數(shù)控加工課程設(shè)計說明書

1、 數(shù)控加工課程設(shè)計說明書一、分析零件圖紙，確定總體加工方案（一）、圖紙分析：該圖是一復(fù)雜軸類零件，零件部分地方較為復(fù)雜，部分加工精度較高，采用數(shù)控車削加上鉆削、滾齒、插齒綜合完成。該零件由外圓柱面、孔、倒角、內(nèi)齒輪，齒輪軸、槽、階梯組成。其中零件最大外徑為19mm,長度為104mm.選擇毛坯尺寸為114x22mm的棒料。（二）、精度等級、表面粗糙度分析：考慮到左右兩端齒輪齒面粗糙度1.6，滾齒機滾齒后要倒角磨齒；外圓表面粗糙度要求最高為0.8，尺寸精度也易于達到，所以外圓精車即可達到要求。同軸度及各圓跳度都要求要裝夾次數(shù)減少。所以，外圓以兩頂尖定位，一次裝夾完成粗精加工。為滿足同軸度要求，打孔

2、時應(yīng)夾外徑為13.9的外圓。（三）、材料和熱處理分析：零件材料為31crmov9是齒輪鋼，預(yù)備熱處理為調(diào)質(zhì)，回火溫度600630 。最終熱處理為滲氮，hv900。 （四）、總體方案：先對毛坯預(yù)備熱處理（調(diào)質(zhì)處理）；用數(shù)控車床粗精車兩端面打中心孔，再以兩中心孔定位，粗車外圓輪廓，精車右端外圓輪廓，切槽。再以外徑為13.9的槽定位，粗精車左端外圓，鉆鉸孔、鏜孔割內(nèi)槽；最后再滾齒，插齒；最終熱處理，再上磨齒機進行磨齒；完成整個零件的加工。 二、確定加工工藝方案（一）裝夾方式及量具選擇：數(shù)控車床夾具使用三爪卡盤自動定心夾具及頂尖；y3150e滾齒機使用專用夾具，插齒機使用專用夾具，磨齒機使用專用夾具。

3、量具有游標(biāo)卡尺，外徑千分尺，百分表。 （二）加工順序：1.備料，下料尺寸22106的棒料，預(yù)備熱處理2.車，粗精車右端面，鉆中心孔3. 粗車，夾左端外圓頂中心孔定位，粗車右端外圓各部，留單邊余量0.24、精車，夾左端外圓頂中心孔定位，精車右端外圓各部至圖紙所示。5、切1.1mm寬的槽6、用3.5mm切槽刀切3.5mm處，4.6mm處以及12mm處，加之外徑為13.9的t型槽至圖紙所示。7、掉頭夾直徑12處外圓,粗精車左端端面及外圓8、鉆鏜直徑為9的孔9、鏜直徑為12.5的孔。10、割寬5mm的內(nèi)槽。11、鉆直徑5和4的頂孔。12、銑鍵槽13、滾齒機滾右端齒14、插齒機插內(nèi)齒輪。15、倒角，倒棱

4、16、最終熱處理17、磨齒機磨齒18、終結(jié)檢驗（三），切削用量選擇（鏜車削）數(shù)控車削加工中的切削用量包括：背吃刀量、主軸轉(zhuǎn)速n或切削速度、進給速度或進給量f。這些參數(shù)均應(yīng)在機床給定的允許范圍內(nèi)選取。車削用量的選擇原則是粗車時，首先考慮選擇盡可能打的背吃刀量，其次選擇較大的進給量f，最后確定一個合適的切削速度v。增大背吃刀量可使走刀次數(shù)減少，增大進給量f有利于斷屑。精車時，加工精度和表面粗糙度要求較高，加工余量不大且較均勻，因此選擇精車的切削用量時，應(yīng)著重考慮如何保證加工質(zhì)量，并在此基礎(chǔ)上提高加工效率。因此，精車時應(yīng)選用較小的背吃刀量和進給量f，并選用性能高的刀具材料和合理的幾何參數(shù)，以盡可能提

5、高切削速度v.(1) 背吃刀量的確定在工藝系統(tǒng)剛度和機床功率允許的情況下，應(yīng)盡可能選擇較大的背吃刀量，以減少進給的次數(shù)。當(dāng)零件精度要求較高時，則應(yīng)考慮留出精車余量，其所留的精車余量比一般普通車削時所留余量小，常取0.10.5mm。（2）進給量的確定式中，f進給量，粗車時一般取為0.30.8mm/r,精車時常取0.10.3mm/r，切斷時常取0.050.2mm/r。（3）主軸轉(zhuǎn)速的確定 n（r/min）1.數(shù)控車削a.粗車端面 取 n= 50 m/min f = 0.3 mm/rb.精車端面 取 n = 80m/min f = 0.15 mm/rb.粗車外輪廓,留單面余量0.2mm 取 n =

6、50 m/min f= 0.3 mm/r ap = 2 mmc.精車外輪廓 取 n= 80 m/min f = 0.15 mm/r ap = 0.2 mmd.切槽取 n = 60m/min f = 0.1 mm/rf.預(yù)鉆孔8mm及打中心孔 取n = 500 r/min f = 0.2 mm/rg.鏜孔取 n =1500 r/min f = 0.2mm/r2.滾齒機滾齒vc = 0.7 m/sf = 1.5 mm/r（四） 刀具明細表序號刀具名稱刀具直徑刀補值190端面車刀d01293偏頭外圓車刀d0231.15mm割槽刀43.5mm割槽刀54mm割槽刀6高速鋼鉆頭87鏜刀8鏜刀d0893mm

7、的內(nèi)切槽刀10滾刀d1011插齒刀d11三、數(shù)值換算1、公差對稱化換算：直徑公差帶代號公差大小/mm上偏差下偏差對稱化后尺寸12g70.018-0.006-0.02411.985100-0.19.9516h70.0180-0.01815.99115.50-0.315.3513.90-0.0313.88516.80-0.116.757.80.0507.82517h80.0180-0.01816.99116.40-0.0416.389h100.0580.05809.02911.50.3011.6530.50.3030.65601060.51.10.101.1590.0509.02511.50-0.

8、111.451.10.101.152、相關(guān)節(jié)點坐標(biāo)計算：如圖所示：通過坐標(biāo)標(biāo)注，各節(jié)點坐標(biāo)清清楚楚。3、刀位點坐標(biāo)值的計算過程刀位點是指刀具的定位基準(zhǔn)點。車刀的刀位點是刀尖或刀尖圓弧中心；鉆頭的刀位點是鉆頭頂點。各類數(shù)控機床的對刀方法是不完全一樣的，這一內(nèi)容將結(jié)合各類機床分別討論。數(shù)控車床的刀位點是工件外形輪廓向外偏移一個刀具半徑值四、數(shù)控的工藝卡片及加工程序 o0001車左端面打中心孔加工步驟加工內(nèi)容刀具主軸轉(zhuǎn)速（m/min或r/min）進給量備注1粗車端面，留精加工余量0.2t01: 90端面車刀500.32精車端面至圖紙要求t01800.153打中心孔t02: 直徑3.35中心鉆5000

9、.2 o0002車外輪廓加工步驟加工內(nèi)容刀具主軸轉(zhuǎn)速（m/min或r/min）進給量備注1粗車外圓輪廓，留精加工余量0.2t01：93偏頭外圓車刀500.3g712精車外圓輪廓至圖紙要求t01：93偏頭外圓車刀800.15g703切1.1mm寬槽t02：1.1mm割槽刀（右刀尖）600.14切3.5mm寬槽及4.6mm滾花槽t03：3.5mm割槽刀（右刀尖）600.15切t型槽及其他槽t04：4mm割槽刀（右刀尖）600.1 o0003精車左端端面，外圓，鉆鏜孔加工步驟加工內(nèi)容刀具主軸轉(zhuǎn)速（m/min或r/min）進給量備注1粗車外圓輪廓，留精加工余量0.2t01：93偏頭外圓車刀500.3g

10、712精車外圓輪廓至圖紙要求t01：93偏頭外圓車刀800.15g703鉆底孔t02：直徑為8mm高速鋼麻花鉆5000.24鏜孔t03：硬質(zhì)合金內(nèi)孔車刀5000.25鏜直徑為12.5mm的孔t04：硬質(zhì)合金內(nèi)孔車刀15000.26割內(nèi)槽t05：硬質(zhì)合金內(nèi)切槽刀600.1程序代碼如下：o0001n10 g54 f0.3 s800 m03 m07 t0101 ;工藝設(shè)定n20 g50 s2000 ；最高轉(zhuǎn)速限制n30 g96 s50 ；恒線速度切削n40 g0 x24 z0.2 ；快速定位接近工件n50 g1 x-2 ；粗切端面n60 g0 x24 z1n80 g96 s80 ；精車恒線速度設(shè)定n

11、90 z0n100 g1 x-2 f0.15 ；精車端面n110 g0 x100 z150 ；返回?fù)Q刀點n120 t0202 ；換2號刀具n130 g97 s500 ；取消恒線速度，設(shè)定轉(zhuǎn)速500r/min。n140 x0 z5 n150 g1 z-3.35 ； 鉆中心孔n160 g0 z5n170 x100 z150n180 m30 ；程序結(jié)束o0002n10 g54 f0.3 s800 m03 m07 t0101 ;工藝設(shè)定 g50 s2000 ；最高轉(zhuǎn)速限制 g96 s50 ；恒線速度切削 g0 x24 z0.2 ；快速定位接近工件 g1 x-2 ；粗切端面 g0 x24 z1 g96

12、s80 ；精車恒線速度設(shè)定 z0 g1 x-2 f0.15 ；精車端面n40 g71 u2 r1 ；g71粗車輪廓循環(huán)n50 g71 p60 q170 u0.4 w0.2 f0.3；粗車輪廓循環(huán)參數(shù)設(shè)定n60 g0 g42 x8 z2 f0.15 ；循環(huán)開始n70 g1 z0n80 x9.95 z-0.58n90 z-15.72n100 g02 x10.36 z-16.94 r3n110 g01 x11.985 z-19n120 z-36.5n130 x15.35n140 x15.991 z-36.64n150 w-7.825 n160 x19n170 z-106 ；循環(huán)結(jié)束n180 g0 x

13、100 z150n190 g96 s80 ；恒線速度切削n200 g70 p60 q170 ；g70循環(huán)精車外輪廓n210 g0 x100 z150 ；返回?fù)Q刀點n220 t0202 ；換1.1mm切槽刀n230 g96 s60 n240 g0 g40 x13 z-27.5 f0.1；取消刀補，快速定位n250 g1 x11.45 n260 g0 x20n270 g0 x100 z150 n280 t0303 ;換3.5mm切槽刀n290 g0 x17 z-38.5 ;切3.5mm槽n300 g1 x-15.96n310 g0 x20n320 z-31.9 ；切4.6mm槽n332 g1 x1

14、1.9n340 g0 x14 n345 z-40.8n350 g1 x11.5 n355 z-31.9 ；切4.6mm槽結(jié)束n360 g0 x20n370 g0 x100 z150n380 t0404 ；換4mm切槽刀n390 g0 x20 z-50.35n400 g1 x14.3 ；粗切直徑為13.9的t型槽及寬12mm槽n410 g0 x20 z-53.5n420 g1 x14.3n430 g0 x20 n435 z-53.5n440 g1 x14.3n450 g0 x20n451 z-57n452 g1 x14.3n453 g0 x20 n455 z-60.6n460 g1 x14.3n

15、470 g0 x20 n475 z-69.5n480 g1 x17.2 ；t型槽粗切結(jié)束n490 g0 x20 n495 z-72n500 g1 x17.2 ；粗切12mm槽n510 g0 x20 n515 z-75n520 g1 x17.2n530 g0 x20n531 z-75n532 g1 x17.2n534 g0 x20 n535 z-77.5n540 g1 x17.2 ； 12mm槽粗車結(jié)束n550 g0 x20 z-75n560 z-45.5n570 g1 x19 ；精車t型槽n580 x14.32 z-49.55n590 g02 x13.885 z-50.35 r1.6n600

16、g01 z-64.6n610 g2 x14.28 z-65.35 r1.6n620 g1 x18.22 z-69.06n630 g3 x17.68 z-69.5 r0.15 ；精車t型槽結(jié)束n640 g1 x16.75 ; 精車12mm槽n645 z-77.5n650 g0 x100 z150n660 m30 ;程序結(jié)束o0003n10 g54 f0.3 s800 m03 m07 t0101 ;工藝設(shè)定n20 g50 s2000 ；最高轉(zhuǎn)速限制n30 g96 s50 ；恒線速度切削n40 g71 u2 r1 n50 g71 p60 q130 u0.4 w0.2 f0.3 ;g71粗車循環(huán)n60

17、 g0 g42 x15.2 z2 f0.15 ；循環(huán)開始n70 g1 z0n80 x16.38 z-1.39n90 z-6n100 x16.991n110 z-21.5n120 x18n130 z-23 ；循環(huán)結(jié)束n140 g0 x19 z2n150 g96 s80n160 g70 p60 q130 ； g70精車循環(huán)n170 g0 x100 z150 n180 t0202 ；換鉆頭n190 g0 g40 x0 z25 s500 f0.2 ；鉆孔開始,取消刀補n200 g1 z-10n210 g0 z2n220 g1 z-20n230 g0 z0n240 z-18n250 g1 z-35n26

18、0 g0 z0 n270 z-33n272 z-50n274 g0 z0n276 z-48n280 g1 z-62n290 p1n300 g0 z2 ；鉆孔結(jié)束n310 g0 x100 z150n320 t0303 ；換鉸刀n330 g0 x0 z5n340 g1 z-62 ；鉸孔n350 p1n360 g0 z2 n370 g0 x100 z150 n380 t0404 ；換鏜刀n390 s1500 f0.2n400 g0 g43 x13.5 z-0.433 ；刀補n405 g1 x12.5 z-0.433 ；鏜孔n410 z-13n420 x8n430 g0 z2n440 x100 z15

19、0n450 t0505 ；換內(nèi)切槽刀n460 g0 g40 s60 x8 z5 f0.1n470 z-27.65n480 g1 x11.1 ；切內(nèi)槽n490 g0 x8n500 w2 n510 g1 x11.1n520 g0 x8n530 z-24.93n540 g1 x9n550 x11.65 z-25.65n555 z-27.65n560 x9 z-28.37n570 g0 x8n580 z5n590 g0 x100 z150n600 m30 ;程序結(jié)束五、mastercam仿真1、刀具軌跡圖：2、加工后的輪廓圖：3、加工后立體圖：4、pro/e制作的三維圖：5、mastercam導(dǎo)出的加

20、工程序：%o0000g21(program name - mymaster22 date=dd-mm-yy - 20-11-11 time=hh:mm - 16:31)(tool - 1 offset - 1)(lface od rough right - 80 deg. insert - cnmg 12 04 08)g0t0101g97s3600m13g0g54x26.z.5g50s3600g96s295g99g1x-1.6f.2g0z2.5x26.z0.g1x-1.6g0z2.g28u0.w0.m05t0100m01(tool - 2 offset - 2)(lrough od finis

21、h right - 35 deg. insert - vnmg 16 04 08)g0t0202g97s3600m13g0g54x18.666z.5g50s3600g96s295g1z0.f.3z-35.436g3x18.687z-35.6r1.3g1z-37.845x19.4z-59.283z-59.3z-60.5z-110.127x22.x24.828z-108.713g0x26.666z-35.246x19.394g1x18.687z-35.6g2x18.4z-35.006r1.3f.1g1z-23.3f.3z-22.3g2x17.4z-21.434r1.f.1g1z-6.8f.3g2x

22、17.2z-6.364r1.f.1g1z-2.186f.3g2x16.932z-1.686r1.f.1g1x15.332z-.3z0.f.3x18.16z1.414g0x19.4z-22.946x19.107g1x18.4z-23.3g3x17.712z-24.055r1.f.1g1x17.2z-24.277z-30.209f.3z-34.425g3x18.687z-35.6r1.3g1x21.515z-34.186g0x22.515z-35.246x19.394g1x18.687z-35.6g3x18.622z-35.889r1.3f.1g1x19.087z-49.874f.3x21.915

23、z-48.459g0x22.915z-60.146x20.107g1x19.4z-60.5g3x18.712z-61.255r1.f.1g1x16.4z-62.26z-62.8f.3z-66.3z-68.156g3x15.733z-68.901r1.f.1g1z-110.127f.3x19.8x22.628z-108.713g0z-109.773x19.093g1x19.8z-110.127x12.067f.1z-86.434f.3x12.279z-86.142g2x12.4z-85.8r1.g1z-77.3z-76.2z-72.9z-70.35x15.712z-68.91g2x16.133z

24、-68.655r1.g1x18.962z-67.24g0z-68.525x17.099g1x16.133z-68.655g3x15.712z-68.91r1.f.1g1x12.4z-70.35z-72.9f.3z-76.2z-77.3z-85.8g3x12.279z-86.142r1.f.1g1x10.641z-88.392g2x10.4z-89.076r2.g1z-104.223f.3g3x9.712z-104.977r1.f.1g1x8.4z-105.548z-110.127f.3x12.467x15.295z-108.713g0x22.z.083x15.244g1x14.986z-.4x

25、16.586z-1.786g3x16.8z-2.186r.8g1z-6.413g3x17.z-6.8r.8g1z-21.558g3x18.z-22.3r.8g1z-23.3g3x17.45z-23.904r.8g1x16.8z-24.186z-30.209z-34.559g3x18.287z-35.6r1.1x18.221z-35.867r1.1g1x19.z-59.287z-59.3z-60.5g3x18.45z-61.104r.8g1x16.z-62.169z-62.8z-66.3z-68.156g3x15.45z-68.759r.8g1x12.z-70.259z-72.9z-76.2z-

26、77.3z-85.8g3x11.904z-86.074r.8g1x10.265z-88.324g2x10.z-89.076r2.2g1z-104.223g3x9.45z-104.826r.8g1x8.z-105.457z-110.327x10.828z-108.913g0x21.6g28u0.w0.m05t0200m01(tool - 4 offset - 4)(lfinish od groove center - wide insert - n151.2-600-4e)g0t0404g97s1592m13g0g54x23.z-44.966g50s3600g96s115g1x14.3f.1g0

27、x23.z-46.963g1x14.3x14.699z-46.763g0x23.z-42.969g1x14.3x14.699z-43.169g0x23.z-48.96g1x14.3x14.699z-48.76g0x23.z-40.972g1x14.3x14.699z-41.172g0x23.z-50.956g1x14.708x15.107z-50.757g0x23.z-38.975g1x14.382x14.781z-39.175g0x23.z-52.953g1x17.014x17.413z-52.753g0x23.z-36.979g1x16.423x16.822z-37.178g0x23.z-

28、33.474x21.022g1x18.193z-34.888x14.251z-38.595g2x13.9z-39.299r1.5g1z-50.255g2x14.302z-51.005r1.5g1x18.973z-55.05g0x21.802g28u0.w0.m05t0400m01(tool - 3 offset - 3)(lfinish od groove center - narrow insert - n151.2-185-20-5g)g0t0303g97s1695m13g0g54x21.6z-76.3g50s3600g96s115x16.g1x11.5f.1g0x16.z-77.914x

29、14.828g1x12.z-76.5x11.5g0x14.828z-74.986g1x12.z-76.4x11.5z-76.5g0x14.828x21.6g28u0.w0.m05t0300m01(tool - 4 offset - 4)(lfinish od groove center - wide insert - n151.2-600-4e)g0t0404g97s1592m13g0g54x23.z-60.5g50s3600g96s115g1x16.4f.1g0x23.z-60.g1x16.4x16.5z-60.05g0x23.z-59.9g1x16.4x16.5z-59.95g0x23.z

30、-61.g1x16.4x16.5z-60.95g0x23.z-61.5g1x16.4x16.5z-61.45g0x23.z-57.086x21.828g1x19.z-58.5z-59.6g3x18.8z-59.7r.1g1x16.z-61.9g3x15.93z-61.976r.1g0x18.758x21.6g28u0.w0.m05t0400m01(tool - 3 offset - 3)(lfinish od groove center - narrow insert - n151.2-185-20-5g)g0t0303g97s1642m13g0g54x22.287z-17.967g50s36

31、00g96s115g1x17.4f.1g0x22.287z-18.067g1x17.4x17.42z-18.057g0x22.287z-17.868g1x17.4x17.42z-17.878g0x22.287z-18.167g1x17.4x17.42z-18.157g0x22.287z-17.768g1x17.4x17.42z-17.778g0x22.287z-18.267g1x17.4x17.42z-18.257g0x22.287z-17.668g1x17.4x17.42z-17.678g0x22.287z-18.367g1x17.4x17.42z-18.357g0x22.287z-17.5

32、68g1x17.4x17.42z-17.578g0x22.287z-18.466g1x17.4x17.42z-18.456g0x22.287z-17.468g1x17.4x17.42z-17.478g0x22.287z-18.566g1x17.4x17.42z-18.556g0x22.287z-17.368g1x17.4x17.42z-17.378g0x22.287z-18.666g1x17.4x17.42z-18.656g0x22.287z-17.269g1x17.4x17.42z-17.279g0x22.287z-18.766g1x17.4x17.42z-18.756g0x22.287z-

33、17.169g1x17.4x17.42z-17.179g0x22.287z-18.866g1x17.4x17.42z-18.856g0x22.287z-17.069g1x17.4x17.42z-17.079g0x22.287z-18.966g1x17.4x17.42z-18.956g0x22.287z-16.969g1x17.4x17.42z-16.979g0x22.287z-19.065g1x17.4x17.42z-19.055g0x22.287z-16.869g1x17.4x17.42z-16.879g0x22.287z-19.165g1x17.4x17.42z-19.155g0x22.2

34、87z-16.77g1x17.4x17.42z-16.78g0x22.287z-19.265g1x17.4x17.42z-19.255g0x22.287z-16.67g1x17.4x17.42z-16.68g0x22.287z-19.365g1x17.4x17.42z-19.355g0x22.287z-16.57g1x17.4x17.42z-16.58g0x22.287z-19.465g1x17.4x17.42z-19.455g0x22.287z-16.47g1x17.4x17.42z-16.48g0x22.287z-19.564g1x17.4x17.42z-19.555g0x22.287z-

35、16.37g1x17.4x17.42z-16.38g0x22.287z-19.664g1x17.4g0g54x21.6z-69.3g50s3600g96s115x16.032g1x11.9f.1g0x16.032z-69.4x16.004g1x11.9x11.92z-69.39g0x16.006x16.086z-69.2g1x11.9x11.92z-69.21g0x16.079z-69.5x16.g1x11.9x11.92z-69.49g0x16.x16.17z-69.1g1x11.9x11.92z-69.11g0x16.16z-69.6x16.g1x11.9x11.92z-69.59g0x1

36、6.x16.289z-69.z-68.g1x11.9x11.92z-68.01g0x18.495z-70.7x16.g1x11.9x11.92z-70.69g0x16.x18.748z-67.9g1x11.9x11.92z-67.91g0x18.725z-70.8x16.g1x11.9x11.92z-70.79g0x16.x18.978z-67.8g1x11.9x11.92z-67.81g0x18.955z-70.9x16.g1x11.9x11.92z-70.89g0x16.x19.208z-67.7g1x11.9x11.92z-67.71g0x19.185z-72.514x14.828g1x

37、12.z-71.1x11.5x12.z-70.85g0x18.496x18.6z-66.086x18.496g1x15.668z-67.5x11.5z-71.1x12.z-70.85x11.23z-29.787g0x8.z-29.897g1x11.25x11.23z-29.887g0x8.z-29.997g1x11.25x11.23z-29.987g0x8.z-30.097g1x11.25x11.23z-30.087g0x8.z-30.197g1x11.25x11.23z-30.187g0x8.z-30.296g1x11.25x11.23z-30.286g0x8.z-30.396g1x11.25x11.23z-30.386g0x8.z-30.496g1x11.25x11.23z-30.486g0x8.z-30.596g1x11.012x10.992z-30.586g0x8.z-30.695g1x10.645x10.625