n CAD/CAM/CNC

GVHD: Lu c Bnh

Phn I:

PHN TCH IU KIN LM VIC V YU CU K THUT CA SN PHM

1 - iu kin lm vic ca chi tit: 1.1. Lich s phat trin cua cng ngh CAD/CAM: - Trong tt c cc loi my mc u c chi tit dng hp. Hp bao gm nhng chi tit c hnh khi rng (xung quanh c thnh vch) thng lm nhim v ca chi tit c s lp cc n v lp (nhm, cm, b phn) ca nhng chi tit khc ln n to thnh mt b phn my nhm thc hin mt nhim v ng hc no ca my. - Hp c rt nhiu kiu v cng dng cng khc nhau ty theo yu cu lm vic. - c im ca cc chi tit hp l c nhiu vch, dy mng ca cc vch khc nhau, trong cc vch li c nhiu gn, nhiu phn li lm; nhiu mt phng phi gia cng lm mt tip xc; c bit trn hp c nhiu l phi gia cng chnh xc thc hin cc mi lp ghp. 1.2 Yu cu ky thut: - Hp c nhng b mt chnh nh: mt y, mt l yu cu chnh xc kh cao. Ngoi ra, cn c cc b mt ph nh: b mt y np, l bt bulng... Nhng yu cu k thut c bn ca hp cn xt n l: + khng phng v khng song song ca cc b mt chnh, chnh xc Cc l, Sai s hnh dng cc l, Dung sai khong cch tm gia cc l, Dung sai khng song song ca cc tm l bng dung sai khong cch tm. + Dung sai khng ng tm ca cc l bng 1/2 dung sai ng knh l nh nht, khng vung gc gia mt u v tm l.
+ khng phng v khng song song ca cc b mt chnh trong khong 0,05-0,1

mm trn ton b chiu di, Ra = 5-1,25. + nhm b mt Rz = 10-20.

SVTH : Trn nh Tr 10C1LT

-1-

 n CAD/CAM/CNC
+ chnh xc b mt cp 7-8.

GVHD: Lu c Bnh

- Vt liu: + Vt liu ch to cc chi tit hp thng dng l gang xm, thp c, hp kim nhm v nhng thp tm hn. + Ty theo iu kin lm vic, s lng hp v vt liu m phi c ch to bng cc phng php khc nhau. Ph bin nht l phi gang c, phi thp c, phi hp kim nhm c, trong mt s trng hp ngi ta dng phi dp, phi hn

Phn II:

THIT K CHI TIT BNG PHN MM -2-

SVTH : Trn nh Tr 10C1LT

 n CAD/CAM/CNC

CAD/CAM

GVHD: Lu c Bnh

1. Gii thiu chung v phn mm CAD/CAM s dng: 1-1. Lich s phat trin cua cng ngh CAD/CAM: - CAD xut hin vo nhng nm trc 1960 vi t cch l cng c v. n nhanh hn rt nhiu. - Theo thi gian CAD pht trin theo hai hng: + Mt mt, CAD c tch hp nhiu tnh nng mi.Vi cc tnh nng ho c trng ca mnh, CAD tr thnh mi trng pht trin cc cng c tnh ton, phn tch, sn xut nh tnh ton ng hc, ng lc hc c cu; tnh ton kh ng, nhit, t; lp trnh cho my CNC, qun l cng ngh,..Ni cch khc CAD ngy cng c tch hp thm nhiu tnh nng mi, nh cc tnh nng mi ny m ngy nay CAD tr thnh mt cng c tuyt vi khng ch cho cc nh thit k m c c cc nh kinh doanh, qun l, ngh thut, qun s,Gii k thut ngy nay quen vi cc thut ng CAD,CAM. + Tuy c nhng tnh nng khc nhau nhng cc phn mm CAD, CAM c nhng im chung l pht trin trong mi trng ho ca CAD hoc trc tip s dng d liu ho ca CAD. + Mt khc mt s hng sn xut khc to ra mi trng m, cho php v khuyn khch tt c cc nh pht trin s dng d liu v cng c iu hnh ca CAD to ra phn mm CAM v CAD khc. Nh vy d bng cch no cc chc nng CAM v CAD cng c pht trin trn nn CAD. Hay ni cch khc cc phn mm CAD hin i tch hp thm cc chc nng CAM v CAD. 1.2- Cac chc nng cua CAD/CAM: 1.2.1- Chc nng cua CAD: a. Chc nng m hinh hoa: - CAD l cng ngh lin quan n vic s dng h thng my tnh gip vic to, sa i, phn tch v ti u ha thit k. - Theo , bt c chng trnh my tnh no c tnh nng ha v mt chng trnh ng dng vi cc chc nng k thut thun tin u c phn loi nh l phn mm SVTH : Trn nh Tr 10C1LT -3nhng

nm 80 th CAD vn ch l cng c v nhng cch s dng n gin, chnh xc v

 n CAD/CAM/CNC

GVHD: Lu c Bnh

CAD. Ni cch khc, cc cng c CAD c nhiu cp khc nhau ty theo ng dng. C th chng ch c nhng cng c v hnh hc nhm to ra hnh dng vt th, hoc c thm cc cng c phn tch dung sai, tnh ton mt s i lng vt l v m hnh ha phn t hu hn mc cao l cc phn mm CAD vi cc chng trnh ng dng nng cao cho phn tch v ti u ha. - Vai tr c bn nht ca CAD l xc nh hnh hc ca thit k nh hnh dng hnh hc ca cc chi tit c kh, cc kt cu kin trc, mch in t, mt bng nh ca trong xy dng Cc ng dng in hnh ca CAD l to bn v k thut vi y cc thng tin k thut ca sn phm v m hnh hnh hc 3D ca sn phm. Hn na, m hnh CAD ny s c dng cho cc ng dng CAE v CAM sau ny. y l li ch ln nht ca CAD v c th tit kim thi gian mt cch ng k v gim c cc sai s gy ra do phi xy dng li hnh hc ca thit k mi khi cn n n. - Mt qu trnh CAD tiu biu c thc hin theo cc bc sau: + Xy dng m hnh hnh hc sn phm. + Phn tch k thut sn phm. + Kim tra v nh gi k thut. + Xy dng bn v k thut. b. Chc nng ve: - Dng chc nng Sketch: Sketch l cng c phc tho c nhim v chnh l to ra cc Profile 2D hay 3D t hnh thnh nn cc m hnh vt c hay cc b mt. Vi cng c tham s ho sketcher ca CAD hin i tr nn linh hot hn trong vic to ra cc bn v k thut. Tuy nhin n c dng to ra cc bn v n gin. - To bn v t m hnh: to bn v 2D ta xut trc tip cc hnh chiu, hnh ct t m hnh. T mt m hnh c th nhanh chng to nhiu bn v v gia cc m hnh v cc bn v c quan h vi nhau v bt k s thay i no t m hnh cng iu c cp nhp n bn v. c. Chc nng phn tich: - l tnh nng tnh ton ng hc, ng lc hc, nhit, ng sut, bin dng, ca cc chi tit, c cu v h thng. Chc nng ny pht trin c lp vi CAD v c tch hp vo CAD lm cho CAD hin i tr nn linh hot hn rt nhiu.

1.2.2 Chc nng cua CAM: - CAM l cng ngh lin quan vi vic s dng h thng my tnh lp k hoch, qun l v iu khin cc qu trnh ch to. SVTH : Trn nh Tr 10C1LT -4-

 n CAD/CAM/CNC

GVHD: Lu c Bnh

- Mt trong nhng lnh vc hon thin nht ca CAM l iu khin chng trnh s (Numerical Control NC). y l k thut s dng cc ch dn c lp trnh iu khin cc my cng c nh my mi, my tin, my phay, my dp My tnh c th sn sinh ra mt lng ng k cc ch dn NC da trn cc d liu hnh hc t c s d liu CAD cng vi nhng thng tin b sung c cung cp bi ngi vn hnh. - Mt chc nng quan trng khc ca CAM l lp trnh robot. Cc robot ny c th vn hnh trong mt t bo gia cng, chn v nh v dao v chi tit gia cng cho cc my NC. Nhng robot ny cng c th thc hin cc nhim v n l nh hn, lp rp hoc vn chuyn thit b hoc chi tit trong phn xng - Lp quy trnh ch to cng l mt mc ch ca CAM. Quy trnh ch to bao gm cc nguyn cng chi tit ca cc bc sn xut t ban u n kt thc, t my ny n my khc trong phn xng 1.3. Gii thiu v phn mm Pro/E wildfine 2.0: - Trn th trng thit k, lp trnh, gia cng c kh hin nay Vit Nam v trn th gii, cng vi cc phn mm ni ting khc nh Catia, UniGraphic, Ideas, Pro/E ang ng vai tr to ln trong ngnh cng nghip c kh chnh xc. - Pro/Engineer Wildfire 2.0 l phin bn mi v m rng ca phn mm Pro/Engineer. Pro/E Wildfire 2.0 l phn mm tin ch thit lp nhanh, chnh xc cc bn v hnh chiu hai chiu, bn v hnh chiu trc o ba chiu v cho php t ng lp cc chng trnh gia cng trn cc my CNC. - S dng Pro/E Wildfire 2.0 c th xoay cc khi ba chiu quan st ro hn hnh dng ca chng cc gc khc nhau. Cng c th to cc chuyn ng quay, chuyn ng tnh tin cho khi ba chiu, m phng qu trnh lp rp cc chi tit my vi nhau, m phng qu trnh hot ng ca my. - Vi cng c thit k linh hot, m phng phn tch ng hc phong ph, phn khun a dng, lp trnh gia cng n nh v cc chc nng trao i, nhng d liu vi cc phn mm h tr nh EMX (khun nha), PXD (khun dp), Assembly Smart (th vin c kh), lm cho Pro/E cng mnh m hn. - Khi c trang b cc k nng v Pro/E, cc bn c kh nng thit k m hnh (Modeling), lp cc bn v chi tit, bn v ch to, bn v lp (Drawing), phn tch ng hc (Assembly), thit k khun nha (Mold v EMX), thit k khun dp tm (Sheet Metal v PXD, DIE) v lp cc chng trnh gia cng nh tin, phay, khoan, ta r, khc, ct dy, - Kt hp vi my gia cng iu khin s (CNC), Pro/E c th to ra mt quy trnh khp kn t thit k, m phng n iu khin sn xut hon thin sn phm.

SVTH : Trn nh Tr 10C1LT

-5-

 n CAD/CAM/CNC

GVHD: Lu c Bnh

Quan st trn mn hnh my tnh, chng ta c th kim tra ton b qu trnh gia cng, sa cha cc li trong chng trnh, trnh c tt c cc sai st trc khi tin hnh gia cng thc trn my CNC. 2. Trnh by trnh t qu trnh thit k sn phm: a. Khi ng Pro Engineer: C hai cch khi ng Pro Engineer : - Kch p chut ln biu tng Pro Engineer trn mn hnh Desktop. - Start > Program>Pro Engineer.Xut hin mn hnh Pro Engineer. Mn hnh gm c: Mt thanh Standard Toolbar. Mt thanh menu toolbar. b. To th mc lm vic trong cng: Chn file: Working Directory chn th mc D:\Pro Engineer. Tt c cc bi tp ta lm trong sut bui lm vic s c lu trong th mc D:\Pro Engineer.

Vo New- chn Part( Type)-Sold(Subtype)-t tn bi tp-ok

SVTH : Trn nh Tr 10C1LT

-6-

 n CAD/CAM/CNC

GVHD: Lu c Bnh

Thanh cng c Pro Engineer gm nhng nhm cng c chnh trong bng: Toolbar Flile Edit View MoDel Display Datum Display Chc nng Qun l tp tin H tr thit k Quan st i tng Hin th i tng Bt tt i tng chun

c. To chi tit trn phn mn pro Engineer: Bc 1: Dng lnh Extrude to khi hnh ch nht vi kch thc 140/100/17 SVTH : Trn nh Tr 10C1LT -7-

 n CAD/CAM/CNC

GVHD: Lu c Bnh

Vo Extrude-chn Placement-chn Defile-chn Mt cn to ,ta chn mt Top-chn Sketch-Close-xut hin mn hnh v nh di

Trn xut hin cc lnh Sketch chng ta thc hin, chn hnh ch nht v thc hin lnh v nh di Ta nhp kch thc 140/100(mm)-kt thc lnh. Nhp chiu dy ca hnh ch nht 17(mm)-kt thc lnh ta c khi hnh ch nht 140/100/17(mm)

SVTH : Trn nh Tr 10C1LT

-8-

 n CAD/CAM/CNC

GVHD: Lu c Bnh

SVTH : Trn nh Tr 10C1LT

-9-

 n CAD/CAM/CNC

GVHD: Lu c Bnh

Bc 2: Thc hin lnh Extrude v bin dng nh di vi chiu dy 8mm Vo Extrude-chn Placement-chon Defile-chn mt Top thc qu trnh thc hinchn ng chun-chn close-tin hnh thc hin

SVTH : Trn nh Tr 10C1LT

-10-

 n CAD/CAM/CNC

GVHD: Lu c Bnh

Bc Bc 3: Dng lnh Extrude n l vi ng knh40 v 2l 16 v cng nh trn chn mt Top da vo cc lnh v Sketch v hnh trn v thc hin qu trnh xuyn sut nh di ( y ta c th dng lnh Hole Tool ct )

SVTH : Trn nh Tr 10C1LT

-11-

 n CAD/CAM/CNC

GVHD: Lu c Bnh

SVTH : Trn nh Tr 10C1LT

-12-

 n CAD/CAM/CNC

GVHD: Lu c Bnh

SVTH : Trn nh Tr 10C1LT

-13-

 n CAD/CAM/CNC

GVHD: Lu c Bnh

Bc 4: Dng lnh Extrude v bin dng nh hnh bn di

Bc 5: Tar M8 bc 1. Bng cch dng lnh Hole Tool thc hin qu trnh tar Vo Hole Tool-chn placement-ti Primary chn mt Top lm mt to tar- chn Diameter-ti Secondary references chn mt Front v trc chun cn ly ng knh-sau nhp gc v ng knh ca hnh trn chun cn gia cng trn n la 55 v kt qu c hnh nh di. Kt thc qu trnh to chi tit

SVTH : Trn nh Tr 10C1LT

-14-

 n CAD/CAM/CNC

GVHD: Lu c Bnh

SVTH : Trn nh Tr 10C1LT

-15-

 n CAD/CAM/CNC Phn III:

GVHD: Lu c Bnh

THIT K QUY TRNH CNG NGH CH TO CHI TIT

I. Phn tch cc c im v yu cu k thut b mt cn gia cng: 1. c im ca chi tit: y l 1 chi tit dng hp nn c nhng c im ca 1 chi tit dng hp: Trong tt c cc loi my mc u c chi tit dng hp. Hp bao gm nhng chi tit c hnh khi rng (xung quanh c thnh vch) thng lm nhim v ca chi tit c s lp cc n v lp (nhm, cm, b phn) ca nhng chi tit khc ln n to thnh mt b phn my nhm thc hin mt nhim v ng hc no ca ton my. Hp c rt nhiu kiu v cng dng cng khc nhau ty theo yu cu lm vic. c im ca cc chi tit hp l c nhiu vch, dy mng ca cc vch khc nhau, trong cc vch li c nhiu gn, nhiu phn li lm; nhiu mt phng phi gia cng lm mt tip xc; c bit trn hp c nhiu l phi gia cng chnh xc thc hin cc mi ghp. Nhn chung, hp l loi chi tit phc tp, kh gia cng, khi ch to phi m bo nhiu yu cu k thut khc nhau 2. Yu cu k thut b mt cn gia cng: Hp c nhng b mt chnh nh mt y, mt l yu cu chnh xc cao. Ngoi ra, cn c cc b mt ph nh b mt y np, l bt bulng Nhng yu cu k thut c bn ca hp l: - khng phng v khng song song ca cc b mt chnh trong khong 0,05 0,1 mm trn ton b chiu di, Ra = 5 1,25. - Cc l c chnh xc cp 6 8, Ra = 2,5 0,63. Sai s hnh dng cc l l 0,5 0,7 dung sai ng knh l - Dung sai khong cch tm gia cc l ph thuc vo chc nng ca n, nu l l lp trc bnh rng th dung sai khong cch tm l 0,02 0,1 mm. Dung sai khng song song ca cc tm l bng dung sai khong cch tm. khng vung gc ca cc tm l khi lp bnh rng cn v trc vt bnh vt l 0,02 0,06 mm. - Dung sai khng ng tm ca cc l bng dung sai ng knh l nh nht. - khng vung gc gia mt u v tm l trong khong 0,01 0,05 trn 100 mm bn knh 3. La chn phng php ch to phi: Trong ch to my ngi ta phn bit 3 dng sn xut l: Sn xut n chic. -16-

SVTH : Trn nh Tr 10C1LT

 n CAD/CAM/CNC Sn xut hng lot. Sn xut hng khi.

GVHD: Lu c Bnh

Vi chi tit nay la san xut n chic. Ta chn hnh dng phi nh sau:

Hnh dng ban u ca phi. Kt hp cc iu kin : - Dng sn xut. - c im vt liu thp C45. - Yu cu k thut ca chi tit - iu kin trang thit b . - Hnh dng phi tng i n gin Ta chn phng php gia cng l dp th tch . III. La chn my v mt s thng s k thut chnh ca my la chn: tin hanh gia cng cac b mt cua khun di ta chon may phay EMCO CONCEPT MILL155 la may 3 truc Cc thng s cua may nh sau: + Vng lm vic ti a: X/Y/Z=300/200/300mm. + Tc chy dao nhanh ti a: Vmax=7,5m/pht. + Cng sut trc chnh: N=4 KW. + Phm vi iu chnh tc : n=15010000v/pht. + Khi lng ti a c th gia cng 20Kg. + Kh nng t chnh xc theo cc trc X/Y/Z=0,004/0,004/0,004mm. + Lc ct ln nht theo phng cc trc 2500N. SVTH : Trn nh Tr 10C1LT -17-

 n CAD/CAM/CNC

GVHD: Lu c Bnh

+ Ngun cung cp 400V/50-60Hz. + S dao ti a : 10.

My phay EMCO CONCEPT MILL 155. III. Xac inh th t cac nguyn cng, bc cng ngh trong tng nguyn cng: 1. Nguyn cng1: Phay mt phng c bin dng nh hnh:

Chn mt bn v mt y lm chun th: - Mt y nh v 3 bc t do dng 3 cht t - Mt bn nh vi 2 bc t do dng 2 cht t SVTH : Trn nh Tr 10C1LT -18-

 n CAD/CAM/CNC

GVHD: Lu c Bnh

2. Nguyn cng 2: - Khoan l 30 - Khoan 2 l 16 - Phay rng l 40

- Mt y nh v 3 bc t do dng 3 cht t - Mt bn nh vi 2 bc t do dng 2 cht t

SVTH : Trn nh Tr 10C1LT

-19-

 n CAD/CAM/CNC

GVHD: Lu c Bnh

3. Nguyn cng 3: Phay rnh 12

- Mt y nh v 3 bc t do dng 3 cht t - Mt bn nh vi 2 bc t do dng 2 cht t

4. Nguyn cng 4: SVTH : Trn nh Tr 10C1LT -20-

 n CAD/CAM/CNC - Khoan 8 l 7,2 - Taro 8 M8

GVHD: Lu c Bnh

- Mt y nh v 3 bc t do dng 3 cht t - Mt bn nh vi 2 bc t do dng 2 cht t

5. Nguyn cng 5: Vt mp cc cnh, cc mt l IV. La chn dao cho tng bc cng ngh, nguyn cng: 1. Nguyn cng 1: Chn dao phay mt u c ng knh dao Dd = 20mm 2. Nguyn cng 2: Chn dao khoan c ng knh D1 = 30mm v D2 = 16mm Chn dao phay mt u lin khi P18 c ng knh dao Dd = 20mm 3. Nguyn cng 3: Chn dao phay c ng knh dao Dd = 12mm 4. Nguyn cng 4: SVTH : Trn nh Tr 10C1LT -21-

 n CAD/CAM/CNC Mi dao khoan 7,2 Mi taro M8 5. Nguyn cng 5: S dng dao vt mp

GVHD: Lu c Bnh

SVTH : Trn nh Tr 10C1LT

-22-