耳型板零件工艺编制及加工仿真设计【三维UG】【含CAD图纸终稿】

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关键词：: 三维UG 含CAD图纸终稿耳型板零件工艺编制加工仿真设计三维 UG CAD 图纸

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内容简介：: 机械加工工艺过程卡片产品型号零件图号产品名称耳型板零件名称耳型板共 1 页第 1 页材料45#毛坯种类型材毛坯外形尺寸每毛坯可制件数1每台件数1备注年产序号工序名称工序内容车间工段设备工艺装备工时准终单件10备料备料毛坯机一20检验检验机一30铣粗加工平面，留余量0.5mm;机二CY-VMC850面铣刀，卡规0.3940铣粗加工R12凸台，留余量0.5mm;机二CY-VMC850球铣刀，卡规0.6550铣粗加工R5凸台，留余量0.5mm;机二CY-VMC850球铣刀，卡规0.0560铣半精加工平面;机二CY-VMC850面铣刀，卡规1.88570铣半精加工R12凸台;机二CY-VMC850球铣刀，卡规0.28280铣半精加工R5凸台;机二CY-VMC850球铣刀，卡规0.6590钻孔钻12.5mm的通孔机二CY-VMC850高速钢钻头，赛规0.07100钻孔钻5的通孔机二CY-VMC850高速钢钻头，赛规0.053110钻孔攻丝4XM5的通孔达到尺寸机二CY-VMC850高速钢钻头，赛规120去毛刺去毛刺130检查检查检一毕业设计（论文）说明书毕业设计（论文）题目耳型板零件工艺编制及加工仿真设计院系班级学生姓名学号所在团队指导老师职称答辩委员会主任主答辩人目录摘要III第一章绪论11.1 课题的研究意义1第二章耳型板零件的工艺分析与设计22.1读图和审图22.2零件图的工艺分析22.2.1数控加工内容的选择22.2.2 耳型板的工艺性分析32.2.3重要部位加工精度分析32.3毛坯32.3.1毛坯种类的选择32.3.2加工余量32.3.3加工基准的选择32.3.4表面加工方法的确定42.3.5夹具的选择42.3.6机床的选择42.4工艺路线42.5切削用量、刀具62.5.1加工余量、工序尺寸和工差的确定62.5.2切削用量的计算62.6 本章小结7第三章UG造型编程及加工83.1三维造型83.2数控加工编程123.2.1凸台的数控加工编程123.2.2钻16*14沉孔的数控加工编程143.3 本章小结20结论21参考文献22致谢23III耳型板加工工艺的编制及自动编程目前，数控铣削加工中普遍采用UG或Mastercam自动编程，而数控加工中主要采用手工编程的方法，而手工编程效率低，准确性差.然而UG包含了三维建模和数控铣削编程模块，在对工件的加工过程中，可以利用UG进行数控铣削自动编程。结合UG强大的参数化功能和后处理器支持多种数控机床功能，可迅速自动生成数控代码,缩短编程人员的编程时间,提高程序的正确性和安全性,降低生产成本,提高工作效率。本文以加工为例，详细介绍了基于UG的自动编程的方法和创建数控铣床后处理文件的方法,并且单独创建后置处理构造器来生成出符合加工人员实际操作的机床程序。在数控铣床上完成该轴的铣削加工，结果表明加工精度符合图纸要求、基于UC的自动编程可以提高NC程序的正确性和安全性、同时还能提高工作效率。关键词：UG、自动编程、数控第一章绪论1.1 UG来源及其优缺点UG 是美国UGS 公司的一款集CAD/CAM/CAE于一身的高端三维CAD 软件。其中包含零件设计、二维工程图、零件加工和仿真以及有限元分析等模块。通过模块之间的无缝集成，实现了零件的三维信息在设计、数控加工以及有限元分析模块之间的共享，具有设计修改方便，更新迅速等特点。随着提高产品加工效率的需求越来越高，数控加工设备的使用也越来越普及，数控铣床、数控铣削加工中心、数控车铣复合加工中心已大量应用于各制造行业中。UG NX6中提供了强大的数控铣削加工模块，包含了粗车加工、精车加工、中心钻孔加工、螺纹加工等操作，能够实现各种复杂回转类零件的数控加工编程。UG自从1990年进入我国以来，以其强大的功能和工程背景，已经在我国的航空、航天、汽车、模具和家电等领域得到广泛的应用。尤其UG软件Pc版本的推出，为UG在我国的普及起到了良好的推动作用。UG NX 6O是NX系列的最新版本，它在原版本的基础上进行了多处的改进。例如，在特征和自由建模方面提供了更加广阔的功能，使得用户可以更快、更高效、更加高质量。地设计产品。对制图方面也作了重要的改进，使得制图更加直观、快速和精确，并且更加贴近工业标准。UG具有以下优势；1、为机械设计、模具设计以及电器设计单位提供一安完整的设计、分析和制造方案。 2、是一个完全的参数化软件，为零部件的系列化建模、装配和分析提供强大的基础支持。 3、可以管理CAD数据以及整个产品开发用期中所有相关数据，实现逆向工程(Reverse design)和并行工程(Concurrennt Engnieer既)等先进设计方法。4、可以完成包括自由曲面在内的复杂模型的创建，同时在图形显示方面运用了区域化管理方式，节约系统资源。5、具有强大的装配功能，并在装配模块个运用了引用集的设计思想，为节省计算机资源提出了行之有效的解决方案，可以极大地提高设计效率。1.2 本论文的研究内容由于UG 的应用多集中在数控铣、加工中心等方面，并且相关铣削方面的学习资料较少，对于UG铣削加工应该更多地与实际铣床相结合。本论文以一个加工为例，介绍了基于UG的自动编程的方法和如XX创建数控铣床后处理文件的方法。在数控铣床上完成该轴的铣削加工，结果表明加工精度符合图纸要求、基于UC的自动编程可以提高NC程序的正确性和安全性、同时还能提高工作效率。数控机床的编程方法分为手工编程和自动编程。从零件图样分析、工艺处理、数据计算、编写程序单、输入程序到程序校验等各步骤主要由人工完成的编程过程称为手工编程。自动编程也称为计算机辅助编程，即程序编制工作的大部分或全部由计算机完成。自动编程工具分为语词式自动编程工具和图形交互式自动编程工具，当今主流的自动编程工具为图形交互式自动编程工具。目前，数控铣削加工中普遍采用UG或Mastercam自动编程，而数控铣削加工中主要采用手工编程的方法，而手工编程效率低，准确性差，本文讨论了基于UG自动编程的数控铣削加工方法，1.3选题意义在学习了数控加工工艺与装备机械制造基础UG数控编程CAD/CAM应用技术数控机床及编程等课程后，为了将所学的知识应用于实际中，加深对知识的掌握程度，提升自身的实际工作能力，故选取基于UG的拨叉凹模的数控铣削加工的课题，综合所学知识，解决出现的问题，完成设计。本课题主要内容是数控铣削加工，包括了零件图的审查、工艺的设计、刀具和机床夹具的选择、切削用量的选择、UG的建模与编程、后处理等，通过一系列的作业操作，完成对零件的加工任务。通过此次课题，可以学习到很多加工和工艺方面的知识，为以后工作打下基础。1.4 论文结构1）运用制图软件绘制零件二维图纸及三维图。2）分析零件的技术要求，确定零件的加工方案。3）合理的选择刀具、切削参数。4）编制零件的数控加工程序并进行仿真加工。5）制定相应的工艺卡片。第二章耳型板零件的工艺分析与设计2.1读图和审图图2-1零件图2.2零件图的工艺分析零件包括一个R12凸台，一个R5凸台，一个直径12.5mm通孔和一个直径5的通孔，4个6XM5的通孔。2.2.1数控加工内容的选择该零件加工内容主要是耳型板，该平面精度要求较高，还有凸台、由曲线构成曲面、尺寸较大的型腔和各类的孔加工，孔是加工中非常大的一部分内容，有沉头孔起到连接螺栓的作用，有通孔起到定位得作用。加工过程中如果采用普通机床，像曲面（球面）、曲线等，难加工，质量难以保证，而且效率低，工人手工操作劳动强度大，故将全部采用数控机床加工。2.2.2 耳型板的工艺性分析一个R12凸台，一个R5凸台，要求的精度也不是很高，其次就是上下表面需要加工。上表面有表面粗糙度Ra3.2的要求，与一个直径12.5mm通孔孔中心有垂直度0.03的要求，所以上表面要求精度较高，要在整体半精加工的基础上，进行精加工。2.3.1毛坯种类的选择该耳型板零件根据前面的分析，其余就是孔的位置精度要求较高，并且在使用过程中只是起到封起来的作用，不承受过大的压力，所以毛坯采用45#型材开料2.3.2加工余量面（所有）加工：根据金属机械加工工艺人员手册表13-27（第1050页），当加工面长度小于等于300mm，加工面宽度小于等于100mm时，精铣余量为0.5mm，那么粗铣余量为2mm。2.3.4表面加工方法的确定根据耳型板零件图上的各需要加工的平面和各大小不同的孔的的尺寸要求和表面粗糙度的要求，确定加工该耳型板各表面的加工方法，如表2-1所示：表2-1 加工方法加工表面尺寸精度等级表面粗糙度Ra/um加工方案R12凸台IT113.2粗铣-精铣R5凸台IT111.6粗铣-精铣一个直径5的通孔IT112.5粗铣-精铣一个直径12.5mm通孔IT86.3钻-扩-铰4个6XM5的通孔IT132.5钻上表面IT92.5精铣2.3.5夹具的选择本零件采用铣床用平口虎钳装夹工件，型号为QH160。2.3.6机床的选择本零件选择加工选用XD-40数控立铣床。 2.4工艺路线该耳型板工序的安排顺序为：在热处理粗基准加工（孔表面、8销孔）粗加工（各尺寸的孔和孔表面）精加工（跑道型平面）工艺过程方案：10备料备料游标卡尺 20检验检验游标卡尺30粗铣粗加工平面，留余量0.5mm; 粗加工R12凸台，留余量0.5mm; 粗加工R5凸台，留余量0.5mm;40半精铣 1.半精加工平面; 2.半精加工R12凸台; 3.半精加工R5凸台;50 钻孔钻12.5mm的通孔；钻5的通孔；60钻孔攻丝 4个6XM5的通孔达到尺寸 70去毛刺去毛刺80检验检验第 65 页共 66 页2.5切削用量、刀具2.5.1加工余量、工序尺寸和工差的确定面加工余量：根据上面的工艺路线安排，粗铣留余量0.5，半精铣留余量0.3，精铣到尺寸。面加工的工序尺寸见表2-2，表2-2 底面加工工序尺寸上下端面毛坯Z=2.574.5+1.5 -0.774.5 +1.5 -0.7粗铣Z=2.172.4IT110.1972.4 0 -0.19Ra12.5精铣Z=0.472IT100.1272 0 -0.12Ra0.8孔加工工序尺寸见表2-3，表2-3 孔加工工序尺寸直径5的通孔毛坯实心钻孔2Z=4.14.1IT117.1Ra12.5扩孔2Z=0.94.9IT11.9Ra6.3铰孔5IT108Ra3.22.5.2切削用量的计算1、粗、精加工平面选择CoroMill 245中的50的直柄立铣刀，经加工也可采用该立铣刀，并采用刀具推荐的切削用量，刀具参数参考图2-2，推荐的进给量参考图2-3，图2-2 CoroMill 245中的50直柄立铣刀参数 2.6 本章小结本章主要完成耳型板零件的工艺设计部份。形成了一些成果，具体可见附件。第三章UG造型编程及加工3.1三维造型先建立新文件，文件名只能是英文和数字组成。在主菜单中依次单击“起始”“建模”命令，进入实体建模环境。以X-Y基准平面为绘制平面，进入草图绘制模块。使用直线与圆弧命令绘制草图，然后再通过尺寸标注，约束命令实现草图的全约束。在绘制过程中可以使用镜像命令镜像上下的缺口部分，绘制圆时注意圆和圆之间的同心关系，还有就是不能出现过约束的情况，最终草图如图3-1。图3-1草图图3-2外轮廓拉伸完成草图后退出草图模式，进入建模模块，在建模模块中首先采用拉伸命令拉伸外轮廓，拉伸高度为25，在选择曲线过程中要使用选择过滤器，通过相连曲线过滤选择最外面的曲线。以图3-1绘制好的实体的上表面为绘制平面，进入草图分别绘制图，完成草图后，分别向下拉伸求差得到图3-3。图3-5 生成界面再使用孔加工命令，设置孔直径8，生成效果如图3-8所示。图3-8 孔生成同样使用草图画圆、草图拉伸、沉头孔、孔命令得到下侧部分的三维造型，如图3-9所示。以环形的底面为绘制平面，绘制腔件的底面，与上相似，具体步骤省略。完成所有造型后，所生成的模型如图3-11。图3-11 生成最终的耳型板模型3.2数控加工编程3.2.1凸台的数控加工编程首先切换到加工模式，在标准工具条中选择“开始”“加工”，此时系统弹出“加工环境”对话框，需要在这里进行初始化，可以在在CAM设置选择栏中选择“mill-contour”模板进行初始化，当然，也可以不在这里进行初始化，在后面选择也可以，系统将进入型腔铣加工环境。（一）创建几何体在操作导航器的几何视图中，设置加工坐标系、零件和毛坯，为创建操作做准备。（1）设置加工坐标系。先将操作导航器转换到几何体视图。在“操作导航器-几何体”中选择“MCS-MILL”，单击右键，在其快捷菜单中选择“编辑”命令。在弹出对话框中的“机床坐标系”中的“指定MCS”栏中，单击“自动判断”图标，然后在图形区域选择耳型板毛坯的上表面，之后单击“确定”，系统将自动在毛坯的顶面中心位置创建加工坐标系，如图3-8所示。图3-8 生成平面铣刀路轨迹（2）设置几何体9 在“操作导航器-几何体”中，双击“WORKPIECE1”图标，将弹出“几何体”对话框。指定部件几何体。在“几何体”对话框中，单击“指定部件”按钮，在图形区域选择耳型板零件，点击“确认”。指定毛坯几何体，在“几何体”对话框中，单击“指定毛坯”图标按钮，将弹出“毛坯几何体”对话框，选择“自动块”，单击“确定”。再次按鼠标中键，结束设置几何体的操作。（二）创建刀具9（1）在“创建操作”工具条中，需要选择“创建刀具”命令，进入“创建刀具”子对话框。（2）先在“创建刀具”对话框中的类型选择项内选择“mill-contour（铣型腔）中的分层铣削”，然后在“刀具子类型”选项栏中选择“立铣刀（MILL）”图标，并输入刀具名称LIXIDAO16，然后单击“应用”，进入“刀具参数”对话框，三齿立铣刀，无底面半径，刀刃长度50，设置参数后单击“确定”，完成刀具的创建。（三）创建操作9在加工创建工具条中，单击“创建操作”命令，系统将弹出“创建操作”对话框。在“创建操作”对话框中，选择“类型”中选择“mill-contour（铣型腔）”，然后在“操作子类型”中，选择型腔铣模板图标CAVITY-MILL铣型腔。在“创建操作”对话框中设置其他参数：程序、刀具，选择刚刚建立的LIXIDAO16、几何体选择刚建立的几何体和毛坯。在“创建操作”对话框中单击“确定”，选择切削区域、设置切削层为0.5mm为一层，这样粗加工后精加工的余量比较小、最后按照工艺部分的设计填写进给率和主轴转速。最后如图3-9所示。铣 R12凸台仿真截图铣 R5凸台刀轨图铣 R5凸台;（四）后处理先在操作导航器中选中各铣削图标，然后在“加工操作”工具条中单击“后处理”按钮，在“后处理”对话框中，后处理选择“MILL-3-AXIS”，单位选择“公制/部件”，选择需要保存的路径为毕业论文的文件夹，单击“确定”后，系统就会生成型腔铣操作的NC加工代码。例如，图3-10 。图3-10 生成数控铣程序3.2.2钻孔的数控加工编程（一）创建刀具9（1）在“创建操作”工具条中选择“创建刀具”命令，进入“创建刀具”对话框。（2）先在“创建刀具”对话框中的类型选择项内选择“drill”，然后在“刀具子类型”选项栏中选择“麻花钻头（DRILLING-TOOL）”图标，并输入刀具名称DRILLING-TOOLD11，然后单击“应用”，进入“刀具参数”对话框，设置参数后单击“确定”，完成刀具的创建。（二）创建操作9（1）在加工创建工具条中，单击“创建操作”命令，系统将弹出“创建操作”对话框。（2）在“创建操作”对话框中，选择“类型”中选择“drill”，然后在“操作子类型”中，选择型腔铣模板图标PECK-DRILLING啄钻。在“创建操作”对话框中设置其他参数：程序、刀具DRILLING-TOOLD11、几何体。在“创建操作”对话框中单击“确定”，指定16个直径为14的孔、指定部件上表面作为起始平面、指定底面作为孔底、指定循环方式为跟随周边、进给和速度，如图3-11所示。图3-11 钻孔操作设置界面（3）生成操作，如图3-12所示。图3-12 生成钻孔操作（三）后处理先在操作导航器中选中各铣削图标，然后在“加工操作”工具条中单击“后处理”按钮，在“后处理”对话框中，后处理选择“MILL-3-AXIS”，单位选择“公制/部件” ，单击“确定”后，系统就会生成钻孔操作的NC加工代码，如图3-13所示。图3-13 钻孔后处理程序该零件其他的数控加工编程与上相似，这里不作详述。下面是程序节选：铣平面程序：%N0010 G40 G17 G90 G70N0020 G91 G28 Z0.0:0030 T00 M06N0040 G0 G90 X-1.5867 Y-1.3807 S0 M03N0050 G43 Z1.9685 H00N0060 Z1.4764N0070 G1 Z1.3583 F9.8 M08N0080 X-1.8898 Y-1.2058N0090 Y-1.3633N0100 Y-1.5748N0110 G2 Y-1.5771 I-.1574 J0.0N0120 G1 X-1.8938 Y-1.8499N0130 Z1.4764N0140 G0 Z1.9685N0150 X-1.9635 Y-.1453N0160 Z1.6929N0170 G3 X-1.9635 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