bao cao nckh.pdf

8/11/2019 BAO CAO NCKH.pdf

1/66

Mc Lc

CHNG 1------------------------------------------------------------------------------------- 1

1. L do chn ti ----------------------------------------------------------------------- 1

2. Phng php nghin cu ------------------------------------------------------------- 2

3. Khnng ng dng thc t----------------------------------------------------------- 3

CHNG 2 ------------------------------------------------------------------------------------ 4

2.1 Tng quan vtm nh hng ca cng nghn thc tin ----------------- 4

2.1.1 Spht trin ca chuyn nghnh gia cng p lc (GCAL): ----------- 4

2.1.2 Pht trin l thuyt bin dng do ------------------------------------------- 5

2.1.3 ng dng CAD/ CAM/ CIM trong cc khu sn xut ------------------ 52.1.4 To ra cc phng php gia cng c bit --------------------------------- 6

2.2 Cng nghdp to hnh tm -------------------------------------------------------- 7

2.2.1 Khi nim -------------------------------------------------------------------------- 7

2.2.2 Phn loi --------------------------------------------------------------------------- 7

2.2.3 Lnh vc ng dng -------------------------------------------------------------- 7

2.2.4 u nhc im ca phng php dp tm -------------------------------- 8

2.2.5 Cc nguyn cng chnh --------------------------------------------------------- 9

2.2.5.1 Nguyn cng ct hnh v t l --------------------------------------- 10

2.2.5.2 Nguyn cng un tm --------------------------------------------------- 11

2.2.5.3 Nguyn cng dp vut -------------------------------------------------- 12

2.2.5.4 Cc nguyn cng khc -------------------------------------------------- 13

2.3 L thuyt bin dng do kim loi ----------------------------------------------- 14

2.3.1 C svt l ca qu trnh bin dng -------------------------------------- 14

2.3.1.1 Khi qut vqu trnh bin dng ------------------------------------- 14

2.3.1.2 Ha bn bin dng-------------------------------------------------------- 18

2.3.1.2 Cc qu trnh kch hot nhit ------------------------------------------ 18

2.3.1.3 ng sut chy v ng cong chy --------------------------------- 20

2.4 C hc qu trnh bin dng ------------------------------------------------------- 21

2.4.1 ng sut -------------------------------------------------------------------------- 21

2.4.2 Bin dng ------------------------------------------------------------------------ 22


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2.4.3 Quan hgia ng sut v bin dng -------------------------------------- 23

2.4.4 iu kin do ------------------------------------------------------------------- 24

2.4.5 Nhng nguyn tc nh lut trong bin dng do ---------------------- 25

CHNG 3---------------------------------------------------------------------------------- 27

3.1 Phn mm pro engineer 5.0------------------------------------------------------- 27

3.1.1 Thit k2D ---------------------------------------------------------------------- 27

3.1.2 Thit kpart 3D ---------------------------------------------------------------- 27

3.2 Thit kchi tit thng xe ra ----------------------------------------------------- 28

3.3 Tch khun chi tit ----------------------------------------------------------------- 30

CHNG 4---------------------------------------------------------------------------------- 344.1 Phn mm eta/ DYNAFORM 5.6 ----------------------------------------------- 34

4.2 Thit lp cc iu kin bin cho chi tit --------------------------------------- 36

4.3 Thng sdp ------------------------------------------------------------------------- 37

4.3 Kt qus b------------------------------------------------------------------------- 41

4.4 Kt qum phng ------------------------------------------------------------------- 44

CHNG 5 ---------------------------------------------------------------------------------- 47

5.1 Phn mm Mastercam -------------------------------------------------------------- 475.1.1 Giao din chnh----------------------------------------------------------------- 47

5.1.2 Modul lathe (modul lp trnh tin chi tit) ------------------------------- 48

5.1.3 Modul mill (modul lp trnh phay chi tit) ------------------------------- 48

5.1.4 Modul wire EDM (modul lp trnh ct dy) ----------------------------- 49

5.1.5 Modul router (modul chuyn lp trnh cho Woodcam) --------------- 49

5.2 Thit lp thng scng nghcho chi tit ------------------------------------- 50

5.2.1 Thit lp thng scho khun cavity -------------------------------------- 50

5.2.2 Thit lp thng sphay th bmt cavity ------------------------------- 50

5.2.3 Thit lp thng sphay tinh bmt cavity ------------------------------ 54

5.2.4 Chng trnh G- code tcc cc thng s m phng ------------- 56

KT LUN ---------------------------------------------------------------------------------- 60

TI LIU THAM KHO ---------------------------------------------------------------- 61


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DANH MC HNH NH

Hnh 1.1: u im ca m phng. -------------------------------------------------------- 1

Hnh 1.2: Quy trnh sn xut chi tit bng phng php dp. ---------------------- 2

Hnh 2.1: S cng nghdp tm. ----------------------------------------------------- 7

Hnh 2.2: ng dng trong thc tin. ----------------------------------------------------- 8

Hnh 2.3: Bkhun dp tm. -------------------------------------------------------------- 8

Hnh 2.4: ng dng t l. --------------------------------------------------------------- 10

Hnh 2.5: S nguyn l t l. ------------------------------------------------------- 11

Hnh 2.6: ng dng un tm. ------------------------------------------------------------ 11

Hnh 2.7: S nguyn l un tm. ---------------------------------------------------- 12Hnh 2.8: S nguyn l dp vut. --------------------------------------------------- 13

Hnh 2.9: Thng sdp vut. ------------------------------------------------------------ 13

Hnh 2.10: Qu trnh bin dng n hi. ---------------------------------------------- 15

Hnh 2.11: Qu trnh trt. --------------------------------------------------------------- 15

Hnh 2.12: Trt song tinh. -------------------------------------------------------------- 16

Hnh 2.13: Cc khuyt tt im. --------------------------------------------------------- 17

Hnh 2.14: Cc khuyt tt mt. ---------------------------------------------------------- 17

Hnh 2.15: Cc khuyt tt ng. ------------------------------------------------------- 17

Hnh 2.16: Biu quan hng sut- bin dng. ----------------------------------- 18

Hnh 2.17: chnh xc ca sn phm. ----------------------------------------------- 19

Hnh 2.18: Nhit kt tinh ca mt svt liu. ----------------------------------- 20

Hnh 3.1: To mi trng part. ---------------------------------------------------------- 28

Hnh 3.2: To bin dng 2d ca chi tit ----------------------------------------------- 28

Hnh 3.3: To khi extrude --------------------------------------------------------------- 29

Hnh 3.4: To gc nghing ca chi tit ------------------------------------------------ 29

Hnh 3.5: dy ca chi tit ------------------------------------------------------------- 30

Hnh 3.6: To gc ln. ------------------------------------------------------------------- 30

Hnh 3.7: Bn vthit k. ----------------------------------------------------------------- 30

Hnh 3.8: To mi trng part. ---------------------------------------------------------- 31

Hnh 3.9: Chn i tng cn tch khun. ------------------------------------------- 31


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Hnh 3.10: Hsco rt. ------------------------------------------------------------------- 31

Hnh 3.11: Thit kphi. ----------------------------------------------------------------- 32

Hnh 3.12: To mt phn khun. -------------------------------------------------------- 32

Hnh 3.13: To thtch phn khun. --------------------------------------------------- 32

Hnh 3.14: To i tng khun. ------------------------------------------------------- 32

Hnh 3.15: Khun trn v khun di. ------------------------------------------------ 33

Hnh 4.1: Giao din chnh. ---------------------------------------------------------------- 34

Hnh 4.2: Trnh tgii thut dynaform. ----------------------------------------------- 36

Hnh 4.3: Import file ----------------------------------------------------------------------- 38

Hnh 4.4: Thit ung ranh gii li. -------------------------------------------------- 38Hnh 4.5: Chia li. ------------------------------------------------------------------------ 39

Hnh 4.6: M hnh chia li -------------------------------------------------------------- 39

Hnh 4.7: To tm chn.------------------------------------------------------------------- 39

Hnh 4.8: Thng sdp ------------------------------------------------------------------- 40

Hnh 4.9: Thng sgn vut. ------------------------------------------------------------ 40

Hnh 4.10: Thit t chi tit v m hnh vt liu ph hy. ------------------------ 41

Hnh 4.11: Qu trnh to hnh sn phm. ---------------------------------------------- 41

Hnh 4.12: Qu trnh dp ththc t. -------------------------------------------------- 42

Hnh 4.13: Kt quFLD1. ---------------------------------------------------------------- 43

Hnh 4.14: Kt quFLD 2 ---------------------------------------------------------------- 43

Hnh 4.15: M hnh sau khi dp. -------------------------------------------------------- 44

Hnh 4.16: Cht lng sn phm. ------------------------------------------------------- 44

Hnh 4.17: Sphn bdy. ---------------------------------------------------------- 44

Hnh 4.18: Sphn bng sut. -------------------------------------------------------- 45

Hnh 4.19: Biu lc. -------------------------------------------------------------------- 45

Hnh 4.20: Qu trnh ko phi. ---------------------------------------------------------- 46

Hnh 4.21: Hnh sn phm thc t. ----------------------------------------------------- 46

Hnh 5.1: Giao din mastercam. --------------------------------------------------------- 47

Hnh 5.2: ng dng thit k. ------------------------------------------------------------- 48

Hnh 5.3: Lp trnh tin. ------------------------------------------------------------------- 48


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Hnh 5.4: Lp trnh phay. ----------------------------------------------------------------- 49

Hnh 5.5: Hnh lp trnh ct dy. -------------------------------------------------------- 49

Hnh 5.6: Hnh lp trnh router. ---------------------------------------------------------- 50

Hnh 5.7: Thit t phi. ------------------------------------------------------------------ 50

Hnh 5.8: Chn bmt gia cng. -------------------------------------------------------- 51

Hnh 5.9: thit t ng chy dao ----------------------------------------------------- 51

Hnh 5.10: Thng s ----------------------------------------------------------------------- 51

Hnh 5.11: Thng sbmt gia cng -------------------------------------------------- 52

Hnh 5.12: Thng sphay th bmt. ------------------------------------------------- 52

Hnh 5.14: Thng sct. ------------------------------------------------------------------ 53Hnh 5.15: Thng sgap setting. -------------------------------------------------------- 53

Hnh 5.16: Kt quphay th. ------------------------------------------------------------ 53

Hnh 5.17: Chn bmt gia cng. ------------------------------------------------------ 54

Hnh 5.18: Thng sng chy dao. ------------------------------------------------- 54

Hnh 5.19: Thng sphay bmt. ------------------------------------------------------ 55

Hnh 5.20: Thng sphay tinh ---------------------------------------------------------- 55

Hnh 5.21: Thng smotion ------------------------------------------------------------- 56

Hnh 5.22: Kt quphay tinh ------------------------------------------------------------ 56

Hnh 5.23: Xut file G- code ------------------------------------------------------------- 56

Hnh 5.24: Kt qukhun trn ----------------------------------------------------------- 58


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1

CHNG 1

GII THIU

1. L do chn ti.Trong nhng nm gn y khoa hc k thut khng ngng pht trin trn

thgii ni chung v Vit Nam ni ring. c bit l trong s c c kh

ha, tng ha em li chnh xc trong gia cng v gim scng nhn

em li nhun cao trong cng nghip sn xut ln v nhnh hin nay. Vi

nhng chnh sch ca nh nc ang c u t mnh mc vcng ngh

v nhn lc nhm mc ch a Vit Nam tr thnh mt nc cng nghip

trong nm 2020.

Hin nay Vit Nam ang c cc nc trn thgii u t rt ln vvn

cng nh cc dn vi smca thng thong ca nh nc. C nhng cng

trnh mang tm quy m quc tcng nh quy m nhv va nhng vn c

mt sdn vn cha p ng c iu kin ca con ngi Vit Nam nh:

sc khe, mi trng, trnh chuyn mn.vi nhng hn ch nn em

quyt nh thc hin ti: THIT KV THI CNG KHUN DPTHNG XE RA .

Hnh 1.1: u im ca m phng.


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Trong qu trnh sn xut khun a phn sdng phng php thcng lthit kt v chto khun xong ri mi thc hin dp thtm ra nhng thngsti u nht cho khun sn phm t c tnh cao nht. ngy nay nhspht

trin ca cng nghthng tin ta c thrt ngn c qu trnh thnghim irt nhiu nh vo nhng phm mm chuyn dng cho tng ngnh khc nhaunh:

Khun nha: 3Dtimon, Planet, Moldflow, Simpoemold.

Khun dp khi: Deform, Matlad, Abaqus,

Khun dp tm: Dynaform, Ansys,

Khun c p lc: Magmasoft, Procast, Adstefa, Capcast, Pam-Cast.

2. Phng phpnghin cu.

Nghin cu thtrng v nhu cu tiu dng xut tng, vi sgip

nhit tnh ca gio vin hng dn v nhng kin thc c c qua cc khc

trng cng nh cc ti liu su tm.

Hnh 1.2: quy trnh sn xut chi tit bng phng php dp.


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3. Khnng ng dng thc t.

Hin ti a scc chi tit thng xe ra u phi nhp tcc trong khu vc

c bit l Trung Quc, cho nn chi tit sau khi thit kqua kim nh v ti

u ha sa cng nghdp tm ra th trng gim chi ph sn xut, hgi

thnh sn phm v c khnng cnh tranh cao ngoi thtrng.

Tnh linh hot.

Tnh khthi.

Tnh n gin.

Tnh kinh t.


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4

CHNG 2

CNG NGHDP TM V L THUYT BIN DNG DO

CA KIM LOI2.1 Tng quan vtm nh hng ca cng nghn thc tin.

2.1.1 Spht trin ca chuyn nghnh gia cng p lc (GCAL).

Cng nghgia cng p lc c trt lu i, nhng mi n vi thknay

mi c pht trin chnh l nhspht trin ca l thuyt bin dng do v

gia cng p lc kim loi da trn c sc hc mi trng lin tc, c hc vt

rn bin dng l thuyt do, kim loi vt l, i stuyn tnh. Ngy nay ang

c mt cuc cch mng vbin dng to hnh. Cc thnh tu ln ca c hc

vt rn bin dng, ton hc, kthut m phng to cho l thuyt v cng

nghGCAL mt sc mnh mi. ta c thc cng nghbin dng ti u, s

dng ht khnng bin dng ca vt liu, tn dng ngun nng lng nht l

kthut m phng a nghnh GCAL gii quyt cng nghto hnh khng

cn ch th, giai on tn ph tin ch to khun th nghim v chi ph

nguyn vt liu thnghim.Phng php cng ngh gia cng bng p lc hay cng ngh bin dng

to hnh l mt phng php cng ngh, va l cng nghchun b to phi

cho cong nghc kh va l cng ngh to hnh sn phm cui cng, khng

nhng cho php to ra hnh dng kch thc sn phm m cn cho sn phm

kim loi cht lng cao vthnh c- l- ha, tit kim nguyn vt liu v cho

nng sut lao ng cao, t hgi thnh sn phm. l cong nghduy nht

cng mt lc bin i hnh dng kch thc v t chc kim loi, nn chng

c khi yu cu cht lng sn phm cao. Trong iu kin bin dng v x

l nhit nht nh, tchc kim loi thay i: ph btchc c, to tchc

th, lm nhht tinh th, to tectua, ph vv lm phn tn cc tp chtnh

lm tng tnh bn, dai va p, khnng chu mi, chu va p, tng tu i

thsn phm. sn phm ca cng nghrt a dng, gia cng nghiu loi vt


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5

liu. c thto ra trng thi siu do, gia cng bin dng ln hoc gia cng cc

vt liu kh bin dng.

Cng nghgia cng kim loi bng p lc l thc o trnh pht trin

ca mt nn cng nghip quc gia.

Cc cng nghgia cng p lc kinh in nh: cn- ko- p- nn- rn- dp,

chim 80tng sn lng kim loi v hp kim, ang tip tc hon thin cng

ngh, bo m nng sut cht lng sn phm. ngnh gia cng p lc cn m

ra mt shng pht trin mi v phng pp cng nghmi.

2.1.2 Pht trin l thuyt bin dng do.

ng dng cc thnh tu khoa hc kthut mi gii bi ton l thuyt giacng p lc. a cc phng php ton mi, quan trng nht l a phng

php s ( phng php phn t hu hn, phng php bin phn, phng

php phn tbin) kt hp s dng my tnh in t vo vic gii bi ton

bin dng do. T c thm phng ng sut v bin dng, m phng qu

trnh chy do ca vt liu, quan st c chiu su bn trong ca qu trnh

bin dng m iu khin chng. a tnh ton ti u g i bi ton cng ngh

to hnh v khun, bo m tn dng ht khnng thit b. Nhphng php

sng dng trong bin dng to hnh gii quyt bi ton bin dng ln, a

nhiu yu tthc vo trong qu trnh gi bi ton bin dng. xy dng nhiu

m hnh thuc tnh vt liu v nht l bn vt liu cao, vt liu composit,

thch ng cc vt liu mi c a vo sdng. kt hp cc yu tbin dng

tc ng bin i tchc bn trong vt liu vi xl nhit to ra vt liu

c tchc kim loi tng i c bn cao, cng nghny thnh cng nghsn xut hng lot ln, nh tit kim nhiu vt liu, nht l vt liu xy

dng. cng bng hng cng nghtc ng bng hiu ng c nhit to ra

siu do hoc tectua, lm vt liu c tnh do c bit, dng bin dng to hnh

cc chi tit c nhiu thnh vch mng, hnh dng phc tp.

2.1.3 ng dng CAD/ CAM/ CIM trong cc khu sn xut.

ng dng cng ngh thng tin tin hnh thit k cng ngh, thit b v

khun nhstrgip ca cc phn mm c kh chto my v cc phn mm


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chuyn dng thit k bin dng to hnh thit knhan h chng cc b

khun dp phc tp, c thnhanh chng thay i kt cu, mu m, nng sut

tng hng trm ln. trc y, mi sn phm mi u phi qua khu sn xut

th, phi thit kchto khun, gia cng th, sau dp thv kim tra cn

chnh sa khun v ch to li khun..ng dng phn mm thit k v m

phng, c khnng kim tra nh gi chnh xc vhnh dng kch thc,

vbn, tin cy ca cng nghv khun, thay cho vic sn sut thtn

km v mt nhiu thi gian.

Hin nay, nhiu my iu khin theo chng trnh sCNC ang c s

dng gia cng cc khun mu dng trong GCAL, nh thit b ny cngvic gia cng cc bmt phc tp c xl nhanh chng, chnh xc. c

cc chng trnh lin kt sau khi xl xong, c thm ha, chuyn sang my

cnc gia cng, khng giai on lp trnh ring. V vy, lin kt khu thit k

v chto khun lm mt.

Mt khc, ng dng hthng iu khin tng, cc mch cng sut

cao, to ra cc khi mch iu khin cc my GCAL, ng thi c nhiu dy

chuyn sn xut tng vi siu khin ca trung tm my tnh.

2.1.4 To ra cc phng php gia cng c bit.

Ngoi cc phng php cng ngh bit nh gia cng bng nng lng

cao, gia cng cc vt liu bt, bimetan.. ngy nay ang pht trin cng ngh

sn xut chi tit t p vt liu ht, tac c th nhn c cc sn phm vi

thnh phn bt k, phn bthnh phn ti cc vng khc nhau ty theo iu

kin chu ti ca sn phm l vt liu composit mi. mt phng php giacng vt liu kh bin dng, cu to bng cc thnh phn (cu t c bit)

bng cng nghp bn lng. cng nghny cn nung nng chy vt liu nn,

cn thnh phn tng bn, gia choc thnh phn c thuc tnh c bit khc

vn trng thi ht rn, sau vo khun v a vo p. T ta c tnh

nng c bit theo yu cu.

Tcc vn nu trn, khoa hc v kthut GCAL ca thgii c rt

nhiu bin i, nhiu phng php tnh ton mi, cng ngh hin i xut


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hin, gii quyt nhim vsn xut mt cch nhanh chng v hiu qukinh

tcao. Mt khc i hi con ngi c trnh cao, c hiu bit su rng v

kin thc c bn v kin thc chuyn ngnh, c trnh tin hc tt.

2.2 Cng nghdp to hnh tm.

2.2.1 Khi nim.

Cng nghdp to hnh tm kim loi l cng nghto ra chi tit (cm chi

tit) c hnh dng v kch thc tkim loi tm, bng cch bin dng to hnh

phi kim loi nhcc dng cc bit gi l khun dp.

2.2.2 Phn loi.

Da vo c im bin dng ngi ta chia thnh hai nhm chnh:Nhm cc nguyn cng ct vt liu: khi to hnh cc chi tit, cc nguyn

cng ca nhm ny thng phi tin hnh bin dng ph hy vt liu, tc l

tch mt phn vt liu ny ra khi mt phn vt liu khc.

Nhm cc nguyn cng bin dng do vt liu: to hnh chi tit chi tit da

trn sbin dng do ca vt liu v hu ht cc trng hp u c sdch

chuyn v phn bla kim loi.

Hnh 2.1: s cng nghdp tm.

2.2.3 Lnh vc ng dng.

Cng nghny c p dng rng ri tcng nghip quc phng, y t, ha

cht, xy dng, giao thng vn ti, c kh chnh xc, cho n nghnh dt may


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cng nghip, ch bin thc phm, c kh tiu dng v c bit l trong cng

nghip in- in t, cng nghthng tin

Hnh 2.2: ng dng trong thc tin.

Sn phm v cng a dng v phong ph, gn gi vi i sng con ngi, t

xong , ni, mm, cho, bt, a, mui, dao, ca, cc, m un nc, dng cv

thit by t, n ni cm in, bp ga, l vi sng, tivi, tlnh, my git, tin

kim loi, ng h, trang sc phn

Hnh 2.3: bkhun dp tm.

2.2.4 u nhc im ca phng php dp tm.

u im:

Nng sut cao do gi thnh thp, tit kim thi gian sn xut.

chnh xc ca sn phm cao, tnh lp ln tt.

C thto ra cc chi tit phc tp.

Nng cao c tnh ca kim loi.


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H s s dng vt liu ca loi hnh cng ngh ny c th t n 80-

90, thm ch c tht 100, trong khi phng php gia cng c kh ch

t 50- 60.

Nhc im:

u t ban u ln( khun v thit b), do ch thch hp vi gia cng

hng lot.

Yu cu i ng ks v cng nhn lnhnghc trnh .

Tnh ton cng nghphc tp.

2.2.5 Cc nguyn cng chnh.

To hnh:

Nn: khc phc hin tng khng bng phng cc bmt ca phi hoc

chi tit.

Dp ni: thay i hnh dng sn phm nhng khng thay i chiu dy vt

liu, c thc hin nhcc phn li v lm ca bphn khun.

Ln vnh: to thnh gtheo ng bao ngoi hoc ng bao trong ca

chi tit. Cun mp: to thnh gmp c dng trn.

To hnh: thay i hnh dng ca phi c dp vut s b nhn

c chi tit c hnh dng cui cng hoc kch thc chnh xc hn.

Tp: lm gim tit din ngang ca mt phn chi tit rng hoc ng

c dp vut s b.

Gin rng (nong): tng tit din ngang mt phn chi tit rng hoc ng.

Tinh chnh: to cho chi tit c hnh dng v kch thc chnh xc hn.

Dp p:

Dp ni mt: to nhng hnh nh li lm trn bmt chi tit, c s thay

i chiu dy vt liu.

p chy ngui: bin i phi dy thnh chi tit hoc phi rng mng bng

cch lm chy do kim loi qua khe hgia chy v ci.

Dp du: to vt lm trn bmt chi tit sau khun l.


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Lp ghp:

Tn: to mi ghp cc chi tit bng inh tn.

p: to ra mi ghp bng cch lp c di.

Gn mp: ghp cc chi tit bng cch to ra cc kha vng.

Un tai: ghp hai chi tit bng cch un tai.

Un mp: ghp hai hoc mt schi tit bng cch un gmp.

Tp:ghp hai chi tit bng cch tp mt trong cc chi tit ghp.

Gin: ghp hai chi tit bng cch gin rng mt chi tit bn trong.

2.2.5.1 Nguyn cng ct hnh v t l.

Phbng kim loi tm thnh cc tm nh.

Ct chi tit tm thnh cc chi tit nh.

Dp ct to chi tit.

Dp to l trn sn phm.

Ct vt liu:

Ct chia: ct phi rng, phi cong hoc phi phng thnh hai hoc mt vi

chi tit ring bit. p dng khi chto nhng chi tit khng i xng, banu chto thnh phi i xng, sau ct chia.

Ct mp: ct bphn tha theo ng bao ngoi hoc phn mp khng

u ca chi tit cng hoc chi tit dp vut.

Ct tinh: ct bphn lng d rt nhtheo ng bao ca phi hoc l

nhm mc ch t c kch thc v hnh dng chnh xc, b mt ct

sch v vung gc vi bmt chi tit.

Hnh 2.4: ng dng t l.


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S nguyn l ct t bng khun:

Hnh 2.5: s nguyn l t l.

Lc ct hnh v t l(F): hnh dng v trng thi lm vic ca chy v

ci, khe hZ, tc bin dng, ln su ca chy.

Cng thc tnh gn ng:

P = F. .k = L.S. .k (2.2.1)Trong :

L: chu vi ct (mm)

S: chiu dy vt liu (mm)

K: hs

: trlc ct ca vt liu ( )

2.2.5.2 Nguyn cng un tm.

Un l mt nguyn cng nhm bin i cc phi c trc thng thnh cc chi

tit c trc cong.

Un:

Un: bin phi phng thnh chi tit cong.

Cun: cun cc mp ca phi to thnh chi tit c dng vng neo hoc

hnh tr.

Vn: quay mt phn phi xung quanh trc dc ca n.

Hnh 2.6: ng dng un tm.


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S nguyn l un tm:

Hnh 2.7: s nguyn l un tm.

2.2.5.3 Nguyn cng dp vut (dp su).

Khi nim:

Dp vut l mt nguyn cng nhm bin i phi phng hoc phi rng

to ra cc phi rng c kch thc v hnh dng cn thit.

Dp vut khng bin mng: l phng php nhn c chi tit rng t

phi phng hoc phi rng. chiu dy vt liu hu nh khng i.

Dp vut c bin mng: l phng php nhn c chi tit rng t phi

phng hoc phi rng c chnh bin mng chiu dy vt liu.

Phn loi theo hnh dng sn phm:

Nhm cc chi tit c hnh dng trn xoay (i xng trc): y ca ni hi;

cc chi tit hnh tr; cc loi bt a kim loi; cc chi tit ca thit bchiu

sng nh pha n, vn..

Nhm cc chi tit c hnh dng hnh hp: thng nhin liu ca ng c;

cc loi vhp; cc chi tit bc trong cc chi tit ca thit bin t; thit

bo

Nhm cc chi tit c hnh dng phc tp c mt trc i xng hoc khng

c trc i xng: chi tit xe my; vt; cnh ca t; chi tit my ko; chi

tit my bay

Phn loi theo c im cng ngh:

Dp vut khng bin mng S = So (chgim ng knh m khng lm

thay i chiu dy phi, khe hgia chy v ci

Z > =S ).


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Dp vut c bin mng S = So, chiu dy phi gim c chnh, ng

knh phi gim mt lng nh, khe hZ


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ng quay ca phi di tc dng ca lc cng tc lm bin dng do cc

bti mt im trn phi quay.

2.3 L thuyt bin dng do kim loi.

2.3.1 C svt l ca qu trnh bin dng.

2.3.1.1 Khi qut vqu trnh bin dng.

Sdch chuyn tng i ca cc cht im, cc phn tca vt rn di

tc dng ca ngoi lc, nhit hoc mt nguyn nhn no dn n sthay

i vhnh dng kch thc vt th, lin kt vt liu c bo ton, c gi

l bin dng do.

Tt cmi phng php gia cng p lc u da trn mt tin chung lthc hin mt qu trnh bin dng do.

Vt liu di tc dng ca ngoi lc s thay i hnh dng v kch thc

m khng mt i slin kt bn cht ca n.

Khnng bin dng do c coi l mt c tnh quan trng ca bin dng

do.

Bin dng mu khi thko:

lm sng tqu trnh bin dng theo di th nghim ko n gin. di

tc dng ca lc ko, mu ko lin tc bko di cho n khi bt. trong th

nghim ko vi cc thit bph hp ta c tho c lc ko v gin di

tng ng, t xc nh ng sut v bin dng theo cc mi quan hsau:

;

(2.3.1)

Vng bin dng n hi.

Vng bin dng n hido (trong bin dng n hi rt nhso vi

bin dng do).

Vng ph hy.

Bin dng n hi v bin dng do trong tinh th:

Bin dng ca vt thl tng hp ca cc qu trnh bin dng trong tng ht

tinh thv trn bin gii ht.


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Bin dng n hi:

Hnh 2.10: qu trnh bin dng n hi.

Bin dng do trong tinh th:

Trt:

Khi mu n tinh thbko, xut hin cc bc trn bmt ca mu. iu

chng tstrt ln nhau gia cc phn tca vt th. Strt xy rachyu trn cc mt nht nh v dc theo nhng phng nht nh gi l

mt trt v phng trt. Mc trt thng bng mt s nguyn ln

khong cch gia cc nguyn ttrn phng trt.

Hnh 2.11: qu trnh trt.

Mt trt v phng trt l nhng mt vphng c mt nguyn t

ln nht. iu ny cng dhiu bi l lc lin kt gia cc nguyn ttrn

mt v phng l ln nht so vi nhng mt v phng khc.

S lng h trt cc ln th khnng xy ra trt cng nhiu, c ngha

cng dbin dng do. bi vy khnng bin dng do ca kim loi c thc nh gi thng qua slng htrt.

Trt chxy ra di tc dng ca ng sut tip.

Phng mng khng thay i trc v sau khi trt.

Mc trt bng snguyn ln khong cch gia cc nguyn t.

ng sut tip cn thit gy ra trt khng ln.

Song tinh (i tinh):


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Khi ng sut tip t ti mt gi trti hn no th mt phn ca mng

tinh thsx dch n mt vtr mi i xng vi phn cn li qua mt mt

phng gi l mt song tinh. Song tinh cng ch xy ra trn cc mt v cc

phng xc nh.

Hnh 2.12: trt song tinh.

Ging nh trt song tinh chxy ra di tc dng ca ng sut tip.Khc vi trt l song tinh km theo sthay i ca phng mng ca phn

tinh thbx dch.

Khong x dch ca cc nguyn ttlthun vi khong cch gia chng ti

mt song tinh v c trsnhhn so vi khong cch cc nguyn t.

ng sut cn thit to thnh i tinh c hc thng ln hn ng sut cn

thit gy ra trt. bi vy trt sgy ra trc v chkhi cc qu trnh trt

gp kh khnth song tinh mi to thnh.

V x dch cc nguyn tkhi to thnh cc song tinh nhnn song tinh khng

dn mt mc bin dng do ng ktrong tinh th(chvi ).

Nu cng vi song tinh cn xy ra trt th trt ng vai tr chnh trong

bin dng do.

Trong cc tinh thlin kt ng ha trnh: Bi, Sb ton bbin dng do

cho n lc ph hy ch yu do song tinh to nn, v thmc bin dngdo trong cc tinh th rt nh, chng c coi l nhng vt liu rn.

i vi nhng tinh th mang lc phng xp cht nh: Zn, Mg, Cb..do

lng htrt t nn thng to thnh song tinh, song ngha song tinh i

vi bin dng do khng ln m quan trng hn l do song tinh lm thay i

phng mng nn c th lm xut hin mt s nh hng mi c li cho

trt. trong trng hp ny bin dng do tng hn so vi cc trng hp bin


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dng do n thun. Tuy nhin s thay i ny khng ln nn cc mng lc

phng xp cht vn l nhng vt liu c tnh do km.

Khuyt tt trong mng tinh th:

Cc dng khuyt tt: cu trc ca tinh thbri lon do sxut hin cc

khuyt tt mng.

Cn cvo cc khuyt tt c thchia chng thnh ba dng:

Khuyt tt im: cc nt trng, cc im xen k.

Khuyt tt ng: cc loi ng.

Khuyt tt mt: bin gii ht, bin gii mt, khuyt tt xp.

Hnh 2.13: cc khuyt tt im.

Hnh 2.14: cc khuyt tt mt.

Hnh 2.15: cc khuyt tt ng (lch).


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2.3.1.2 Ha bn bin dng.

Hin tng ng sut chy tng ln theo mc bin dng trong qu trnh

bin dng.

nh hng n tch cht sn phm.

Xy ra bin dng nhit cn tng i thp.

Ha bn bin dng lm tng ti trng i vi dng c bin dng, i hi

tiu hao v lc v cng bin dng ngy cng tng. V vy, t mt mc

bin dng no trong nhiu trng hp phi tin hnh cc bc nhit

luyn trung gian nhm gim bt ng sut chy v khi phc tnh do.

trnh hin tng ha bn bin dng, thc hin bin dng nhit cao,song chnh xc v cht lng bmt sn phm li km hn nhiu so vi

bin dng ngui.

Hnh 2.16: biu quan hng sut- bin dng.

Nguyn nhn ca hin tng ha bn:

Lch khng ngng c sinh ra.

Khi chuyn ng, lch hoc gp phi chng ngi vt hoc ct nhau, n

li, rng lch.

Mun tip tc chuyn ng phi tng ng sut.

Tt c nhng nhn tno ngn cn ssn sinh v chuyn ng ca lch

u l nguyn nhn dn n ha bn bin dng.

2.3.1.2 Cc qu trnh kch hot nhit.

Khi tng nhit :

Tnh cht kim loi thay i, trnn mm v do hn.

Lc v cng bin dng nh, ng sut bin dng ln.


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Dboxi ha bmt dn n cht lng bmt km.

chnh xc ca sn phm khng cao.

Hnh 2.17: chnh xc ca sn phm.

Nhit bin dng:

Bin dng ngui:

Thng thc hin nhit phng.

Nhit nhhn nhit kt tinh li.

Lc bin dng ln, ha bn vt liu, khnng bin dng do thp.

V dvi Thp- C: bin dng nhit phng l bin dng ngui.

Bin dng na nng:

Nung nng khi bin dng.Nhit bin dng khong xung quanh nhit kt tinh li.

Gim lc bin dng, nng cao kh nng bin dng do, ng sut chy

gim do shi phc, mt phn kt tinh li.

V dvi thp- c: bin dng nhit khong t650-800C.

Bin dng nng:

Nung nng khi bin dng.

Nhit bin dng cao hn nhit kt tinh li.

Gim ng klc bin dng, tnh do ca vt liu cao, ng sut chy gim

nhiu do kt tinh li.

V dvi thp- C: bin dng nng nhit 1150-1250C.


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Hnh 2.18: nhit kt tinh ca mt svt liu.

2.3.1.3 ng sut chy v ng cong chy.

ng sut chy:

ng sut cn thit (xc nh trong trng thi ng sut n) lm cho vt

liu t c trng thi do hoc duy tr trng thi do gi l ng sut chy

(cn gi l bin dng- k hiu hoc ).

ng sut chy l mt thng sc bn ca vt liu, n phthuc trc ht

vo bn thn vt liu (thnh phn, cu trc, tchc)v cc iu kin bindng (nhit , mc bin dng, tc bin dng, trng thi ng sut ).

ng cong chy:

ng cong biu din sph thuc ca ng sut chy vo mc bin

dng (hoc tc bin dng) gi l ng cong chy hoc l ng cong

ha bn.

Hnh 2.19: biu thp C15.


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2.4 C hc qu trnh bin dng.

2.4.1 ng sut.

nh ngha ng sut ti mt im:

Hnh 2.20: ni lc v ng sut trong vt th.

ng sut ti php v tip:

ng sut theo cc phng:

Trn mt mt phng c 3 thnh phn: mt ng sut php v hai ng suttip.

ng sut kthut v ng sut thc:

ng sut kthut:


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ng sut thc:

Ch : Trong bin dng do ta sdng ng sut thc.

Chuyn thta cc sang hta chnh da vo cc bt bin ca ten

x ng sut.Ten x ng sut c ba bt bin:

Bt bin l bt bin bc nht:

Bt bin l bt bin bc hai:

Bt bin l bt bin bc ba:

, , l nghim phng trnh.

2.4.2 Bin dng.

Bin dng di v bin dng gc:


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Bin dng kthut (bin dng gin di):

Bin dng thc (bin dng logarit):

Ta c:

Ch : Bin dng trong cng nghgia cng p lc l bin dng ln nn ta s

dng bin dng thc.

2.4.3 Quan hgia ng sut v bin dng.Trong bin dng n hi, quan hgia ng sut v bin dng tun theo nh

lut hoocke:


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Trong bin dng do, ta c quan hgia ng sut v bin dng nh sau:

Skhc nhau c bn gia cc m un E v G trong bin dng n hi vi m

un D trong bin dng do l chE v G l hng si vi mt vt liu

nht nh cn D thay i trong qu trnh bin dng.

Trong bin dng n hi E= tg= const, cn trong bin dng do D= tgm

th lun lun thay i trong qu trnh bin dng.

2.4.4 iu kin do.

L iu kin kim loi qu ttrng thi n hi sang trng thi do.

Xt trng hp thanh trn theo hng trc. thanh sbbin dng do nu

ng sut no ko trn tit din ca n t ti hn chy. Trng hp tng qut: khi vt th chu ti trng bn ngoi, bn trong vt

thxut hin ng sut tng ngt ti ng sut chy ca vt liu th vt

liu th vt thny bbin dng do.


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Trong cc biu thc trn k l gi ng sut tip chy, c xc nh trong

trng hp ct thun ty. Theo iu kin Tresca th: ; theo

iu kin do ca Mises th:

Nhng biu thc ring ca iu kin do: Trng thi ng sut phng:

Trng thi bin dng phng:

Trng thi ng sut i xng trc:

( )

( )

2.4.5 Nhng nguyn tc nh lut trong bin dng do.

Quan h gia ng sut chy v bin dng thc xc nh theo ng cong

chy ca vt liu.


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Vt th bin dng tun theo nh lut do, nh lut th tch khng i,

nguyn tc trlc bin dng nhnht.

nh lut thtch khng i:

Th tch vt thkhng thay i trc v sau khi bin dng. tng cc thnh

phn bin dng trn ng cho chnh bng 0.

Nguyn tc trlc bin dng nhnht:

Nu cc cht im trong vt thbin dng sdch chuyn trn phng no c

trlc nhnht.


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CHNG 3

THIT KV TCH KHUN CHI TIT VI SH

TRCA PRO ENGINEER 5.03.1 Phn mm pro engineer 5.0.

Pro/E l phn mm ca hng Prametric Technology, Corp.

Pro engineer l nm trong ti CAD m dn thit kthng gi, trong

cn c Unigraphic (NX), CATIA, I- DEAS.

Pro engineer c sdng rng ri trn thgii v ng thi n cng c

sdng rt phbin Vit Nam. Pro engineer rt mnh trong thit k, khun mu v gia cng.

N cn tch hp thm module Expert Moldbase Extension (chuyn dng

cho thit kkhun mu).

3.1.1 Thit k2D.

Chc nng v cng dng mt s lnh phc tho: ng thng (line), ch

nht (rectangle), trn (cycle), cung , bo cung (fillet) , vt cnh (chamfer),

ng cong (spline), kch thc (dimension)

Chc nng v cng dng ca mt s lnh rng buc theo: phng ngang

(Horizontal), vung gc (Vertical), tip tuyn (Tangent), im gia (Mid-

Point), ng tm (Coincident), i xng (Symmectric), bng (Equal), song

song (Parallel).

Ngoi ra cn c cc lnh phtr nh: ct (delete segment), to ch(text),

chn i tng t th vin (palette), i xng (mirror), sao chp (offset),.

3.1.2 Thit kpart 3D.

Chc nng mt s lnh thng dng nh: extrude, revolve, sweep, blend,

style.


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3.2 Thit kchi tit thng xe ra.

Sau khi ci t phn mm ta bt u thit kchi tit.

B1: Khi to mt part- solid mi nhsau:

Hnh 3.1: to mi trng part.

B2: Chn mt front, sau phc tho bin dng sketch:

Hnh 3.2: to bin dng 2d ca chi tit.


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B3: To khi solid bng extrude, nh sau:

Hnh 3.3:to khi extrude.

B4: To gc nghing cho chi tit, nh sau:

Hnh 3.4: to gc nghing ca chi tit.

B5: To chiu dy cho chi tit, bng lnh shell:


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Hnh 3.5: dy ca chi tit.

B6: To cc gc ln, bng lnh round nhu sau:

Hnh 3.6: to gc ln.

Vy l chi tit thit kxong, ta sao lu dliu li di dng *.prt to lng

khun v sao lu di dang *.IGS phn tch.

Hnh 3.7: bn vthit k.

3.3 Tch khun chi tit.


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Sau khi thit kpart, tip tc ta tin hnh tch khun.

B1: Khi to mt manufacturing- mold cavity mi nhsau:

Hnh 3.8: to mi trng part.B2: Ly khi c stch khun, nh sau:

Hnh 3.9: chn i tng cn tch khun.

B3: To co rt cho khun:

Hnh 3.10: hsco rt.

B4: Thit kphi vi kch thc nh sau:


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Hnh 3.11: thit kphi.

B5: To mt phn khun bng lnh Fill nhsau:

Hnh 3.12: to mt phn khun.

B6: To thtch phn khun bn lnh volume split:

Hnh 3.13: to thtch phn khun.

B7: To khun cavity v core nh sau:

Hnh 3.14: to i tng khun.


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B8: Tch khun thnh hai tm:

Hnh 3.15: khun trn v khun di.

Sau khi tch thnh 2 lng khun cavity v core ta sao lu di dng .IGS

m phng gia cng.

Kt lun:

Qu trnh tch khun hon tt, cc gc ln v kch thc tng i

m bo cho qu trnh phn tch v gia cng.


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CHNG 4

PHN TCH SN PHM VI SHTRCA ETA/

DYNAFORM 5.64.1 Phn mm eta/ DYNAFORM 5.6.

Dynaform do hng LSTC ca Msn xut.

Dyaform l mt phn rt mnh vm phng squ trnh dp tm.

N ra i cng kh lu, nhng sdng i hi phi c kin thc l thuyt

rt nhiu.

Ngoi ra trn th gii hin nay cn s dng cc phn mm khc nh:ABAQUS, MARC, EPDAN, INDEEP, ROBUST, DEDRAN, DEFORM,

FORGE2/3, PAM-STAMP, ANSYS L/S.

Giao din chnh:

Hnh 4.1: giao din chnh.


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Thanh file maneger:

Cho php ngi sdng cc hot ng nh: database,

data input/ output, submitting jobs and print setup.

c minh ha nh hnh bn.

Thanh part control:

C sdliu trong i tng (part) gm c: thit t

ca ng, mt, cng tr phn t. Mi part ch c

duy nht mt s ID ring. C th to ra 1000 parttrong c s d liu. Ngoi ra cn c mt s chc

nng khc.

Thanh preprocess:

Chc nng ny cho php ngi dng xy dng hoc

chnh sa m hnh, to ra m hnh t cc phn t,

kim tra/ thay th m hnh, to ta boundary (ng

bin gii) t m hnh. Cn nhng chc nng trong

th thoi ny rt hay. y l mt bc quan trng

trc khi m phng.

Thanh DFE (DIE FACE ENGINEERING):

DFE (DIE FACE ENGINEERING) pht trin htrtora mt khun nhanh v dhn.

Chc nngbao gm:

To ra mt phn khun ring bit.

To mp cnh khng nhn.

Sa v phn chia bmt.

Chia li v kim tra/ thay th.


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Tng din y l, ng ranh gii v ng bn ngoi.

Tng v htrxy dng tm chn.

Thanh BSE (BLANK SIZE ENGINEERING):

BSE (BLANK SIZE ENGINEERING) l chc nng thit t

kch thc phi, c nh v lp phi. cho qu trnh m

phng dp phi nhanh hn.

Thanh setup:

Ci t cc thng scho qu trnh dp, c thci t nhanh

(quicksetup) hoc tng ci t (autosetup).

Thanh definition:

Ngi dng c ththit t cng cdp, nh ngha vt

liu v thng s, to ra cht dn hng, to ra v chnh

sa ng c, nh ngha slin kt gia cc bmt, gn

vut, xem chuyn ng ca cc thit bv chnh sa bin

dng phi.

Ngoi ra cn c mt s thanh cng c khc nh: option menu, utilities,

view option, analysis.

4.2 Thit lp cc iu kin bin cho chi tit.

Trnh tthc hin qu trnh thit lp v m phng:

Hnh 4.2: trnh tgii thut dynaform.

Thng svt liu [11].

Mc thp: SS400- JIS (tng ng mc thp CT3- TCVN).

Gii hn bn nhnht: 400 N/


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Gii hn chy khong: 235 ~ 245 N/

Nhit dung ring: 0.700 J/g-C

dn nhit: 3.70 W/m-K

Nhit ti a: 400 C

Nhit ti thiu: -40.0 C

Thnh phn:

4.3 Thng sdp.Lc dp vut: [3, tr. 259]

L: chu vi hnh hp (1200 x 2 + 1000 x 2= 4400 mm)

s: chiu dy phi (1 mm)

: gii hn bn ca phi (400 N/)

: hsphthuc vo hsvut. (tra bng, chn = 0.37)

Lc chn: [3, tr. 259]

: lc p ring (tra bng, chn = 2 N/)

: din tch phn phi bchn (1200 x 200 = 240000)

8

Cng bin dng: [3, tr. 260]

: lc dp ( 651200 N/)

: su vut (230 mm)

898

Khe hgia chy v ci: [1, tr. 177]

Z = 1,2s

(N)

(N)

. .8 (J)


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s: chiu dy phi (1 mm)

Z: khe h(1,2)

Sau khi chi tit c thit ktphn mm proengineer lu di nh dng

IGS.

Bc 1:

Fileimport: phi v chi tit (y phi cng c thit ktproe). Chnh

sa tn v ID. Xong, ok.

Hnh 4.3: import file.

Bc 2:

Tool- blank generator: thit t ng ranh gii v chia li phi. Ta chn

boundary line, chn kch thc phn t(element size ) l 30. Xong, ok.

Hnh 4.4: thit ng ranh gii li.


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Hnh 4.8: thng sdp.

Tip tc, ta thit t thng sgn vut:

Thit t thng stphn mm.

Tnhng cng thc nh trn ta chn cc thng s.

Hnh 4.9: thng sgn vut.

Xong.

Tip theo ta chn submit job phn mm gii thut cc thng s va thit

lp.

Bc 5:

Toolautosetup: thit lp cc thng svvn tc dp, lc chn phi, khe h

Vn tc dp vut tra bng stay : 2000 mm/s

Lc chn phi: 100 tn

Khe h: 1.2


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4.3 Kt qus b.

Hnh 4.10: thit t chi tit v m hnh vt liu ph hy.

Qu trnh dp to hnh sn phm thng xe ra:

Hnh 4.11: qu trnh to hnh sn phm.

y l cc bc thc hin qu trnh dp to hnh tm sn phm, sn phm tngthi im vt liu sbin dng cc mc khc nhau. Do trong qu trnh cn


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c cc thng sti u gim bt sph hy ng kca vt liu cng nh ccphn nhn rch trong sn phm.

Hnh 4.12: qu trnh dp ththc t.

Cc sn phm sau khi dp thqua cc ln dp th sn phm vn cn nhn cc phn hc nhng vi sn phm thng xe ra th nhn l c thchp nhnc v n vn m bo cc thng skthut a ra.

Ming thnh sn phm c nhiu lp nhn l qu trnh chn phi khi qutrnh dp sn sinh ra mc ch ca n m bo cho qu trnh ko phi c iny cc lng khun.

Kt quthFLD ln 1:


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Hnh 4.13: kt quFLD1.

Sau khi m phng vn cn nhn ming phi (do tm chn phi thit knh

hn mt phi), xut hin nhiu vt nt (mu ).

Ta tip thit lp li thng schthay i khe h, to thm tm chn ln hn

bmt phi na.

Kt quthFLD ln 2:

Hnh 4.14: kt quFLD 2

Kt qum phng cho thy cht lng sn phm vn m bo, nhn ca

cc bmt gim so vi lc u.

Vy l qu trnh thit t cc thng sv qu trnh gii thut tphn mm

hon tt.


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4.4 Kt qum phng.

Sn phm:

Hnh 4.15: m hnh sau khi dp.

Sau khi m phng sn phm tng i m bo cc tnh nng.

Cht lng sn phm:

Hnh 4.16: cht lng sn phm.

Cht lng sn phm khng c cc vng rch (mu ) m ch tp trung

cc vng an ton (mu tm) m bo ng yu cu kthut, khng c vng

rch t trong qu trnh dp.

Chiu dy:

Hnh 4.17: sphn bdy.


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Tm hnh chng ta cng thy c chc mt vng nh(mu vng) cn li

phn ln l vng (mu xanh), vng m t dy tiu chun 1mm.

dy nht ca chi tit: 1.2mm

mng nht ca chi tit: 0.8mm

ng sut:

Hnh 4.18: sphn bng sut.

Kt qutm hnh cho ta thy phn ng sut phn btng i u phn

thn sn phm, gi trng sut tng i t yu cu.

Lc chn v lc dp:

Hnh 4.19: biu lc.

Tbiu ta thy c thi gian dp chi tit tng ng vi cc thng s

lc chn v lc dp.

Lc chn: 100 tn.

Lc dp: 300 tn.

Thi gian: 13,6 pht


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Qu trnh ko phi:

Hnh 4.20: qu trnh ko phi.

Tm hnh ko phi ta thy c sdch chuyn ca cc phn tvt liu,

do cc thng slc chn v lc dp c ti u nn qu trnh ko phi tng

i u trn vnh chi tit.

Hnh 4.21: hnh sn phm thc t.

Kt lun:

Nhsm phng squ trnh bin dng m cng vic tnh ton chnh xc v

nhanh hn, i vi chi tit thng xe ra ny th chnh xc chcn tng

i.


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CHNG 5

GIA CNG KHUN CHI TIT VI SHTRCA

MASTERCAM X45.1 Phn mm MasterCAM.

Mastercam l mt phn mm chuyn trong gia cng (CAM).

N c ng dng rt nhiu trong cc khu cng nghip, cng ty, x nghip..

trong nc ln ngoi nc.

Mastercam c ththit lp gia cng cc vt liu kim loi v gtrn cc chu

trnh nh: tin, phay, ct dy. Mastercam cn c Add-In trong Solidwork to nn bi hon ho trong

thit kgia cng.

Mastercam tng i d tip cn v gi chp l nn c ng o cc

Designer nghin cu.

5.1.1 Giao din chnh.

Hnh 5.1: giao din Mastercam.


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Toolbar: thanh cng c.

Window graphic: vng hin thha.

Support design & process: thanh htrthit kv gia cng.

Setup parameter: vng thit lp cc thng sgia cng.

Hnh 5.2: ng dng thit k.5.1.2 Modul lathe (modul lp trnh tin chi tit).

Rough: lp trnh tin th cho chi tit.

Finish: lp trnh tin tinh cho chi tit.

Thread: lp trnh tin ren cho chi tit.

Groove: lp trnh tin rnh cho chi tit.

Face: lp trnh tin mt u cho chi tit.

Cutof: lp trnh tin ct t cho chi tit.

Drill: khoan lcho chi tit.

Sau y l mt shnh nh vlp trnh tin trong mastercam:

Hnh 5.3: lp trnh tin.

5.1.3 Modul mill (modul lp trnh phay chi tit).

Contour: lp trnh theo bin dng.

Drill: khoan lchi tit.

Pocket: phay hc chi tit.

Face: phay bmt chi tit.


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Surface rough: phay th bmt chi tit.

Surface finish: phay tinh bmt chi tit.

Sau y l mt shnh nh vlp trnh phay:

Hnh 5.4: lp trnh phay.

5.1.4 Modul wire EDM (modul lp trnh ct dy).Contour: lp trnh ct theo bin dng (c thiu chnh gc nghing).

Canned:

Hnh 5.5: hnh lp trnh ct dy.

5.1.5 Modul rounter (modul chuyn lp trnh cho Woodcam).

Nhn chung cc lnh lp trnh ging nh phn mill, ngoi ra cn c cc kiu

lp trnh:

Saw: lp trnh ca, src cc chi tit. Block dril: lp trnh khoan theo hng cho chi tit.

Modul ny chuyn gia cng cc sn phm g theo tiu chun to cho

ngi dng nhng tnh nng mi v nhanh hn hn so vi cc phng php

thcng khc.


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Hnh 5.6: hnh lp trnh rounter.

5.2 Thit lp thng scng nghcho chi tit.

Sau khi lng khun c (cavity v core) c tch tproe v c lu

di dng IGS. By gita chuyn dliu import vo Mastercam.

5.2.1 Thit lp thng scho

khun cavity.

Thit lp kch thc phi:

800x1000x450

Bin dng phi: hnh hp, hnh

tr, khi solid, add file v c th

thit t theo cc hng (x, y, z).Gc phi trng vi gc ta .

Kch thc phi: chn 2 gc,

chn ng vin ca hp, chn

cc bmt, cc khi, cc on.

Sau khi ci t xong, chn ok.

Hnh 5.7: thit t phi.

5.2.2 Thit lp thng sphay th bmt cavity.

Toolpathsurface rough- radial: chn cc bmt cn phay (mu vng).


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Hnh 5.8: chn bmt gia cng.

Sau enter, xut hin bng v chn radial point.

Mc ch ca vic to ra im xoay bn phay trong

lc phay cc bin dng cong.

Chn ok.

Hnh 5.9: thit t ng chy dao.

Toolpath parameter: (thng svng chy

dao)

Chn dao sphere (dao phay cu).

Tool diameter (ng knh dao): 50

Conner radius (bn knh dao): 25

Feed rate (tc ct): 100

Spindle speed (tc trc chnh): 1000

Spindle direction (hng quay trc chnh): cw (clockwise: cng chiu kim

ng h).

Plunge rate (tc n do theo trc z): 10Retrac rate (tc hi dao): 20

Hnh 5.10: thng s

dao gia cng.


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Surface parameter: (thng svbmt)

Clearance (khong cch an ton): 50 (gi trtuyt i)

Retract plane (mt phng an ton): 25 (gi trtng i)

Feed rate (mt phng hi dao): 5 (gi trtng i)

Chn ok.

Hnh 5.11: thng sbmt gia cng.

Rough radial parameter: (thng sphay th)

Total tolerane (tng lng d gia cng): 0.05

Cutting method (phng php ct): zigzag

Max.angle increment (gc tng ln nht): 0.5

Start angle (gc bt u):0

Start offset distance (khong cch bt u):1

Sweep angle (gc qut): 360

Hnh 5.12: thng sphay th bmt.

Chn cutting depths:


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Adjusment to top cut (thay i khong cch ct theo hng ng): 0.2

Adjusment to orther cuts (thay i khong cch theo cc hng khc): 0.2

Hnh 5.14: thng sct.

Chn gap setting:

Gap size: % or tool dimater (kch thc khe h): 300

Motion (loi chuyn ng): follow surface

Mc ch to ra ng khi gp khc v bgy.

Xong, ok.

Hnh 5.15: thng sgap setting.

Vy l xong vic thit t thng sphay th cavity.

Hnh 5.16: kt quphay th.


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5.2.3 Thit lp thng sphay tinh bmt cavity.

Toolpathsurface finishparalle: (mu vng)

Hnh 5.17: chn bmt gia cng.

Toolpath parameter (thng sng chy dao):

Chn dao phay sphere (dao phay cu).

Tool diameter (ng knh dao): 20

Conner radius (bn knh dao): 10

Feed rate (tc ct): 80

Spindle speed (tc quay trc chnh): 700

Spindle direction (hng quay dao trc chnh): cw (clockwise: cng chiu

kim ng h).

Plunge rate (tc ct theo trc z): 7

Retract rate (tc hi dao): 20

Hnh 5.18: thng sng chy dao.


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Chn gap setting:

Gap size: % or tool dimater (kch thc khe h): 300

Motion (loi chuyn ng): follow surface

Mc ch to ra ng khi gp khc v bgy.

Chn ok.

Hnh 5.21: thng smotion.

Vy l xong qu trnh thit t thng sphay tinh bmt cavity.

Hnh 5.22: kt quphay tinh.

5.2.4 Chng trnh G- code tcc cc thng s m phng.

Chn biu tng G1trn thanh qun l ng chy dao.

Chn th mc lu file.NC, sau ok.

Hnh 5.23: xut file G- code.


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on m g- code:

Vy l qu trnh lp cho khun cavity hon tt, vic cn li l chun b

g (rt quan trng cho vic gia cng) v thit lp li chun phi cho my CNC l

c thgia cng.

Thit lp thng scho khun core.

Nhn chung cch thao tc m phng gia cng cho khun core ging vi cch

thao tc khun cavity, chcn thit t li cc bmt gia cng, chct..


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Sau yl hnh dng ca qu trnh gia cng th v tinh:

Hnh 5.24: kt qukhun trn.

y l G- code c to ra tqu trnh m phng:


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Kt lun:

Qu trnh gia cng gia cng lng khun cavity v core hon t t, nhn

chung qu trnh gia cng vn cn nhng sai s nhng vn m bo c yu

cu k thut. Thng smastercam tng i dhiu, l tin cho vic gia

cng cc chi tit tmy CNC v l nn tng cho vic nghin cu cc phn

mm CAM khc.


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KT LUN

Qu trnh ng dng cng nghCAD/ CAE/ CAM c ng dng trong

thit kthng xe ra chl mt qu trnh in hnh trong cng nghgia cngp lc ni chung, cng nghdp tm ni ring. Qua qu trnh thit k m

phng, cc thng sc ti u mt cch nhanh chng v chnh xc. Tuy

ti hon thnh nhng vn cn mt shn chnh: thng sc tnh vt

liu phi nhp bng tay (th vin chhtrcc chun ISO) i hi phi a

thng v chun TCVN, kin thc phng php phn tch phn t hu hn

cn hn ch, ti liu ting vit cha p ng hon thin .nhng ti

vn m bo cc yu cu ra nh: tnh cng ngh, thc tin, tnh miTrong qu trnh hon thnh ti di s gip nhit tnh ca thy

Th.S Vi Trung Kin v cc thy trong khoa c in Trng i Hc Lc

Hng. Ngoi ra em xin chn thnh cm nthy Th.S Nguyn Trung Kin B

mn gia cng p lc trng i Hc Bch Khoa H Ni, PGS. TS inh B

TrVin KThut Qun Scng gip em rt nhiu trong phn CAE.

ti n y l hon tt em xin chn thnh cm n cc thy, chc cc

thy v cc bn c nhiu sc khe, may mn trong cuc sng.


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TI LIU THAM KHO

Ting vit

[1]. Cng nghto hnh tm kim loi, Nguyn Mu ng.[2]. C sl thuyt bin dng do kim loi, inh B Tr.

[3]. Stay thit kkhun dp tmV.L MartrencoL.I Rudman, Bin Dch

V Trn Khc Nh, Nxb Hi Phng.

[4]. Gio trnh Bmn gia cng p lc,Vin C Kh- i hc bch khoa H

Ni.

[5]. Thuyt minh ti nghin cu khoa hc 2011, i Hc KThut Cng

Nghip Thi Nguyn.

[6]. ti c sdng mt sti liu ca cc nghin cu sinh, cao hc, ging

vin v sinh vin trong cc trng.

Ting anh

[7]. Application manual dynaform 5.6.

[8]. Training Dynaform.

[9]. Help Dynaform.[10]. Help Mastercam x4

[11]. Training Mastercam.

Wedsite

[12]. http://www.matweb.com

[13]. http://metalformingvn.net

[13].http://www.wikipedia.org

bao cao nckh.pdf

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