GIA CNG TC CAO

1. Khi nim

Cho n nay trn th gii vn cha c mt nh ngha thng nht cho thut ng Gia
cng tc cao. Theo l thuyt c Salomons a ra vo nm 1931 th Gia cng tc
cao l gia cng vi vn tc ct nhanh hn vn tc ct khi gia cng truyn thng t 5 n 10
ln. V sau ny c thm mt s cch hiu khc v HSM nh gia cng vi tc trc chnh
cao (high spindle speed maching), gia cng vi bc tin ln (high feed machining), gia cng
nng sut cao (high productive machining). Tuy nhin, cc cch hiu ny ch mang tnh
tng i v mt tc (ca trc chnh v bn my) c xem l nhanh i vi loi vt liu
ny c th b xem l chm vi mt loi vt liu khc hoc c xem l nhanh ngy hm nay
s b xem l bnh thng nu tc ct c nng ln trong tng lai.

Ngy nay, khi nim thng c nhc n khi ni v HSM l : Gia cng tc cao
l phng php gia cng s dng tc trc chnh cao v bc tin ln vi lng dch dao
ngang nh v chiu su ct nh. Khi nim ny trc quan gip mi ngi c th phn bit
HSM vi cc phng php gia cng khc nhng n cha th hin ht bn cht ca HSM v
HSM l mt phng php gia cng c tng hp t nhiu yu t cng ngh nh my mc,
thit b, phn mm lp trnh v ch ct gt t hiu qu gia cng cao nht.

Hnh 1. Tc ct ca HSM so vi gia cng truyn thng

2. u im v ng dng ca HSM

So vi gia cng truyn thng, HSM c nhiu u im nh :

- Tc bc tch kim loi nhanh

- Lc ct thp

- Cht lng b mt gia cng tt

- Gia cng c vt liu c cng cao

- Gia cng c chi tit thnh rt mng

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- Khng cn ti ngui

Nh nhng u im ny m HSM c ng dng ngy cng ph bin trong hu ht cc

lnh vc c lin quan n gia cng c kh.

Khun mu

Hnh 2. Gim nguyn cng vi HSM khi gia cng khun mu

Trong ngnh khun mu (khun p nha, khun thi, khun dp..), HSM c th c
ng dng c trong gia cng th, gia cng bn tinh v gia cng tinh. i vi nhng tm khun
ln, khi lng gia cng nhiu, ngi ta dng HSM trong gia cng bn tinh lm ng u
lng vt liu cn li sau khi gia cng th bng nhng dao c ng knh ln v chiu su ct
dy sau gia cng tinh nng cao cht lng b mt. i vi cc chi tit nh, HSM c th
c dng cho ton b qu trnh gia cng. Vic s dng HSM c th thay i qui trnh cng
ngh gia cng t nng cao nng sut. C th, HSM c kh nng thay th phng php gia
cng bng tia la in EDM gia cng tinh nhng tm khun c nhit luyn (hnh 2B),
hoc thm ch hon thnh ton b qu trnh gia cng t th n tinh trn mt khi kim loi
c nhit luyn t trc (hnh 2C)

To mu nhanh

Vng i ca sn phm ngy cng ngn ng ngha vi vic nghin cu, th nghim sn
phm mi cng phi din ra ngy cng nhanh. Hin nay, cng vic ny c thc hin bng
hai phng php chnh l to mu nhanh (rapid prototyping) v phay HSM. So vi to mu
nhanh, HSM c u im l gia cng c nhiu loi vt liu vi bng b mt cao hnv
thi gian to mu nhanh hn nu t l vt liu phi ct b khng qu ln.

in t vin thng.

c im ca sn phm trong ngnh ny l sn lng thng rt ln do tc gia

cng chnh l yu t sng cn i vi nh sn xut. Ly Iphone 5 lm v d. V ca chic
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in thoi ny lm bng nhm v c gia cng bng phng php phay bao m c tnh
v bn. Vi kt cu thnh rt mng v sn lng ln n vi chc triu chic, nu khng s
dng HSM th cc cng ty gia cng c kh kh c th tr thnh nh cung cp ca Apple, hng
cng ngh lun t ra yu cu rt cao v cht lng v chi ph khi tm kim i tc.

Hng khng

Nh khi lng ring nh, nhm thng c dng ch to cc ph tng trong my

bay v tu v tr. V d, hng Boeing dng phi nhm dng khi gia cng cc chi tit ln.
Cch lm ny bo m c c tnh cho chi tit my v khng cn tn thi gian ch to g
v lp rp cc chi tit nh li vi nhau. Tuy nhin nu gia cng phng pho gia cng truyn
thng kh t c chnh xc cao nht l i vi nhng chi tit di hoc thnh mng v
nhm kh mm. Hn ch ny c khc phc nu phay bng phng php HSM v khi ,
lc ct nh s khng lm bin dng chi tit gia cng.

Y t

y cng l mt lnh vc ng dng HSM rt nhiu v cc dng c y khoa hoc cc chi

tit cy ghp vo c th ngi thng rt b v i hi chnh xc cao. gia cng c
chng phi dng dng c ct rt b v my HSM c s vng quay trc chnh rt cao.

3. My CNC

My CNC l yu t thng c ngh n u tin khi bn v cng ngh HSM. Hin

nay, mc d trn th trng c mt s loi u phay cao tc m rng kh nng cng ngh
cho my CNC nhng nhng my CNC c gn u phay cao tc vn khng c xem l
my phay HSM bi my phay HSM ng ngha phi p ng c nhng yu cu c bn sau
y :

- Trc chnh c cng sut ln v s vng quay cao : > 22 kw & 40.000 v/ph

- Tc bn my cao : 40-90 m/s

- Gia tc chuyn ng ln : > 1g

- Tc x l d liu nhanh : 50-2000 block/s

- Tc truyn ti d liu nhanh : 250 kbit/s

- Dung lng lu tr ln : > 50 MB

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- C kh nng ni suy ng NURBS

- cng vng, ng tm v kh nng n nh nhit ca trc chnh cao

- C ty chn lm mt xuyn qua trc chnh

- C kh nng c trc cu lnh trong chng trnh gia cng

4. Dng c ct

Theo thng k ca hng dng c ct Sandvik, c n 80% 90% khi lng gia cng
HSM c tin hnh bng dao phay ngn hoc dao phay cu ng knh t 1mm n 20mm.
Hai loi dng c ct ny cng dng nguyn khi hoc ghp mnh (insert) nhng c tnh
hnh hc v vt liu lm ra chng c s khc bit ph hp vi cng ngh phay HSM.

Bng 1

V hnh hc, dng c ct HSM thng c thit k gia cng vi chiu su ct nh

(hnh 5A). Hnh dng v s lng li ct c th c la chn ty theo iu kin gia cng
(ct vt liu no, th hay tinh, phay phng hay hay phay rnh ) nhng quan trng l kch
thc cc li ct phi chnh xc bo m tnh cn bng, hn ch rung ng trong qu
trnh ct. Mt s loi cn c thit k l thng thi kh hoc dung dch lm ngui.

V vt liu, hai tnh cht c bn ca vt liu dng lm dng c ct l bn v cng

nhit cao. Thp gi khng tha mn c hai yu cu ny nn hu nh khng cn c
s dng trong gia cng HSM, thay vo l nhng loi vt liu carbide, gm (ceramic), gm
kim loi (cermet) v c bit l vt liu siu cng nh CBN (cubic boron nitride), PCD
(polycrystalline diamond). c im ca nhng loi vt liu ny l cng cng cao th cng
gin chnh v vy, cng ngh ph b mt c s dng rt rng ri trong ch to dng c ct
cho HSM. S kt hp gia vt liu nn v lp ph cho ra i rt nhiu loi dng c ct vi
nhng c tnh ring p ng ti a yu cu ct gt. Cc hp cht thng c dng lm lp
ph l TiC (chng mi mn), TiN (chng dnh li ct), TiAlN (chu nhit cao, cch nhit

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tt) Hai phng php ph c s dng l lng ng vt cht bay hi (Physical Vapor
Deposition PVD) vi chiu dy lp ph 2 5 m v lng ng ha hc (Chemical Vapor
Deposition CVD) vi chiu dy lp ph 5 10 m.

Nhn chung, gi ca dng c ct dnh cho HSM kh cao, tuy nhin nu so snh v kh
nng ct gt v bn, n rt ng u t khai thc trit nhng u im ca HSM.

5. u g dng c ct

u g dng c ct c nhim v gi cht dng c ct v truyn momen xon cho n

trong qu trnh ct gt. Yu t quan trng nht nh hng n iu kin lm vic ca u g
l s cn bng v n cng quan trng hn trong cng ngh HSM v khi quay tc cao
(trn 8000 rpm), s rung ng s nh hng xu n cht lng b mt gia cng v gy hi
cho trc chnh ca my.

Hin nay ph bin hai loi u g l u g cn (CAT, SK, BT) v u g HSK trong loi
HSK E/F Series c dng nhiu trong cc my HSM v nhng u im sau :

- Kch thc nh gn, trng lng nh

- Tip xc vi trc chnh theo c b mt cn v mt vai nn cng vng hn loi CAT &
BT ch tip xc bng mt cn

- C kt cu rng m ly trc chnh nn lc ly tm sinh ra trong lc trc chnh quay s

cng gi cht trc chnh trong thn ca n v hn ch tc ng xu n trc chnh trong
trng hp dng c ct b gy.

6. Ch ct

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 Ngoi tc cao v bc tin ln, im khc bit r nt gia HSM v cc kiu gia
cng khc l HSM c lng n dao ngang v chiu su ct rt b gim lc ct v va p.
Ch ct da trn thc nghim vi mt s loi vt liu v kiu gia cng c cho trong
bng 2 v bng 3

Vt liu gia cng v vt liu lm dng c ct khng ngng c nghin cu v ng

dng. iu ny dn n vic rt kh xc nh c iu kin ct ti u trong nhng trng
hp gia cng c th. V vy, trc khi gia cng HSM, nhng ngi lm cng ngh ngoi vic
tham kho ch ct do nh ch to dng c ct a ra cn phi tin hnh ct th tm ra
ch ct ph hp nht vi yu cu gia cng iu kin hin c.

Mt im khc bit na so vi gia cng truyn thng l gia cng HSM thng khng
cn ti ngui. Trong gia cng truyn thng, tc ct chm nn c thi gian nhit
truyn t phoi vo phi, lm tng cng ca phi dn n vic cn lc ct ln hn tch
phoi. Nhit lng ln hn li c truyn vo phi v qu trnh ny c tip din v phi dng
dung dch ti ngui h nhit v y phoi ra khi vng ct. Tuy nhin, trong gia cng
HSM, phn ln nhit s c truyn vo phoi do , ch cn dng kh nn thi phoi ra khi
vng ct trnh hin tng phoi bm trn dng c ct v b ct li mt ln na.

7. Chin lc chy dao

Chin lc chy dao rt quan trng khi lp trnh gia cng HSM v n nh hng trc
tip n hiu sut, cht lng gia cng cng nh bn ca my CNC v tui th dng c ct.
Mi phn mm lp trnh gia cng CAM u c cc chin lc chy dao ring ph hp vi
tng trng hp gia cng c th. Chng c th khc nhau v tn gi, phng thc lp trnh
nhng nhn chung u ging nhau mt s ng chy dao c bn nh sau :

ng vo dao tip tuyn v xon (helical)

Tc chuyn ng khi phay HSM rt cao nn hn ch ti a vic va p, cc phn

mm CAM u c cc ty chn vo dao (lead-in) tip tuyn hoc xon vic tip xc gia
dng c ct v phi c trn mt hn.

ng chy dao cung trn.

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 Nhng gc nhn trn ng chy dao buc bn my phi chuyn hng t ngt. iu
ny gy hi cho dng c ct my CNC nn b phn tnh ton HSM trn my CNC s t ng
iu chnh gim tc khi n nhng vng c gc nhn ny. Tuy nhin, vic gim tc nh vy
va lm gim tc gia cng, va lm thay i lc ct c th lm gy dng c ct. Chnh v
vy, nhng phn mm lp trnh gia cng HSM lun c chc nng thay th nhng gc nhn
bng cc cung trn ng chy dao c lin tc trong khi tnh ton ng chy dao.

ng chy dao Trochoidal.

Chin lc trochoidal sinh ra ng chy dao l nhng ng trn lin tip nhau nhm
mc ch gi cho lc ct khng thay i trong qu trnh gia cng v bo m ly i ht phn
vt liu tha do chin lc chy dao cung trn li khi gp nhng gc qu hp.

7. Kt lun

HSM l mt phng php gia cng tin tin, c nhiu u im v nng sut v cht
lng. Tt nhin, t c nhng u im ni trn, HSM cng c nhng yu cu cn c
p ng v my mc, thit b, dng c ct v chin lc chy dao. Nhng yu t ny v
ang khng ngng c nghin cu nng cao hiu qu ca phng php gia cng tc
cao v tip tc lm cho khi nim tc cao ch mang tnh tng i.

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