Mc Lc

CHNG 1 -------------------------------------------------------------------------------------1
1. L do chn ti ----------------------------------------------------------------------- 1
2. Phng php nghin cu ------------------------------------------------------------- 2
3. Kh nng ng dng thc t----------------------------------------------------------- 3
CHNG 2 ------------------------------------------------------------------------------------4
2.1 Tng quan v tm nh hng ca cng ngh n thc tin -----------------4
2.1.1 S pht 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 ------------------ 5
2.1.4 To ra cc phng php gia cng c bit ---------------------------------6
2.2 Cng ngh dp 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 s vt l ca qu trnh bin dng -------------------------------------- 14
2.3.1.1 Khi qut v qu 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

2.4.3 Quan h gia 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 k 2D ---------------------------------------------------------------------- 27
3.1.2 Thit k part 3D ---------------------------------------------------------------- 27
3.2 Thit k chi tit thng xe ra ----------------------------------------------------- 28
3.3 Tch khun chi tit ----------------------------------------------------------------- 30
CHNG 4 ---------------------------------------------------------------------------------- 34
4.1 Phn mm eta/ DYNAFORM 5.6 ----------------------------------------------- 34
4.2 Thit lp cc iu kin bin cho chi tit --------------------------------------- 36
4.3 Thng s dp ------------------------------------------------------------------------- 37
4.3 Kt qu s b ------------------------------------------------------------------------- 41
4.4 Kt qu m phng ------------------------------------------------------------------- 44
CHNG 5 ---------------------------------------------------------------------------------- 47
5.1 Phn mm Mastercam -------------------------------------------------------------- 47
5.1.1 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 s cng ngh cho chi tit ------------------------------------- 50
5.2.1 Thit lp thng s cho khun cavity -------------------------------------- 50
5.2.2 Thit lp thng s phay th b mt cavity ------------------------------- 50
5.2.3 Thit lp thng s phay tinh b mt cavity ------------------------------ 54
5.2.4 Chng trnh G- code t cc cc thng s m phng ------------- 56
KT LUN ---------------------------------------------------------------------------------- 60
TI LIU THAM KHO ---------------------------------------------------------------- 61

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 ngh dp tm. -----------------------------------------------------7
Hnh 2.2: ng dng trong thc tin. -----------------------------------------------------8
Hnh 2.3: B khun 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. ---------------------------------------------------- 12
Hnh 2.8: S nguyn l dp vut. --------------------------------------------------- 13
Hnh 2.9: Thng s dp 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 h ng sut- bin dng. ----------------------------------- 18
Hnh 2.17: chnh xc ca sn phm. ----------------------------------------------- 19
Hnh 2.18: Nhit kt tinh ca mt s vt 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 v thit k. ----------------------------------------------------------------- 30
Hnh 3.8: To mi trng part. ---------------------------------------------------------- 31
Hnh 3.9: Chn i tng cn tch khun. ------------------------------------------- 31

Hnh 3.10: H s co rt. ------------------------------------------------------------------- 31

Hnh 3.11: Thit k phi. ----------------------------------------------------------------- 32
Hnh 3.12: To mt phn khun. -------------------------------------------------------- 32
Hnh 3.13: To th tch 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 t gii thut dynaform. ----------------------------------------------- 36
Hnh 4.3: Import file ----------------------------------------------------------------------- 38
Hnh 4.4: Thit ung ranh gii li. -------------------------------------------------- 38
Hnh 4.5: Chia li. ------------------------------------------------------------------------ 39
Hnh 4.6: M hnh chia li -------------------------------------------------------------- 39
Hnh 4.7: To tm chn.------------------------------------------------------------------- 39
Hnh 4.8: Thng s dp ------------------------------------------------------------------- 40
Hnh 4.9: Thng s gn 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 th thc t. -------------------------------------------------- 42
Hnh 4.13: Kt qu FLD1. ---------------------------------------------------------------- 43
Hnh 4.14: Kt qu FLD 2 ---------------------------------------------------------------- 43
Hnh 4.15: M hnh sau khi dp. -------------------------------------------------------- 44
Hnh 4.16: Cht lng sn phm. ------------------------------------------------------- 44
Hnh 4.17: S phn b dy. ---------------------------------------------------------- 44
Hnh 4.18: S phn b ng 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

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 b mt gia cng. -------------------------------------------------------- 51
Hnh 5.9: thit t ng chy dao ----------------------------------------------------- 51
Hnh 5.10: Thng s ----------------------------------------------------------------------- 51
Hnh 5.11: Thng s b mt gia cng -------------------------------------------------- 52
Hnh 5.12: Thng s phay th b mt. ------------------------------------------------- 52
Hnh 5.14: Thng s ct. ------------------------------------------------------------------ 53
Hnh 5.15: Thng s gap setting. -------------------------------------------------------- 53
Hnh 5.16: Kt qu phay th. ------------------------------------------------------------ 53
Hnh 5.17: Chn b mt gia cng. ------------------------------------------------------ 54
Hnh 5.18: Thng s ng chy dao. ------------------------------------------------- 54
Hnh 5.19: Thng s phay b mt. ------------------------------------------------------ 55
Hnh 5.20: Thng s phay tinh ---------------------------------------------------------- 55
Hnh 5.21: Thng s motion ------------------------------------------------------------- 56
Hnh 5.22: Kt qu phay tinh ------------------------------------------------------------ 56
Hnh 5.23: Xut file G- code ------------------------------------------------------------- 56
Hnh 5.24: Kt qu khun trn ----------------------------------------------------------- 58

CHNG 1
GII THIU
1. L do chn ti.
Trong nhng nm gn y khoa hc k thut khng ngng pht trin trn
th gii ni chung v Vit Nam ni ring. c bit l trong s c c kh
ha, t ng ha em li chnh xc trong gia cng v gim s cng nhn
em li nhun cao trong cng nghip sn xut ln v nh nh hin nay. Vi
nhng chnh sch ca nh nc ang c u t mnh m c v cng 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 th gii u t rt ln v vn
cng nh cc d n vi s m ca thng thong ca nh nc. C nhng cng
trnh mang tm quy m quc t cng nh quy m nh v va nhng vn c
mt s d n 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 K V THI CNG KHUN DP
THNG XE RA .

Hnh 1.1: u im ca m phng.

Trong qu trnh sn xut khun a phn s dng phng php th cng l

thit kt v ch to khun xong ri mi thc hin dp th tm ra nhng thng
s ti u nht cho khun sn phm t c tnh cao nht. ngy nay nh s pht
trin ca cng ngh thng tin ta c th rt ngn c qu trnh th nghim i
rt nhiu nh vo nhng phm mm chuyn dng cho tng ngnh khc nhau
nh:
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 php nghin cu.
Nghin cu th trng v nhu cu tiu dng xut tng, vi s gip
nhit tnh ca gio vin hng dn v nhng kin thc c c qua cc k hc
trng cng nh cc ti liu su tm.

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

3. Kh nng ng dng thc t.

Hin ti a s cc chi tit thng xe ra u phi nhp t cc trong khu vc
c bit l Trung Quc, cho nn chi tit sau khi thit k qua kim nh v ti
u ha s a cng ngh dp tm ra th trng gim chi ph sn xut, h gi
thnh sn phm v c kh nng cnh tranh cao ngoi th trng.
Tnh linh hot.
Tnh kh thi.
Tnh n gin.
Tnh kinh t.

CHNG 2
CNG NGH DP TM V L THUYT BIN DNG DO
CA KIM LOI
2.1 Tng quan v tm nh hng ca cng ngh n thc tin.
2.1.1 S pht trin ca chuyn nghnh gia cng p lc (GCAL).
Cng ngh gia cng p lc c t rt lu i, nhng mi n vi th k nay
mi c pht trin chnh l nh s pht trin ca l thuyt bin dng do v
gia cng p lc kim loi da trn c s c hc mi trng lin tc, c hc vt
rn bin dng l thuyt do, kim loi vt l, i s tuyn tnh. Ngy nay ang
c mt cuc cch mng v bin dng to hnh. Cc thnh tu ln ca c hc
vt rn bin dng, ton hc, k thut m phng to cho l thuyt v cng
ngh GCAL mt sc mnh mi. ta c th c cng ngh bin dng ti u, s
dng ht kh nng bin dng ca vt liu, tn dng ngun nng lng nht l
k thut m phng a nghnh GCAL gii quyt cng ngh to hnh khng
cn ch th, giai on tn ph tin ch to khun th nghim v chi ph
nguyn vt liu th nghim.
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 ngh chun b to phi
cho cong ngh c 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 v thnh c- l- ha, tit kim nguyn vt liu v cho
nng sut lao ng cao, t h gi thnh sn phm. l cong ngh duy 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, t chc kim loi thay i: ph b t chc c, to t chc
th, lm nh ht tinh th, to tectua, ph v v lm phn tn cc tp chtnh
lm tng tnh bn, dai va p, kh nng chu mi, chu va p, tng tui
th sn phm. sn phm ca cng ngh rt a dng, gia cng nghiu loi vt

liu. c th to ra trng thi siu do, gia cng bin dng ln hoc gia cng cc
vt liu kh bin dng.
Cng ngh gia cng kim loi bng p lc l thc o trnh pht trin
ca mt nn cng nghip quc gia.
Cc cng ngh gia cng p lc kinh in nh: cn- ko- p- nn- rn- dp,
chim 80 tng 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 s hng pht trin mi v phng pp cng ngh mi.
2.1.2 Pht trin l thuyt bin dng do.
ng dng cc thnh tu khoa hc k thut mi gii bi ton l thuyt gia
cng 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 t bin) kt hp s dng my tnh in t vo vic gii bi ton
bin dng do. T c th m 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 gi bi ton cng ngh
to hnh v khun, bo m tn dng ht kh nng thit b. Nh phng php
s ng dng trong bin dng to hnh gii quyt bi ton bin dng ln, a
nhiu yu t thc 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 s dng. kt hp cc yu t bin dng
tc ng bin i t chc bn trong vt liu vi x l nhit to ra vt liu
c t chc kim loi tng i c bn cao, cng ngh ny thnh cng ngh
sn xut hng lot ln, nh tit kim nhiu vt liu, nht l vt liu xy
dng. cng bng hng cng ngh tc 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 nh s tr gip ca cc phn mm c kh ch to my v cc phn mm

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

khun dp phc tp, c th nhanh 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 k ch to khun, gia cng th, sau dp th v kim tra cn
chnh sa khun v ch to li khun..ng dng phn mm thit k v m
phng, c kh nng kim tra nh gi chnh xc v hnh dng kch thc,
v bn, tin cy ca cng ngh v khun, thay cho vic sn sut th tn
km v mt nhiu thi gian.
Hin nay, nhiu my iu khin theo chng trnh s CNC ang c s
dng gia cng cc khun mu dng trong GCAL, nh thit b ny cng
vic gia cng cc b mt phc tp c x l nhanh chng, chnh xc. c
cc chng trnh lin kt sau khi x l xong, c th m ha, chuyn sang my
cnc gia cng, khng giai on lp trnh ring. V vy, lin kt khu thit k
v ch to khun lm mt.
Mt khc, ng dng h thng iu khin t ng, cc mch cng sut
cao, to ra cc khi mch iu khin cc my GCAL, ng thi c nhiu dy
chuyn sn xut t ng vi s iu 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 b thnh phn ti cc vng khc nhau ty theo iu
kin chu ti ca sn phm l vt liu composit mi. mt phng php gia
cng vt liu kh bin dng, cu to bng cc thnh phn (cu t c bit)
bng cng ngh p bn lng. cng ngh ny cn nung nng chy vt liu nn,
cn thnh phn tng bn, gia c hoc 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.
T cc vn nu trn, khoa hc v k thut GCAL ca th gii c rt
nhiu bin i, nhiu phng php tnh ton mi, cng ngh hin i xut

hin, gii quyt nhim v sn xut mt cch nhanh chng v hiu qu kinh
t cao. 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 ngh dp to hnh tm.
2.2.1 Khi nim.
Cng ngh dp to hnh tm kim loi l cng ngh to ra chi tit (cm chi
tit) c hnh dng v kch thc t kim loi tm, bng cch bin dng to hnh
phi kim loi nh cc dng c c 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 s bin dng do ca vt liu v hu ht cc trng hp u c s dch
chuyn v phn b la kim loi.

Hnh 2.1: s cng ngh dp tm.

2.2.3 Lnh vc ng dng.
Cng ngh ny c p dng rng ri t cng nghip quc phng, y t, ha
cht, xy dng, giao thng vn ti, c kh chnh xc, cho n nghnh dt may

cng nghip, ch bin thc phm, c kh tiu dng v c bit l trong cng
nghip in- in t, cng ngh thng 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 c v
thit b y t, n ni cm in, bp ga, l vi sng, tivi, t lnh, my git, tin
kim loi, ng h, trang sc ph n

Hnh 2.3: b khun 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 th to ra cc chi tit phc tp.
Nng cao c tnh ca kim loi.

H s s dng vt liu ca loi hnh cng ngh ny c th t n 8090, thm ch c th t 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 k s v cng nhn lnh ngh c trnh .
Tnh ton cng ngh phc tp.
2.2.5 Cc nguyn cng chnh.
To hnh:
Nn: khc phc hin tng khng bng phng cc b mt ca phi hoc
chi tit.
Dp ni: thay i hnh dng sn phm nhng khng thay i chiu dy vt
liu, c thc hin nh cc phn li v lm ca b phn khun.
Ln vnh: to thnh g theo ng bao ngoi hoc ng bao trong ca
chi tit.
Cun mp: to thnh g mp 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 b mt 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 h gia chy v ci.
Dp du: to vt lm trn b mt chi tit sau khun l.

10

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 s chi tit bng cch un g mp.
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.
Ph bng 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 ch to nhng chi tit khng i xng, ban
u ch to thnh phi i xng, sau ct chia.
Ct mp: ct b phn tha theo ng bao ngoi hoc phn mp khng
u ca chi tit cng hoc chi tit dp vut.
Ct tinh: ct b phn lng d rt nh theo 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 b mt chi tit.

Hnh 2.4: ng dng t l.

11

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 h Z, 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: h s
: tr lc 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.

12

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 ch nh 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 b chiu
sng nh pha n, v n..
Nhm cc chi tit c hnh dng hnh hp: thng nhin liu ca ng c;
cc loi v hp; cc chi tit bc trong cc chi tit ca thit b in t; thit
b o
Nhm cc chi tit c hnh dng phc tp c mt trc i xng hoc khng
c trc i xng: chi tit xe my; v t; 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 (ch gim ng knh m khng lm
thay i chiu dy phi, khe h gia chy v ci
Z > =S ).

13

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

knh phi gim mt lng nh, khe h Z<S.
Dp vut xui.
Dp vut ngc (chi tit c hnh dng phc tp).
Phn loi theo chn phi:
Dp vut khng c h thng chn phi.
Dp vut c s dng h thng chn phi.
S nguyn l dp vut:

Hnh 2.8: s nguyn l dp vut.

Hnh 2.9: thng s dp vut.

2.2.5.4 Cc nguyn cng khc.
Nguyn cng ln vnh: ln vnh l l mt nguyn cng nhm to ra vnh
g xung quanh l trn cc phi.
Nguyn cng tp ming: tp ming lm gim tit din ngang ca mt on
phi ng hoc chi tit hnh tr to thnh cc chi tit dng chai, l hoc
cc chi tit c tit din ngang thay i.
Nguyn cng mit: mit l phng php gia cng kim loi bng p lc
nhm to hnh chi tit rng t phi phng hoc phi rng da vo chuyn

14

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

b ti mt im trn phi quay.
2.3 L thuyt bin dng do kim loi.
2.3.1 C s vt l ca qu trnh bin dng.
2.3.1.1 Khi qut v qu trnh bin dng.
S dch chuyn tng i ca cc cht im, cc phn t ca vt rn di
tc dng ca ngoi lc, nhit hoc mt nguyn nhn no dn n s thay
i v hnh dng kch thc vt th, lin kt vt liu c bo ton, c gi
l bin dng do.
Tt c mi phng php gia cng p lc u da trn mt tin chung l
thc 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 s lin kt bn cht ca n.
Kh nng bin dng do c coi l mt c tnh quan trng ca bin dng
do.
Bin dng mu khi th ko:
lm sng t qu trnh bin dng theo di th nghim ko n gin. di
tc dng ca lc ko, mu ko lin tc b ko di cho n khi b t. trong th
nghim ko vi cc thit b ph hp ta c th o c lc ko v gin di
tng ng, t xc nh ng sut v bin dng theo cc mi quan h sau:

(2.3.1)

Vng bin dng n hi.

Vng bin dng n hi do (trong bin dng n hi rt nh so vi
bin dng do).
Vng ph hy.
Bin dng n hi v bin dng do trong tinh th:
Bin dng ca vt th l tng hp ca cc qu trnh bin dng trong tng ht
tinh th v trn bin gii ht.

15

Bin dng n hi:

Hnh 2.10: qu trnh bin dng n hi.

Bin dng do trong tinh th:
Trt:
Khi mu n tinh th b ko, xut hin cc bc trn b mt ca mu. iu
chng t s trt ln nhau gia cc phn t ca vt th. S trt xy ra
ch yu 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 t trn phng trt.

Hnh 2.11: qu trnh trt.

Mt trt v phng trt l nhng mt v phng c mt nguyn t
ln nht. iu ny cng d hiu bi l lc lin kt gia cc nguyn t trn
mt v phng l ln nht so vi nhng mt v phng khc.
S lng h trt cc ln th kh nng xy ra trt cng nhiu, c ngha
cng d bin dng do. bi vy kh nng bin dng do ca kim loi c th
c nh gi thng qua s lng h trt.
Trt ch xy ra di tc dng ca ng sut tip.
Phng mng khng thay i trc v sau khi trt.
Mc trt bng s nguyn ln khong cch gia cc nguyn t.
ng sut tip cn thit gy ra trt khng ln.
Song tinh (i tinh):

16

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

tinh th s x dch n mt v tr 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 ch xy ra di tc dng ca ng sut tip.
Khc vi trt l song tinh km theo s thay i ca phng mng ca phn
tinh th b x dch.
Khong x dch ca cc nguyn t t l thun vi khong cch gia chng ti
mt song tinh v c tr s nh hn 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 s gy ra trc v ch khi cc qu trnh trt
gp kh khn th song tinh mi to thnh.
V x dch cc nguyn t khi to thnh cc song tinh nh nn song tinh khng
dn mt mc bin dng do ng k trong tinh th (ch vi ).
Nu cng vi song tinh cn xy ra trt th trt ng vai tr chnh trong
bin dng do.
Trong cc tinh th lin kt ng ha tr nh: Bi, Sb ton b bin dng do
cho n lc ph hy ch yu do song tinh to nn, v th mc bin dng
do 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 h trt 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

17

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 th b ri lon do s xut hin cc
khuyt tt mng.
Cn c vo cc khuyt tt c th chia 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).

18

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 b mt sn phm li km hn nhiu so vi
bin dng ngui.

Hnh 2.16: biu quan h ng 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 t no ngn cn s sn 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, tr nn mm v do hn.
Lc v cng bin dng nh, ng sut bin dng ln.

19

D b oxi ha b mt dn n cht lng b mt 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 nh hn nhit kt tinh li.
Lc bin dng ln, ha bn vt liu, kh nng bin dng do thp.
V d vi 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 s hi phc, mt phn kt tinh li.
V d vi thp- c: bin dng nhit khong t 650-800C.
Bin dng nng:
Nung nng khi bin dng.
Nhit bin dng cao hn nhit kt tinh li.
Gim ng k lc bin dng, tnh do ca vt liu cao, ng sut chy gim
nhiu do kt tinh li.
V d vi thp- C: bin dng nng nhit 1150-1250C.

20

Hnh 2.18: nhit kt tinh ca mt s vt 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 s c bn ca vt liu, n ph thuc trc ht

vo bn thn vt liu (thnh phn, cu trc, t chc) v cc iu kin bin
dng (nhit , mc bin dng, tc bin dng, trng thi ng sut ).
ng cong chy:
ng cong biu din s ph 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.

21

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 sut

tip.
ng sut k thut v ng sut thc:

ng sut k thut:

22

ng sut thc:

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

Chuyn t h ta cc sang h ta 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:

23

Bin dng k thut (bin dng gin di):

Bin dng thc (bin dng logarit):

Ta c:
(

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

dng bin dng thc.
2.4.3 Quan h gia ng sut v bin dng.
Trong bin dng n hi, quan h gia ng sut v bin dng tun theo nh
lut hoocke:

24

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

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

un D trong bin dng do l ch E v G l hng s i 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= tg m
th lun lun thay i trong qu trnh bin dng.
2.4.4 iu kin do.
L iu kin kim loi qu t trng thi n hi sang trng thi do.
Xt trng hp thanh trn theo hng trc. thanh s b bin 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
th xut hin ng sut tng ng t ti ng sut chy ca vt liu th vt
liu th vt th ny b bin dng do.

25

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:
iu kin do ca Mises th:

; theo

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.

26

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

nguyn tc tr lc bin dng nh nht.
nh lut th tch khng i:
Th tch vt th khng thay i trc v sau khi bin dng. tng cc thnh
phn bin dng trn ng cho chnh bng 0.

Nguyn tc tr lc bin dng nh nht:

Nu cc cht im trong vt th bin dng s dch chuyn trn phng no c
tr lc nh nht.

27

CHNG 3
THIT K V TCH KHUN CHI TIT VI S H
TR CA PRO ENGINEER 5.0
3.1 Phn mm pro engineer 5.0.
Pro/E l phn mm ca hng Prametric Technology, Corp.
Pro engineer l nm trong t i CAD m dn thit k thng gi, trong
cn c Unigraphic (NX), CATIA, I- DEAS.
Pro engineer c s dng rng ri trn th gii v ng thi n cng c
s dng rt ph bin 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 k khun mu).
3.1.1 Thit k 2D.
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 (MidPoint), ng tm (Coincident), i xng (Symmectric), bng (Equal), song
song (Parallel).
Ngoi ra cn c cc lnh ph tr nh: ct (delete segment), to ch (text),
chn i tng t th vin (palette), i xng (mirror), sao chp (offset),
.
3.1.2 Thit k part 3D.
Chc nng mt s lnh thng dng nh: extrude, revolve, sweep, blend,
style.

28

3.2 Thit k chi tit thng xe ra.

Sau khi ci t phn mm ta bt u thit k chi tit.
B1: Khi to mt part- solid mi nh sau:

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.

29

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:

30

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 k xong, ta sao lu d liu li di dng *.prt to lng
khun v sao lu di dang *.IGS phn tch.

Hnh 3.7: bn v thit k.

3.3 Tch khun chi tit.

31

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

B1: Khi to mt manufacturing- mold cavity mi nh sau:

Hnh 3.8: to mi trng part.

B2: Ly khi c s tch khun, nh sau:

Hnh 3.9: chn i tng cn tch khun.

B3: To co rt cho khun:

Hnh 3.10: h s co rt.

B4: Thit k phi vi kch thc nh sau:

32

Hnh 3.11: thit k phi.

B5: To mt phn khun bng lnh Fill nh sau:

Hnh 3.12: to mt phn khun.

B6: To th tch phn khun bn lnh volume split:

Hnh 3.13: to th tch phn khun.

B7: To khun cavity v core nh sau:

Hnh 3.14: to i tng khun.

33

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.

34

CHNG 4
PHN TCH SN PHM VI S H TR CA ETA/
DYNAFORM 5.6
4.1 Phn mm eta/ DYNAFORM 5.6.
Dynaform do hng LSTC ca M sn xut.
Dyaform l mt phn rt mnh v m phng s qu trnh dp tm.
N ra i cng kh lu, nhng s dng 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.

35

Thanh file maneger:

Cho php ngi s dng cc hot ng nh: database,
data input/ output, submitting jobs and print setup.
c minh ha nh hnh bn.

Thanh part control:

C s d liu 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 part
trong 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 h tr to

ra mt khun nhanh v d hn.

Chc nng bao gm:
To ra mt phn khun ring bit.
To mp cnh khng nhn.
Sa v phn chia b mt.
Chia li v kim tra/ thay th.

36

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

T ng v h tr xy 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 s cho qu trnh dp, c th ci t nhanh
(quicksetup) hoc t ng ci t (autosetup).

Thanh definition:
Ngi dng c th thit t cng c dp, nh ngha vt
liu v thng s, to ra cht dn hng, to ra v chnh
sa ng c, nh ngha s lin kt gia cc b mt, gn
vut, xem chuyn ng ca cc thit b v 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 t thc hin qu trnh thit lp v m phng:

Hnh 4.2: trnh t gii thut dynaform.

Thng s vt liu [11].
Mc thp: SS400- JIS (tng ng mc thp CT3- TCVN).
Gii hn bn nh nht: 400 N/

37

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 s dp.

Lc dp vut:

[3, tr. 259]

(N)

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/

: h s ph thuc vo h s vut. (tra bng, chn = 0.37)

(N)
Lcchn: [3, tr. 259]
: lc p ring (tra bng, chn

= 2 N/

: din tch phn phi b chn (1200 x 200 = 240000

Cng bin dng:

[3, tr. 260]

( . .8)
: lc dp ( 651200 N/

(J)
)

: su vut (230 mm)

898

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

Z = 1,2s

38

s: chiu dy phi (1 mm)

Z: khe h (1,2)
Sau khi chi tit c thit k t phn mm proengineer lu di nh dng
IGS.
Bc 1:
File import: phi v chi tit ( y phi cng c thit k t proe). 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.

39

Bc 3:
Preprocess element: chia li phn t, chn Max size l 30.

Hnh 4.5: chia li.

Sau khi chia li ta c nh hnh sau:

Hnh 4.6: m hnh chia li.

Bc 4:
Part create: to ra tm chn t mt chy.

Hnh 4.7: to tm chn.

Bc 5:
Setup draw die: ci t cc thng s cho khun dp. Ta chn quicksetup/
draw, sau chn phi, tm chn, ci (mu xanh l mu chn cn mu
cha c thit lp).

40

Hnh 4.8: thng s dp.

Tip tc, ta thit t thng s gn vut:
Thit t thng s t phn mm.
T nhng cng thc nh trn ta chn cc thng s.

Hnh 4.9: thng s gn vut.

Xong.
Tip theo ta chn submit job phn mm gii thut cc thng s va thit
lp.
Bc 5:
Tool autosetup: thit lp cc thng s v vn tc dp, lc chn phi, khe h
Vn tc dp vut tra bng s tay : 2000 mm/s
Lc chn phi: 100 tn
Khe h: 1.2

41

4.3 Kt qu s 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 tng
thi im vt liu s bin dng cc mc khc nhau. Do trong qu trnh cn

42

c cc thng s ti u gim bt s ph hy ng k ca vt liu cng nh cc

phn nhn rch trong sn phm.

Hnh 4.12: qu trnh dp th thc t.

Cc sn phm sau khi dp th qua cc ln dp th sn phm vn cn nhn
cc phn hc nhng vi sn phm thng xe ra th nhn l c th chp nhn
c v n vn m bo cc thng s k thut a ra.
Ming thnh sn phm c nhiu lp nhn l qu trnh chn phi khi qu
trnh dp sn sinh ra mc ch ca n m bo cho qu trnh ko phi c in
y cc lng khun.
Kt qu th FLD ln 1:

43

Hnh 4.13: kt qu FLD1.

Sau khi m phng vn cn nhn ming phi (do tm chn phi thit k nh
hn mt phi), xut hin nhiu vt nt (mu ).
Ta tip thit lp li thng s ch thay i khe h, to thm tm chn ln hn
b mt phi na.
Kt qu th FLD ln 2:

Hnh 4.14: kt qu FLD 2

Kt qu m phng cho thy cht lng sn phm vn m bo, nhn ca
cc b mt gim so vi lc u.
Vy l qu trnh thit t cc thng s v qu trnh gii thut t phn mm
hon tt.

44

4.4 Kt qu m 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 k thut, khng c vng
rch t trong qu trnh dp.
Chiu dy:

Hnh 4.17: s phn b dy.

45

T m hnh chng ta cng thy c ch c 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: s phn b ng sut.

Kt qu t m hnh cho ta thy phn ng sut phn b tng i u phn
thn sn phm, gi tr ng sut tng i t yu cu.
Lc chn v lc dp:

Hnh 4.19: biu lc.

T biu 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

46

Qu trnh ko phi:

Hnh 4.20: qu trnh ko phi.

T m hnh ko phi ta thy c s dch chuyn ca cc phn t vt liu,
do cc thng s lc 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:
Nh s m phng s qu trnh bin dng m cng vic tnh ton chnh xc v
nhanh hn, i vi chi tit thng xe ra ny th chnh xc ch cn tng
i.

47

CHNG 5
GIA CNG KHUN CHI TIT VI S H TR CA
MASTERCAM X4
5.1 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 th thit lp gia cng cc vt liu kim loi v g trn cc chu
trnh nh: tin, phay, ct dy.
Mastercam cn c Add-In trong Solidwork to nn b i hon ho trong
thit k gia cng.
Mastercam tng i d tip cn v gi c hp l nn c ng o cc
Designer nghin cu.
5.1.1 Giao din chnh.

Hnh 5.1: giao din Mastercam.

48

Toolbar: thanh cng c.

Window graphic: vng hin th ha.
Support design & process: thanh h tr thit k v gia cng.
Setup parameter: vng thit lp cc thng s gia 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 l cho chi tit.
Sau y l mt s hnh nh v lp 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 l chi tit.
Pocket: phay hc chi tit.
Face: phay b mt chi tit.

49

Surface rough: phay th b mt chi tit.

Surface finish: phay tinh b mt chi tit.
Sau y l mt s hnh nh v lp 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 th iu 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, s rc 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
th cng khc.

50

Hnh 5.6: hnh lp trnh rounter.

5.2 Thit lp thng s cng ngh cho chi tit.
Sau khi lng khun c (cavity v core) c tch t proe v c lu
di dng IGS. By gi ta chuyn d liu import vo Mastercam.
5.2.1 Thit lp thng s cho
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 b mt, cc khi, cc on.
Sau khi ci t xong, chn ok.

Hnh 5.7: thit t phi.

5.2.2 Thit lp thng s phay th b mt cavity.
Toolpath surface rough- radial: chn cc b mt cn phay (mu vng).

51

Hnh 5.8: chn b mt 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 s v ng 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): 10
Retrac rate (tc hi dao): 20

Hnh 5.10: thng s

dao gia cng.

52

Surface parameter: (thng s v b mt)

Clearance (khong cch an ton): 50 (gi tr tuyt i)
Retract plane (mt phng an ton): 25 (gi tr tng i)
Feed rate (mt phng hi dao): 5 (gi tr tng i)
Chn ok.

Hnh 5.11: thng s b mt gia cng.

Rough radial parameter: (thng s phay 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 s phay th b mt.

Chn cutting depths:

53

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 s ct.

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 b gy.
Xong, ok.

Hnh 5.15: thng s gap setting.

Vy l xong vic thit t thng s phay th cavity.

Hnh 5.16: kt qu phay th.

54

5.2.3 Thit lp thng s phay tinh b mt cavity.

Toolpath surface finish paralle: (mu vng)

Hnh 5.17: chn b mt gia cng.

Toolpath parameter (thng s ng 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 s ng chy dao.

55

Surface parameter (thng s phay b mt):

Clearance (khong cch an ton): 50 (gi tr tuyt i)
Retract plane (mt phng an ton): 25 (gi tr tng i)
Feed rate (mt phng hi dao): 5 (gi tr tng i)
Chn ok.

Hnh 5.19:thng s phay b mt.

Finish paralle parameter (thng s phay tinh):
Total tolerance (tng lng d gia cng): 0.05
Cutting method (phng php ct): zigzag
Max.stepover (lng d y ln nht): 1.2
Machining angle (gc gia cng my): 0
Chn ok.

Hnh 5.20: thng s phay tinh.

56

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 b gy.
Chn ok.

Hnh 5.21: thng s motion.

Vy l xong qu trnh thit t thng s phay tinh b mt cavity.

Hnh 5.22: kt qu phay tinh.

5.2.4 Chng trnh G- code t cc 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.

57

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 th gia cng.
Thit lp thng s cho khun core.
Nhn chung cch thao tc m phng gia cng cho khun core ging vi cch
thao tc khun cavity, ch cn thit t li cc b mt gia cng, ch ct..

58

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

Hnh 5.24: kt qu khun trn.

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

59

Kt lun:
Qu trnh gia cng gia cng lng khun cavity v core hon tt, nhn
chung qu trnh gia cng vn cn nhng sai s nhng vn m bo c yu
cu k thut. Thng s mastercam tng i d hiu, l tin cho vic gia
cng cc chi tit t my CNC v l nn tng cho vic nghin cu cc phn
mm CAM khc.

60

KT LUN
Qu trnh ng dng cng ngh CAD/ CAE/ CAM c ng dng trong
thit k thng xe ra ch l mt qu trnh in hnh trong cng ngh gia cng
p lc ni chung, cng ngh dp tm ni ring. Qua qu trnh thit k m
phng, cc thng s c ti u mt cch nhanh chng v chnh xc. Tuy
ti hon thnh nhng vn cn mt s hn ch nh: thng s c tnh vt
liu phi nhp bng tay (th vin ch h tr cc 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 mi
Trong 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 n thy Th.S Nguyn Trung Kin B
mn gia cng p lc trng i Hc Bch Khoa H Ni, PGS. TS inh B
Tr Vin K Thut Qun S cng 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.

61

TI LIU THAM KHO

Ting vit
[1]. Cng ngh to hnh tm kim loi, Nguyn Mu ng.
[2]. C s l thuyt bin dng do kim loi, inh B Tr.
[3]. S tay thit k khun dp tm V.L Martrenco L.I Rudman, Bin Dch
V Trn Khc Nh, Nxb Hi Phng.
[4]. Gio trnh B mn gia cng p lc,Vin C Kh - i hc bch khoa H
Ni.
[5]. Thuyt minh ti nghin cu khoa hc 2011, i Hc K Thut Cng
Nghip Thi Nguyn.
[6]. ti c s dng mt s ti 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