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19THE IMPORTANCE OF AUTOMATION IN THE DESIGN OF SHAPED
SURFACES
Sh. N. Fayzimatov, A. M. Gafurov
Fergana Polytechnic institute
ABSTRACT
This article provides information about the methods of processing complex surface parts using automated design systems at domestic manufacturing enterprises.
Keywords: project, production, digital program management, software, design programs, G-codes, position, computer graphics, database.
The life cycle of an industrial product involves a number of stages. This includes the project, production preparation (PP), product sales, operation and disposal stages. Time is an important factor in the activities of any industrial enterprise. The duration of each stage of the product life cycle process has a radical impact on its cost-effectiveness.
The complex automation of the project is carried out by ALT (CAD), which covers the main stages of the life cycle process of industrial production. The components of the ALT (CAD) engineering industry include computing systems and CAE-SYSTEM (Computer Aided Engineering), CAD-SYSTEM (Computer Aided design) design systems, CAM-SYSTEM (Computer Aided Manufacturing) technological process design systems. The design phases of the CAE and ALT (CAD) systems belong to the production preparation phase of the CAM system. Coordination of CAD / CAM / SAE systems is done through the PDM (Product Data Management) project data management system. General information about automated project systems (ALT (CAD)) is described in many project works.
In addition, the main functions of CAM-systems in the processing of complex surface parts are:
1. Design of technological processes of processing;
2. Development of control programs for CNC machines and industrial robots;
3. Construction of the trajectory of the relative movement of the tool and the workpiece during machining;
4. Modeling of processing processes;
5. Creation of post-processors for certain types of CNC machines;
6. Calculation of processing time;
7. Formulation and design of technological project results in the form of a set of technological documentation.
The current level of PP automation in multi-purpose CNC machines can be provided by considering the capabilities of modern CAD / CAM systems.
General information about ALT (CAD) / CAM systems: The world leaders in CAD / CAM / CAE high-end systems are CATIA (Dassault SYSTEM), NX or Unigraphiss system (Siemens PLM Software or UGS), Pro / Engineer ( PTC). These systems provide automation of processing programs in many areas of engineering, including CNC-Manufacturing.
The greatest interest in this work is the precise programming, automation of CNC milling-drilling and drilling machines, as well as the possibility of systems to create additional documentation required for the complex technological preparation of CNC machine tools. Therefore, a review of CAM systems is provided based on the information we are interested in. In addition, special attention is paid to mid-level systems.
3D modeling and optimization of product features are performed in Catia, NX, Pro / Engineer software. They all consist of a series of modules that design, design, qualify, solve all the problems of the technologist. In general, the systems are designed for any milling equipment, machining, laser cutting equipment, high pressure water, etc. with any CNC machine.
The most widely used systems in ALT (CAD) systems in the local mechanical engineering plants such as JV LLC "UZSUNGWOO", JV LLC "UZ-HANWOO", LLC "Avtooyna" are: EdgeCAM systems (Pathtrace Ltd), SurfCAM Velos, SurzCAM .), FeatureCAM (DelCAM), Powermill (Delcam), GibbsCAM (Gibbs and Associates), SprutCAM (Sprut Technology Ins.), T-Flex (Top Systems), GeMMa-3D and others.
The EdgeCAM system is a set of software and maintenance procedures. These programs and routines allow you to get RDB codes in a form that is easy to mill, process.
Design and modeling of processing technology in EdgeCAM is carried out in a single graphical environment. the EdgeCAM system does not take into account their accuracy when processing complex surface parts, so the processing of complex surface parts must be programmed manually, which in turn is very time consuming and requires good knowledge of the
technologist in this area. In addition, the system cannot provide additional documentation for setting up the machine. The coding program allows users to
configure code generators using a simple template that decides the basic data structures and formats needed to manage CNC machines.
SurfCAM system-Automated design and preparation system for the production of parts of different levels of complexity based on the preparation of control programs for NURBS surface models and coordinated RDB machines, SURFCAM tools and materials include information on the recommended processing methods, various tool materials and determines the cutting speed and thrust speed for the machined parts.
1.2-fig. SurfCAM. Body parts processing program.
SURFCAM has a large set of ready-made post-processors (more than 300) for various types of CNC machines and systems, as well as the ability to develop new postprocessors based on the post-processor.
The hole processing module automates the hole processing process. Typically, a frequently used machining template is created once. Such a template may include, for example, a set of multi-hole processing operations. You can create any number of templates you need for frequently used processes and change the specific settings for processing a particular part. Points arranged in diameters with axial lines defining the depth of the holes can be set in the form of circles. The order of hole processing is set and controlled using various optimization methods. This allows you to create the shortest trajectories and provides minimal bench time. The correct positioning mode provides high accuracy, minimizing the feeding of each hole and a one-way approach.
However, like EdgeCAM, the SurfCAM system does not take into account their accuracy when processing holes. The purpose of the exact hole processing route is done manually by the technologist and stored as a template. The system cannot automatically create additional documents to configure the machine.
The FeatureCAM package complements the Power Solution complex and creates completely new possibilities for solving production problems.
FeatureCAM modules allow programming of 2.5-5 coordinate processing. FeatureCAM has three most important technologies: it is a database-based technology (which allows processing data to be collected), a technology that is based on processing elements (which allows easier and faster programming), and this when importing from
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1.3-fig. FeatureCAM. Body parts processing program. other ALT (CAD) systems. the ability to recognize elements (allows for maximum data retrieval from an imported ALT (CAD) model).
Before choosing an automatic cutting tool, the technologist will need a sequence of possible operations to process the body part. It should be noted that it does not depend on the accuracy of the part to be processed, so the technologist must control the route and, if there are important parts of the part, create it manually from the list of recommended operations. This, of course, complicates the programming process of processing precise details. In addition to the above systems, FeatureCAM does not allow you to create additional documentation to configure the desktop.
Conclusions:
1. Processing of parts with high requirements for size, shape and accuracy of placement is still one of the most pressing problems of modern engineering. Processing of such details on CNC milling, drilling and metal cutting machines is very suitable. The adaptive machining control system controls the cutting element guide, advanced auxiliary and cutting tools, automatic adjustment of the cutter directly on the machine.
2. Technological preparation of production is a serious and time-consuming task in the processing of parts on CNC machines. The main solution to this problem is to automate it using ALT (CAD) / CAM systems.
3. Existing CAM-systems do not take into account the accuracy of the detail in the programming of its processing. Many tasks, such as determining the optimal technology for processing complex surface parts and selecting the right cutting tools, are not automated. In this regard, technologists have to solve these tasks manually on the basis of various reference data, which increases the CNC time on CNC machines.
Thus, the study of the problem situation showed that the capabilities of CAM systems in the programming of detail processing are very limited. This is the PP time effect on CNC machines. Therefore, they are fully automated and need to be further developed in CAM systems.
Research goals and objectives: The aim of this work is to reduce the complexity and design time by increasing the level of automation of parts on CNC milling and drilling machines and expanding the functions of modern ALT (CAD) / CAM systems at the PP stage.
To achieve this goal, the following research tasks must be solved:
1. To study the reasons for the long duration of technological preparation for the production of detail products on CNC machines.
2. Development of a mathematical model of complex systems that allows to create optimal processing technology in automated mode, select cutting tools and prepare data for production in the CAM system.
3. Development of an automated algorithm in the ALT (CAD) system of technological documentation required for setting up the machine.
4. Implement these ideas in the form of software for technological design of part processing processes, and then use them as part of ALT (CAD) / CAM systems.
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