毕业设计（论文）-模具数控加工.doc

镇江高等职业技术学校毕 业 设 计 (论 文) 模具数控加工系 名： 机电工程系 专业班级： 0621班 学生姓名： 王彬 学 号： 062802154 指导教师姓名： 沈宝国 指导教师职称： 助教 2011 年 5 月目录摘要1引 言1第一章 模具零件数控技术的工艺分析11.1被加工零件图样的分析11.3确定加工顺序及走刀路线21.4刀具的选择21.5切削用量的选择31.6填写数控加工工序卡3第二章运用MASTERCSM编制加工程序5第三章 加工实际操作233.1设备及成品展示23结 论26致 谢27参考文献28模具数控加工专业班级： 0621班 学生姓名：王彬指导教师姓名：沈宝国 指导教师职称：助教摘要数控技术是数控机床研究的核心。是制造业实现自动化、网络化、柔性化、集成化的基础。本文对六方椭圆板零件进行工艺流程分析；正确选用数控加工机床；加工余量、切削用量、机床夹具以及刀具。完成课设计可以增加一定的实践经验，学会独立分析问题，解决问题，学会编写毕业设计论文及查找参考资料、文献的方法，并通过该课题的完成能熟练地掌握CAD二维制图、 CAM等软件的使用方法，最终了解并掌握各种零件的数控加工工艺流程的制定以及程序的编制过程，对在学校所学的数控专业内容有更为全面的掌握。本设计主要是对一个模具零件先进行工艺分析，在运用运用Mastercam软件自动编程的工艺过程，以及使用加工中心进行实操加工过程【关键词】：工艺分析、刀具、 数控编程1引 言近几年来，机械加工业大量采用数控机床取代传统的普通机床进行机械加工，普通机械逐渐被数控机械所代替。数控机床综合了微电子、计算机、信息处理、自动检测、自动控制、电机与拖动，电子和电力、精密测量、气液压及现代机械制造技术等多种先进技术的机电一体化产品，是数控机床的心脏。随着计算机技术的日新月异的发展，基于微机的开放式数控是数控技术发展的必然趋势，在传统数控技术方面，我国处于相对落后的状态，开放式数控为我国数控产业的发展提供了良好的契机。加强和重点扶持数控技术的研究和发展，我国的数控产业才有可能发展壮大，才有可能够在未来处于不败之地。4第一章 模具零件数控技术的工艺分析工艺分析主要包括以下内容：分析被加工零件图样；确定加工方案；制定数控加工工艺路线；工序的划分；加工顺序的安排；设计数控加工工序；刀具选择；切削用量的确定等。图1 加工零件图图1所示为数控铣削加工零件。该零件长度为120mm，宽度为100mm，厚度为12mm，除了需要加工上面的成型面外，还要加工一个深孔四个小孔，采用的毛坯材料为45钢。1.1被加工零件图样的分析塑料模具上模板轮廓由直线和圆弧组成，几何元素之间关系描述清楚完整。零件加工表面上，不宜有毛刺飞边，精度要求最好为1.6。需要进行精加工，未标注公差为-0.5，精度要求较高。零件材料选用45钢，切削加工性能较好。根据上述分析，塑料模具上模板内外轮廓应采用粗、精加工分开进行，才能保证零件的尺寸精度要求，在零件原有尺寸的基础上放大0.9，用于满足铸造制品收缩率的要求。1.2确定装夹方案从零件图纸来看，该零件一次装夹就可以完成所有加工工序。由于零件选用的毛坯尺寸是12010012，工件尺寸不大装夹时采用平口钳固定。1.3确定加工顺序及走刀路线加工顺序的拟定按照基准先行的原则确定。因此先加工出用做加工基准的上平面，然后每次刀具的对刀都以上平面为基准来确定刀具参数的设置，然后在加工其他轮廓。该零件加工精度很容易保证，粗、精加工可以同时进行。加工外轮廓时，要沿轮廓线的切向进刀、退刀，防止过切或撞刀。加工内轮廓时，有以下方案：1.先钻工艺孔，然后从工艺孔下刀到既定深度。2.在空间螺旋下刀逐渐到既定深度。1.4刀具的选择根据零件的结构特点，铣削台阶面时受到轮廓宽度的限制，为提高加工效率所选刀具直径应尽可能的大，但应小于或等于轮廓最小槽宽。所选加工塑料模零件刀具见图2所示。图2 铸造模具零件数控加工刀具卡片 1.5切削用量的选择选择主轴转速与进给速度时，先查切削用量手册，确定切削速度与每齿进给量。1.6填写数控加工工序卡下面将把各个工步的加工内容及所用刀具等内容填写在表11的数控加工工序卡中。工步号工步内容刀具号刀具规格 mm主轴转速 r/min进给速度 mm/min吃刀深度 mm1粗铣椭圆面台阶面T0112150060系统自定2精铣台阶面T026800100系统自定3粗铣六边形台阶面T0312100080系统自定4精铣六边形台阶面T036800100系统自定5钻孔T03258001000.56钻孔T04108001000.5表1 铸造模具零件数控加工工序卡第二章运用MASTERCSM编制加工程序CAM软件自动生成NC程序代码之后，软件要进行语法检错与译码，转换成仿真模块所接受的格式，然后刀具轨迹计算模块计算刀具轨迹，驱动软件实现仿真运动。同时控制刀具沿轨迹走刀，对毛坯切削的动态图像显示过程进行全方位的模拟仿真，并对代码进行反读校验。仿真过程可以随意放大、缩小和旋转，便于观察细节；可以调节仿真速度；能显示多道加工轨迹的加工结果；仿真过程中可以检查刀柄干涉、快速移动过程(G00)中的干涉、刀具无切削刃部分的干涉情况；可以将切削余量用不同颜色区分表示，并把切削仿真结果与零件理论形状进行比较。灵活、强大的加工仿真将加工的风险降为最低。修改过的程序记录如下O0001N104 T1 M6(铣椭圆凸台和六边形凸台）N106 G0 G90 G54 X57.347 Y58.645 A0. 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F500.N1970 G0 Z50.N1972 M5N1974 G91 G28 Z0.N1976 G28 X0. Y0. A0.N1978 M01N1980 T2 M6(精铣椭圆和六边形凸台）N1982 G0 G90 G54 X15. Y70.981 A0. S0 M5N1984 G43 H219 Z50.N1986 Z10.N1988 G1 Z-3. F3.6N1990 X53.971 Y48.481N1992 G2 X68.971 Y22.5 R30.N1994 G1 Y-22.5N1996 G2 X53.971 Y-48.481 R30.N1998 G1 X15. Y-70.981N2000 G2 X-15. R30.N2002 G1 X-53.971 Y-48.481N2004 G2 X-68.971 Y-22.5 R30.N2006 G1 Y22.5N2008 G2 X-53.971 Y48.481 R30.N2010 G1 X-15. Y70.981N2012 G2 X15. R30.N2014 G1 X9.5 Y61.454N2016 X48.471 Y38.954N2018 G2 X57.971 Y22.5 R19.N2020 G1 Y-22.5N2022 G2 X48.471 Y-38.954 R19.N2024 G1 X9.5 Y-61.454N2026 G2 X-9.5 R19.N2028 G1 X-48.471 Y-38.954N2030 G2 X-57.971 Y-22.5 R19.N2032 G1 Y22.5N2034 G2 X-48.471 Y38.954 R19.N2036 G1 X-9.5 Y61.454N2038 G2 X9.5 R19.N2040 G1 X4. Y51.928N2042 X42.971 Y29.428N2044 G2 X46.971 Y22.5 R8.N2046 G1 Y-22.5N2048 G2 X42.971 Y-29.428 R8.N2050 G1 X4. Y-51.928N2052 G2 X-4. R8.N2054 G1 X-42.971 Y-29.428N2056 G2 X-46.971 Y-22.5 R8.N2058 G1 Y22.5N2308 G1 Y22.5N2310 G2 X-41.971 Y27.696 R6.N2312 G1 X-3. Y50.196N2314 G2 X3. R6.N2316 G1 Z2. F500.N2318 G0 Z50.N2320 M5N2322 G91 G28 Z0.N2324 G28 X0. Y0. A0.N2326 M01N2328 T3 M6(钻直径25的通孔）N2330 G0 G90 G54 X0. Y0. A0. S0 M5N2332 G43 H3 Z10.N2334 G99 G81 Z-20. R10. F3.8N2336 G80N2338 M5N2340 G91 G28 Z0.N2342 G28 X0. Y0. A0.N2344 M0128第三章 加工实际操作3.1设备及成品展示机床行程为 750430500（单位为mm），如图3所示。图3 所选机床运用该机床所加工出来的产品如下：图4 加工成型图3.2加工过程中所遇到及应注意的问题对刀的时候，首先要先找正外形，然后再让四边对中。每次开机前一定要机床回零。程序运行的时候，时刻把手