毕业设计（论文）-数控设计凹模表面的CAM数控粗加工设计.doc

数控课程设计（凹模的cam软件数控粗加工）数控cam粗加工课程设计说明书设计题目：凹模表面的cam数控粗加工设计组 长: 李维财组 员: 蔡华君 郭世庆 何良军 蒋崇胜 李 伟 罗阳波 莫小华 倪艳祥 胡 鹏 方 雷 欧阳光仁学 生： 李 维 财指导老师：刘元2007年1月数控cam粗加工课程设计任务书设计题目：凹模表面的cam数控粗加工设计班 级： 04机电学 生： 李 维 财学 号: 25指导老师：刘 元2007年1月凹模cam软件数控粗加工当我们使用机床加工零件时，通常都需要对机床的各种动作进行控制，一是控制动作的先后次序，二是控制机床各运动部件的位移量。采用数控机床加工零件时，只需要将零件图形和工艺参数、加工步骤等以数字信息的形式，编成程序代码输入到机床控制系统中，再由其进行运算处理后转成驱动伺服机构的指令信号，从而控制机床各部件协调动作，自动地加工出零件来。当更换加工对象时，只需要重新编写程序代码，输入给机床，即可由数控装置代替人的大脑和双手的大部分功能，控制加工的全过程，制造出任意复杂的零件。数控加工的原理可用如下框图表示：由图可以看出，数控加工过程总体上可分为数控程序编制和机床加工控制两大部分。总的来说，数控加工有如下特点：（1）自动化程度高，具有很高的生产效率。除手工装夹毛坯外，其余全部加工过程都可由数控机床自动完成（若配合自动装卸手段，则是无人控制工厂的基本组成环节）。减轻了操作者的劳动强度，改善了劳动条件。省去了划线、多次装夹定位、检测等工序及其辅助操作，有效地提高了生产效率。（2）对加工对象的适应性强，改变加工对象时，除了更换刀具和解决毛坯装夹方式外，只需重新编程即可，不需要作其它任何复杂的调整，从而缩短了生产准备周期。（3）加工精度高，质量稳定。加工尺寸精度在0.0050.01mm之间，不受零件复杂程度的影响，由于大部分操作都由机器自动完成，因而消除了人为误差，提高了批量零件尺寸的一致性，同时精密控制的机床上还采用了位置检测装置，更加提高了数控加工的精度。（4）易于建立与计算机间的通信联络，容易实现群控。由于机床采用数字信息控制，易于与计算机辅助设计系统连接，形成cad/cam一体化系统，并且可以建立各机床间的联系，容易实现群控。对于加工肥皂盒注塑凹模这样精度较高，在一般普通机床上很难加工或加工效率较低时，选用数控机床进行加工是比较好的，既省时又高效，同时也提高了经济效益。根据实际工作情况以及数控机床学习的要求，我将运用数控编程软件mastercam，nc程序分析软件mcu以及数控仿真器（fanuc系统），全程仿真模拟再现凹模的数控加工。由上面的数控加工的原理图分析，可知进行数控仿真模拟加工的一般步骤：1、 零件图纸的工艺分析2、 相关数值的计算3、 程序清单4、 程序调试和检验，输入数控机床5、 调入程序，设定好刀具，毛坯，等机床参数6、 仿真模拟加工下面就按照上述的步骤来进行。1、零件图纸的工艺分析要加工的零件如下图：图中所展现的零件就是零件底座，该图为最终成型零件152.4152.444.45 mm3。查塑料模具手册查得，该模具材料为40号钢，淬火处理，精度为10级。毛坯形状为152.4152.444.45 mm3。模具得分型面以及凹模型腔内为要加工表面。由凹模型腔形状可知，采用普通机床很难加工，因此选用数控机床，由于是要进行面加工以及挖槽加工，所以采用数控铣床或加工中心。工艺过程分析：1、 凹模型腔内的加工。该型腔表面直接关系到成品的质量，因此要求较高，但在此设计部分只设计粗加工，所以在粗加工的同时，留有0.5mm的精加工余量。查手册。选f20mm的球鼻铣刀，型腔底部阶梯的深度为-7.74mm，相对毛坯表面的深度为-15.397mm。粗铣xy平面的进给量取3mm，z向进给量取0.5mm，走刀多次，切削方式采用等矩环切（由外向内环切）、螺旋下刀方式。切削进给速度0.5mm/r、主轴转速1200n/min。2 、相关数值的计算根据零件图纸和确定的加工路线，算出数控机床所需输入数据，如零件轮廓相邻几何元素的交点和切点，用直线或圆弧逼近零件轮廓时相邻几何元素的交点和切点等的计算。这一部分工作由软件mastercam以及其自带的post来自动生成。采用mastercam软件自动编程。现将部分关键操作详述如下 首先根据零件尺寸及材料要求创建坯料：40钢 ， 152.4152.444.45 mm3 使用边界盒创建坯料。 接着创建刀具路径。由前面的工艺分析可知，先铣模具的上表面，然后再挖槽。所以在刀具路径的子菜单中先选择面铣。接着选择面铣边界，接着弹出参数选择选项卡。选平面铣刀f12mm接着开始设计加工凹模的刀具加工路径。在刀具子菜单中选 曲面加工粗加工挖槽粗加工所有的曲面执行。就又会出现刀具参数选定对话框，在该对话框中和上面的平面铣一样设定相关的加工- 20 -最终生成的刀具路径为：3、程序清单将mastercam post出的nc代码导出：（由于程序太长，只节选关键部分）%o0000(program name - 4)(date=dd-mm-yy - 13-01-07 time=hh:mm - 15:25)n100g21n102g0g17g40g49g80g90( 20. bull endmill 4. 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