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Phn A: GII THIU CHUNG

I. t vn . Trong nhng nm gn y, s pht trin nhanh chng ca khoa hc k thut thc y cc ngnh cng nghip sn xut t ng pht trin theo. Trong lnh vc c kh ch to, s ra i ca my cng c iu khin bng chng trnh s vi s tr gip ca my tnh, gi tt l my CNC, a ngnh c kh ch to sang mt thi k mi, thi k sn xut hin i. Hu ht cc khu cng nghip nc ta hin nay t nhiu u c b tr cc my cng c CNC phc v sn xut, bao gm cc loi my Phay, Tin, Bo, Mi, Khoan... c s trc iu khin 2, 3, 4, 5. Nhng cc c s sn xut hu nh cha bit cch khai thc ht kh nng gia cng trn my. L do ch yu l trnh lp trnh ca cn b k thut Vit Nam cn yu, cc chng trnh iu khin my CNC c ngi lp trnh vit bng tay, cha bit s dng cc phn mm h tr lp trnh. ng dng cng ngh CAD/CAM phc v cho my cng c CNC l vn c nhiu ngi quan tm, bi cng ngh ny khng ch phc v trong sn xut hin i, m cn gp phn nng cao nng sut ch to sn phm gia cng c kh. Cht lng ca mt sn phm gia cng c kh khng ch l vn v bn, bng b mt, m cn bao hm c chnh xc v v tr tng quan, chnh xc hnh dng hnh hc ca chi tit gia cng. ch to c nhng sn phm c kh c nhng tnh nng nh vy, i vi chng ta hin nay cn nhiu kh khn, chnh v vy m hu ht cc sn phm c kh phc tp v c chnh xc cao, hin nay chng ta phi nhp ngoi vi gi cao. Ngy nay, nhiu phn mm ha phc v trong lnh vc thit k 3 chiu, m phng chuyn ng, h tr lp trnh gia cng trn my cng c CNC ln lt c gii thiu cc nc pht trin nh: Mastercam, Solid Work, Cimatron, Catia, Pro/Engineer, Unigrafic... Cc phn mm tin ch ny cng c mt Vit Nam. y l nhng phn mm rt mnh, cho php chng ta nhanh chng thit lp c cc bn v 2D, 3D ca chi tit my v cho php t ng chuyn m chng trnh gia cng trn my cng c CNC. Theo bo co gn y nht, cc nh phn tch cng nghip hng u ca M bu chn Delcam ng u trong cc nh cung cp CADCAM trong khu vc Bc M, Chu u v ng th 3 ng Nam . Delcam c hn 125 vn phng h tr hn 80 quc gia trn th gii. Phn mm ca Delcam c s dng bi hn 9.000 t chc trn 80 quc gia, bao gm cc hip hi, t chc a quc gia ti cc nh thit k, ch to khun c lp v n t nhiu ngnh cng nghip khc nhau nh : Khng gian, ng c, thit b in, giy dp, gm, bao b, chi, dng c th thao, trang sc v bin qung co. Delcam sm c cng nhn nh chuyn gia cung cp cc gii php thit k cho nhng cng ty s dng cc mu c tnh thm m phc tp, nh l nh cung cp hng

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u th gii vi h thng CADCAM cho nn cng nghip ch to khun v phn mm gia cng tin tin. Cha kha cho s thnh cng ca Delcam l lun lun sn sng p ng v tha mn cc nhu cu ca khch hng. Power Mill l mt phn mm trong gi sn phm ca Delcam, y l phn mm CAM h tr gia cng phay trn my CNC. V n ch h tr phay nn giao din v cch thc s dng phn mm cng gn gi vi ngi s dng hn. y cng l mt li th ca Power Mill. Phn mm POWER MILL SP9 l mt trong s phn mm mnh, cho php t ng nhn c chng trnh gia cng iu khin chuyn ng cc my cng c CNC, sau khi chng ta thit lp bn v ca chi tit my, chn phi, vt liu, dao c v kiu chy dao. II. L do chn ti Trong chu k hnh thnh sn phm, vic lp trnh gia cng l khu v cng quan trng. N quyt nh sn phm c t cc yu cu k thut hay khng. Trc y khi cc phn mm CAM cha pht trin nn nhng ngi lp trnh phi g tng cu lnh ln my CNC (Lp trnh bng tay), vic ny ch t kt qu i vi nhng chi tit n gin cn i vi nhng chi tit phc tp c khi phi tn ti my ngn cu lnh nn ngi lp trnh bng tay khng th qun l ht c th s mc sai st nh hng ti cht lng sn phm thm ch l hng. Do vic ng dng cc phn mm CAM lp trnh s khc phc nhng vn trn. Hin nay, cc phn mm CAM xut hin rt nhiu nhng ch c mt s l c ph bin v nhiu ngi bit n. Qua mt thi gian tm hiu ngi thc hin chn phn mm POWER MILL SP9 lm ti tt nghip v y l mt phn mm CAM rt mnh n rt d s dng vi giao din trc quan thch hp vi vic hc tp, nghin cu cng nh ng dng vo thc t. III. Mc ch nghin cu v i tng nghin cu Mc ch trc mt: Tm hiu v s dng thnh tho mt phn mm hon thnh tt n tt nghip. Bn cnh rn luyn kh nng khai thc v s dng phn mm ng thi nm c cc bc gia cng mt chi tit hon chnh cng nh kh nng trnh by mt ti liu. Mc ch lu di: Hc hi thm mt phn mm lm hnh trang cho tng lai khi i xin vic ti cc cng ty c s dng phn mm POWER MILL. i tng nghin cu: Phn mm POWER MILL, cc ti liu hng dn v cc chi tit gia cng. IV. Phng php nghin cu Tham kho ti liu: Ti liu Help ca POWER MILL, cc ti liu khc c lin quan nh: Sch vit v phn mm, gio trnh CAD/CAM.
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Tra cu ti liu trn cc trang Web lin quan. Thc hnh trn my tnh: Trc tip lm vic trn my tnh kim tra l thuyt. Tin hnh gia cng trn my phay CNC VMC-650. V. Gii hn ti Do iu kin v thi gian c hn nn ngi thc hin ch nghin cu cc phn sau: 2D Toolpath: Cc chu trnh gia cng 2D. 3D Toolpath: Cc chu trnh gia cng 3D th (Roughing Toolpath) v tinh (Finishing Toolpath). Multiaxis Toolpath: Cc chu trnh gia cng trn trc th 4 Lp cc bc gia cng cc chi tit mu thng qua cc bn v gia cng. Gia cng sn phm hon chnh. V y l ln u tin nghin cu mt phn mm nn khng trnh khi nhng sai st, mong nhn c s ng gp kin ca qu thy c cng cc bn.

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Phn B

LP TRNH GIA CNG VI POWER MILL 9.0

Chng I

TNG QUAN V PHN MM POWER MILL 9.0

I.Khi ng phn mm II. Thot khi phn mm III. Vng lm vic ca power mill

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Chng I : Tng quan v Power Mill

1. Khi ng phn mm Powermill khi ng ging nh tt c cc chng trnh c s dng trong windows _Click vo biu tng trn

start_programs_delcam_powermill - PowerMILLxxxx ( y xxx l kiu powermill m bn mun s dng). Hoc c th Double Click vo ng dn nhanh ca powermill trn mn hnh
1. Menu Bar 2. Main Toolbar 3. Graphics Window 4. View Toolbar

5. Explorer

6. Status Bar 7. Tool Toolbar 8. Information Toolbar

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B tr trn mn hnh : Mn hnh c chia lm 8 phn chnh : Menu Bar Click vo cc mc trn thanh Menu chnh h cc Menu xung , chng bao gm cc Menu nh hn v cc lnh . Main toolbar Cung cp nhanh cc lnh thng c s dng trong powermill. Graphics Windows Vng lm vic,vng ha ca phn mm mi hot ng chnh u lm vic trn ny View toolbar Cung cp nhanh cc khung nhn thng s dng trong powermill. Cung cp cho chng ta cc gc nhn theo cc chun cho trc. Explorer Cung cp cc khung nhn v cc cng c to lp, hiu chnh, bao gm : NCprograms (Chng trnh NC),Toolpaths (ng chy dao ), Tools ( Dao c ), Patterns( Kiu dng ), Feature Sets ( Tp hp cc c im ),Workplanes( Mt phng lm vic ), Levels( Cc mc), Models and Groups ( M hnh v cc nhm ).Ngoi ra n cn hin th cc Macro ca bn c th sn sng s dng . Status bar Hin th cc thng tin . N c th a ra cc ch dn ngn gn i vi cc i tng nm pha di con tr chut, hoc tin hnh tnh ton cc tham s. Tool toolbar Cung cp cc phng tin to lp con dao trong powermill . Information Toolbar y l phn din tch a ra cc li nhc v cc la chn hin hnh 2. Thot khi Power Mill Mun thot khi Power Mill, ch cn thc hin cc bc sau: Di con tr chut ti menu bar Chn File\ Exit Xc nhn thot khi Power Mill : chn Yes khi c hi.

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Hoc di tr chut ti nt close khi Power Mill Hoc dng phm tt : Alt+F4 3. Lm vic vi Power mill

gc trn bn phi, kch chut v xc nhn thot

M cc m hnh . Cc m hnh bn c th m c c ui iges v c lu tr trong th mc examples.

1.T File trn Menu la chn Examples , hp thoi s hin th nh sau :

i tng c la chn 1 cch t ng a v th mc to ra khi ci t trong tutorial file. 2.Trong cc kiu files hp thoi , la chn kiu file c ui iges(*.ig*). 3.Click vo Champer.igs, khi powermill s c v m file ny ra . 4.Ca s s bo co kt qu ca s chuyn i, k c cc li mc phi trong qu trnh chuyn i. Bn c th kim tra ton b qu trnh chuyn i . Trong trng hp c th ny khng c bt c li no trong qu trnh chuyn i .

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5. Click vo nt Exit ng ca s chuyn i li v khi s nhn thy s hin th 6.Chi tit c chuyn i s hin th theo gc nhn tiu chun, gc nhn ny c th c la chn khi n nt ISO1 trn thanh view toolbar ( Thanh cng c ny mc nh nm bn tay phi mn hnh). M hnh c la chn s c hin th nh sau :

7.Khi mun chuyn i gia m hnh li v m hnh mt hoc t m hnh mt

sang m hnh li ca mu, chn la ch wireframe v shade.

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CHNG II

MT S BC CHUN B
I. Thit lp c bn
a) Ly chi tit b) To phi c) Chiu cao dch chuyn nhanh d) To dao e) Ch ct

II.Mt s option ph tr gia cng

a) Feature set b) Pattern c) Boundary

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I. Mt s thit lp c bn Cc bc chun bi cn thit trc khi tin hnh gia cng chi tit : a) Ly chi tit gia cng C th insert chi tit gia cng bng cch vo File import chn ng dn hoc m bng File - Examples b) To phi cho chi tit gia cng 1.nh ngha phi . 2.Xc nh chiu cao dch chuyn nhanh . 3.Xc nh im bt u gia cng . nh ngha phi : nh ngha phi theo kch thc ca phi, chi tit s c gia cng t phi. Trong trng hp ny phi c dng hnh ch nht. 1.T Main toolbar Click block (Toolbar theo mc nh nm pha trn ca mn hnh). Khi ny hp thoi block s c hin th :

2.Kim tra cc i lng : *nh ngha c thit lp t Min /Max limis. *Trong vng Esstimate (nh gi s gii hn ) chn Expansion (phn m rng ) bng 0 v Type (kiu) l Model. Click Caculate nh ngha phi mt cch t ng theo m hnh 3.T thanh View toolbar la chn Resize to Fit,chi tit s c hin th gia mn hnh. 4.By gi kch thc ca phi ln hn kch thc ca chi tit khng ng k. Kch thc theo phng X v Y m bo rt tt v chng c hnh thnh bng cch ko di cc mt phng i qua cc im xa nht ca chi tit.Tuy nhin kch thc theo trc z cn phi gii
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hn tng ln

. 5.T Opacity trn hp thoi Block c th thay i trong sut ca phi . 6.Click vo Accept ng hp thoi li . 7.T View toolbar la chn Resize to Fit, khi ny chi tit s c ko v gia mn hnh . c ) Chiu cao dch chuyn nhanh Chiu cao dch chuyn nhanh l chiu cao m khi dao chy khng, m bo an ton cho phi c nh v v kp cht. Chiu cao an ton theo phng Z v im an ton theo phng Z c nh ngha bi Rapid Move Heights. Chiu cao Z c nh ngha trong Rapid Movement l ca phi v chiu cao tng thm so vi chiu cao tuyt i so vi gc to phi .

1.Chn Rapid Move Heights trn Main Menu Toolbar. Hp thoi Rapid Move Heights s c hin th . Safe Area _ plane: mt phng Cylinde: Sphere: Box: ng trn gia cng mutil axis Mt cu - gia cng mutil axis Khi

i vi gia cng 3 trc bnh thng ta thng chn Plane . Reset to safe Heights t dng ly li chiu cao an ton cho chi tit . Trn menu tool bar, Start and end point cnh Rapid move height thit lp im u v im cui gia cng .

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d) To dao 1. to con dao, s dng vng din tch ca Tool trn hp thoi Finishing 2.Kch vo mi tn trn nt Create tool thanh cng c toolbar hin th cc kiu dao cn to . Chn la con dao mun s dng, double click vo s cho chng ta chnh sa cc thng s Dao. Tip : chnh sa tn, kch thc ca dao Chiu di, ng knh dao Nhp vo exploer ta s thy con dao mnh va to ra.

Cnh Tip c Shank dng to phn ui dao.

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Tng t vo Shank chn Add shank component chnh sa cc thng s cn thit chiu di, ln

Holder l tab bn cnh, l phn to cn dao, tng t nh Shank ta to Holder vi nh nghi chiu di chiu rng.

Cutting data s dng ch ct c sn, c lu vo trong th vin. y l mt cng c rt hay, vi cc nh my sn xut hang lot vi cng mt lc gia cng trn mt loi vt

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liu ta c th s dng gim bt thi gian lp trnh. y chnh sa ci t cc ch ct c bn cho dao. Trc ht to mt s dao tng t nh lm trn. Tool Type Diameter Name End Mill Ball Nosed Ball Nosed 12 3 6 12EM 3BN 6BN

Ball Nosed 10 10BN Active 1 con dao va c to chn setting

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Chn Edit cutting data

Axial Depth of cut: chiu su ct theo trc Z. Radial depth of cut: lng dch chuyn dao ngang. Suface Speed: tc ct b mt. Feed/tooth: t l gia tc trc chnh v tc ct. Spindle Speed: tc trc chnh Cutting Feed rate: Tc ct

Tng t tip tc vi cc con dao m mnh to. a thm dao vo th vin Trn Exploer chn Tools right Click chn Add all tools to database

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e) Cc thng s gia cng Cc thng s gia cng chnh bao gm cc thng s v ng dch chuyn dao v lng n dao, tc trc chnh

Vi cc thng s gia cng ta c th chnh sa khi chng ta thit lp cc toolpath. thit lp cc chu trnh gia cng ta vo chn toolpath trategies S cho ta cc chu trnh chn la gia cng bao gm cc Option khc nhau v 2.5D,3D,Drill, ty yu cu ca chi tit m ta chn la cc ch ph hp. S ni r phn ny cc chng tip theo.

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II. Mt s Option ph tr cc chu trnh gia cng a) Feature set c to t cc hnh hc 2D v c ty chnh ring l tng chi tit c th to thnh cc khi nh l Boss(khi bao pha bn ngoi). Pocket l khi b rng cn gi l cc hc Slot l cc ng rnh,thng c to khi con dao chy trn mt ng c Hole l cc l ch yu phc v khi ta tin hnh cc chu trnh khoan l C 6 kiu thit lp c trng ca feature trong gia cng 2D Pocket ty chnh hc c ngha khi gia cng dao s nhn gia cng pha bn trong ng bin ca n . Slot ng rnh, khi gia cng s ly ng c 2d lm ng chy dao Boss khi to feature n s ch gia cng bn ngoi chi tit khc vi Pocket Hole y gi l cc l ,thng c s dng khi ta thc hin cc chu trinh khoan. N c th c nh ngha t mt im hoc mt ng trn khp kn. Circular Pocket cc hc trn,cng c th nh ngha t 1 im hoc 1 ng trn khp kn. Circular Pocket cc o tr cng c th nh ngha t 1 im hoc 1 ng trn khp kn.

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Vo Exploer right click vo feature set xut hin mt s la chn, creat feature set to i tng.

Type Boss vi ng bin ngoi ta c kt qu Vi la chn Boss s c mt khi c hnh dng bao trm kn c chi tit nh mt khi c.

Tip theo to 2 pocket Trong Feature from ta s c cc ty chnh vi Absolute c ngha ta s t nh ngha chiu cao cho chi tit ca mnh .

Bc tip theo ta s to cc l khoan (hole)

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Sau khi to ta s c mt hnh tng th nh hnh bn. Cui cng trong cng c Exploer s xut hin mt cy th mc chng ta c th tham kho v chnh sa . Feature nhm ph gip khi chng ta gia cng cc chi tit 2D s c vn dng khi i su vo cc chu trnh gia cng 2.5D, phn tip theo ca ti b) Pattern Parrtern l mt c trng ca 2D va 3D wireframe c to ra nhm to cc ng toolpath c bn. Right click vo pattern t Exploer chn toolbar

Creat pattern v ta s c mc nh Pattern name l 1 Khi to creat pattern s t ng cho ta s v s c Active ngay

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Ta c th s dng mt hay nhiu option cho pattern Automatic pattern generation. Cho chng ta cc kiu pattern t ng Insert file vo pattern Save pattern Insert Boundary vo pattern Insert ng toolpath vo pattern Insert mode Insert Sketch Insert cuver Wireframe mode

Automatic pattern generation

Sau khi chn mt phng ta c nh hnh trn Level Level l cng c n gin h tr vic c nhiu la chn khc nhau ,khi n l mt nhm ca Suface Trong Exploer chn right click ln level chn creatlevel

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Select mt vi mt phng ta c hnh nh di y Phi cn thn khi chn v s c nhng mt phng rt nh c th chng ta s st . Khi chn nhiu mt phng phi gi phm SHIFT

Trong pattern toolbar chn creat pattern insert mode into pattern active la chn select suface boundary to ra bin ca chi tit. sau khi chn n cc mode i s c bin dng nh hnh bn. Tip s s dng cng c Split. Vo Exploer chn Edit Split select Chn v b hai ng c trn ta c

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Vo Exploer hoc trong vng ha chn Edit Merge chn Ok

vo Exploer right click vo pattern chn Instrument . ta c th chnh sa hai ng c cho n cng chiu vi nhau.

Vo Exploer hoc toolbar chn creat pattern ri chn biu tng Automatic pattern generation Trong y ta c nhiu la chn, ty theo tng chi tit m ta la chn cc ch khc nhau.

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Trn y l mt s hnh nh minh ha khi s dng cng c Pattern . c) Buondary Buondary l mt hay nhiu ng khp kn, dng gii hn cc vng gia cng. Cc ng chy dao cho cc chu trnh gia cng. L mt cng c rt mnh cho vic ti u ha ng gia cng. Vo Exploer chn Boundaries create boundary

Ngi lp trnh c th to cc boundary theo cc cch khc nhau da vo cc c tnh ca vic hnh thnh ng bin. User defined y l ch t to Boundary do chnh ngi lp trnh a ra.

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C th insert cc file , a vo cc ng Pattern, toolpath, Boundary, c to t trc. Mode: to phi cho Boundary Sketch: dng cc im cc ng 2d to ng bin. Curve modeling v Wirefame modeling c h tr nhiu hn khi ci phn mm Cad ca delcam, nh Power Shape. Edit v Clear dng chnh sa v xa cc ng boundary.

Select Suface Boundary Trc ht to mt con dao v sau khi ty chn Select suface Boundary Ty chn cc mt ca chi tit s t ng ly cc ng bao ca chi tit cng vi bn knh ca con dao. C ngha khi n ly ng bao ca cc suface xong s offset ra mt khong cch bng bn knh con dao mnh to. Shallow Boundary C th hiu n l ng chiu ln mt mt phng no ca chi tit. Vi ty chnh cc thng s nh hnh di ta s c kt qu nh bn cnh

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Silhouette Boundary Cn gi l ng in bng ca chi tit. Vi ty chn nh hnh di ta c kt qu.

Edit Boudary Trong Exploer chn Boundary right click chn edit boundary Transform : bao gm Move: dch chuyn theo cc trc X,Y,Z Rotate : xoay quanh cc trc ta d mt gc nht nh Scale: phng to hay thu nh chi tit theo cc trc X,Y,Z Mirror : to chi Boundary i xng qua cc mt phng XY,YZ,ZX

Point : chnh sa cc im bao gm xa di chuyn thm cc im nm trn ng boundary Spline Selected : chuyn cc im trn ng boundary thnh mt ng xuyn sut. Polygonize Selected: chuyn i cc ng Curve boundary i vo vng gii hn bi cc ng thng. Offset 3D : Offset Boundary theo c 3 phng X,Y,Z Offset 2D : Offset Boundary theo ng thi 2 phng X,Y.
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Chng III

CC CHU TRNH GIA CNG 2D

I. II. III. IV. V. Offset AreaClear Feature Set Profile AreaClear Feature Set Face milling

Drilling
2D Machine Winzard

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Chng 4 : Cc chu trnh 2D

Sau khi to phi v cc Feature ta tin hnh gia cng. Vo Creat strategies 1. Offset AreaClear Feature Set Khi thit lp cc thng s c bn nh pha di

sau khi Apply ta c

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2) Profile AreaClear Feature Set

Vi chn la Profile AreaClear feature set ta c ng chy dao st vi thnh hc. Vi cc hc su ct nhiu lt ta phi chn la cc ng lead in v lead out . (s ni phn lead in,lead out).

3) Face milling
Face milling l ch phay mt phng , vi chu trnh ny ta c th s dng phay vt mt cc chi tit . Vi face milling n s vt ht mt phng trn Work Plance : nh ngha gc ta - Block nh ngha phi - Tool thit lp dao - Face milling : -Ta c cc th sau Face Z Position ta phay mt phng . ta c th nhp s hoc click vo bn cnh nh ngha chiu cao Z.

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-Tolerance nh ngha dung sai dao -Step over dch chuyn dao ngang -XY expansion khong dch ra so vi khi chi tit -Raster Angle gc lch -Style chin lc ng chy dao ty chnh ca ngi lp trnh

4) Drilling
M toolpath strategies t v chn Drilling

Drilling s cho chng ta chn cc l gia cng

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Trong Feature selection chn la cc l t select bo gm ty chnh cc hole trong feature set. Ci t cc thng s Feed rate v Spindle speed ph hp ri chn Apply ta c kt qu nh hnh di y

5) 2D Machine Winzard Gi s ta c bn v chi tit nh hnh trn vo toolpath strategies chn 2.5D Area Clearance

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chn 2D machining Wizard

Create New Feature set name (nhp mt tn mi) - Next Tip chn ng c to mt Pocket,khi click ln n s xut hin mu vng

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ng vin ny s xut hin mu vng khi click Tip s chn Creat Pocket Ta s c Ta s ty bn tri. to 3 loi l Pocket Boss Slot chnh chiu cao v gc lch cho Pocket ny bng cch thay

cc thng s Define Top By v Define Bottom By ,Draft Angle Sau khi hon thin ta s c

Bc tip theo ta s chn tip ci o nh trong v to mt BOSS Feature

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Tip tc ta to mt Slot Feature

Vi ch Wire Frame ta s c nh trn . Next ta s c giao din mi

Chn Slot sau Next s to cc thng s gia cng cn thit.

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Block : to phi gia cng, ln lt chn Rapid Move Height, Feed Rates. Start Point. Sau khi hon thnh chn Next.

Tip chn Profile ArealClear Feature set sau nhp vo Create to chu trnh gia cng. Sau ta thit lp cc thng s gia cng c bn nh gii thiu phn gia cng Profile ArealClear Feature set. Ta c cc ng chy dao nh sau

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Khng nn tt vi m tr li Select Feature chn POCKET v BOSS sau lm tng t nh va lm trn. Nhng ln ny ta s to phi gia cng bng Boundary . Vo click ng bin v vo Boundary Creat User Define

Creat User Boundary User Define t Mode v Accept Boundary ny s c dng to phi Click vo Block to phi

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To phi bnh thng v la chn Mode, Accept kt thc qu trnh to phi . ng vi t t

Select Next

Tng t tip tc to m chu trnh gia cng mi. Kt qu o mt

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CHNG 5

CC CHU TRNH GIA CNG 3D

I.

Cc chu trnh gia cng th

1.
2.

3. 4.

Rest Machining Cc thng s trong chu trnh Offset AreaClear Model Raster Area Clear Example Raster Area Clear Example

II. Cc chu trnh gia cng tinh 1. Raster Finishing 2. Radial finishing 3. Spiral finishing 4. 3D Offset Finishing 5. Constan Z Finishing

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Chng IV: Cc chu trnh 3D

I) Chu trnh gia cng 3D th
1. Offset Area Clear

To mt chu trnh gia cng mi vo tab 3D Area Clearance Chn Offset Areaclear model ng chy dao ca Offset Area Clear example c nh hnh bi bin dng chi tit bao quanh vng gia cng. Ta c th m phng di dng 3D thy r cc ng chy dao s li lng d b mt nh th no.

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Ch ti cc thng s,thickness, Step Over, Step down, trong Lead in Move chn thickness, RamPing th click Option chnh sa cc thng s.

Right click mouse chn simulate from start s cho ta thanh toolpart simulation. n s Chn ViewMill On/Suspend chn Shiny Shaded

Nhn Play qu trnh m phng c thc ph hin y l kt qu cui cng sau khi thc hin i th ht chu trnh gia cng. Vi chi tit 3D n s i ch khng gia cng ht c ng chy dao th s ng ch m theo bin dng chi tit .

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2. Rest Machining Gia cng vi lng d c li t chu trnh chy dao trc ng cn Gia cng trn ng ch dao c sn. ng chy Trc ht ta to mt con dao gia cng m t mi Right Click mouse vo toolpa trong Exploer toolpath

Chn setting t Offset AreaClear Model

Chn coppy toolpath Activate vi con dao mi to o t li tn cho chng trnh v chnh sa cc nh ch thng s.

Chnh sa cc thng s ph hp s nh l stepover, thickness, stepdown thickness

V quan trng l nh du vo Rest ng d Machining . Chn toolpath v chn tn n ch chu trnh m mnh gia cng trc tr .

Apply to cc chy dao mi ng

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ViewMill On

the Rainbow Shaded Image

Power Mill cho bit c bi cc mu sc khc nhau c phn bit cc chu trnh khc t nhau. Thot khi m phng gia cng 3D tr v mi trng lm vic quen thuc ca c thu Power mill.

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3. Cc thng s trong chu trnh Offset AreaClear Model -

Thickness

Click vo thickness ta ch chnh sa cc thng s v Radial(lng d thnh bn) , ng Axial(lng d mt y) cho ph h vi chi tit cn gia cng. t hp Zheight

Nu stepdow c chn ch Mannual trong chu trnh gia cng Offset AreaClear n ch Model th ta s c 5 gi tr c chnh sa l Number, Stepdown, Value, Intermediate cui cn
cng l Flat.

Number : s lng cc kh c chia ra thnh cc phn bng nhau c thay i ng khi ng

Stepdown : Vi vic t Z Height th cn chnh sa li chiu cao ca Z v th c c to u c

bi chiu cao Z v im th nht l im i cng ca phoi khi to . p th chnh li stepdow gia cc l gia cng a lp
Value khi to mi Z height th ta s chnh sa mi gi tr Value i s

Flat : nhn ra vng gi hn ca khi v to Zheight (+ lng d) ti gi tr ny n gii ng t Intermediate : thm m s danh ngha ca Zheight nm trong Zheight hin ti. mt m hi
Ramping :
Ramp Length Zig angle Zag angle Tool

liu

zig angle l gc ca dao i xu a xung n vo vt zag angle l ph thuc vo m phng thit lp c mt

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c ngha l zag angle l gc c thit lp bi ngi lp trnh. Mc nh n bng 0

4. Raster Area Clear Example T tab 3D Area Clearance chn Raster Area Clear Example

Chnh sa cc thng s cho ph hp vi chu trnh gia cng Step down , Step over, Thickness

ng chy dao c to chy theo bin dng chi tit nu c o n m theo o cn khng n chy thng.

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II. Gia cng tinh 3D

C rt nhiu chu trnh gia cng bin dng 3D . Nhng ngi nghin cu ch a ra mt s chu trnh c bn lm tin cho ngi c. 1. Raster Finishing

Vo toolpath strategies icon

Chn Raster finishing ri OK Name : t tn cho chu trnh Angle : gc lch bnh thng ta t 0 Start coner : l gc m bt u gia cng Odering: l ch cho ta chn ng toolpath. Mc nh s l One Way. Khi chn ch ny th chng ta s c rt nhiu ng a dao ln v xung. chn Two way ta s c ng chy dao hp l hn . Arc fit: khi hiu chnh Arc fit ta s thy r vi cc chi tit c gc cnh
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Sau khi hiu chnh Arc Fit tng ln ta s nhn thy kt qu r rt

trc v sau khi chnh Arc Fit Ta cng c nhng chin lc chy dao tng t. Nh l Radial finishing

Spiral finishing

2. 3D Offset Finishing
3D offset finishing da vo offset do ng bng ca chi tit to ra, n s nhng ng chy dao tng t. 3D Offset finishing hiu qu hn nu ta s dng n kt hp vi Boundary.

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Chi tit c gia cng th. Vo Exploer chn Boundary, Creat Buondary shallow. t tn cho ng bin . Dung sai . Ty chnh v shallow l 2 thng s Upper Angle v Lower Angle . l hai thng s quan trng thay i ng bin Boundary. Ngoi ra cn c hai gi tr Thickness l lng d so vi b mt y v b mt hng chi tit. Apply ta c ng Boundary

Trong Tab Finishing ta chn 3D Offset finishing

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t tn

Stepover

Trong Buondary chn ng boundary va to lc ny

Lead and link chn nh hnh bn .

Apply ta s thy c ng chy dao Toolpath s t tnh ton v cho chng ta nhng ng chy dao Offset da vo ng Boundary m ta to ra. Vi cc ng chy dao khng ta c th thay i chng bng cch vo Lead and Link chnh sa chng v d : thay i Short link l on suface. Long link v safe link l skim. Apply ta c kt qu
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3. Constan Z Finishing

Chn Contan Z finishing trong tab Finishing. t tn cho chu trnh Chn dao Stepdow Boundary chnh sa Trimming chn Keep Outside gia cng lng d cn li.

Cn khng s dng Boundary ta s c nh hnh di.

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thay i cc ng chy dao xung,thot dao th vo chnh sa phn lead and link .

Kt qu tt c cc chu trnh ta c sn phm nh hnh trn

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Chng V

CC CHU TRNH GIA CNG VI TRC TH4

I. II. III. Suface Finishing Profile Finishing Pattern Finishing

IV. Rotate Finishing

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GIA CNG VI TRC TH 4

1. Rotate Finishing
Chu trnh ny l chu trnh gia cng vi trc xoay l trc X. L mt trong nhng chu trnh th hin r nht v gia cng trn trc th 4.

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Trc ht ta tm hiu v mt vi thng s ca chu trnh. X Limit : l gii hn gia hn vng gia cng dc theo trc X Technique : L ni chnh sa cc chin lc chy dao, c 3 chin lc l Circular, Line v Spiral. Direction : iu chnh hng chy dao, n c 3 chn la Any, Clim, Conventional Stepover : i vi la chn Circular v Spiral th y l bc tin ca ng chy dao. Cn i vi Line th y l khong cch gia 2 ng chy dao. Y Offset : l khong cch dch chuyn so vi gc ta theo phng Y trnh s va chm vi nh hoc u mt gia cng.

Angular Limit : ch c s dng khi chng ta chn ch Circle v Line

z S tart an g le

c nh ngha l gc bt u v gc kt thc ca chu trnh. Start v End

E n d an gle y

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a) Circular Rotary Machining

Tng t cc chu trnh khc vi chu trnh Rotate finishing ta cng thit lp cc thng s cho dao . Thit lp Rapid Height , Start Point, End point t li tn Reset to Bock Limit n t ng ly kch thc. Technique chn Circular Reset to Full Circle gia cng ton b chi tit. Sau nhn Apply cho ta kt qu

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b) Line Rotate Machining Tng t chu trnh trn nhng chng ta chnh sa mt vi Option Technique chn Line Angular Gii hn vng gia cng bng gc. (-90 ti 90) Ta s c ng chy dao nh sau

Chnh sa Direction t Clim thnh Any ta s c

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c) Spiral Rotary Machining Technique chn Spiral

2. Pattern Finishing Pattern Finishing l mt chu trnh c th gia cng nhiu ch c 3 trc v 4 trc. y ta c th gia cng nhiu trc vi chu trnh ny c th ta c th gia cng trc vt ,cc rnh vi. Trc tin vo Pattern Exploer to mt ng c 3D t bin dng ca chi tit.
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sau khi c c ng Pattern ta c th chnh sa bng cch nhp vo Pattern chn Edit cuver chnh sa. Sau khi hon thnh ta nhp chn Creat Strategies vo Tab Finishing chn Pattern.

Click Ok s cho ta cc Option

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Name : t tn cho chu trnh. Drive Curve : check vo Use toopath s dng ng chy dao trc. cn khng check th cho la chn ng Pattern c to Lower Limit : Drive Curve theo ng curve. Drop chiu xung mt chi tit. Gouge Avoidance chn Trace . Multiple cuts: chn Offset Up, ty chn ny cho ta chn la ph thuc vo ng cuve ca ta to n nm v tr nht nh so vi chi tit m ta chn Offset Up hay Down. Tip l chn la Maximum Stepdown l khong cch gia hai lt ct lin tip. Number of cuts l s ng dao mnh mun to . iu quan trng khi chn la gia cng 4 trc l Tool Axis Click vo tool Axit chn Towards Line Chn Direction I=1, J=0,K=0 Click Apply nhn kt qu
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Mt vi gc nhn ca chi tit V d v ng dng gia cng theo Curve Ta c th ng dng Curve gia cng cc trc vt, vi dao nh hnh . Cc rnh trn xoay. Rt nhiu chi tit trong thc t c th ng dng c phng php ny. 3. Profile Finishing Xin php c ly mt chi tit ca n kha 03 c th hiu r hn v chu trnh ny. Vo tab Finishing chn Profile Finishing, click Ok Chng ta c giao din
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Ta c Name : Tn chu trnh Driver curve : Side c 2 la chn Inside Edge v Outside Edge. Radial offset : l khong cch gia ng chy dao v mt bn. Lower limit : chn Driver curve Axial offset : l khong cch ca ng chy dao thp nht so vi b mt y. Cc thng s cn li ging nh cc thng s c trnh by Pattern Finishing.

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Gi s gia cng rnh ca chi tit nh hnh v. Sau khi chn Profile Finishing ta thit lp cc thng s cn thit nh trn, sau chn b Click chut ln b mt gia cng l mt y ca rnh,tip Apply.

Ta s thy s khc bit ca 2 chn la Inside Edge v Outside Edge

Bn tri l Inside v bn phi l Outside

ng chy dao khi n chi tit i .

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4. Suface Finishing Tng t ta cng vo tab Finishing chn Suface Finishing. Chn cc thng s tng t nh hnh bn. Ch chn ToolAxis l Toward Line . Pattern cho php hai chn la l U v V c ngha cho chng ta chn la ng chy dao theo hng song song vi trc X hoc Y. Click chn mt gia cng . Apply ta c nh hnh di.

Ch : cc chu trnh Pattern Finishing, Profile Finishing,Suface Finishing khi s dng gia cng cho cc chu trnh trn my 3 trc phi ToolAxis Vartical.

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Chng VI

CHNH SA NG TOOLPATH
I. Lead and Link II. Edit Toolpath III. Feed and Speeds

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Lead and link l mt option ca Power Mill cho php ngi lp trnh hon thin ng gia cng bao gm cc chnh sa v ng dao vo,ra (lead in, lead out, link) c mt ch d chy do hp l nht.
Lead Out Approach move Links

Lead In

Retract move

Trn tool bar chn Lead and link

cho ta bng.

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a) Z Heights
Skim v Plunge l hai gi tr c thit lp dng iu khin tc trc chnh khi n theo phng Z, nhm hn ch khong thi gian trc chnh chy xung vi mt vn tc chm khng cn thit. Skim distance l khong cch t im cui cng ca ng chy dao ny ti im bt u ca ng chy dao k tip. Phn mm s t ng xc inh vn tc ca trc chnh khi i xung. Plunges distance l khong cch tnh t b mt gia cng. L khong cch m t y my s chy vi tc xung dao ct gi an ton.

b) Lead in
Lead in l ng vo dao, ng bt u khi dao chy vo phi bt u tham gia ct gt. C nhiu chin lc chy vo nh None, Vertical Arc, Horizontal Arc, Horizontal Arc Left, Horizontal Arc Right, Extended Move, Boxed and Ramp. chn ch Lead in v lead out l none ta c kt qu nh hnh bn.

Vertical Arcs Chn Lead in Vertical Arcs vi cc thng s Angle 90, Radius
Tangent Angle

Toolpath Segment

Radius Lead

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Horizontal Arc Tng t nh Vertical Arcs nhng Horizontal Arc t tnh cung trn theo hng trc Z cn,vertical Arc theo trc X,Y.

Tangent Angle

Toolpath Segment

Radius Lead

Extended move

Ko di ng toolpath theo mt khong cch nht nh

Lead Out tangential to toolpath

Distance

Distance Lead In tangential to toolpath

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b) Lead out
Hon ton tng t lead in.

c) Extentions
L phn hnh hc c cng thm vo vi ng cc ng Lead. Bao gm dng ng thng v ng cung trn.

Hnh trn cho ta thy r khi ta vi Angle 45. II. Edit toolpath

chn Strain

y l mt trong nhng phn rt hay ca Power Mill chng ta c th d dng chnh sa cc ng toolpath nh sp xp c cc ng chy dao, xa chnh sa ng toolpath Right click chn Edit toolpath hoc Right Click trn tool bar chn toolpath li thanh cng c ra.

1. Tranform toolpath Transform l cng c cho ngi s dng c th di chuyn , to ng toolpath bng cch mirro hoc xoay cc ng toolpath.

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Edit transform Di chuyn mt khong theo gi tr nhp vo. Rotate m gc quanh trc nht nh. Mirror qua mt mt phng nht nh. 2. Edit Limit a) Edit limiting Plane Gii hn vng gia cng bng mt phng , mt phng ny c nh ngha vung gc vi cc h trc ox,oy,oz. Trong gii hn mt phng c cc gii hn gm Inner, Outer, Both. Bao gm mt trn hoc di, mt tri hoc phi, v c hai.
X Plane Y Plane Z Plane

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b) Edit Limiting Boundary Ngi lp trnh cng c th s dng boundary gii hn min gia cng cho ng toolpath . cng vi cc gii hn Inside, Outside, or Both.

3. Edit Reoder

Edit reoder l mt trong nhng option cho chng ta sp xp xa b cc ng toolpath khng cn thit.

4. Feed and Speeds Chnh sa tc gia cng ,cc thnh phn v vn tc trc chnh, vn tc ct. Tc xung dao
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icon feed and speeds

sau khi chnh sa cc thng s ph hp vi chu trnh gia cng ta chn Apply.

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Chng VII

M PHNG V XUT FILE NC

I. II. III. M phng gia cng Xut File NC Setup sheet

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Click chut phi vo toolbar chn Simulation v Viewmill Xut hin toolbar Viewmill

Trn thanh cng c th hin cc ch m phng . No image: cho thy mi ng chy dao Dynamic image : cho thy phi dng n gin Plan shaded Image: cho thy b mt gia cng Shiny shaded Image: cho thy dng bng. Rainbow shaded image: cc chu trnh khc nhau th hin cc mu khcnhau Cut direction shaded Image: Vi chn la Dynamic image Plan shaded Image

Shiny shaded Image

Rainbow shaded image

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Cut direction shaded Image:

Simulation bar Cho thy con dao ang c s dng start iu chnh tc

Dng chn cc chu trnh m phng .

Pause

reset cc chu trnh

Ngi lp trnh c th thay i tc cng nh c th tp trung xem xt cc ng chy dao m phng c th hon thin mt chin lc chy dao hon thin.

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II. Xut file chng trnh NC Setting Preferences Trong Expoer chn NC Programs chn Preferences. Chn Post gia cng ty my m ta chn la cho ph hp

Creating the NC program Trong Exploer chn Nc program chn creat NC Program.

Trong NC Program c th thm hoc bt i cc

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chng trnh. thm chng trnh vo th ch cn Click chut v ko chu trnh vo chu NC Program. b th click chut phi v chn remove tool path

Tip chn activate ng chu trnh mun xut file NC hoc chn tt c . sau vo NC Program click chut phi chn setting, xut hin bng nh hnh bn la chn th t cc chu trnh v Apply n. Vo Exploer chn NC Program chn Write.

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III. Setup Sheet Setup sheet l mt trong nhng cng c cho chng ta thy r cc cng c gia cng v dao c, ng knh, hnh dng, chiu di cc thng s y nht. Sau khi to mt chng trnh NC nh mc trn ta chn Add tt c cc chu trnh vo file NC va c to ri right click vo NC programs

y l ni chng ta cp nht ngy thng v nhng ghi ch cho NC va c to.

Sau lm tng t nh trn nhng phn Setup Sheet khng chn setting m chn Snapshot - All toolpath

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Hoc chn Preview phn mm s t ng tnh ton cho chng ta v cho chng ta cc thng s.

click vo cc chu trnh thy c cc thng s.

Cui cng l Setup sheet Export xut file.

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Phn C

BI TP

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Bi tp 2 : Gia cng lng khun in thoi

PHIU NGUYN CNG Kch thc phi : 150x100x20 Vt liu : Meka Ngi thc hin : Trng Vn Hng Phay CNC TT Bc cng ngh
1 2 3 4 5 6 Phay Ph Bn tinh Tinh mt y Tinh nt nhn Tinh mt trn Tinh mt bn PHIU GIA CNG B MN : CNG NGH T NG TH T CC BC CNG NGH

Dao Chu trnh

Rester Area Clearance Rester Area Clearance Optimised Constand Z Finishing 3D Offset Finishing Raster Finishing Constant Z Finishing TT Type dao 1 End Mill 2 End Mill 3 Ball Mill 3 Ball Mill 3 Ball Mill 3 Ball Mill

mm
16 5 4 4 4 4

t
(mm)

S
(vg/ph)

F
(mm/ph)

2 1 0.2 0.2 0.2 0.2

2500 2500 4000 4000 4000 4000

500 500 700 700 700 700

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Cc bc thc hin trong Power Mill. Bc 1: xut bn v t phn mm khc ( Pro WF4.0) Bc 2: Insert bn v vo power mill. Bc 3: Hiu chnh chi tit cho ng gia cng, theo trc ta mc nh ca phn mm.

Bc 4: To phi. Ta chn box calculator

Bc 5: Chn chu trnh phay,to dao chin lc gia cng hp l. a) Phay ph Chu trnh phay: Raster Area Clearance Dao : END MILL 16 Step over : 10 Thickness 1.0 Stepdown: 2 Cut direction : Any Raster Angle: Manual 90
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b) Phay bn tinh. Chu trnh phay: Raster Area Clearance Dao :END MILL 5 Step over : 2.5 thickness : 0.5 Srepdown: 1 Rest machining tool path ph D16 Cut direction : Any Raster Angle: Manual 90

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c) Chy tinh mt y Creat Boundary user difined : bientrong Chu trnh phay : Optimised Constand Z Finishing Dao : Ball Mill 4

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Step Over : 0.2 Thickness : 0 Boundary : Bin trong,

Trimming : Keep inside

d) Chy tinh b mt nt nhn Creat Boundary user difined : bienngoai Chu trnh phay : 3D Offset Finishing Dao : Ball Mill 4 Step Over : 0.2 Thickness : 0 Boundary : Bientrong,Trimming : Keep outside Limit toolpath : Boundary Bienngoai ,outer

e) Chy tinh thnh bn Chu trnh phay : Constand Z Finishing Dao : Ball Mill 4 Step Over : 0.2 Thickness : 0 Boundary : Bientrong,Trimming : Keep outside Limit toolpath : Boundary Bienngoai ,outer
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S dng cng c Edit Reoder xoa cc ng khng cn thit i

f) Chy tinh mt trn Chu trnh phay : Dao : Ball Mill 4 Step Over : 0.2 Thickness : 0 Boundary : Bienngoai,Trimming : Keep inside

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