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盘形零件造型创建及数控铣加工工艺设计与仿真数字化制造含NX三维及CAD图

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盘形零件三维模型创建及数字化制造Plate types parts to create three-dimensional modeling and digital manufacturing摘要随着数控技术的不断发展和应用领域的日益扩大，数控加工技术对国计民生的一些重要行业（IT、汽车、轻工、医疗等）的发展起着越来越重要的作用。由于效率、质量是先进制造技术的主体，高速、高精地加工技术可极大地提高效率，提高产品的质量和档次，并且能缩短生产周期和提高市场竞争能力。而对于数控加工而言,无论.是手工编程还是自动编程，它们在编程前都要对所加工的零件进行工艺分析，拟定加工方案，选择合适的刀具，确定切削用量，对一些工艺问题(如对刀点、加工路线等)也需做一些处理，并在加工过程中掌握控制精度的方法,如此才能加工出合格的产品。本文着重介绍了运用UG软件对遥控器的三维造型设计和数控加工过程，在遥控器的设计中要遵循人机工程学，使设计的遥控器更加合理、更加舒适，同时也要把握当今遥控器发展趋势，满足大众的需求度，通过对壳体的设计后进行数控加工，要确定铣削方式、走刀方式等一系列设置，通过粗加工、二次开粗、曲面和腔槽的精加工最终得出遥控器壳体数控加工程序。关键词：UG ;三维造型 ;数控加工 ;切削用量;铣削方式;走刀方式Abstract With the continuous development of numerical control technology and application field of widening, nc machining technology to the national economy and peoples livelihood some important industry (IT, automobile, light industry, medical, etc.) is playing a more and more important role in the development. Due to the efficiency, quality is the main part of the advanced manufacturing technology, high speed, high precision machining technology can greatly improve efficiency, improve product quality and grade, and can shorten the production cycle and improve the market competition ability. For nc machining, whatever. It is manual programming or automatic programming, before they will be processed by the parts of process analysis, drafting processing scheme, choosing the appropriate cutting tools, cutting parameter is determined, to some process problems (such as the cutting point, processing route, etc.) also need to do some processing, and master the methods of control accuracy in the machining process, so to work out qualified products. This paper introduces the using UG software for the remote control of the three dimensional modelling design and nc machining process, in the design of the remote control should follow the man-machine engineering, the design of the remote control more reasonable and more comfortable, but also to grasp the development trend of remote control, meet the needs of the masses, through the study of the nc machining of the design of the shell after, to determine the milling mode, feeding mode and a series of set, through the rough machining, secondary thick, curved surface and the cavity groove finishing final remote shell nc machining program. Key words: UG; Three-dimensional modelling; Nc machining; Cutting parameter; The milling method; Feeding way目录摘要iAbstractii第1章 绪论11.1 课题来源及研究的目的和意义11.2 盘类零件的加工特征分析21.3盘类零件数控加工工艺内容与步骤2第2章 基于UG的零件建模22.1UG软件简介22.2UG零件建模过程3第3章 盘类零件的数控加工工艺方案分析83.1 盘形零件的工艺分析83.1.1 根据零件图和产品装配图，对零件进行工艺分析83.1.2 盘形零件的工艺分析83.2 毛坯选择103.3.夹具选择103.31夹具的种类103.32常见的装夹方式113.33夹具的确定113.4机床的选择123.5 刀具的选择123.51刀具材料选择的基本要求133.52刀具材料分析133.53刀具选择原则153.6定位基准的选择153.7 加工顺序的安排173.8切削用量的选择173.81 确定背吃刀量183.82确定主轴转速183.83 确定进给速度18第4章 工艺卡片204.1工艺过程卡片204.2工序卡片21第5章 基于UG的数控加工255.1UGCAM具体操作步骤255.2加工后置处理34结论35致谢36参考文献37附件38第1章 绪论1.1 课题来源及研究的目的和意义数控加工就是泛指在数控机床上进行零件加工的工艺过程。数控机床是一种用计算机来控制的机床，用来控制机床的计算机不管是专用计算机，还是通用计算机都统称为数控系统。数控机床的运动和辅助动作均受控于数控系统发出的指令。在数控机床上加工零件与在普通机床上加工零件，其加工方法并无多大差异，但是在机床的运动控制上却有很大的区别。在普通机床加工时，机床的运动受控于操作工人。如机床的开启、主轴转速的变换、走刀路径、运动部件的位移量，以及机床的停止等都是依靠操作工人来控制的。在数控机床上加工零件时，机床的运动和辅助动作的实现均受控于数控系统发出的指令。而数控系统的指令是由程序员根据工件的材质、加工要求、机床的特性和系统所规定的指令格式编制的。编写加工指令的过程就称为编程。所谓编程，就是把加工零件的工艺过程、工参数、运动要求用数字指令形式记录在介质上，并输入数控系统。数控系统根据程序指令向伺服装置和其它功能部件发出运动或终断信息来控制机床的各种运动。当零件的加工程序结束时，机床便会自动停止。任何一种数控机床，在其数控系统中若没有输入程序指令，数控机床不能工作。CAM(computer Aided Manufacturing，计算机辅助制造的核心是计算机数值控制(简称数控)，是将计算机应用于制造生产过程的过程或系统。1952年美国麻省理工学院首先研制成数控铣床。数控的特征是由编码在穿孔纸带上的程序指令来控制机床。此后发展了一系列的数控机床，包括称为“加工中心”的多功能机床，能从刀库中自动换刀和自动转换工作位置，能连续完成锐、钻、饺、攻丝等多道工序，这些都是通过程序指令控制运作的，只要改变程序指令就可改变加工过程，数控的这种加工灵活性称之为“柔性”。CAD/CAM技术从诞生至今已有三十多年的历史,历经二维绘图、线框模型、自由曲面模型、实体造型、特征造型等重要发展阶段。其间还伴随着参数化、变量化、尺寸驱动等技术的融入.通过三十多年的努力,CAD/CAM技术在基础理论方面日趋成熟,同时推出了许多商品化系统,诸如：Pro/EUGII,I-DEAS,Euclid-IS,CATIA,SolidWorks等。CADCAM技术的应用不仅可以从根本上改变传统的产品设计开发和生产过程，突破时间地域环境的限制，实现并行工程而且可以提高产品质量，缩短产品研发周期，降低成本，增强企业适应市场的能力和市场竞争能力，其经济效益和社会效益将是非常可观和直接的。1.2 盘类零件的加工特征分析盘类零件是机械加工中常见的典型零件之一。它的应用范围很广.如:支撑传动轴的各种形式的轴承；夹具上的导向套；汽缸套等.盘类零件通常起支撑和导向作用。不同的盘类零件也有很多的相同点，如主要表面基本上都是圆柱型的，它们有较高的尺寸精度，形状精度和表面粗糙度要求，而且有高的同轴度要求等诸多共同之处。1.3盘类零件数控加工工艺内容与步骤（1） 选择适合在数控机床上加工零件，确定工序内容。（2） 分析被加工零件的图样，明确加工内容及技术要求。（3） 确定零件的加工方案，制定数控加工工艺路线。如划分工序、安排加工顺 序、处理及非数控加工工序衔接。（4） 加工工序的设计。如选择零件的定位基准、确定夹具方案、划分工步、取 刀具和辅具、确定切削用量等。（5） 数控加工程序的调整。如选取对刀点和换刀点、确定刀具补偿和加工路线 等。第2章 基于UG的零件建模2.1UG软件简介 UG（Unigraphics NX）是Siemens PLM Software公司出品的一个产品工程解决方案，它为用户的产品设计及加工过程提供了数字化造型和验证手段。Unigraphics NX针对用户的虚拟产品设计和工艺设计的需求，提供了经过实践验证的解决方案。UG同时也是用户指南（user guide）和普遍语法（Universal Grammer）的缩写。UGNX软件是由多个模块组成的，主要包括CAD、CAM、CAE、注塑模、钣金件、Web、管路应用、质量工程应用、逆向工程等应用模块，其中每个功能模块都以Gateway环境为基础，它们之间既有联系又相互独立。2.2UG零件建模过程（1） 打开UG界面后，单击【文件】【新建】命令或者单击按钮，出现“新建文件”对话框，选择【零件】命令后单击【确定】按钮，出现一个新建文件的界面。（2） 单击【拉伸】，然后在拉伸工具对话框选择【草图】绘制命令，创建草图。（3） 单击【完成草图】，进入【拉伸】工具对话框，拉伸厚度为23mm。（4） 单击确定，单击【拉伸】，然后在拉伸工具对话框选择【草图】绘制命令，创建草图。（5） 单击【完成草图】，进入【拉伸】工具对话框，拉伸厚度为10mm，布尔运算为求和。 （6） 单击【拉伸】，然后在拉伸工具对话框选择【草图】绘制命令，创建草图。（7） 单击【完成草图】，进入【拉伸】工具对话框，拉伸厚度为10mm，布尔运算为求差。（8） 单击【拉伸】，然后在拉伸工具对话框选择【草图】绘制命令，创建草图。（9） 单击【完成草图】，进入【拉伸】工具对话框，拉伸厚度为10mm，布尔运算为求和。（10） 单击【孔】命令，在星形凸台中央创建沉头孔。（11） 单击【拉伸】，然后在拉伸工具对话框选择【草图】绘制命令，创建草图（12） 单击【完成草图】，进入【拉伸】工具对话框，拉伸厚度为8mm，布尔运算为求差。（13） 单击【拉伸】，进入工具对话框，选择拉伸曲线，拉伸厚度为10mm，布尔运算为求和。（14） 单击【倒角】命令，对各倒角倒角，保存文件。第3章 盘类零件的数控加工工艺方案分析3.1 盘形零件的工艺分析工艺规程，是指导施工的技术文件。一般包括以下内容：零件加工的工艺路线，各工序的具体加工内容，切削用量、工时定额以及所采用的设备和工艺装备等。3.1.1 根据零件图和产品装配图，对零件进行工艺分析机械加工工艺规程是规定零件机械加工工艺过程和操作方法等的工艺文件之一，它是在具体的生产条件下，把较为合理的工艺过程和操作方法，按照规定的形式书写成工艺文件，经审批后用来指导生产。机械加工工艺规程一般包括以下内容：工件加工的工艺路线、各工序的具体内容及所用的设备和工艺装备、工件的检验项目及检验方法、切削用量、时间定额等。1) 计算年生产纲领，确定生产类型。 2) 分析零件图及产品装配图，对零件进行工艺分析。 3) 选择毛坯。 4) 拟订工艺路线。 5) 确定各工序的加工余量，计算工序尺寸及公差。 6) 确定各工序所用的设备及刀具、夹具、量具和辅助工具。 7) 确定切削用量及工时定额。 8) 确定各主要工序的技术要求及检验方法。 9) 填写工艺文件。 在制订工艺规程的过程中，往往要对前面已初步确定的内容进行调整，以提高经济效益。在执行工艺规程过程中，可能会出现前所未料的情况，如生产条件的变化，新技术、新工艺的引进，新材料、先进设备的应用等，都要求及时对工艺规程进行修订和完善。3.1.2 盘形零件的工艺分析每一个工件的加工方案，都是根据工件的类型、具体的加工内容以及给定的加工约束条件进行综合分析后确立的，在清楚加工内容后，结合机床类型和夹具类型，制定工艺路线，确定每一序所使用的刀具。 1.图样分析通过分析图样可以得出，零件的加工面为以下部分： 1）六方凸台轮廓，需要控制总长，注意对六边形尺寸的控制。2）封闭的环形槽,外轮廓，内轮廓，深。3）6个封闭的曲线槽，槽底距上表面，要控制的尺寸有、64。中间环形槽加工控制尺寸54及64尺寸加工16mm孔，注意其粗糙度为Ra1.6反面加工星形轮廓螺纹孔,底孔深，螺孔深。2.加工方案分析：（工件两面轮廓中心对其问题是本零件加工难点之一，假设按图顺序先加工上表面，后使用上表面为基准加工下表面，就会导致两面轮廓中心对其偏差较大，在此工艺流程中粗基准被重复使用是造成两面轮廓不对中的主要原因，在此可以加工出中间孔，以孔为基准加工反面星形，可以很好的解决这一问题。 此零件几何轮廓不规则，在此使用计算机编程来满足加工需求。加工此零件时，我们采用自上而下分层加工的方式，可以最大限度的简化我们的程序，提高加工的效率。 零件上比较精密表面的加工，常常是通过粗加工、半精加工和精加工逐步达到的。对这些表面仅仅根据质量要求选择相应的最终加工方法是不够的，还应正确地确定从毛坯到最终成形的加工方案。本工件毛坯为钢板，因此我们加工的时候采用平口钳夹紧工件，简单可靠高效。平口钳装夹前校正钳口与机床轴线的平行度跳动0.02mm以内。下表面面粗铣精铣使大表面粗糙度达到要求，设定大表面的平面为加工Z0平面，建立各刀具的长度补偿值，粗精铣四周台阶，铣削沟槽，采用自上而下分层铣削按顺序依次加工腰形沟槽及。 使用立铣刀粗精加工腰形槽内侧轮廓，保证精度，去除余量。这里我们使用刀具半径补偿的方式来保证精度，粗加工时我们将#1刀具半径补偿值修改成大于刀具尺寸，留下精铣余量，粗加工后测量长度和切削深度，在做出相应的调整，对于沟槽的铣削，排屑问题使我们在加工中不得不考虑的问题，尤其是在粗加工中，由于切削量较大，会产生大量的铁屑，沟槽的排屑条件较差，会造成铁屑大量积累，造成加工面被铁屑划伤，大量切削热集中使得刀具寿命降低。所以在对沟槽进行粗加工时优先选用容屑槽较大的刀具，及优先使用直径较大的刀具，切削刃较少的刀具，可以有效改善沟槽的切削条件。反面装夹工件，使用寻边器在16mm孔口对中心，设定工件坐标系后，上表面面粗铣精铣使大表面粗糙度达到要求，设定大表面的平面为加工Z0平面，建立各刀具的长度补偿值，粗精铣四周台阶，最后加工沟槽部分。上表面无法通过打中心孔的方法来下刀，所以我们采用键槽铣刀加工，由于考虑到刀具中心的切削速度为零，下刀的方式不宜采用直线下刀，可采用螺旋下刀或斜线下刀，可有效避免下刀过程中断刀，腰槽轮廓应留有精加工余量粗铣，粗铣完成后直接下刀到所需要的深度，一次成型。卸下工件，去除毛刺。3.2 毛坯选择 毛坯材料为45号钢板，厚度为45mm。 45号常用中碳调质结构钢。该钢冷塑性一般，退火、正火比调质时要稍好，具有较高的强度和较好的切削加工性，经适当的热处理以后可获得一定的韧性、塑性和耐磨性，材料来源方便。适合于氢焊和氩弧焊，不太适合于气焊。焊前需预热，焊后应进行去应力退火。正火可改善硬度小于160HBS毛坯的切削性能。该钢经调质处理后，其综合力学性能要优化于其他中碳结构钢，但该钢淬透性较低，水中临界淬透直径为1217mm，水淬时有开裂倾向。当直径大于80mm时，经调质或正火后，其力学性能相近，对中、小型模具零件进行调质处理后可获得较高的强度和韧性，而大型零件，则以正火处理为宜，所以，此钢通常在调质或正火状态下使用。调质处理后零件具有良好的综合机械性能，广泛应用于各种重要的结构零件，特别是那些在交变负荷下工作的连杆、螺栓、齿轮及轴类等。但表面硬度较低，不耐磨。可用调质+表面淬火提高零件表面硬度。3.3.夹具选择3.31夹具的种类机床夹具是机床上用以装夹工件（和引导刀具）的一种装置。其作用是将工件定位，以使工件获得相对于机床和刀具的正确位置，并把工件可靠地夹紧。夹具按照用途可分为以下几类：1）通用夹具通用夹具是指已经标准化的，在一定范围内可用于加工不同工件的夹具。例如，车床上三爪卡盘和四爪单动卡盘，铣床上的平口钳、分度头和回转工作台等。这类夹具一般由专业工厂生产，常作为机床附件提供给用户。其特点是适应性广，生产效率低，主要适用于单件、小批量的生产中。2）专用夹具专用夹具是指专为某一工件的某道工序而专门设计的夹具。其特点是结构紧凑，操作迅速、方便、省力，可以保证较高的加工精度和生产效率，但设计制造周期较长、制造费用也较高。当产品变更时，夹具将由于无法再使用而报废。只适用于产品固定且批量较大的生产中。3）通用可调夹具和成组夹具其特点是夹具的部分元件可以更换，部分装置可以调整，以适应不同零件的加工。用于相似零件的成组加工所用的夹具，称为成组夹具。通用可调夹具与成组夹具相比，加工对象不很明确，适用范围更广一些。4）组合夹具组合夹具是指按零件的加工要求，由一套事先制造好的标准元件和部件组装而成的夹具。由专业厂家制造，其特点是灵活多变，万能性强，制造周期短、元件能反复使用，特别适用于新产品的试制和单件小批生产。5）随行夹具随行夹具是一种在自动线上使用的夹具。该夹具既要起到装夹工件的作用，又要与工件成为一体沿着自动线从一个工位移到下一个工位，进行不同工序的加工。3.32常见的装夹方式1) 平口钳装夹：一般适合板类零件；2) 卡盘装夹：一般适用于轴类零件；3) 压板装夹：适用于异形零件，使用范围较大，但是不宜操作，生产效率较低；4) 专用夹具装夹：试用产品单一，生产效率高。5) V形铁装夹：适用于轴类零件。3.33夹具的确定 此零件毛坯属于槽板类，可以使用平口钳配合V行铁装夹，此种装夹方案一般在铣床上使用较多。操作方便，夹紧迅速，夹紧力可靠。3.4机床的选择通过以上对零件的工艺分析，可知加工此零件需要的设备主要为车床及铣床，对于设备的型号的选择主要考虑一下几个方面：1) 机床的加工范围：例如机床的回转直径或者加工行程是否能够满足零件的机构需求。2) 机床的加工精度：所选择的机床的加工精度必须大于零件的加工精度，这样才能够保证零件加工的可靠性3) 机床的切削速度范围：主要体现在机床的主轴转速，一般来说较大的回转直径的设备，转速都比较低，而较小的回转直径的设备转速较高，从切削速度的角度来看，较大的设备是不适合加工较小尺寸的零件。4) 机床的切削功率：机床所提供的切削力必须保证零件的顺利加工，也就是说机床提供的切削力必须大于零件的切削抗力。5) 机床的刚性6) 机床的经济性:在满足上述条件的情况下，竟可能选择成本较低的设备，这样可以大大降低生产成本。根据上述各点，为此零件选择一台车床及铣床，具体型号参数如下:表3-1 铣床主要参数3.5 刀具的选择随着我国科技的发展，机械加工的强度在不断加大，精度也在不断提高。高速切削刀具切削性能的好坏，取决于构成刀具切削部分的材料，几何形状和刀具结构。刀具材料对刀具的使用寿命、加工效率、加工质量和加工成本等都有很大影响。因此要重视刀具材料的正确选择与合理的选用。3.51刀具材料选择的基本要求 具备的优良性能的刀具材料，是保证刀具高效工作的基本条件。刀具切削部分在强烈摩擦、高压、高温下工作，应具备如下的基本要求。 1. 高硬度和高耐磨性 刀具材料的硬度必须高于被加工材料的硬度才能切下金属，这是刀具材料必备的基本要求，现有刀具材料硬度都在60HRC以上。刀具材料越硬，其耐磨性越好，但由于切削条件较复杂，材料的耐磨性还决定于它的化学成分和金相组织的稳定性。 2. 足够的强度与冲击韧性 强度是指抵抗切削力的作用而不致于刀刃崩碎与刀杆折断所应具备的性能。一般用抗弯强度来表示。冲击韧性是指刀具材料在间断切削或有冲击的工作条件下保证不崩刃的能力，一般地，硬度越高，冲击韧性越低，材料越脆。硬度和韧性是一对矛盾，也是刀具材料所应克服的一个关键。 3. 高耐热性 耐热性又称红硬性，是衡量刀具材料性能的主要指标。它综合反映了刀具材料在高温下保持硬度、耐磨性、强度、抗氧化、抗粘结和抗扩散的能力。 4. 良好的工艺性和经济性 为了便于制造，刀具材料应有良好的工艺性，如锻造、热处理及磨削加工性能。当然在制造和选用时应综合考虑经济性。当前超硬材料及涂层刀具材料费用都较贵，但其使用寿命很长，在成批大量生产中，分摊到每个零件中的费用反而有所降低。因此在选用时一定要综合考虑。3.52刀具材料分析 常用刀具材料有工具钢、高速钢、硬质合金、陶瓷和超硬刀具材料，目前用得最多的为高速钢和硬质合金。 1) 高速钢 高速钢是一种加入了较多的钨（W）、铬（Cr）、钒（V）、钼（Mo）等合金元素的高合金工具钢，有良好的综合性能。高速钢具有较高的硬度，一般硬度为62-67HRC和耐热性。在切削温度高达500-650时仍能进行切削。其强度和韧性是现有刀具材料中最高的。抗弯性是一般硬质合金的2-3倍，是陶瓷的5-6倍。韧性很好，可以在有冲击、振动的场合应用。它可以用于加工有色金属、结构钢、铸铁、高温合金等范围广泛的材料。 2) 硬质合金 硬质合金是用高硬度、难熔的金属碳化物（WC、TIC等）和 金属粘结剂在高温条件下烧结而成的粉末冶金制品。硬质合金的常温硬度达89-93HRA，760时其硬度为77-85HRA，在800-1000时硬质合金还能进行切削。刀具寿命比高速钢刀具高几倍甚至几十倍。可加工包括淬硬钢在内的多种材料。但是强度和韧性比高速钢差，常温下冲击韧性仅为高速钢的1/81/30，因此硬质合金承受切削振动和冲击的能力较差。硬质合金是常用的刀具材料之一，常用于制造车刀和面铣刀，也可以用硬质合金制造深孔钻、铰刀、拉刀和滚刀。尺寸较小和形状复杂的刀具可以采用硬质合金制造。但是整体硬质合金刀具的成本较高，其价格是高速钢刀具的8-10倍。 3) 陶瓷的分类及选用 制作刀具的陶瓷材料是以人造化合物为原料，在高压下形成，在高温下烧结而成的。它有很高的硬度和耐磨性，耐热性高达1200以上，化学稳定性好，与金属的亲和力小，可提高切削速度35倍，但是陶瓷的最大弱点是抗弯强度低，冲击韧性差，因此主要用于钢、铸铁、有色金属等材料的精加工和半精加工。按成分陶瓷可分为以下几种：高纯氧化铝陶瓷、复合氧化铝陶瓷、复合氮化硅陶瓷 4) 涂层刀具简述 涂层刀具是近20 年出现的一种新型刀具材料，是刀具发展中的一项重要突破，是解决刀具材料中硬度、耐磨与强度、韧性之间矛盾的一个有效措施。涂层刀具是在一些韧性较好的硬质合金或高速钢刀具基体上，涂覆一层耐磨性高的难熔化金属化合物而获得的。常用的涂层材料有TiC、TiN和Al2O3等。除上述单层涂层刀片外，还有TiC+TiN、TiC+TiN+ Al2O3等两层、三层的复合涂层，其性能更优。但是涂层刀具不适宜加工高温合金、钛合金及非金属材料，也不适宜粗加工有夹砂、硬皮的锻铸件。 5) 金刚石刀具 金刚石刀具分为天然金刚石和人造金刚石刀具。天然金刚石具有自然界物质中最高的硬度和导热系数。但由于价格昂贵，加工、焊接都非常困难，除少数特殊用途外很少作为切削工具应用在工业中。人造金刚石又分为单晶金刚石和聚晶金刚石（PCD），聚晶金刚石的晶粒随机排列，属各向同性体，常用于制造刀具。但由于碳对铁的亲和作用，特别是在高温下，金刚石能与铁发生化学反应，因此它不宜于切削铁及其合金工件。 6) 立方氮化硼 立方氮化硼（CBN）是由六方氮化硼经高温高压处理转化而成，是纯人工合成的材料。其硬度高达8000HV，仅次于金刚石。CBN是一种新型刀具材料，它可耐1300-1500高温，热稳定性好；它的化学稳定性也很好，即使温度高达1200-1300也不与铁产生化学反应。立方氮化硼能以硬质合金切削铸铁和普通钢的切削速度对冷硬铸铁、淬硬钢、高温合金等进行加工。 3.53刀具选择原则刀具的选择是数控加工工艺中的重要内容之一，不仅影响机床的加工效率，而且直接影响零件的加工质量，应考虑以下方面：1) 根据零件材料的切削性能选择刀具。如车或铣高强度钢、钛合金、不锈钢零件，建议选择耐磨性较好的可转位硬质合金刀具。2) 根据零件的加工阶段选择刀具。即粗加工阶段以去除余量为主，应选择刚性较好、精度较低的刀具，半精加工、精加工阶段以保证零件的加工精度和产品质量为主，应选择耐用度高、精度较高的刀具，粗加工阶段所用刀具的精度最低、而精加工阶段所用刀具的精度最高。如果粗、精加工选择相同的刀具，建议粗加工时选用精加工淘汰下来的刀具，因为精加工淘汰的刀具磨损情况大多为刃部轻微磨损，涂层磨损修光，继续使用会影响精加工的加工质量，但对粗加工的影响较小。3) 根据加工区域的特点选择刀具和几何参数。在零件结构允许的情况下应选用大直径、长径比值小的刀具；切削薄壁、超薄壁零件的过中心铣刀端刃应有足够的向心角，以减少刀具和切削部位的切削力。加工铝、铜等较软材料零件时应选择前角稍大一些的立铣刀，齿数也不要超过4齿。3.6定位基准的选择 在制定零件加工的工艺规程时，正确地选择工件的定位基准有着十分重要的意义。定位基准选择的好坏，不仅影响零件加工的位置精度，而且对零件各表面的加工顺序也有很大的影响。合理选择定位基准是保证零件加工精度的前提，还能简化加工工序，提高加工效率，零件的定位基准的选择应该遵从以下三个原则。 1）基准重合原则。为了避免基准不重合误差，方便编程，应选用工序基准作为定位基准，尽量使工序基准、定位基准、编程原点三者统一。2）便于装夹的原则。所选择的定位基准应能保证定位准确、可靠，定位、夹紧机构简单、易操作，敞开性好，能够加工尽可能多的表面。3）便于对刀的原则。批量加工时在工件坐标系已经确定的情况下，保证对刀的可能性和方便性。a. 粗基准的选择所谓粗基准就是以不加工的表面作为基准；在选择粗基准时应该注意竟可能选择加工余量均匀；加工余量最小，表面平整、光洁、尺寸足够大的表面作为粗基准；也可以以不加工的表面作为粗基，准粗基准应尽量避免重复使用，因为粗基准的重复定位会造成很大的定位误差。 本例中粗基准直接选择在盖板零件的外圆及大端面，此处和铸造面比较光滑平整，有利于对加工精度的保证。b. 精基准的选择精基准的选择应从保证零件加工精度出发，同时考虑装夹方便、夹具结构简单。选择精基准一般应考虑如下原则：1) “基准重合”原则为了较容易地获得加工表面对其设计基准的相对位置精度要求，应选择加工表面的设计基准为其定位基准。这一原则称为基准重合原则。如果加工表面的设计基准与定位基准不重合，则会增大定位误差。2) “基准统一”原则当工件以某一组精基准定位可以比较方便地加工其它表面时，应尽可能在多数工序中采用此组精基准定位，这就是“基准统一”原则。采用“基准统一”原则可减少工装设计制造的费用，提高生产率，并可避免因基准转换所造成的误差。3) “自为基准”原则当工件精加工或光整加工工序要求余量尽可能小而均匀时，应选择加工表面本身作为定位基准，这就是“自为基准”原则。此外，用浮动铰刀铰孔、用拉刀拉孔、用无心磨床磨外圆等，均为自为基准的实例。4) “互为基准”原则为了获得均匀的加工余量或较高的位置精度，可采用互为基准反复加工的原则。例如加工精密齿轮时，先以内孔定位加工齿形面，齿面淬硬后需进行磨齿。因齿面淬硬层较薄，所以要求磨削余量小而均匀。此时可用齿面为定位基准磨内孔，再以内孔为定位基准磨齿面，从而保证齿面的磨削余量均匀，且与齿面的相互位置精度又较易得到保证。 遵从基准统一原则，此零件的精加工基准选择以粗基准加工出A基准作为精基准，在后续孔加工中遵从基准重合基准统一原则依然选择此基准为精基准，这样可以很有效的提高加工精度。3.7 加工顺序的安排 在安排加工顺序时一般应遵循以下原则：1) 先基准面后其它 应首先安排被选作精基准的表面的加工，再以加工出的精基准为定位基准，安排其它表面的加工。该原则还有另外一层意思，是指精加工前应先修一下精基准。例如，精度要求高的轴类零件，第一道加工工序就是以外圆面为粗基准加工两端面及顶尖孔，再以顶尖孔定位完成各表面的粗加工；精加工开始前首先要修整顶尖孔，以提高轴在精加工时的定位精度，然后再安排各外圆面的精加工。2) 先粗后精 这是指先安排各表面粗加工，后安排精加工。3) 先主后次 主要表面一般指零件上的设计基准面和重要工作面。这些表面是决定零件质量的主要因素，对其进行加工是工艺过程的主要内容，因而在确定加工顺序时，要首先考虑加工主要表面的工序安排，以保证主要表面的加工精度。在安排好主要表面加工顺序后，常常从加工的方便与经济角度出发，安排次要表面的加工。例如，图5.5所示的车床主轴箱体工艺路线，在加工作为定位基准的工艺孔时，可以同时方便地加工出箱体顶面上所有紧固孔，故将这些紧固孔安排在加工工艺孔的工序中进行加工。此外，次要表面和主要表面之间往往有相互位置要求，常常要求在主要表面加工后，以主要表面定位进行加工。4) 先面后孔 这主要是指箱体和支架类零件的加工而言。一般这类零件上既有平面，又有孔或孔系，这时应先将平面（通常是装配基准）加工出来，再以平面为基准加工孔或孔系。此外，在毛坯面上钻孔或镗孔，容易使钻头引偏或打刀。此时也应先加工面，再加工孔，以避免上述情况的发生。3.8切削用量的选择 切削用量包括主轴转速（切削速度）、背吃刀量（切削深度）、进给量（进给速度）。对于不同的加工方法，需要选择不同的切削用量，并编入程序单内。3.81 确定背吃刀量背吃刀量ap（）ap是指平行于铣刀轴线方向测量的切削层尺寸， 主要根据机床、夹具、刀具和工件的刚度来决定。由于零件精度要求不高，从“切削用量简明手册”可查得，可以一次净加工余量，即ap等于加工余量，即粗铣时ap=1mm。3.82确定主轴转速b）切削速度c（m/min），c是指铣刀旋转时的切削速度n=1000c/d0根据切削原理可知，切削速度的高低主要取决于被加工零件的精度、材料、刀具的材料和刀具耐用度等因素，可见表5-1选取参数2：表5-1 铣削时切削速度工件材料硬度/HBS切削速度VC/ (m/min)高速钢铣刀硬质合金铣刀钢225184266150225325123654120325425621 3675续表5-1工件材料硬度/HBS切削速度VC/ (m/min)高速钢铣刀硬质合金铣刀铸铁19021366615019026091845901603204.5102130铝70120100200200400从理论上讲，VC的值越大越好，因为这不仅可以提高生产率，而且可以避免生成积屑瘤的临界速度，获得较低的表面粗糙度值。但实际上由于机床、刀具等的限制。3.83 确定进给速度进给量（进给速度）f（mm/min或mm/r） 是数控机床切削用量中的重要参数，主要根据零件的加工精度和表面粗糙度要求以及刀具、工件的材料性质选取。当加工精度，表面粗糙度要求高时，进给量数值应选小些，一般在2050mm/min5范围内选取。最大进给量则受机床刚度和进给系统的性能限制，并与脉冲当量有关。 = 式中： 切削时单位时间内工件与铣刀沿进给方向的相对位移，单位mm/minfz铣刀每齿工作台的移动距离，即每齿进给量（mm/z）铣刀的转速铣刀齿数每齿进给量fz的选取主要取决于工件材料的力学性能、刀具材料、工件表面粗糙度值等因素。工件材料的强度和硬度越高，fz越小，反之则越大；工件表面粗糙度值越小，就fz越小；硬质合金铣刀的每齿进给量高于同类高速钢铣刀，可参考表5-2选取：表5-2 铣刀每齿进给量fz工件材料每齿进给量fz/（mm/z）粗铣精铣高速钢铣刀硬质合金铣刀高速钢铣刀硬质合金铣刀钢0.100.150.100.250.020.050.100.15铸铁0.120.200.150.30铝0.060.200.100.250.050.100.020.05参数、都由实验确定，也可参考有关切削用量手册选用。综上可以得出（机床有的或较接近的转速取百位近似值）详见表5-3。表5-3 切削参数表刀具格式车削背吃刀量mm进给速度mm/min主轴转速r/min外圆车刀粗车2100800精车0.3901300合金铣刀粗铣15002500精铣0.33003500切削进给速度也可由机床操作者根据被加工工件表面的具体情况进行手动调整，以获得最佳切削状态。第4章 工艺卡片4.1工艺过程卡片(厂名)机械加工工艺过程卡片产品型号零件图号产品名称零件名称共 页第 页材料牌号45钢毛坯种类锻件毛坯外形尺寸每毛坯可制件数1每台件数设备工序号工序名称工序内容车间工段设备工艺设备工时准备单件1下料钢板下料火焰切割火焰切割机2普铣粗铣六方普铣可转为50面铣刀3立加1加工六角形一面立式数控铣床50面铣刀、16铣刀、12铣刀、16铰刀4立加2加工星形一面立式数控铣床50面铣刀、11钻头、16铣刀、12铣刀、单刀螺纹铣刀5去毛刺工件锐角边倒钝钳工台锉刀6清洗清洗机7终检游标卡尺设计（日期）审核（日期）标准化（日期）会签（日期）标记处数更改文件号签字日期标记处数更改文件号签字日期4.2工序卡片表3-11机械加工工序卡片厂名机械加工工序卡片产品型号零件图号产品名称零件名称典型零件共 页第 页车间工序号工序名材料牌号145号钢毛坯种类毛坯外形尺寸每毛坯可制件数每台件数锻件122X122X45mm11设备名称设备型号设备编号同时加工件数立式铣床XD-401家具编号夹具名称切削液平口虎钳工位器具编号工位器具名称工步工时准终单件工步号工步内容工艺装备主轴转速（r/min）切削速度（mm/min）进给量（mm/r）背吃刀量（mm）进给次数工步工时机动/s辅助/s1下料火焰切割设计（日期）审核（日期）标准化（日期）会签（日期）标记处数更改时间签字日期标记处数更改时间签字日期表3-12机械加工工序卡片厂名机械加工工序卡片产品型号零件图号产品名称零件名称典型零件共 页第 页车间工序号工序名材料牌号3毛坯种类毛坯外形尺寸每毛坯可制件数每台件数锻件122X122X45mm11设备名称设备型号设备编号同时加工件数立式铣床XD-40家具编号夹具名称切削液平口虎钳工位器具编号工位器具名称工步工时准终单件工步号工步内容工艺装备主轴转速（r/min）切削速度（m/min）进给速度（mm/r）背吃刀量（mm）进给次数工步工时机动/s辅助/s1铣削六方50面铣刀6001000.211设计（日期）审核（日期）标准化（日期）会签（日期）标记处数更改时间签字日期标记处数更改时间签字日期厂名机械加工工序卡片产品型号零件图号产品名称零件名称典型零件共 页第 页车间工序号工序名材料牌号545钢毛坯种类毛坯外形尺寸每毛坯可制件数每台件数锻件122X122X45mm1设备名称设备型号设备编号同时加工件数立式铣床XD-40家具编号夹具名称切削液平口虎钳工位器具编号工位器具名称工步工时准终单件工步号工步内容工艺装备主轴转速（r/min）切削速度（mm/min）进给速度（mm/r）背吃刀量（mm）进给次数工步工时机动/s辅助/s1精铣大面50面铣刀游标卡尺10006000.622粗铣六方凸台12铣刀游标卡尺25001060.21213粗铣腰槽12铣刀25001060.24粗铣圆环12铣刀游标卡尺25001060.215.8425精铣各加工部位12铣刀游标卡尺35001260.216钻孔15.8钻头游标卡尺5301060.20.117精铰16预孔至尺寸16铰刀605020.08116.82.52设计（日期）审核（日期）标准化（日期）会签（日期）标记处数更改时间签字日期标记处数更改时间签字日期表3-12机械加工工序卡片厂名机械加工工序卡片产品型号零件图号产品名称零件名称典型零件共 页第 页车间工序号工序名材料牌号3毛坯种类毛坯外形尺寸每毛坯可制件数每台件数锻件122X122X45mm11设备名称设备型号设备编号同时加工件数立式铣床XD-40家具编号夹具名称切削液平口虎钳工位器具编号工位器具名称工步工时准终单件工步号工步内容工艺装备主轴转速（r/min）切削速度（m/min）进给速度（mm/r）背吃刀量（mm）进给次数工步工时机动/s辅助/s1精铣大面50面铣刀游标卡尺10006000.622粗铣六方凸台12铣刀游标卡尺25001060.21214粗铣圆孔12铣刀游标卡尺25001060.215.8425精铣各加工部位12铣刀游标卡尺35001260.216铣螺纹12螺纹铣刀游标卡尺5301060.20.11标记处数更改时间签字日期标记处数更改时间签字日期厂名机械加工工序卡片产品型号零件图号产品名称零件名称典型零件共 页第 页第5章 基于UG的数控加工5.1UGCAM具体操作步骤1、 打开UG8.0软件，选择，打开三维模型，单击开始，弹出菜单栏，选择加工。2、 弹出CAM加工对话框，选择型腔铣削后单击确定，进入UG8.0加工环境。3、 选择几何视图4、 双击，弹出坐标对话框，单击指定MCS5、 选择点作为坐标原点单击确定6、 安全设置选项，单击下拉箭头，选择平面，选择工件最高平面向Z轴正方向偏移5mm作为安全平面7、 单击创建刀具，选择需要加工的刀具种类，单击确定8、 对刀具参数进行设置，如直径，长度，R角等9、 单击创建几何体按钮，设置工件几何体，选择型腔铣削，单击子几何体类型workpice，单击确定弹出对话框，对指定部件，指定毛坯进行设置，指定部件。10、 指定毛坯，选择包容块作为工件毛坯，单击确定，完成设置。11、 单击创建工序，选择平面铣削，添加设置好的刀具，几何体进入平面铣削工序对话框。12、 设置切削区域13、 检查刀具设置、刀轴的设置14、 设置刀轨，选择跟随周边。15、 对切削参数进行设置16、 对非切削移动进行设置17、 对竟给率和速度进行设定18、19、 单击生成刀具轨迹20、 加工零件外形及内部凹槽，设置方法同上，最终轨迹如下加工星形一边不在一一赘述，方法同上，刀具轨迹如下21、 单击确定，完成工序设置，单击后处理，弹出对话框，选择查找后处理器，找到你需要的后处理器，或者使用系统自带后处理器，指定程序的输出位置。将程序输出的格式设置为cnc，或t22、 生成G代码 5.2加工后置处理系统进行处理后，生成指定路径文件名的程序文件，由于文件过于庞大程序可参见附录这样程序的加工后置处理就完成了，由此生成的程序能够在数控机床上进行应用，以加工出所需要的模型。 结论本论文讨论了运动UG的不同命令来进行三维造型的具体应用。UG是CAD/CAM集成软件，在进行三维造型设计和数控加工编程以及动态仿真方面有着很强大的功能。通过使用这些集成软件，不但可以第一时间直观看到物件的三维实体，还可以在后期加工中通过仿真模拟来实现对铣削方式、使用刀头、走刀方式、加工步骤等最合理的选择，这样使实际生产上的返工率和物件报废率大大降低，也很大程度的提高了加工效率和精度。因此，应用好UG的三维设计和数控加工编程功能是提高企业生产效率和物件精确度的重要途径。在进行设计时，充分运用UG的的功能来做出想要得到的造型。一般完成一个造型设计可以有不同的方式，这就需要根据自己的需求来选择最熟练的，但是应该将每一种方法都熟记于心，要对UG软件进行不断的熟悉，作为一个专业软件，这是将来赖以生存的工具，要有不断钻研专业知识的精神，不断提高自己处理能力，增强自己的综合竞争力。在进行数控加工时，也得到了很多收获，数控加工过程中涉及加工方式的选择、一些参数的选择、刀具的选择、刀轨路径的选择等，这些专业性很强的知识很值得钻研下去，完全熟练化的掌握。35致谢为期将近4个月的毕业设计结束了，在指导老师的耐心指导下我不仅顺利地完成了毕业设计任务，同时也学到了很多知识与技巧，收获非常大，这将近4个月的学习使我的专业水平上升了一个台阶，还锻炼了我们独立思考的能力。作为学生的我很多时候自己会遇到不能解决的问题，老师的教育方式是点拨式，让我们发挥了主人翁意识，做到真正意义上的自主学习与实践。老师不仅为我们提供专业支持，更教会我们积极的心态与思想。设计期间，老师悉心为我们指导每个疑问，在查阅我的草稿和论文时，仔细严谨，一丝不苟，是我们学习的榜样，在此，我要向黄老师表示诚挚的感谢。另外，在此次设计中，也需要感谢的是和我同组的同学们，他们对于我的问题也给予了有建设性的意见。大家在一起共同奋斗，互相讨论，对我的毕业设计有很大帮助，并且，我们在一起共同营造了一个融洽的学习生活环境，建立了良好的友谊。没有所有的这些帮助，就没有我本次毕业设计保质保量的完成。最后，感谢老师为我们提供课题。37参考文献1 张武军等.UGNGINEER中文野火版4.0数控加工实例精解M.北京：机械工业出版社，20082黄圣杰，王俊祥.UGNGINEER 基础及应用教程M.北京：电子工业出版社，20013 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H01Z3.G01 Z-1. F250. M08X-12.437 Y37.541G17 X-10.169 Y36.614 I1.732 J1.X10.169 I10.169 J-36.614X12.437 Y37.541 I.535 J1.927X12.953 Y38.435X11.768 Y41.358 I-1.732 J1.X-11.768 I-11.768 J-41.358X-12.953 Y38.435 I.547 J-1.924X-12.695 Y37.988X-7.499 Y40.988Z2.G00 Z5.X-26.551 Y29.988Z3.G01 Z-1.X-26.809 Y30.435X-29.933 Y30.871 I-1.732 J-1.X-41.701 Y10.488 I29.933 J-30.871X-39.762 Y8. I1.94 J-.488X-38.73X-36.793 Y9.5 I0.0 J2.X-26.624 Y27.114 I36.793 J-9.5X-26.293 Y29.541 I-1.401 J1.427X-26.551 Y29.988X-31.747 Y26.988Z2.G00 Z5.X-39.246 Y-8.Z3.G01 Z-1.X-39.762X-41.701 Y-10.488 I0.0 J-2.X-29.933 Y-30.871 I41.701 J10.488X-26.809 Y-30.435 I1.392 J1.436X-26.293 Y-29.541X-26.624 Y-27.114 I-1.732 J1.X-36.793 Y-9.5 I26.624 J27.114X-38.73 Y-8. I-1.936 J-.5X-39.246Y-14.Z2.G00 Z5.X-12.695 Y-37.988Z3.G01 Z-1.X-12.953 Y-38.435X-11.768 Y-41.358 I1.732 J-1.X11.768 I11.768 J41.358X12.953 Y-38.435 I-.547 J1.924X12.437 Y-37.541X10.169 Y-36.614 I-1.732 J-1.X-10.169 I-10.169 J36.614X-12.437 Y-37.541 I-.535 J-1.927X-12.695 Y-37.988X-7.499 Y-40.988Z2.G00 Z5.X-41.411 Y-50.46Z3.G01 Z-1.X-32.363X-26.947 Y-53.862X-32.363 Y-50.46X-50.46 Y-40.012X-49.5 Y-38.349X-52.462 Y-36.64X-57.962 Y-27.113 I5.5 J9.526Y27.113X-52.462 Y36.64 I11. J0.0X-5.5 Y63.753X5.5 I5.5 J-9.526X52.462 Y36.64X57.962 Y27.113 I-5.5 J-9.526Y-27.113X52.462 Y-36.64 I-11. J0.0X5.5 Y-63.753X-5.5 I-5.5 J9.526X-49.5 Y-38.349X-50.46 Y-40.012Y-50.46X-41.411X-41.412 Y-60.06X-12.017 Y-60.061X-5.532 Y-63.804X-5.531X-5.106 Y-64.039X-5.105X5.532 Y-63.804 I5.104 J9.817X12.018 Y-60.061X32.363 Y-60.06Y-50.46X50.46Y-40.012X32.363 Y-50.46X26.948 Y-53.862X32.363 Y-50.46Y-60.06X60.X60.06 Y-60. I0.0 J.06Y40.012X50.46Y50.46X32.363X26.947 Y53.862X32.363 Y50.46X50.46 Y40.012X60.06Y60.X60. 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