File New Part g tn Bai3-W to ra file Bai3-W.prt. Ch : - nh n v o chiu di l mm. - nh hng y phi theo mt chun DTM2 (Top), cnh di DTM3 (Front), cnh ngn bn tri DTM1 (Left). 1.2. Lp chi tit vo phi Chn New t menu File. Trong hp thoi New, chn Manufacture NC Assembly nh trong hnh 40. G vo tn file, v d Bai3. Pro/E s to ra file Bai3.Mfg trng, sn sng nhn cc thng tin hnh hc v cng ngh gia cng. Trc ht np m hnh phi gia cng trong file Bai3-W.prt. T Menu Manager chn MFG Model Assemble Workpeace. Trong danh sch file hin ra, chn Bai3W.prt. Tip theo, np thng tin v chi Hnh 40: Hp thoi New, to file tit (REF.Model). T Menu Manager chn MFG Model Assemble Ref Model. Trong danh sch file hin ra, chn Bai3.prt. 27

B mn c in t & CTM c bit Ta c m hnh chi tit lng phi nh trong hnh 41. Trong bc tip theo chng ta s hoch nh tin trnh cng ngh. Chi tit ny s c gia cng bng 1 nguyn cng. l nguyn cng phay, t tn l Mill, c thc hin trn my phay ng CNC 3 trc. Nguyn cng phi gm 2 bc: 1. Phay th lng khun vi NC Sequence u tin ly tn l Rough. 2. Phay tinh lng khun vi NC Sequence th hai Finish. Tuy nhin, to tnh hung phi sp xp li cc bc, chng ta lp trnh gia cng tinh trc. Hnh 41: M hnh lp rp (chi tit lng phi) 2. Gia cng 2.1. To nguyn cng Trong bc ny chng ta phi chn my gia cng, xc nh to gc phi, mt phng thot dao. Qu trnh gia cng ch qua mt nguyn cng. V vy chng ta ch phi thc hin bc ny mt ln. Trong Menu Manager chn Machining Operation m hp thoi Operation Setup. Trong hp thoi ny nh ngha cc thnh phn cho nguyn cng: 1. Operation Name: t tn nguyn cng, nhp Mill. 2. NC Machine: Click ln biu xc nh loi my gia cng tng v cc thng s v my. Loi my cn dng l my phay 3 trc. Chn OK chp nhn my. 3. Machine Zero: nh ngha h to phi hin ti cha c h to no trong m hnh gia cng nn cn phi to mt h to mi. Click ln biu tng trong Hnh 42: Hp thoi Operation Setup

28

B mn c in t & CTM c bit Menu Manager MACH SYS Creat chn phi v m hp thoi COORDINATE SYST chn 3 mt phng nh ngha gc to phi. Sau khi kt thc nhn OK. Vi mong mun cc trc to hng theo 3 cnh khi hp ca phi, chng ta chn 3 mt phng k nhau ca phi. Ch cho trc X hng sang phi, Z (mi tn ) hng ln trn nh trong hnh 43. 5. Retract: Mt phng an ton, xc nh v tr dao trc v sau khi thc hin mt bc gia cng. Mt ny phi nm ngoi phi v cch mt phi mt khong nht nh. Trong hp thoi (hnh 44), chn Surface Along Z Axis, g khong cch theo trc Z, v d 5 vo Enter Z Depth OK. kt thc nh ngha nguyn cng, chn OK. Hnh 43. To phi

Hnh 44: Hp thoi Retract Selection 2.2. To cc bc (NC Sequences) 1. Phay tinh (S dng kiu phay b mt Surface Mill) Trong bc ny chng ta s lp trnh phay tinh lng khun vi dao phay ngn D=3, mi dao hnh chm cu bn knh R=1,5. Chu trnh phay c dng l phay b mt (Surface Mill). Phng php ny to ra mt ng qu o dao phng (Flat Tool Path) trn Retract Surface, sau chiu ng ny ln b mt gia cng hnh thnh qu o dao thc (projected tool path).

29

B mn c in t & CTM c bit

Hnh 45: Chn phng php Surface Mill Trong Menu Manager, chn Machining NC Sequence Machining Surface, 3Axis Done. Trong SEQ SETUP, nh du cc Name, Comments, Tool, Parameters, Surface, Define Cut, sau chn Done. Nhp cc thng tin theo yu cu to ra NC Sequence. 1. Name: G tn "Finish" cho NC Sequence <CR>. 2. Comments: G li ch gii, v d "Phay tinh long khuon" OK. 3. Tool: nh ngha thng s dao bng cch in cc gi tr vo hp thoi Tools Setup va xut hin. Nhp tn dao l T0001 trong Name, ku dao phay (Mill) trong Type, ng knh dao l 3 trong Cutter Diameter, bn knh gc dao (Corner Radius) l 1.5, s rng dao (Number of teech) l 2. Chn Apply. Nhn OK chp nhn.

30

B mn c in t & CTM c bit 4. Parameters: Chn Set trong Menu Manager m hp thoi Param tree(Hnh 46). Xc nh cc thng s cng ngh v in vo bng ca hp thoi. Ch cc thng s: STEP_OVER: Khong cch gia cc ng chy dao. Gi tr cng nh th b mt cng mn hn. PROF_STOCK_ALLOW: V l bc gia cng cui cng nn lng d xung quanh profile Hnh 46: Thng s cng ngh gia cng tinh ly gi tr 0. Sau khi nhp xong cc thng s, chn menu File Save nhp tn file v chn File Exit trong hp thoi. Chn Done trong Menu Manager kt thc nhp thng s. 5. Surfaces: Chn tt c cc b mt to thnh lng khun v cc vu li. C 3 phng php nh ngha b mt gia cng: Model: nh ngha t m hnh chi tit. Mill Volume: nh ngha th tch gia cng. Mill Surface: nh ngha b mt gia cng. y ta chn Model nh ngha b mt gia cng bng cch chn cc b mt trc tip trn m hnh. Model Done, yu cu chn cc b mt gia cng, ta chn tt c cc b mt ca lng khun cn gia cng.

Hnh 47: ng chy dao chn ng v nhanh cc b mt c th kt hp cc k thut Querry Seleect v Pick Many. Querry Select a ra danh sch cc i tng c th ngi dng chn ng i tng mong mun. Vi cng c Pick Many, ngi dng ch cn dng phm tri chut chon 2 gc ca ca s. Cc i tng nm gn trong ca s s c chn. 31

B mn c in t & CTM c bit Sau khi chn ht cc b mt click ln Done/ Return. M hp thoi Cut Defintion trong hp thoi ny chn: Straingh Cut (Ct thng) v Relative to x-Axis (gc ng chy dao theo phng x) nhp gi tr l 0. Click OK. Nh vy ta to ra cc ng chy dao trn b mt Retrac surface, cc ng chy dao ny s chiu ln b mt gia cng thc hin gia cng. Chng ta nh ngha xong cc thng s gia cng. kim tra kt qu, chn Play Path Screen Play Done. Sau mt lt ch tnh ton, ta s nhn thy dao chy v ng qu o dao c v ra di dng khung dy. m phng di dng Solid, chn NC Check Run. Trong hnh 48 l kt qu Play Path v NC Check bc gia cng th lng khun. - Hnh bn phi th hin qu trnh to thnh Tool Path trong lng khun (ng xanh l cy) t hnh phng ca n trn Retract Plane. - Hnh di, bn tri l Tool Path do mi dao sinh ra. - Hnh di, bn phi l kt qu chy NC Check. Ta thy dao n mt ln ht chiu su.

Hnh 48: Kt qu gia cng tinh lng khun theo b mt Nu chp nhn kt qu th chn Done/Return Done Sequ nhn NC Sequence va to v kt thc. 2 Phay th lng khun (Volume) Bc ny nhm phay th lng khun, dng phng php phay khi (Voume). bng dao chm cu D=10 mm. Bng phng php Volume, mt khi vt liu trong lng phi s c ct theo tng lp. Cc lp ct song song vi mt rt dao, cch nhau mt khong c quy nh bi cc thng s STEP_DEPTH v WALL_SCALLOP_HGT. B dy nh nht cho php ca lp ct c quy nh bi thng s MN_STEP_DEPTH. Khong cch gia cc ng chy dao trong mt phng c xc nh bi cc thng s STEP_OVER, NUMBER_PASSES, BOTTOM_SCALLOP_HGT, and STEPOVER_ADJUST. Cc ng dng ch yu ca phay Volume l: 32

B mn c in t & CTM c bit - Kho mt phi. - Gia cng ph vt liu bao ngoi chi tit. - Gia cng ph cc rnh, hc hoc cc hc c o. - Gia cng tinh hc, chn gi tr PROF_ONLY cho thng s ROUGH_OPTION. Vn quan trng khi phay l chn ng i tng gia cng. Khi gia cng c th c chn trn c s cc i tng hnh hc c sn hoc c to ra t Sketch. Ni chung, k thut chn khi kh phc tp, phi lm quen v rt kinh nghim dn. Cc s trong hnh 49 bn minh ho v so snh hai phng php chn khi. Nu dng tu chn Surf & Bnd (mt v bao). Chn y hc 1 v cc mt bn 2. Kt qu l c khi 3, cho php gia cng c c mt trn ca phi ln hc. Nu dng tu chn Surfaces, sau chn y hc 4 th khi gia cng c hnh thnh ch cho php phay ring hc. Hnh 49: Phng php chn khi Vi trng hp ca bi ny, chng ta dng Window chn khi. L do dng Window cho trng hp ny l n n gin. Trong Menu Manager, chn Machining NC Sequence New Sequence Volume Done. Trong Seq Setup Menu, nh du cc Name, Tool, Parameters, Window, sau chn Done. Nhp cc thng tin theo yu cu to ra NC Sequence. 1. Name: G "Rough" t tn cho NC Sequence <CR>. 2. Tool:nh ngha thng s dao phay cu bng cch in cc gi tr vo hp thoi Tools Setup va xut hin. Nhp tn dao l T0002 trong Name, ku dao phay (Mill) trong Type, ng knh dao l 10 trong Cutter Diameter, bn knh gc dao (Corner Radius) l 5, s rng dao (Number of teech) l 2. Chn Apply. Nhn OK chp nhn. 3. Parameters: Chn Set trong Menu Manager m hp thoi Param tree. Xc nh cc thng s cng ngh, in vo bng ca hp thoi nh hnh 50. Sau khi nhp xong cc thng s, chn menu File Save nhp tn file v OK, chn File Exit trong hp thoi. Chn Done trong Menu Manager kt thc nhp thng s.

33

B mn c in t & CTM c bit

Hnh 50:Chn cc thng s phay th lng khun 4. Window: To ca s T Menu Manager, chn Create Wind, g tn Window, v d Cavity Select Tangent Chain chn ng bao trn ming lng khun OK. Mt ng bao kn c hnh thnh (chiu ng bao ming khun) trn mt phng rt dao. Chng ta nh ngha xong cc thng s gia cng. kim tra kt qu, chn Play Path Screen Play Done. Ta s nhn thy dao chy v ng qu o dao di dng khung dy. m phng Solid, chn NC Check Run. Trong hnh 51 l kt qu Play Path v NC Check gia cng th.

Hnh 51: Kt qu gia cng tinh lng khun theo b mt Nu chp nhn kt qu th chn Done/Return Done Sequ nhn NC Sequence va to v kt thc.

34

B mn c in t & CTM c bit 3. Sp xp li cc bc (Reoder) Chng ta c to ra mt li, l to bc phay tinh trc phay th (hnh 52-a). By gi phi s dng tin ch Reoder ca Pro/E sp xp li chng, ngha l a bc phay th ln trc bc tinh. Trong Menu Manager, chn NC Sequence Utilities Reoder NC Sequnce. Trong danh sch NC Sequence, chn Rough Done Sel Yes Done. Trong ca s trng thi chng ta s thy thng bo v kh nng chuyn, v d: Do you want to include CUA1 in group definition? Yes " The only reoder possibility is to insert feature [9-12] before [6]" Chn Done. Xut hin thng bo tip: "Fature [9-12] will be insert before feature [6]. Confirm/Cancal". Chn Confirm. Kt qu sp xp (a) (b) li nh trong hnh 52-b. kim tra kt qu, chn Hnh 52: Sp xp li th t cc bc PlayPath Screen Play Done Ta s nhn thy dao chy v ng qu o dao di dng khung dy. m phng Solid, chn NC Check Run. Trong hnh 53 l kt qu Play Path v NC Check nguyn cng Mill, sau khi sp xp li th t cc bc. Chng ta thy dao ang gia cng tinh b mt c gia cng th.

Hnh 53: Kim tra kt qu sp xp li bc gia cng

35

B mn c in t & CTM c bit 2.3. Ghi v s dng CL Data file Cho n y, cc d liu mi ch c lu tr trong file m hnh gia cng. Cn phi xut d liu ny ra CL Data file c lp, t c th to ra chng trnh NC. Mun to ra chng trnh NC, phi c Post-Processor. Phn mm Pro/E tiu chun ch c th to ra CL Data File di dng ngn ng APT. 1. Xut CL Data ra file Trong Menu Manager, chn Manufacture Machine CL Data Output Select Set tn Operation hoc tn NC Sequence File. Trong menu Output Type, nh du CL File v Interactive Done. Trong hp thoi Save As, g tn file (Bai3) vo dng New File OK. Kt qu, nhn c file Bai3.NCL. 2. c d liu t file Sau khi khi ng Pro/E, t menu File Open Chn tn file (Bai3.mfg) Open. M hnh gia cng xut hin trn mn hnh ho. T Menu Manager, chn CL data Input. Trong hp thoi Open, chn tn file: Bai3.NCL Open. Tr li Menu Manager, chn Display CL nh du Tool Done/Return. Sau mt thi gian tnh ton, qu o dao s c v trn m hnh gia cng. Mun chy m phng, chn NC Check Run. bi 4: Chc nng Expert Machinist ca ProNC Qua bi ny chng ta s lm quen vi mt cng c khc ca ProNC, Expert Machinist. Cng c ny c mt s tin ch, cho php chn cc i tng v ch gia cng d dng v trc quan hn, theo phong thi mt ng dng Windows thc s. Chi tit gia cng trong bi ny phc tp hn trong cc bi trc (hnh 54), gm: - Vu li (Slab) 1. - 2 hc h (Step) c v trn y 2. - 2 hc kn (Pocket) c v trn y 3. - Mt bn (Profile) 4. - Rnh (Slot) 5. - Dy l (Hole Patten) 6. - Mt phng (Face) 7. Hnh 54: Chi tit gia cng Chi tit ny c th c gia cng trong 1 nguyn cng (Mill), dng my phay 3 trc. Nguyn cng gm 9 bc (NC Sequence) sau: 1. Face: Kho mt u n nh ca vu li 1. 2. Slab: Gia cng mt 7, li vu li 1. 3. Profile: Gia cng mt 4, to bc hnh ch "D". 4. Slot: Gia cng rnh 5. 5, 6. Poket: Gia cng cc hc 3. 7, 8. Step: Gia cng cc hc h 2. 9. Hole patten: Khoan dy l 6. 36

B mn c in t & CTM c bit Nhim v ca bi thc hnh gm To m hnh gia cng. To nguyn cng phay (Mill). Chn cc i tng (Feature) gia cng. To cc bc gia cng (NC Sequence). Ghi CL Data ra fle v c d liu t file. 1. To m hnh gia cng Chng ta s to m hnh gia cng t file cha m hnh gia cng Bai4.prt, sau to m hnh phi bao ra ngoi chi tit bng cng c c bit ca NC Expert. 1.1. Khi ng Pro/E vi Expert Machinist Pro/E c 2 ch lm vic: Ch ProNC nh chng ta quen dng. Ch th hai, Expert Machinist c khi ng nh sau: Chn New t menu File. Trong hp thoi New, chn Manufacturing NC Expert nh trong hnh 55. G vo tn file, v d Bai4. Pro/E s to ra file Bai4.Mfg. Pro/E a ra NC-WIZARD. Loi b n bng cch bm vo nt Quit NC-Wizard. Mt s menu v thanh cng c Feature xut hin (hnh 56). Trn thanh ny cha cc nt cng c chn cc Feature, Hnh 55: Hp thoi New, to file iu khin hin th m hnh v to cc bc gia cng. ngha ca cc nt nh sau: Hnh 56: Thanh cng c Feature 1. To hc c y (Create Pocket Feature) 2. To hc thng (Create Thru Pocket Feature) 3. Ta rnh phc hp (Create Channel Feature) 4. To rnh thng (Create Slot Feature) 5. To hc h (Create Step Feature) 6. To mt phng (Create Face Feature) 7. To vu li (Create Slab Feature) 8. To bc (Create Flange Feature) 9. To mt bin (Create Profile Feature) 10. To nh vu (Create Boss Top Feature) 11. To dy l (Create Hole Pattern Feature) 12. To l di bc (Create Entry Hole Feature) 13. Bt tt hin th phn vt liu b ct (Toggle Display of Material Removal) 37

B mn c in t & CTM c bit 14. To b mt t do (Create Free Form Feature) By gi, Expert Machinist sn sng cho vic lp trnh. File m hnh gia cng Bai4.mfg c to ra cn rng, cn nhp cc d liu hnh hc v cng ngh cho n. 1.2. To m hnh gia cng Trc ht phi nhp d liu hnh hc ca chi tit gia cng. T thanh menu, chn NC Setup NC Model Create Model. Chp nhn tn mc nh ca m hnh gia cng, trong hp thoi Open, chn file cha m hnh chi tit Bai4.prt a n vo m hnh gia cng. M hnh chi tit hin ln cng vi menu NC MODEL nh hnh 57. ng tt menu ny vi.

Hnh 57: M hnh lp rp (chi tit lng phi) Vic tip theo l to m hnh phi. Chn Create Stock, hp thoi to phi xut hin nh trong hnh 58. Trong ch mc nh (Default Billet v Envelope), phi c t ng to ra c dng hnh hp bao kht ton b chi tit gia cng. Trong kch thc phi (Stock Size), hin gi tr kch thc chiu di (Length), rng (Width), dy (Thickness) ca hp. Hin ti cc con s ny b m, ngha l cha sa c. Ti tm ca phi c 3 mi tn mu , ch dc theo phng ca cc cnh phi: X theo chiu di, Y theo b rng, Z theo b dy. y cha phi h to phi v phng ca cc mi tn c th cng khng trng vi cc trc to phi. C th sa phng ca cc mi tn ny, nhng khng nht thit. Trong tu chn (Option) ca hp thoi c 2 mc sa m hnh phi l lng d (Allowances) v sa i hin th (Modify Outline).

38

B mn c in t & CTM c bit

Hnh 58: To phi vi Expert Machinist Chng ta cn thm 5 mm chiu cao phi kho mt u. Bm vo mi tn bn cnh mc Allowances. Mc ny c dn ra, cho php sa cc gi tr kch thc (hnh 59). Chiu cao by gi ng vi trc Y, do kch thc tng ng ca n li nm trong mc Width v c gi tr mc nh l 50. Cn ko thm 5 mm theo chiu dng ca trc Y, vy ta nhp gi tr 5 vo ct c du "+" ca mc Width ri bm OK. Lp tc kch thc chiu cao phi c i thnh 55 v hnh nh phi cng cao ln 5 mm. Chp nhn kch thc phi va sa, nhn tn phi mc nh, chn Done kt thc vic to phi, ng thi cng kt thc to m hnh gia cng.

Hnh 59: Hiu chnh kch thc phi 2. To nguyn cng Nguyn cng s dng l nguyn cng phay, t tn l Mill, c thc hin trn my phay ng CNC 3 trc. Chng ta phi nh ngha my, h to v mt rt dao. 2.1. nh ngha my ct T thanh menu, chn NC-Setup Machine Tool Manager, xut hin hp thoi Machine Tool Setting nh trong hnh 60. Hp thoi ny cho php gn cc thng 39

B mn c in t & CTM c bit s ca my, nh tn my, loi my, s trc, tn b iu khin, trc chnh, trc chy dao, dao, vng gia cng. Sau khi nhp cc thng s, bm OK.

Hnh 60: Hp thoi nh ngha my 2.2. nh ngha nguyn cng T thanh menu, chn NC-Setup Operation. Hp thoi tip theo (Operation Setup) xut hin nh trong hnh 61. Trong hp thoi ny c th t tn nguyn cng, chn my (nu c nhiu my c nh ngha trc), xc nh h to v mt rt dao, v tr khi u v kt thc, nh ngha c cu kp,... nh ngha h to mi, bm vo mi tn Program Zero. Tip theo, chn 3 mt phng xc nh gc to , chn phng cc trc to . Th tc thc hin tng t nh trong cc bi trc. n y, vic nh ngha nguyn cng hon tt. Chng ta c th bt u nh ngha cc bc gia cng (NC Sequence).

Hnh 61: nh ngha h to v mt rt dao

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B mn c in t & CTM c bit 3. nh ngha cc bc gia cng (NC Sequence) Trong mi trng Pro/E truyn thng, nh thy trong cc bi trc, chng ta chn i tng gia cng trong khi nh ngha bc gia cng. Trong Expert Machinist, c th chn trc ton b cc Feature ri mi to thng s ct hnh thnh bc gia cng. 3.1. Chn cc i tng (Feature) gia cng chn cc i tng gia cng c th dng menu hoc dng thanh cng c nh trong hnh 56. Thanh cng c tin dng hn nn chng ta s thin v s dng thanh cng c. To Face Feature Nh biu tng ch r, Feature ny nhm kho mt trn ca phi, ngha l ht mt lp trn ton b b mt trn ca phi ti im cao nht ca chi tit, trong trng hp ny l nh ca vu li. Sau khi nhn biu tng trn, mt hp thoi xut hin, cho php cho php xc nh vng gia cng (hnh 62). Hnh 62: Hp thoi Face Feature Nhn tn mc nh ca Feature mi l Face1. Vi mi tn ca mc Define Feature Floore c nhn sn, h thng ch ngi dng chn mt mt phng xc nh b dy lp ct. Chn mt phng trn nh ca vu trn, xong chn Done/Return. Tu chn th hai, Define Program Zero yu cu nh ngha h to . Chng ta s dng h to chung cho ton nguyn cng nn bm OK b qua yu cu ny. (Toggle Bm phm Display Of Material Removal), chng ta s thy vng Hnh 63: Phi sau khi b kho mt pha trn b mt i, trn phi ch cn li vt liu cho nhng ln ct sau (hnh 63). i sang ch hin th Shade nhn r hn. To Slab Feature Slab tng t nh Face nhng c phn li khng b ct. Sau khi kch vo phm, hp thoi Milling Feature xut hin v ch chn b mt gii hn di ca Feature. 41

B mn c in t & CTM c bit Chn mt phng tng ng, xong bm Done/Return OK. Phn phi cn li nh trong hnh 64.

Hnh 64: To Slab Feature To Profile Feature Profile Feature nh ngha b mt vin xung quanh phn li ch "D" ca chi tit. Kch vo phm m hp thoi Milling Feature. Ln ny, Pro/E a ra yu cu Define Feature Walls. Chn ht cc mt xung quanh ca chi tit Done Sel Done/Return OK. Kt qu sau khi loi Profile Feature nh trong hnh 65. Hnh 65: To Profile Feature To Slot Feature Feature ny cho php gia cng rnh tit din ch nht ct ngang chi tit. Sau khi kch vo phm, hp thoi hin ra nhc chn mt y ca rnh. Sau khi chn mt y rnh, chn Done/Return OK. Kt qu nhn c nh trong hnh 66. Hnh 66: To Slot Feature

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B mn c in t & CTM c bit To Pocket Feature Pocket Peature l hc c gii hn bi cc thnh bn thng ng v y. Hnh dng ca hc c th bt k ch khng bt buc phi trn hay ch nht. Cnh gia cc mt c th c bo trn. Sau khi kch vo biu tng, chn mt y hc Done Done/Return. Chi tit c 2 hc ging nhau nhng phi thc hin 2 ln ring bit, mi ln mt hc. To Step Feature Step Feature l bc, c gii hn bi thnh bn thng ng khng khp kn v mt y. N to thnh bc trn chi tit. Step tng t nh Pocket nhng h. To Step tng t nh Pocket. Kch vo biu tng, chn mt y Done Done/Return. Chi tit c 2 Step ging nhau, phi to 2 ln. Hnh 68: Step Feature

Hnh 67: Pocket Feature

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B mn c in t & CTM c bit To Hole Pattern Feature Vi Hole Pattern Feature, chng ta s khoan 4 l 5 cn li. Hp thoi Drill Gruop c nhiu tu chn (hnh 69). B qua 2 mc trn v chng ta chp nhn tn mc nh ca nhm l khoan (Drill Group Name) v dng h to phi chung (Program Zero Selection). Trong s cc phng php chn l mc Hole Selection: theo trc (Axes), b mt cha ming l (Surfaces), ng knh (Diameters), theo tham s (By Parameter), dng phng php chn theo ng knh. Chn Diameters Add Select Chn 1 l bt k trong nhm. Trong hp thoi Diameter(s) of holes to drill hin s 5, chng t l va chn c ng knh l 5 mm v tt c cc l 5 c chn. Bm OK kt thc chn l. Hnh 69: Hp thoi khoan n y chng ta chn tt c cc Feature cn thit gia cng. Chng c lit k y trong Menu Manager. M hnh phi cng cho thy khng cn g gia cng na (hnh 70). Mi Feature th hin hnh hc v phng php gia cng.

Hnh 70: Kt qu sau khi chn xong cc Feature 3.2. To qu o dao Tip theo l to qu o chy dao gia cng cc Feature. Mun vy phi chn li tng Feature v nhp thm cc thng s cng ngh cn thit. vo ch gia cng. Trong hp thoi Select Feature, tt c Bm phm cc Feature va to c lit k ra thnh danh sch. Chng ta c th chn Feature bt

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B mn c in t & CTM c bit k trong danh sch gia cng. Theo th t, chn Feature u tin, l Face1 OK. Hp thoi Face Milling xut hin (hnh 71).

Hnh 71: Nhp d liu Face Milling

Hnh 72: Tool Path c to ra

Cc thng s cng ngh chnh cn nhp nh sau: Tn bc: FaceMill Thng s dao Thng s cng ngh ng knh 50 mm Lng chy dao (F) 200 mm/ph Chiu di 20 mm Tc trc chnh (S) 2000 v/ph Bn knh gc 3 mm Chiu su lp ct 3 mm S rng 8 Khong cch gia cc ng chy 3 mm dao V cha c dao no c nh ngha nn trong mc Cutting Tool cn hin ch None. Bm biu tng dao, hp thoi nh ngha dao xut hin. Nhp thng s dao xong bm Apply OK. 45

B mn c in t & CTM c bit nh du cc mc nh trong hp thoi. Bm Tool Path Properties nhp tc trc chnh v lng chy dao OK. Trong Menu Manager, ngay sau FACE1[OP010] hin biu tng ng chy dao vi tn FACE1.TP1[OP010] nh hnh 72. Kch phi vo s hin menu con chn cc chc nng: - Tool Path Player hin ng chy dao. - Output Tool Path xut d liu chy dao ra file. - Edit Defination nh ngha li Tool Path. - Delete xo Tool Path. C th chn Tool Path Player y hoc trn thanh menu chnh kim tra ng chy dao. Trong khi ng chy dao hin ln trong vng ho th CL Data tng ng vi Tool Path hin hnh xut hin trong ca s (hnh 73). S dng cc cng c y ca s iu khin qu trnh m phng. tip tc to Tool Path cho cc Feature tip theo, cn lp li cc th tc tng t. Chc nng Machine Feature cng c th c gi bng cch kch phi chut vo tn Feature v chn Create Tool Path trong Menu Manager nh trong hnh 74. Cc thng s cn nhp v hp thoi cho tng Tool Path c lit k trong bng di y. Sau mi bc cn dng Tool Path Player kim tra li kt qu lp trnh. Mun p dng Tool Path Player cho ton b nguyn cng th kch phm phi vo tn nguyn cng (OP010[MACH01]). Trn thanh menu View ca hp thoi Play Path c th chn ch m phng Wireframe (khung dy), NC Check (solid), hoc Gouge Check (kim tra va chm).

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B mn c in t & CTM c bit

Hnh 73: CL Data ca Tool Path Hnh 74: To Tool Path tip theo Hy nhp cc thng s sau y to cc Tool Path tip theo. SlabMill v ProfileMill Dng dao v thng s cng ngh nh bc trc. SlotMill Tn bc: SlotMill Thng s dao Thng s cng ngh ng knh 6 mm Lng chy dao (F) 200 mm/ph Chiu di 50 mm Tc trc chnh (S) 2500 v/ph Bn knh gc 0 mm Chiu su lp ct 3 mm S rng 2 Khong cch gia cc ng chy dao 3 mm

PocketMill v StepMill Tn bc: PocketMill v StepMill Thng s dao Thng s cng ngh ng knh 6 mm Lng chy dao (F) Chiu di 50 mm Tc trc chnh (S) Bn knh gc 3 mm Chiu su lp ct S rng 2 Khong cch gia cc ng chy dao

200 mm/ph 2500 v/ph 3 mm 3 mm 47

B mn c in t & CTM c bit Hole Group Drill Thng s dao ng knh 5 mm Chiu di 50 mm Gc mi dao 118 S rng 2 Tn bc: DrillGroup Thng s cng ngh Lng chy dao (F) Tc trc chnh (S) Chiu su lp ct Khong cch gia cc ng chy dao

150 mm/ph 2500 v/ph 5 mm 0 mm

4. Ghi CL Data ra fIle v c d liu t file Cho n y, cc d liu mi ch c lu tr trong file m hnh gia cng. Cn phi xut d liu ny ra CL Data file c lp, t c th to ra chng trnh NC. Mun to ra chng trnh NC, phi c Post-Processor. Phn mm Pro/E tiu chun ch c th to ra CL Data File di dng ngn ng APT. 4.1. Xut CL Data ra file Trong Menu Manager, chn Manufacture Machine CL Data Output Sel By Menu tn Operation hoc tn NC Sequence File. Trong menu Output Type, nh du CL File v Interactive Done. Trong hp thoi Save As, g tn file (Bai4) vo dng New File OK. Kt qu, nhn c file Bai4.NCL. 4.2. c d liu t file Sau khi khi ng Pro/E, t menu File Open Chn tn file (Bai4.mfg) Open. M hnh gia cng xut hin trn mn hnh ho. T Menu Manager, chn CL data Input. Trong hp thoi Open, chn tn file: Bai4.NCL Open. Tr li Menu Manager, chn Display CL nh du Tool Done/Return. Sau mt thi gian tnh ton, qu o dao s c v trn m hnh gia cng. Mun chy m phng, chn NC Check Run.

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