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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
 

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IC660EBA025RR Current Source Analog Output, 24/48Vdc Power, Elec Asm only

IC694MDL754 12/24VDC Output (0.75 amps/point)Module 32 point. Requires terminal block IC694TBBx32 box style or IC694TBSx32 spring clamp. Terminal block is sold seperaby. Output response Time is 0.5ms.

IC756HDV010CS-99 DV Draw Development on HP/UX Op Sys, Simplified Chinese, Version 9.9

IC800SLT004 SL series amplifier breakout terminal block for third party controller interface

SLC/1746 System 1746-OB16 DC OUTPUT MODULE FOR PROGRAMMABLE CONTROLLER

Distributed I/O 1790-15CMCBL LDX I/O LONGER RIBBON CABLE, 15CM (LOTS OF 5)

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1794-IF8IH FLEX I/O 8 Analog Input

194E-CA00-P11 194E Load switch

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2090-CSWM1DF-18AA14 Kinetix Cable Single DSL 2090-Series

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HE693SNP900 SNP slave module for Series 90-30 with 1 RS-232 port and 1 RS-485 port .

IC610MDL125RR 115Vac Input (8 points)

IC647HSTSS10KM-35 Historian v3.5 Standard Server 10000 Points (M4 Key)

IC660BBD100RR 115Vac I/O Block, 8 Circuit, Ph B

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IC756WDN010J-28 DataViews Development System for Visual Basic, Java, C++, & Native C 1 User, Japanese v2.8

CompactLogix System 1769-IA8I 8 POINT 120 VAC INDIVIDUALLY ISOLATED INPUT MODULE

PLC-5/1771 System 1771-PSC POWER SUPPLY CHASSIS, 4 SLOTS

Distributed I/O 1798-BP8 FLEXARMOR 8 SLOT BASE PLATE

Operator Interface 2711P-K6C3D PV PLUS 600 COLOR, KEYPAD, DH485, DC PS

Support 9323-S5250R SUPT REINSTATEMENT CONTRACT FOR 9323S5250

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RSI Software Products 9324-RLDFBDENE RSLOGIX 5000, FBD EDITOR ENG

RSI Software Products 9305-RSVADSFRE RSVIEW32 ACTIVE DISPLAY SERVER (FRENCH)

RSI Software Products 9322-ECCEENE ENTERPRISE CONTROL - CONTROLS EDITION

Motion Control 2094-PRF MODULE, 230V OR 460V, POWER RAIL SLOT FILLER

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IC200UEX013 14 point Exp.(8) 12VDC In, (6) Relay Out, 12VDC Power Supply (includes IC200CBL501)

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OFSCSPBST Quantum OFS SMALL 10LIC SUBSCR RENEWAL

FVR 1. 5E11S-4JE 2. 8KVA 3.7A 1.5KW 3相AC380V/50Hz/60Hz

1492-J3-Y 2.5 square mm Standard Terminal Block

1492-SPM3D080-N MCB Supplementary Protector 8 A

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Pico Controllers 1760-PICOSOFTPRO PICOSOFTPRO SOFTWARE

PLC-5/1771 System 1771-OQ16K CONFORMALLY COATED,ISOLATED OUTPUT MODULE,24V DC

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Communications 1786-XT CONTROLNET 75 OHM TERMINATOR PLUG

Operator Interface 9399-2SE32GRES RSVIEW32 GETTING RESULTS GUIDE (SPANISH)

Support 9701-VWSTS SUPT RENEWAL CONTRACT FOR 9701VWSTENE

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EtherNet/IP Products 1771-DMC1 CONTROL COPROCESSOR - MAIN MODULE

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44A728335-014 Test & Upgrade - PowerMotion

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IC693MDL753LT 12/24 Vdc Output, Pos Logic (32 Pts) (LT)

Silver Series 2711E-K14C6 PANELVIEW 1400E KEYPAD TERMINAL 14" COLOR CRT

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1492-SPM1D320-N MCB Supplementary Protector 32 A

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198-SHB Operating Handle Black

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2094-BC04-M03-S Kinetix 6000 Integrated Axis Module

DEMOCD00007 Batch Demo CD

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IC210BAR020 AC (85 to 264VAC) Power Source, (12) AC in/8 out (Relay, 8 Amp), Expandable, with without LCD/Keypad

IC647ARC025 PA Reporting Client 25 Pak

IC647PPSAPF Proficy Process Systems App Server with iFIX

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Application-specific products 1803-EEM12E4 EEM,16 PULSES,24V DC, 16 ANALOG,4 TO 20 MA, NEMA 4

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1492-RFB4 IEC Term Blck 8 x 97 x 43.8mm Spr Clp

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1497-M-M4-0-N Control Circuit Transber

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1764-LSP MicroLogix 1500 Processor

188-K4B060 6 A Miniature Circuit Breaker

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2090-XXNPMF-16S12 Kinetix Drives 12m Standard Cable

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GC647SCL001 GCScheduler Server Client ( Plan+ View)

IC200PBI001CA Remote I/O Profibus DP network interface unit conbal coated.

IC646PPT100 4-day OpenProcess Training per Student

IC647NCA915 CIMPLICITY Change Approval for 1500 Point Server

IC690CBL701 Cable, PCM to IBM-PC/XT Class Computers, 10 feet (3m)

IC697VPC464RR Plug & Play PC Coprocessor, 486DX2/66, 32 Mbytes

IC800STI105S1RR 5A, 115V, S2K Stepper Controller

SLC/1746 System 1746-A2 2-SLOT EXPANSION CHASSIS FOR FIXED HARDWARE STYLE

Industrial Computers 6181P-17NPXPH VERSAVIEW INTEGRATED DISPLAY COMPUTER 17-INCH

Application-specific products 9358-PBNTK30ENE RSBATCH NT FOR PROCESSLOGIX BACK-UP KEY 30 UNITS

Operator Interface 2711-K5A2L1 PV550 MONOCHROME KEY, DH485

Support 9301-2SE2100ITR SUPT REINSTATEMENT CONTRACT FOR 93012SE2100IT

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280-PWRM35D-M4 ArmorStart Three-Phase Power Media

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1585J-M8CBJM-0M3 RJ45 Ethernet Media

1756-PAR2XT Extended Temp AC Redundant Supply Bundle

188-K1C500-N Miniature Circuit Breaker 50 A

194E-NX48 125 A Special IEC Load Switch

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2090-UXNFBMP-S03 MP-Series 3 m Length Feedback Cable

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IC660TBA101 Terminal Assembly for IC660BBA101

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280-MTR35-M3 ArmorConnect Brake and Motor Cable

FX1N-24MR-D 直流主机14入/10出?继电器输出

1492-M5X10H101-200 Connection Products

1494H-BA3H2 Heavy Duty Fusible Safety Discon Switch

软启动器 3RW44442BC45

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1585D-M4TB-10 Micro D-Code, QD Style Ethernet Media

1756-CN2R ControlLogix Communication Module

1794-IV16 Flex 16 Point Digital Input Module

194E-CA20EX-6 194E Load switch

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