数控加工工艺及编写程序说明书.doc

目录1 数控车削加工工艺.11.1、零件图纸分析11.2、确定装夹方案11.3、确定加工顺序及进给路线31.4、选择刀具及机床41.5、选取切削用量41.6、编写程序52 数控铣削加工工艺.72.1 零件图样工艺分析.72.1.1 数控铣削加工内容的选择. 72.1.2 零件结构工艺分析.72.1.3 零件坯料工艺性分析.82.2、拟定加工工艺方案8 2.2.1 确定生产类型.8 2.2.2 拟定工艺路线.82.2.3 设计数控铣削加工工艺.8 2.3 编写程序.93 设计总结.174 参考文献.17数控车削加工工艺1.1、零件图纸分析如图所示，该零件图为数控车削的轴类零件，该零件需加工内容有车端面、外圆、倒角、圆弧、螺纹、槽、退刀槽，其中多个直径有较严的尺寸精度和表面粗糙度等要求；该零件直径变化不大，尺寸标注完整，轮廓描述清楚；零件材料为45钢，无热处理要求和硬度要求；生产纲领为小批量。通过上述分析，采取以下几点工艺措施：对于该零件上右端起70mm有精度和公差要求的尺寸，采用一次装夹完成加工；分两次装夹加工；毛坯选48mm棒料。1.2、确定装夹方案 一次装夹：左端采用三爪自定心卡盘定心夹紧；图一二次装夹因为加工好的表面精度高，故在装夹时要用铜皮包裹然后装夹。图二1.3、确定加工顺序及进给路线 加工顺序按由粗到精、先近后远原则确定。所谓先精后粗是指按照粗车半精车精车的顺序进行，逐步提高加工精度。这里所说的远与近，是按加工部位相对于对刀点的距离大小而言的。在一般情况下，离对刀点的部位后加工，以便缩短刀具移动距离，减少空行程时间。对于车削而言，先近后远还有利于保持坯件或半成品的刚性，改善切削条件。（1）建立工件坐标系原点均定于工件右端面的中心。（2）拟定工艺路线1、下料48x100的棒料;2、光端面;3、粗车外轮廓，如图一所示，留精加工余量1mm;4、精车外轮廓，至图纸指定尺寸;5、切两个槽10x7.5mm;6、掉头装夹，如图二所示；7、光端面；8、粗车外轮廓，留精加工余量为1mm；9、精车外轮廓，至图纸要求尺寸；10、车倒角2x45；11、切退刀槽6x2；12、车螺纹。(3)走刀路线一次装夹：光端面车倒角车外圆切槽二次装夹：光端面车倒角车外圆切槽车螺纹1.4、选择刀具及机床 外圆、倒角、顺圆弧选用高速钢主偏角为90，负偏角为35的外圆车刀加工，装在第一刀架位(T0101)； 切槽选用宽度为6mm的槽刀，分别装在第二刀架位(T0202)； 车螺纹选用高速钢60外螺纹车刀，无刀尖半径，装在第三刀架位(T0303)。 经查资料，选用CK7150A型数车床，系统为FANUC 0i。1.5、选取切削用量 （1）背吃刀量 粗车循环时，其背吃刀量ap=2mm;半精车时ap=0.5mm；精车ap=0.25mm。 （2）主轴转速 粗车时，查表确定主轴转速为n=900r/min，精加工时主轴转速n=1500r/min,车螺纹的主轴转速，根据主轴转速公式计算，取主轴转速n=320r/min。 （3）进给速度 粗车时，选取进给速度F=0.3mm/r,精车时取进给速度F=0.1mm/r。根据相关公式计算得，粗车时，进给速度为120mm/min，精车时进给速度为90mm/min。车螺纹时，进给速度等于螺纹导程2mm/r。1.6、编写程序第一次装夹：O1701;18N10 G98S900M03T0101;N20 G00X50Z-1;N30 G01X0F120M07;N40 G01X50Z3F300;N50 G71U2R1;N60G71P70Q150U1W0F90S1500;N70 G01X25.98Z0F120;N80 X29.98Z-2;N90 Z-13;N100 G02X33.98Z-15R2;N110 G01X35.98;N120 X39.98Z-17;N130 Z-35;N140 X44.98;N150 Z-71;N160 G70P70Q150;N170 G00X100Z100;N180 T0202;N190 G00X50Z-40;N200 G01X29.05F120;N210 X50F300;N220 Z-44;N230 X29.05F120;N240 X50F300;N250 Z-55;N260 X29.05F120;N270 X50F300;N280 Z-59;N290 X29.05F120;N300 X50F300M09;N310 G00X100Z100;N320 M30;第二次装夹：O1702;N10 G98S900M03T0101;N20 G00X50Z-1;N30 G01X0F120M07;N40 G01X50Z4F300;N50 G701U2R1;N60 G71P70Q90U1W0F90S1500;N70 G01X26Z0;N80 X30Z-2;N90 Z-28;N100 G70P70Q90;N110 G00X100Z100;N120 T0202;N130 G00X50Z-22;N140 G01X30F120;N150 X50F300;N160 G00X100Z100;N170 T0303;N180 G00X32Z4;N190 G92X29Z-24F2;N200 X28.4;N210 X27.9;N220 X27.8;N230 G00X100Z100M09;N240 M30;数控铣床加工工艺一、 零件图样工艺分析2.1.1、数控铣削加工内容的选择如图所示，该零件为一槽轮板，加工内容包括所有平面和由直线和圆弧组成的内外轮廓。2.1.2、零件结构工艺性分析该零件尺寸标注完整，清晰。经查表，两凹槽间的距离加工精度等级为IT8，凹槽的宽度加工精度为IT10；70 mm圆加工精度为IT12，宽度间加工精度等级为IT10；同时，槽还有对称度要求均为0.04mm，标注基准是对称轴线，此外，零件的表面粗糙度除需挖槽铣削的平面为6.3m外，个表面均为3.2m，故该零件的表面为重要加工面。2.1.3、零件毛坯的工艺性分析 根据图纸要求，选取85x85x25的板料为毛坯，材料为45钢，切削性能良好。二、制定机械加工工艺方案 2.2.1、确定生产类型 零件数量为1件，属于单件小批量生产。 2.2.2、拟定工艺路线 （1）确定工件的定位基准。以工件四个侧面为定位基准。 （2）选择加工方法。该零件的加工表面为平面、内外轮廓，加工表面的最高加工等级精度为IT8，表面粗糙度为3.2。采用加工方法为粗铣、半精铣、精铣。 （3）拟定工艺路线。 按85x85x25下料。 在普通铣床上铣削6个面，保证80x80x20。 去毛刺。 在数控铣床上铣凸台和直方槽。 去毛刺。 检验。 涂油入库。 2.2.3、设计数控铣削加工工艺 （1）选择加工设备。选用大连生产的DL715A型铣床，系统为FANUC 0i. （2）选择工艺装备。 该零件采用平口虎钳定位夹紧。 刀具选择如下： 20的硬质合金立铣刀：粗铣、半精铣、精铣6个基准面。 4的硬质合金立铣刀：粗铣、半精铣、精铣凸台和直方槽。 量具选择如下：分度头、量程为150mm，分度值为0.02mm的游标卡尺。 （3）确定工步和走刀路线 确定工步如下：粗铣、半精铣、精铣六个面；粗铣、半精铣、精铣凸台圆槽。 （4）确定切削用量 切削用量根据工件材料、刀具材料及图样要求选取。数控粗铣、精铣的各个工步所用铣刀直径相同，加工余量和表面粗糙度也相同，故可选择相同的切削用量。零件材料为45钢属一般材料，切削加工性好。查表得粗铣时主轴转速取n=800r/min，进给速度F=120mm/min；精铣时主轴转速n=1500r/min，进给速度F=180mm/min。三、编程N100 G0 G17 G40 G49 G80 G90N102 G91G28 Z0.N104 S1500 M3N106 G0 G90 G54 X1.4 Y-34.6N108 Z50.N110 Z10.N112 G1 Z-5. F180.N114 X1.2 Y-34. F500.N116 Y-25.6N118 X1.043 Y-24.4N120 X.317 Y-23.8N122 X-.317N124 X-.665 Y-24.N126 X-1.133 Y-24.6N128 X-1.2 Y-33.N130 X-1.4 Y-34.6N132 X-4. Y-37.N134 X4.N136 Y-25.N138 G3 X-4. R4.N140 G1 Y-37.N142 G0 Z50.N144 X28.6 Y-29.6N146 Z10.N148 G1 Z-5. F180.N150 X28.372 Y-31. F500.N152 X28.106 Y-31.4N154 X27.059 Y-32.N156 X28.4 Y-31.8N158 X31.2 Y-33.4N160 Y-25.6N162 X31.6 Y-23.6N164 X31.104 Y-24.6N166 X29.619 Y-25.6N168 X26.947 Y-28.N170 X24.62 Y-31.N172 X23.141 Y-33.8N174 X22.237 Y-34.6N176 X31.692 Y-34.4N178 X34.4N180 X34.2 Y-33.6N182 Y-20.2N184 X34.6 Y-19.N186 X33.74 Y-19.8N188 X30.784 Y-21.2N190 X27.22 Y-23.6N192 X24.29 Y-26.4N194 X21.776 Y-29.8N196 X19.893 Y-33.6N198 X19.084 Y-34.4N200 X16.692 Y-34.161N202 X15.548 Y-34.674N204 G2 X8.66 Y-37. R38.N206 G1 X37.N208 Y-8.66N210 G2 X34.674 Y-15.548 R38.N212 G1 X34.161 Y-16.692N214 X32.985 Y-17.131N216 G3 X17.131 Y-32.985 R26.999N218 G1 X16.692 Y-34.161N220 G0 Z50.N222 X27.443 Y-1.4N224 Z10.N226 G1 Z-5. F180.N228 X27.433 Y-1.6 F500.N230 X31.576N232 X34.4 Y-1.4N234 X34.2 Y-.2N236 X34.4 Y1.4N238 X24.683 Y1.2N240 X24.335 Y1.N242 X23.8 Y.2N244 X23.957 Y-.6N246 X24.683 Y-1.2N248 X25. Y-4.N250 X37.N252 Y4.N254 X25.N256 G3 Y-4. R4.N258 G0 Z50.N260 X28.859 Y29.46N262 Z10.N264 G1 Z-5. F180.N266 X31.2 Y24.66 F500.N268 Y30.06N270 X31.4 Y31.66N272 X23.627 Y31.86N274 X24.378 Y31.46N276 X25.422 Y29.86N278 X27.877 Y27.06N280 X31.199 Y24.46N282 X31.6 Y23.66N284 X34.6 Y19.06N286 X34.2 Y19.86N288 Y32.86N290 X34.4 Y34.46N292 X19.051N294 X19.792 Y33.86N296 X21.058 Y31.06N298 X23.409 Y27.46N300 X26.208 Y24.46N302 X29.665 Y21.86N304 X33.589 Y19.86N306 X34.444 Y19.06N308 X34.161 Y16.692N310 X34.674 Y15.548N312 G2 X37. Y8.66 R38.N314 G1 Y37.N316 X8.66N318 G2 X15.548 Y34.674 R38.N320 G1 X16.692 Y34.161N322 X17.131 Y32.985N324 G3 X32.985 Y17.131 R26.999N326 G1 X34.161 Y16.692N328 G0 Z50.N330 X.317 Y23.8N332 Z10.N334 G1 Z-5. F180.N336 X.665 Y24. F500.N338 X1.133 Y24.6N340 X1.2 Y32.8N342 X1.4 Y34.4N344 X-1.4N346 X-1.2 Y33.8N348 Y25.6N350 X-1.043 Y24.4N352 X-.317 Y23.8N354 X-4. Y25.N356 G3 X4. R4.N358 G1 Y37.N360 X-4.N362 Y25.N364 G0 Z50.N366 X-28.88 Y29.26N368 Z10.N370 G1 Z-5. F180.N372 X-31.024 Y24.66 F500.N374 X-29.809 Y25.46N376 X-27.083 Y27.86N378 X-24.585 Y31.06N380 X-23.587 Y31.66N382 X-31.4N384 X-31.2 Y31.06N386 Y24.86N388 X-31.6 Y23.66N390 X-34.1 Y19.66N392 X-31.039 Y21.06N394 X-27.395 Y23.46N396 X-24.413 Y26.26N398 X-21.739 Y29.86N400 X-19.869 Y33.66N402 X-19.051 Y34.46N404 X-34.4N406 X-34.2 Y33.66N408 Y20.26N410 X-34.6 Y19.06N412 X-34.161 Y16.692N414 X-32.985 Y17.131N416 G3 X-17.131 Y32.985 R26.999N418 G1 X-16.692 Y34.161N420 X-15.548 Y34.674N422 G2 X-8.66 Y37. R38.N424 G1 X-37.N426 Y8.66N428 G2 X-34.674 Y15.548 R38.N430 G1 X-34.161 Y16.692N432 G0 Z50.N434 X-28.308 Y-1.4N436 Z10.N438 G1 Z-5. F180.N440 X-31.692 Y-1.6 F500.N442 X-28.233N444 X-25.6 Y-1.4N446 X-24.335 Y-1.N448 X-23.8 Y-.2N450 X-23.957 Y.6N452 X-24.683 Y1.2N454 X-34.4 Y1.4N456 X-34.2 Y0.N458 X-34.4 Y-1.6N460 X-37. Y-4.N462 X-25.N464 G3 Y4. R4.N466 G1 X-37.N468 Y-4.N470 G0 Z50.N472 X-27.752 Y-31.8N474 Z10.N476 G1 Z-5. F180.N478 X-28.052 Y-31.4 F500.N480 X-28.624 Y-29.4N482 X-28.449 Y-32.N484 X-26.999 Y-32.2N486 X-23.029 Y-34.N488 X-23.48 Y-33.N490 X-25.467 Y-29.8N492 X-27.94 Y-27.N494 X-30.489 Y-25.N496 X-31.6 Y-23.8N498 X-31.2 Y-24.6N500 X-31.255 Y-33.6N502 X-31.692 Y-34.6N504 X-22.139N506 X-18.962N508 X-19.739 Y-34.N510 X-21.09 Y-31.N512 X-23.456 Y-27.4N514 X-26.275 Y-24.4N516 X-29.762 Y-21.8N518 X-33.74 Y-19.8N520 X-34.6 Y-19.N522 X-34.2 Y-20.N524 Y-33.N526 X-34.4 Y-34.6N528 X-37. Y-37.N530 X-8.66N532 G2 X-15.548 Y-34.674 R38.N534 G1 X-16.692 Y-34.161N536 X-17.131 Y-32.985N538 G3 X-32.985 Y-17.131 R26.999N540 G1 X-34.161 Y-16.692N542 X-34.674 Y-15.548N544 G2 X-37. Y-8.66 R38.N546 G1 Y-37.N548 G0 Z50.N550 X-38. Y-38.N552 Z10.N554 G1 Z-5. F180.N556 X38. F500.N558 Y38.N560 X-38.N562 Y-38.N564 G0 Z50.N566 X-5. Y-25.N568 Z10.N570 G1 Z-5. F180.N572 Y-36.742 F500.N574 X-7.4 Y-36.252N576 G2 X-15.138 Y-33.761 R37.N578 G1 X-15.902 Y-33.419N580 X-16.194 Y-32.636N582 G3 X-32.636 Y-16.194 R27.999N584 G1 X-33.419 Y-15.902N586 X-33.761 Y-15.138N588 G2 X-36.252 Y-7.4 R37.N590 G1 X-36.742 Y-5.N592 X-25.N594 G3 Y5. R5.N596 G1 X-36.742N598 X-36.252 Y7.4N600 G2 X-33.761 Y15.138 R37.N602 G1 X-33.419 Y15.902N604 X-32.636 Y16.194N606 G3 X-16.194 Y32.636 R27.999N608 G1 X-15.902 Y33.419N610 X-15.138 Y33.761N612 G2 X-7.4 Y36.252 R37.N614 G1 X-5. Y36.742N616 Y25.N618 G3 X5. R5.N620 G1 Y36.742N622 X7.4 Y36.252N624 G2 X15.138 Y33.761 R37.N626 G1 X15.902 Y33.419N628 X16.194 Y32.636N630 G3 X32.636 Y16.194 R27.999N632 G1 X33.419 Y15.902N634 X33.761 Y15.138N636 G2 X36.252 Y7.4 R37.N638 G1 X36.742 Y5.N640 X25.N642 G3 Y-5. R5.N644 G1 X36.742N646 X36.252 Y-7.4N648 G2 X33.761 Y-15.138 R37.N650 G1 X33.419 Y-15.902N652 X32.636 Y-16.194N654 G3 X16.194 Y-32.636 R27.999N656 G1 X15.902 Y-33.419N658 X15.138 Y-33.761N660 G2 X7.4 Y-36.252 R37.N662 G1 X5. Y-36.742N664 Y-25.N666 G3 X-5. R5.N668 G0 Z50.N670 X-3.898 Y-5.564N672 Z10.N674 G1 Z-5. F180.N676 X4.71 Y3.036 F500.N678 X5.445 Y3.436N680 X5.46 Y3.636N682 X4.696 Y4.036N684 X4.31 Y4.436N686 X4.003 Y5.636N688 X-4.8 Y-3.164N690 X-5.477 Y-3.564N692 X-4.748 Y-3.964N694 X-4.176 Y-4.564N696 X-3.898 Y-5.5