Machining simulation design by software CATIA.

Ruzarovsky, Roman ; Matusova, Miriam ; Zvolensky, Radovan 等

1. INTRODUCTION

The market of today is more and more dynamical and the market development is managed by customers. It is not only needed mass manufacturing of products. Manufacturing company has to compete by broad range of products in present. Manufacturing programme variety expressively raises complexity of manufacturing design and control. The most important presumption of company good result is the request achievement to general production cycle reduction, from product design to its customer delivery with minimum production cost (Kuric, 2002). The other requirements that are asked to the manufacturing system and modern machine industry in present are oriented to:

* high productivity in short production load and production assortment flexibility,

* through time shortening of manufacturing,

* storage and reserve state reduction,

* production costs depression,

* increase of time and performance utilization of machines,

* increase of production and products quality.

2. SIMULATION

It is possible to characterize the term simulation as automatic software control of total blocks format (programme sentences lines). It is normally synchronous displayed the tool motion in simulation with text file control (or binary file of CAD/CAM systems). This motion characterizes the next motion of cutting tool by machining and it is showed the curved line of tool axis position change. It is removed the material through the cutting tool on tool machine which is displayed by most of graphic simulation systems. It is important to have the product documentation before and after tool machining in machining simulation creation. Software has to save the work-piece design and also semi-finished product in the memory. It is needed to define the semi-finished product in term of material type. It is qualified the physical, chemical and physic-chemical factors that could be problematic. It is possible to choose the machining method on the ground of the defined factors. (Hruskova, 2007).

It is determined the choice of clamping fixture by design of machining method. Eventually it could be:

* Universal clamping fixtures,

* Grouped clamping fixtures,

* Modular clamping fixtures,

* Special clamping fixtures.

2.1 Modular clamping fixtures

Elements of the modular clamping fixture system are the one of the right selected choice of clamping fixtures. The flexibility of modular clamping fixtures enables to adapt its position to the work-piece (Javorova, 2004). It is possible to create the database of modular fixture clamping elements by software Catia. The database elements are deigned as parametric. It is possible to change the dimension of clamping fixture in the work-piece clamping design process (Charbulova, 2007). The selection of the concrete modular clamping fixtures is conditioned by the type of production. The costs of the clamping fixture preparation could rise by the piece production.

3. THE SIMULATION DESIGN PROCESS

It is realized the machining simulation in one of the working environment in Catia software. The name of working environment module is "Surface Machining" (Start [??] Machining [??] Surface Machining). After the activation of relevant icon will be divided the tree into three parts:

* Process List--technology information,

* Product List--before designed model geometry information,

* Resources List--information about the machine and tools.

By design of simulation is it possible to select the machining such as roughing, milling, drilling e.g. It has to set the basic parameters of machining after the selection of concrete machining method. It is possible to select from more alternatives by hole drilling design (Fig. 1).

[FIGURE 1 OMITTED]

It is activated the table for drilling parameters definition after selection of concrete drilling method. It is going to be set in colour change of drill tool after the confirmation of basic data drilling as are machining surface, breakthrough of tool, drilling holes e.g. (Fig. 2).

[FIGURE 2 OMITTED]

After the click on fist mark on the top of table will be appeared the table (Fig. 3). In this table it is necessary to assign the distance of tool breaking into the work-piece (Approach clearance "A"), the cut depth before break (Max. depth of cut "Dc") and the cut breaking with drive up (Retract offset "Or"). The distance "A" will be choosing to stop the tool crash in the work-piece. The distance "Dc" will be choosing in 2 mm and the distance "Or" in 1 mm e.g. So the drill will be drilled into the depth in 2 mm and then will be coming back in 1 mm and the whole process will be repeated to requested depth. At the end it will be changed in depth mode "By tip (Dt)" to "By shoulder (Ds)".

[FIGURE 3 OMITTED]

It will be appeared the table with definition of select drill parameters after the click on third mark on the top of table (Fig.4). In this table will be defined the length of tool (the length of cutting edge, the total length e.g.). These lengths it is possible to adapt into tool which can be choosing for drilling process. In the next step it will be also choosing tools, drill, milling cutter e.g.

[FIGURE 4 OMITTED]

It is needed to define the clamping elements, the machine and the coordinate system following the definition of basic drilling parameters. The simulation will be realized in the defined coordinate system (Fig. 3).

[FIGURE 5 OMITTED]

Following is integrated the drilling operation with right defined drill into the sequential graph by the software CATIA V5. After the confirmation of the simulation running it came to the graphics simulation, Fig.6.

[FIGURE 6 OMITTED]

The advantage of the software CATIA is the possibility to choice of machining method. The advance of the milling simulation design is the same as by the drilling operation. It is possible to generate NC program thereafter. The disadvantage of the simulation design is the necessity to leave the exact course training of software by the operator.

4. CONCLUSION

The creation of the database of modular clamping fixture elements is able to provide for effective and flexible selection and the following application of the clamping fixtures by work solutions in the praxis. It is enabled to reduce costs to repeating creations of the same or the design similar clamping fixtures. On the model example it is possible to verify the designed methodology of clamping fixture creation right in the software. In this way it is increased the productivity by design and also it is removed the potential lost time. The lost time is caused by the incorrect assembly and formation of the fixture clamping.

5. REFERENCES

Charbulova, M.; Pechacek, F.(2007).Modular clamping systems. pp. 149-153, ISBN 86-83803-22-4, 7th International Conference RaDMI 2007, Trstenik

Hruskova, E. (2007). Selection efficiency of parametrical designed elements. pp .191-194, ISBN 973-9087-83-3, 8th International Conference Modern Technologies in Manufacturing 2007, Cluj-Napoca

Javorova, A. (2004). Modular fixtures analysis. pp. 215-218, ISBN80-227-2076-3, Akademicka Dubnica 2004

Kuric, I.; and kol. (2002). Pocitacom podporovane systemy v strojdrstve, EDIS, ISBN Zilina 351s.