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数控编程工艺及加工效率的研究

由于后控板塑件在洗衣机上为外观件，表面光洁度要求较高，所以在模具型腔加工制造过程中必须保证型腔尺寸的公差要求和表面粗糙度要求。对于该模具型腔零件，从内向外主要由以下几部分构成：塑件型腔面、分型面、排气槽、侧抽芯槽、模架面、回程杆垫片槽等。在编制数控编程工艺时，一般按照整体粗加工、分型面半精加工、分型面精加工、型腔面半精加工、型腔面精加工、型腔局部形状清角的工艺思路进行编程，并按照分区域编程的思路，逐渐完成整体零件的编程工作。



图1 洗衣机后控板模具型腔

2.1 整体粗加工刀具的选择

在编制粗加工程序时，粗加工刀具型号的选择直接决定了开粗的加工效率。若开粗刀具选择过小，致使每刀的下刀量较小，而且刀具的进给速度也较小，最终导致工件的加工效率很低。若开粗刀具选择过大，表面上看起来粗加工时间很少，但是开粗效果不理想，本应开粗到位的区域没有开粗到位，需要增加整体中粗程序或大范围的清角程序，这样总体的加工时间也会增加。所以在粗加工刀具选择方面，不但要考虑到工件的整体尺寸大小，还要考虑该零件的材料去除量大小。对于中小型零件来说，原则上把开粗时间 控 制 在 5h 以 内 ，初 步 选 定 开 粗 刀 具 为 直 径 为 32mm的牛鼻刀，刀具定义为D32R0.8mm。
2.2 型腔精加工刀具的选择

在对模具零件型腔进行精加工时，由于模具的型腔面在塑件上为外观面，表面光洁度要求较高，并考虑到模具的型腔面大部分为曲面，所以在精加工刀具选择方面，优先选择球头铣刀进行加工，刀具符号用B及 R 表 示 ，如 直 径 为 20mm 的 球 头 刀 定 义 为B20R10mm。本次研究列出了 3 种精加工刀具选择方案：第 1种方案为大直径球头铣刀（B16R8mm）整体精加工、小直径球头铣刀（B8R4mm）局部清角的编程加工工艺；第 2 种方案为较大直径球头铣刀（B12R6mm）整体光刀、小直径球头铣刀（B8R4mm）清角的编程加工工艺；第3种方案为整体用小直径球头（B8R4mm）刀一次加工到位，如表 1 所示。然后对以下
 

CFDA-7WPB-0070-AZ "AHVi, AHVis, Bis and BHVis Series Motor Encoder Feedback Cable, 90 Degree Connector, 7 M"

GF-1326RS-10 Connecting FlashCable to Starrett Calipers, Micrometers - 10 ft.

IC200TBM001 I/O auxilary barrier style

IC646NSL899 Proficy SQL 2008 - Processor License

IC647IFCLNTSRO050M iFIX iClientTS Read Only 50 PK (M4 Part)

IC647PSF000 Proficy Process Systems 5000+ I/O with iFIX

IC693MDL940CA Conformal Coated Relay Output module 2 amp, non isolated 16 points.

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IC646MRB700 Logic PC 700 Tag Runtime System

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20BC056A0AYNANC1 PowerFlex 700 AC Drive 56 A 30 kW 20B

20F11ND5P0AA0NNNNN PowerFlex 753 AC Packaged Drive

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140CPU11302 Quantum CPU256K,8K用户逻辑,10K寄存器,1MB和1MB+

281D-F12B-10C-RR-3FR ArmorStart Direct Online RVSG Starter

C200H-OC223 输出单元, 5点, 继电器独立接点 同上

1492-PP3 IEC Term Blck 1.5x47x40 mm Partition Plt

接口模块 6ES7461-0AA00-7AA0 用于 IM461-0 的终端连接器

变送器 3RS10301DW20

1497-D-AXSX-0-N Control Circuit Transformer

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1762-IQ8 MicroLogix 8 Point Digital Input Module

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GC647PME050 GlobalCare Complete for Proficy Change Management Server Machine Edition Version - 50 Concurrent Users

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Industrial Computers 6189-RDB7C VVCE 700, KEY/TOUCH DISPLAY MODULE

Process Control 9399-RSBEEUG RSBATCH EQUIPMENT EDITOR USER'S GUIDE

Operator Interface 2711-B5A1L2 PV550 MONO KEY&TOUCH, RIO & RS232 PRINT

Support 9303-23S0EFFR SUPPORT REINSTATEMENT CONTRACT FOR 9303-23S0EFF

Support 9371-ETBP3S SUPT RENEWAL CONTRACT FOR 9371ETBP3

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CBL-3P-MP-30 Power Cable, MTR-3S6x-H Series Servo Motors, 30 Ft.

IC641CTL971 CIMPLICITY Control 90-70 Programmer with Paper Documentation Library

IC800SLM075N2XE25 750W, 230 VAC SL Servo Motor, Holding Brake, 2.5K Quad Encoder

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1494V-FS60 Fuse Block

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运行版软件 6AV2104-0HA04-0AA0 SIMATIC WinCC Runtime Advanced 4096 PowerTags V14

1585J-M4HBJM-1 RJ45 Ethernet Media

1756-OA16I ControlLogix 16 Point D/O Module

188-K1B130-N Miniature Circuit Breaker 13 A

194E-FA63-P11 194E Load switch

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2090-U3CBB-DM12 Ultra 3000 Breakout Board Kit

BC646MSP001 Logic Developer State Professional with Proficy GlobalCare Complete

GC647ASC050 GC SDK 50 Pak

IC200ACC302 I/O input simulator

IC646CSPC001 Proficy Cause+ for Intelligent HMI/SCADA Client Enabler - 1X CAL

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IC697ALG230 Analog Input, Voltage/Current, 8 Channels

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IC694MDL732 Output module 12/24 VDC 0.5 amps 8 points, positive logic.

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MicroLogix 1500/1769 System 1769-PA4 120/240 VAC INPT. PWR SUPPLY 4A @ 5VDC, 2A @ 24VDC

PLC-5/1771 System 1771-DA ASCII I/O MODULE

Distributed I/O 1797-IE8 EX ANALOG INPUT MODULE, 16 BIT, 8 PT., S.E.

Operator Interface 2711P-K4M20D PV PLUS 400 GRAYSCALE, KEYPAD, ETHERNET, DC PS

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A06B-0116-B075#0008 BM1/4000 Servo Motor, 32K Serial Encoder

IC200UAL005-24 Qty of 24, 23 point PLC, (13) 24VDC In, (1) 24VDC Out, (9) Relay Out, (2) Analog In & (1) Analog Out, 24VDC Power Supply. Battery (IC200ACC403) is required for long-term data retention & Real Time Clock

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MTR-1350-N-D-E-0RR Stepping Motor Nema34

ZA06B-0085-B503#0100 B22/2000is Servo Motor with Straight Shaft, Key, Brake and IP67 Sealing

20BD2P1A3NYNAEC1 PowerFlex 700 AC Drive 2.1 A at 1 Hp 20B

20G11TC567JN0NNNNN PowerFlex 755 AC Packaged Drive

25-MAP-FB PowerFlex 520 Frame B Adaptor Plate

140XTS00100 Quantum 40点模块端子条, IP20

FRN55F1S-4C 77 KVA 105A 55KW 3相AC380V/50Hz/60Hz

H5S-B 外形:72×72mm最小设定时间:1分?控制输出:AC250V 15A 1开2路

1492-SPM3C200-N MCB Supplementary Protector 20 A

软启动器 3RW40471BB14

数字量输入信号板 6ES7 221-3AD30-0XB0 SB 1221 DI 4 x 5 V DC，200 kHz

150-SB4NUR SMC-50 SOLID STATE MOTOR CONTROLLER 180A

1734-TB3 POINT I/O Terminal Base

1783-MX08T Stratix 8000 Copper 8 Port Exp. Module

193-ESM-SA-100 E300/E200 Screw Mounting Adapter

20-750-I1B-E395F370 PowerFlex 750 Replacement Inverter

2090-CPWM7DF-16AA02 MP-Series 2m Servo Power Cable

2098-UWCPRGM UltraWARE Programming MED Software

GA647IFCLNTSRO010 GCA iFIX iClientTS Read Only 25 PK Runtime Version

GP-0602NT-SDP16SB GagePort Digital NT 2-port input (for Solartron Digital Probes) - Sale s BOM.

IC5005TBX0010 PanelPC 15 inch Performance Unit with Windows XP

IC647HSTAE500KM Alarm and Events Option for Historian - Standard Server 500,000 Points (M4 Key)

IC647SRVSSFPRD PA SmartStart for Production

IC693MDL740RR 12/24 Vdc Output, 05 Amp, Positive Logic (16 Points)

IC756HDV010J-99 DV Draw Development on HP/UX Op Sys, Japanese, Version 9.9

Pico Controllers 1760-LDF GFX CPU STANDARD

PLC-5/1771 System 1771-IV DRIVER LOGIC INPUT MODULE, 12-24V DC, 8 INPUT

Distributed I/O 1791D-16V0X 24VDC COMPACTBLOCK I/O EXPANSION, 16 IN SOURCE

Communications 1784-PKTX PCI BUS CARD W/ DH+,DH485,RIO SCANNER

Operator Interface 2706-PCABLE1 INVIEW PROGRAM DOWNLOAD CABLE

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电机启动器 3VU13402NL00

150-C30NBD SMC-3 30A Smart Motor Controller

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CP9B-0WEB-0070-AZ Shielded motor power cable for B2is/B4is motors (straight connector). 7 meters

GFH-001 Servo Product Specification Guide

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