数控加工课程设计说明书范本

数控加工课程设计说明书一、分析零件图纸，确定总体加工方案（一）、图纸分析：该图是一复杂轴类零件，零件部分地方较为复杂，部分加工精度较高，采用数控车削加上钻削、滚齿、插齿综合完成。该零件由外圆柱面、孔、倒角、内齿轮，齿轮轴、槽、阶梯组成。其中零件最大外径为19mm,长度为104mm.选择毛坯尺寸为114x22mm的棒料。（二）、精度等级、表面粗糙度分析：考虑到左右两端齿轮齿面粗糙度1.6，滚齿机滚齿后要倒角磨齿；外圆表面粗糙度要求最高为0.8，尺寸精度也易于达到，所以外圆精车即可达到要求。同轴度及各圆跳度都要求要装夹次数减少。所以，外圆以两顶尖定位，一次装夹完成粗精加工。为满足同轴度要求，打孔时应夹外径为13.9的外圆。（三）、材料和热处理分析：零件材料为31CrMoV9是齿轮钢，预备热处理为调质，回火温度600630 。最终热处理为渗氮，HV900。 （四）、总体方案：先对毛坯预备热处理（调质处理）；用数控车床粗精车两端面打中心孔，再以两中心孔定位，粗车外圆轮廓，精车右端外圆轮廓，切槽。再以外径为13.9的槽定位，粗精车左端外圆，钻铰孔、镗孔割内槽；最后再滚齿，插齿；最终热处理，再上磨齿机进行磨齿；完成整个零件的加工。 二、确定加工工艺方案（一）装夹方式及量具选择：数控车床夹具使用三爪卡盘自动定心夹具及顶尖；Y3150E滚齿机使用专用夹具，插齿机使用专用夹具，磨齿机使用专用夹具。量具有游标卡尺，外径千分尺，百分表。 （二）加工顺序：1.备料，下料尺寸22106的棒料，预备热处理2.车，粗精车右端面，钻中心孔3. 粗车，夹左端外圆顶中心孔定位，粗车右端外圆各部，留单边余量0.24、精车，夹左端外圆顶中心孔定位，精车右端外圆各部至图纸所示。5、切1.1mm宽的槽6、用3.5mm切槽刀切3.5mm处，4.6mm处以及12mm处，加之外径为13.9的T型槽至图纸所示。7、掉头夹直径12处外圆,粗精车左端端面及外圆8、钻镗直径为9的孔9、镗直径为12.5的孔。10、割宽5mm的内槽。11、钻直径5和4的顶孔。12、铣键槽13、滚齿机滚右端齿14、插齿机插内齿轮。15、倒角，倒棱16、最终热处理17、磨齿机磨齿18、终结检验（三），切削用量选择（镗车削）数控车削加工中的切削用量包括：背吃刀量、主轴转速n或切削速度、进给速度或进给量f。这些参数均应在机床给定的允许范围内选取。车削用量的选择原则是粗车时，首先考虑选择尽可能打的背吃刀量，其次选择较大的进给量f，最后确定一个合适的切削速度v。增大背吃刀量可使走刀次数减少，增大进给量f有利于断屑。精车时，加工精度和表面粗糙度要求较高，加工余量不大且较均匀，因此选择精车的切削用量时，应着重考虑如何保证加工质量，并在此基础上提高加工效率。因此，精车时应选用较小的背吃刀量和进给量f，并选用性能高的刀具材料和合理的几何参数，以尽可能提高切削速度v.(1) 背吃刀量的确定在工艺系统刚度和机床功率允许的情况下，应尽可能选择较大的背吃刀量，以减少进给的次数。当零件精度要求较高时，则应考虑留出精车余量，其所留的精车余量比一般普通车削时所留余量小，常取0.10.5mm。（2）进给量的确定式中，f进给量，粗车时一般取为0.30.8mm/r,精车时常取0.10.3mm/r，切断时常取0.050.2mm/r。（3）主轴转速的确定 n（r/min）1.数控车削a.粗车端面 取 n= 50 m/min f = 0.3 mm/rb.精车端面 取 n = 80m/min f = 0.15 mm/rb.粗车外轮廓,留单面余量0.2mm 取 n = 50 m/min f= 0.3 mm/r ap = 2 mmc.精车外轮廓 取 n= 80 m/min f = 0.15 mm/r ap = 0.2 mmd.切槽取 n = 60m/min f = 0.1 mm/rf.预钻孔8mm及打中心孔 取n = 500 r/min f = 0.2 mm/rg.镗孔取 n =1500 r/min f = 0.2mm/r2.滚齿机滚齿Vc = 0.7 m/sf = 1.5 mm/r（四） 刀具明细表序号刀具名称刀具直径刀补值190端面车刀D01293偏头外圆车刀D0231.15mm割槽刀43.5mm割槽刀54mm割槽刀6高速钢钻头87镗刀8镗刀D0893mm的内切槽刀10滚刀D1011插齿刀D11三、数值换算1、公差对称化换算：直径公差带代号公差大小/mm上偏差下偏差对称化后尺寸12g70.018-0.006-0.02411.985100-0.19.9516h70.0180-0.01815.99115.50-0.315.3513.90-0.0313.88516.80-0.116.757.80.0507.82517h80.0180-0.01816.99116.40-0.0416.389H100.0580.05809.02911.50.3011.6530.50.3030.65601060.51.10.101.1590.0509.02511.50-0.111.451.10.101.152、相关节点坐标计算：如图所示：通过坐标标注，各节点坐标清清楚楚。3、刀位点坐标值的计算过程刀位点是指刀具的定位基准点。车刀的刀位点是刀尖或刀尖圆弧中心；钻头的刀位点是钻头顶点。各类数控机床的对刀方法是不完全一样的，这一内容将结合各类机床分别讨论。数控车床的刀位点是工件外形轮廓向外偏移一个刀具半径值四、数控的工艺卡片及加工程序 O0001车左端面打中心孔加工步骤加工内容刀具主轴转速（m/min或r/min）进给量备注1粗车端面，留精加工余量0.2T01: 90端面车刀500.32精车端面至图纸要求T01800.153打中心孔T02: 直径3.35中心钻5000.2 O0002车外轮廓加工步骤加工内容刀具主轴转速（m/min或r/min）进给量备注1粗车外圆轮廓，留精加工余量0.2T01：93偏头外圆车刀500.3G712精车外圆轮廓至图纸要求T01：93偏头外圆车刀800.15G703切1.1mm宽槽T02：1.1mm割槽刀（右刀尖）600.14切3.5mm宽槽及4.6mm滚花槽T03：3.5mm割槽刀（右刀尖）600.15切T型槽及其他槽T04：4mm割槽刀（右刀尖）600.1 O0003精车左端端面，外圆，钻镗孔加工步骤加工内容刀具主轴转速（m/min或r/min）进给量备注1粗车外圆轮廓，留精加工余量0.2T01：93偏头外圆车刀500.3G712精车外圆轮廓至图纸要求T01：93偏头外圆车刀800.15G703钻底孔T02：直径为8mm高速钢麻花钻5000.24镗孔T03：硬质合金内孔车刀5000.25镗直径为12.5mm的孔T04：硬质合金内孔车刀15000.26割内槽T05：硬质合金内切槽刀600.1程序代码如下：O0001N10 G54 F0.3 S800 M03 M07 T0101 ;工艺设定N20 G50 S2000 ；最高转速限制N30 G96 S50 ；恒线速度切削N40 G0 X24 Z0.2 ；快速定位接近工件N50 G1 X-2 ；粗切端面N60 G0 X24 Z1N80 G96 S80 ；精车恒线速度设定N90 Z0N100 G1 X-2 F0.15 ；精车端面N110 G0 X100 Z150 ；返回换刀点N120 T0202 ；换2号刀具N130 G97 S500 ；取消恒线速度，设定转速500r/min。N140 X0 Z5 N150 G1 Z-3.35 ； 钻中心孔N160 G0 Z5N170 X100 Z150N180 M30 ；程序结束O0002N10 G54 F0.3 S800 M03 M07 T0101 ;工艺设定 G50 S2000 ；最高转速限制 G96 S50 ；恒线速度切削 G0 X24 Z0.2 ；快速定位接近工件 G1 X-2 ；粗切端面 G0 X24 Z1 G96 S80 ；精车恒线速度设定 Z0 G1 X-2 F0.15 ；精车端面N40 G71 U2 R1 ；G71粗车轮廓循环N50 G71 P60 Q170 U0.4 W0.2 F0.3；粗车轮廓循环参数设定N60 G0 G42 X8 Z2 F0.15 ；循环开始N70 G1 Z0N80 X9.95 Z-0.58N90 Z-15.72N100 G02 X10.36 Z-16.94 R3N110 G01 X11.985 Z-19N120 Z-36.5N130 X15.35N140 X15.991 Z-36.64N150 W-7.825 N160 X19N170 Z-106 ；循环结束N180 G0 X100 Z150N190 G96 S80 ；恒线速度切削N200 G70 P60 Q170 ；G70循环精车外轮廓N210 G0 X100 Z150 ；返回换刀点N220 T0202 ；换1.1mm切槽刀N230 G96 S60 N240 G0 G40 X13 Z-27.5 F0.1；取消刀补，快速定位N250 G1 X11.45 N260 G0 X20N270 G0 X100 Z150 N280 T0303 ;换3.5mm切槽刀N290 G0 X17 Z-38.5 ;切3.5mm槽N300 G1 X-15.96N310 G0 X20N320 Z-31.9 ；切4.6mm槽N332 G1 X11.9N340 G0 X14 N345 Z-40.8N350 G1 X11.5 N355 Z-31.9 ；切4.6mm槽结束N360 G0 X20N370 G0 X100 Z150N380 T0404 ；换4mm切槽刀N390 G0 X20 Z-50.35N400 G1 X14.3 ；粗切直径为13.9的T型槽及宽12mm槽N410 G0 X20 Z-53.5N420 G1 X14.3N430 G0 X20 N435 Z-53.5N440 G1 X14.3N450 G0 X20N451 Z-57N452 G1 X14.3N453 G0 X20 N455 Z-60.6N460 G1 X14.3N470 G0 X20 N475 Z-69.5N480 G1 X17.2 ；T型槽粗切结束N490 G0 X20 N495 Z-72N500 G1 X17.2 ；粗切12mm槽N510 G0 X20 N515 Z-75N520 G1 X17.2N530 G0 X20N531 Z-75N532 G1 X17.2N534 G0 X20 N535 Z-77.5N540 G1 X17.2 ； 12mm槽粗车结束N550 G0 X20 Z-75N560 Z-45.5N570 G1 X19 ；精车T型槽N580 X14.32 Z-49.55N590 G02 X13.885 Z-50.35 R1.6N600 G01 Z-64.6N610 G2 X14.28 Z-65.35 R1.6N620 G1 X18.22 Z-69.06N630 G3 X17.68 Z-69.5 R0.15 ；精车T型槽结束N640 G1 X16.75 ; 精车12mm槽N645 Z-77.5N650 G0 X100 Z150N660 M30 ;程序结束O0003N10 G54 F0.3 S800 M03 M07 T0101 ;工艺设定N20 G50 S2000 ；最高转速限制N30 G96 S50 ；恒线速度切削N40 G71 U2 R1 N50 G71 P60 Q130 U0.4 W0.2 F0.3 ;G71粗车循环N60 G0 G42 X15.2 Z2 F0.15 ；循环开始N70 G1 Z0N80 X16.38 Z-1.39N90 Z-6N100 X16.991N110 Z-21.5N120 X18N130 Z-23 ；循环结束N140 G0 X19 Z2N150 G96 S80N160 G70 P60 Q130 ； G70精车循环N170 G0 X100 Z150 N180 T0202 ；换钻头N190 G0 G40 X0 Z25 S500 F0.2 ；钻孔开始,取消刀补N200 G1 Z-10N210 G0 Z2N220 G1 Z-20N230 G0 Z0N240 Z-18N250 G1 Z-35N260 G0 Z0 N270 Z-33N272 Z-50N274 G0 Z0N276 Z-48N280 G1 Z-62N290 P1N300 G0 Z2 ；钻孔结束N310 G0 X100 Z150N320 T0303 ；换铰刀N330 G0 X0 Z5N340 G1 Z-62 ；铰孔N350 P1N360 G0 Z2 N370 G0 X100 Z150 N380 T0404 ；换镗刀N390 S1500 F0.2N400 G0 G43 X13.5 Z-0.433 ；刀补N405 G1 X12.5 Z-0.433 ；镗孔N410 Z-13N420 X8N430 G0 Z2N440 X100 Z150N450 T0505 ；换内切槽刀N460 G0 G40 S60 X8 Z5 F0.1N470 Z-27.65N480 G1 X11.1 ；切内槽N490 G0 X8N500 W2 N510 G1 X11.1N520 G0 X8N530 Z-24.93N540 G1 X9N550 X11.65 Z-25.65N555 Z-27.65N560 X9 Z-28.37N570 G0 X8N580 Z5N590 G0 X100 Z150N600 M30 ;程序结束五、MASTERCAM仿真1、刀具轨迹图：2、加工后的轮廓图：3、加工后立体图：4、PRO/E制作的三维图：5、MASTERCAM导出的加工程序：2019整理的各行业企管，经济，房产，策划，方案等工作范文，希望你用得上，不足之处请指正%O0000G21(PROGRAM NAME - MYMASTER22 DATE=DD-MM-YY - 20-11-11 TIME=HH:MM - 16:31)(TOOL - 1 OFFSET - 1)(LFACE OD ROUGH RIGHT - 80 DEG. 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