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數(shù)控技術(shù)課程設(shè)計(jì)說(shuō)明書設(shè)計(jì)題目數(shù)控機(jī)床操作與仿真加工華中世紀(jì)星數(shù)控銑床專業(yè)班級(jí):學(xué)生姓名:學(xué)號(hào):指導(dǎo)教師:2011年11月12日目錄序言·························································31型腔的加工··············································31.1零件圖的分析··················································31.1.1表面粗糙度················································31.1.2表面粗糙度················································31.2零件工藝分析及確定工藝路線,選擇數(shù)控機(jī)床設(shè)備··················51.2.1確定裝夾方案,定位基準(zhǔn),編程原點(diǎn),加工起點(diǎn),換刀點(diǎn)········51.2.2制定加工方案及加工路線····································51.2.3刀具的選用················································51.2.4確定加工參數(shù)··············································51.2.5制定加工工藝卡片··········································51.3編制加工程序··················································51.4使用仿真軟件進(jìn)行仿真加工······································61.4.1選擇機(jī)床··················································61.4.2定義毛坯··················································61.4.3安放夾具·················································81.4.4放置零件·················································91.4.5激活機(jī)床并車床回零·······································101.4.6對(duì)刀并設(shè)置長(zhǎng)度補(bǔ)償····································111.4.7設(shè)置工件坐標(biāo)系·········································151.4.8導(dǎo)入程序并自動(dòng)加工·····································162凸臺(tái)溝槽的數(shù)控銑削編程加工·····························182.1零件圖的分析··················································182.1.1零件圖樣·················································182.1.2表面粗糙度···············································182.2零件工藝分析及確定工藝路線,選擇數(shù)控機(jī)床設(shè)備··················182.2.1確定裝夾方案,定位基準(zhǔn),編程原點(diǎn),加工起點(diǎn),換刀點(diǎn)········182.2.2制定加工方案及加工路線···································182.2.3刀具的選用···············································182.2.4確定加工參數(shù)·············································192.2.5制定加工工藝卡片·········································192.3編制加工程序·················································192.4使用仿真軟件進(jìn)行仿真加工······································192.4.1選擇機(jī)床·················································192.4.2定義毛坯·················································202.4.3安放夾具·················································212.4.4放置零件·················································222.4.5選擇刀具·················································232.4.6激活機(jī)床并車床回零····································242.4.7對(duì)刀并設(shè)置長(zhǎng)度補(bǔ)償·································242.4.8設(shè)置刀具偏置··································282.4.9導(dǎo)入程序并自動(dòng)加工·································293字母的數(shù)控銑削編程加工··························313.1零件圖的分析·················································313.1.1零件圖樣·················································313.1.2精度分析·················································313.1.3表面粗糙度···············································313.2零件工藝分析及確定工藝路線,選擇數(shù)控機(jī)床設(shè)備··················313.2.1確定裝夾方案,定位基準(zhǔn),編程原點(diǎn),加工起點(diǎn),換刀點(diǎn)········313.2.2制定加工方案及加工路線···································313.2.3刀具的選用···············································313.2.4確定加工參數(shù)·············································313.2.5坐標(biāo)值計(jì)算·············································323.2.6制定加工工藝卡片·········································323.3編制加工程序··················································323.4使用仿真軟件進(jìn)行仿真加工·····································333.4.1選擇機(jī)床·················································333.4.2定義毛坯·················································333.4.3安放夾具·················································343.4.4安放零件·················································353.4.5選擇刀具·················································363.4.6激活機(jī)床·········································3.4.7對(duì)刀并設(shè)置長(zhǎng)度補(bǔ)償····························3.4.8設(shè)置刀具偏置············································3.4.9導(dǎo)入程序并自動(dòng)加工································參考文獻(xiàn)··························································44序言數(shù)控技術(shù)課程設(shè)計(jì)實(shí)習(xí)是高等本科機(jī)械專業(yè)中重要的一個(gè)實(shí)踐環(huán)節(jié)。是在學(xué)生學(xué)完技術(shù)基礎(chǔ)課和專業(yè)課進(jìn)行的。是培養(yǎng)學(xué)生理論聯(lián)系實(shí)際、解決生產(chǎn)實(shí)際問(wèn)題能力的重要步驟。通過(guò)對(duì)數(shù)控機(jī)床加工程序的編制,使學(xué)生綜合運(yùn)用所學(xué)知識(shí),進(jìn)行一次數(shù)控技術(shù)的實(shí)踐性訓(xùn)練。從而培養(yǎng)學(xué)生具有加工編程能力,初步設(shè)計(jì)計(jì)算能力以及分析和處理生產(chǎn)中所遇到的數(shù)控技術(shù)方面技術(shù)問(wèn)題的能力。由于能力有限,設(shè)計(jì)尚有許多不足之處,希望老師給予指教。1型腔的加工1.1零件圖的分析1.1.1零件圖樣圖1-SEQ圖1-\*ARABIC1加工零件如上圖,是一個(gè)槽形零件,由直線插補(bǔ)完成,材料為10低碳鋼,毛坯尺寸為:,采用銑床加工。1.1.2表面粗糙度加工的內(nèi)壁面有粗糙度為的要求,對(duì)于粗糙度要求,主要是通過(guò)選用合適的刀具及其幾何參數(shù),正確的加工路線,合適的切削用量及冷卻液等措施來(lái)保證。1.2工藝分析及確定工藝路線,選擇數(shù)控機(jī)床設(shè)備1.2.1確定裝夾方案,定位基準(zhǔn),編程原點(diǎn),加工起點(diǎn),換刀點(diǎn)由于毛坯為長(zhǎng)方形,用工藝板夾緊定位。由于工件結(jié)構(gòu)簡(jiǎn)單,換算容易,故編程原點(diǎn)選為毛坯的上端面左前頂點(diǎn)。1.2.2制定加工方案及加工路線根據(jù)工件的形狀及加工要求,選用數(shù)控銑床加工。數(shù)控系統(tǒng)選用華中世紀(jì)星數(shù)控銑床。確定加工工藝路線為:從左向右,從前向后,分為三個(gè)循環(huán),最后再?gòu)淖笙蛴易叩叮鲜稣麄€(gè)過(guò)程再循環(huán)三次。1.2.3刀具的選用由于工件內(nèi)輪廓圓弧倒角為。故選擇的刀具直徑尺寸應(yīng)為的平底立銑刀。刀具為硬質(zhì)合金涂層刀具。1.2.4確定加工參數(shù)主軸轉(zhuǎn)速(n):硬質(zhì)合金材料的刀具切削低碳鋼工件時(shí)切削速度,根據(jù)資料及加工經(jīng)驗(yàn),取v,根據(jù)公式,主軸轉(zhuǎn)速取1.2.5制定加工工藝卡片表1-1零件的加工工藝表1-1零件的加工工藝卡工步號(hào)加工內(nèi)容刀具S(主軸轉(zhuǎn)速)r/minF(進(jìn)給量)mm/min1直線插補(bǔ)T0112001002圓弧插補(bǔ)T0112001003鉆孔T0112001001.3編寫加工程序采用絕對(duì)值編程,絕對(duì)值坐標(biāo)用X`、Y地址表示,且坐標(biāo)尺寸采用小數(shù)點(diǎn)編程。加工程序如表1-3所示。表1-2加工程序表1-2加工程序程序號(hào)O001編程系統(tǒng)華中世紀(jì)星程序簡(jiǎn)要說(shuō)明%001;N10G90G54;N20M03S1200;N30G00Z10;N40X14Y14;N50Z2;N60M98P0002L1;N70G91G01Y-42;N80X-72;N90Y42;N100X72;N110G90G00Z2;N120X66Y35;N130G01Z-8N140G03X66Y35R-16F100;N150G00Z2N160X50Y35N170G01Z-8N180G90G00Z2;N190X0Y0;N200M05;N220G91G28X0Y0Z0;N220M02;%002;N10G91G01Z-6F100;N20M98P0003L3;N30G01X72;N60M99;%0003;N10G91G01X72F100;N20Y7;N30X-72;N40Y7;N50M99;主程序名絕對(duì)方式編程,建立工件坐標(biāo)系主軸正轉(zhuǎn),1200r/minZ向快速移動(dòng)到工件上表面10mm處刀具中心快速移動(dòng)到點(diǎn)(14,14,10)Z向定位到點(diǎn)(14,14,2)調(diào)用002子程序1次增量方式,Y向直線插補(bǔ)X向直線插補(bǔ)Y向直線插補(bǔ)X向直線插補(bǔ)絕對(duì)方式編程,Z軸退到2mm處刀具中心快速移動(dòng)到點(diǎn)(66,35,2)Z向走刀逆時(shí)針圓弧插補(bǔ),插補(bǔ)整個(gè)圓快速抬刀刀具中心快速移動(dòng)到點(diǎn)(50,35,2)Z向走刀快速抬刀快速移動(dòng)到工件原點(diǎn)主軸停止返回到機(jī)床坐標(biāo)原點(diǎn)程序結(jié)束子程序名增量方式,Z向進(jìn)刀調(diào)用O03子程序3次X向插補(bǔ)子程序結(jié)束并返回主程序子程序名增量方式,X向走刀Y向走刀X向走刀Y向走刀子程序結(jié)束并返回主程序1.4使用仿真軟件經(jīng)行仿真加工1.4.1選擇機(jī)床打開菜單“機(jī)床/選擇機(jī)床”指令后,選擇控制系統(tǒng)類型和相應(yīng)的機(jī)床,并按“確定”按鈕。這里所選控制系統(tǒng)類型為華中世紀(jì)星系統(tǒng),“機(jī)床類型”選擇“銑床”,并按“確定”按鈕。選擇好機(jī)床后,界面右側(cè)顯示它的加工范圍等重要參數(shù)如圖1-2所示:圖1-21.4.2定義毛坯打開菜單“零件/定義毛坯”單擊“定義毛坯”指令后,參數(shù)設(shè)定為“毛坯1、10低碳鋼、如圖1-3所示。圖1-31.4.3安裝夾具打開菜單“零件”單擊“安裝夾具”指令后,彈出對(duì)話框如圖1-4,選擇毛坯1,夾具選擇工藝板。圖1-41.4.4放置零件打開菜單“零件”單擊“安裝零件”指令后,彈出對(duì)話框,選擇毛坯1,點(diǎn)擊安裝零件,如圖1-5。點(diǎn)擊上下左右鍵移動(dòng)夾具到合適位置,如圖1-6。圖1-5圖1-61.4.5激活機(jī)床并回零點(diǎn)擊“急停按鈕”使其由變成狀態(tài)。點(diǎn)擊按鈕,按+X,直到變成。同樣的操作使變成。此時(shí)CRT顯示屏如圖1-7所示。圖1-71.4.5選擇刀具打開菜單“機(jī)床/選擇刀具”選擇刀具并確認(rèn)如圖1-8所示:圖1-81.4.6對(duì)刀并設(shè)置長(zhǎng)度補(bǔ)償(1)X和Y方向?qū)Φ饵c(diǎn)擊菜單“機(jī)床/基準(zhǔn)工具””按鈕,選擇彈性棒,如圖1-9;點(diǎn)擊按鈕,使其指示燈亮,再利用按鈕進(jìn)行手動(dòng)操作;直到工具和工件較為接近,選擇厚度為的塞尺檢驗(yàn),如圖1-10所示;點(diǎn)擊按鈕,使其指示燈亮,再按,顯示手輪,進(jìn)行微調(diào),直到塞尺檢驗(yàn)合適,如圖1-11所示。點(diǎn)擊“測(cè)量/剖面圖測(cè)量”,在“選擇測(cè)量平面”中選擇“Y-Z”此時(shí),系統(tǒng)自動(dòng)測(cè)出X軸坐標(biāo),如圖1-12。同樣操作可得Y方向的對(duì)刀值,如圖1-13.。圖1-9圖1-10圖1-111-12圖1-13(2)Z方向?qū)Φ恫鸪鶞?zhǔn)工具,將01號(hào)刀添加到主軸上,類似X對(duì)刀方式,并用厚度為的塞尺檢驗(yàn),直到提示信息顯示“塞尺檢驗(yàn)結(jié)果:合適”;點(diǎn)擊“測(cè)量/剖面圖測(cè)量”,在“選擇測(cè)量平面”中選擇“X-Y”此時(shí),系統(tǒng)自動(dòng)測(cè)出Z軸坐標(biāo),如圖1-14。圖1-141.4.7設(shè)置工件坐標(biāo)系在控制面板上點(diǎn)擊進(jìn)入子頁(yè)面,如圖1-15,點(diǎn)擊,依次輸入X軸、Y軸、Z軸的坐標(biāo)值X-550,Y-450,Z-378,并分別摁輸入,顯示界面如圖1-16。返回并摁下,輸入G54,如圖1-17。圖1-16圖1-171.4.8導(dǎo)入程序并自動(dòng)加工點(diǎn)擊,選擇路徑如圖1-18,點(diǎn)擊確認(rèn)。圖1-18點(diǎn)擊按鈕,并點(diǎn)擊,加工結(jié)果如圖1-19。圖1-192溝槽的數(shù)控銑削編程加工2.1零件圖的分析2.1.1零件圖樣圖2-1加工零件如圖2-1,是一個(gè)溝槽形零件,由直線插補(bǔ)和圓弧插補(bǔ)完成,材料為10低碳鋼,毛坯尺寸為:,采用銑床加工。2.1.2加工的內(nèi)壁面有粗糙度為的要求,對(duì)于粗糙度要求,主要是通過(guò)選用合適的刀具及其幾何參數(shù),正確的加工路線,合適的切削用量及冷卻液等措施來(lái)保證。2.2工藝分析及確定工藝路線,選擇數(shù)控機(jī)床設(shè)備2.2.1由于毛坯為長(zhǎng)方形,用工藝板夾緊定位。由于工件結(jié)構(gòu)簡(jiǎn)單,換算容易,故編程原點(diǎn)選為毛坯的上端面左前頂點(diǎn)。2.2.2根據(jù)工件的形狀及加工要求,選用數(shù)控銑床加工。數(shù)控系統(tǒng)選用華中世紀(jì)星數(shù)控銑床。確定加工工藝路線為:從前向后,從左向右,從后向前,從右向左。2.2.3選擇的刀具直徑尺寸應(yīng)為的平底立銑刀。刀具為硬質(zhì)合金涂層刀具。銑削深度為3mm。2.2.4主軸轉(zhuǎn)速(n):硬質(zhì)合金材料的刀具切削低碳鋼工件時(shí)切削速度,根據(jù)資料及加工經(jīng)驗(yàn),取v,根據(jù)公式,主軸轉(zhuǎn)速取1.2.5制定加工工藝卡片表2-1零件的加工工藝表2-1零件的加工工藝卡工步號(hào)加工內(nèi)容刀具S(主軸轉(zhuǎn)速)r/minF(進(jìn)給量)mm/min1直線、圓弧插補(bǔ)T011000802孔加工T011000802.3編寫加工程序采用絕對(duì)值編程,絕對(duì)值坐標(biāo)用X`、Y地址表示,且坐標(biāo)尺寸采用小數(shù)點(diǎn)編程。加工程序如表2-2所示。表2-2加工程序表2-2加工程序程序號(hào)O001編程系統(tǒng)華中世紀(jì)星程序簡(jiǎn)要說(shuō)明%002;N10G90G54;N20M03S1000;N30G00X15Y5;N40Z10;N50G01Z-3F80;N60Y85;N70X105.796;N80G03X125Y76.037R15;N90G01Y27.804;N100X102.071Y5;N110X15;N120G00Z10;N130X70Y50;N140G01Z-3F80;N150G00Z100;N160G91G28X0Y0Z0;N170M05;N180M02;程序名絕對(duì)方式編程,G54工件坐標(biāo)系主軸正轉(zhuǎn),1000r/min快速定位至(15,0,0)快速定位至(15,0,10)Z向進(jìn)給Y向進(jìn)給X向進(jìn)給逆時(shí)針圓弧插補(bǔ)Y向進(jìn)給倒角X向進(jìn)給快速抬刀快速定位至(70,50,10)Z向進(jìn)給快速定位至(0,0,100)返回機(jī)床原點(diǎn)主軸停止程序結(jié)束2.4使用仿真軟件經(jīng)行仿真加工2.4.1選擇機(jī)床打開菜單“機(jī)床/選擇機(jī)床”指令后,選擇控制系統(tǒng)類型和相應(yīng)的機(jī)床,并按“確定”按鈕。這里所選控制系統(tǒng)類型為華中世紀(jì)星系統(tǒng),“機(jī)床類型”選擇“銑床”,并按“確定”按鈕。選擇好機(jī)床后,界面右側(cè)顯示它的加工范圍等重要參數(shù)如圖2-2所示:圖2-22.4.2定義毛坯打開菜單“零件/定義毛坯”單擊“定義毛坯”指令后,參數(shù)設(shè)定為“毛坯2、10低碳鋼、如圖2-3所示。圖2-32.4.3打開菜單“零件”單擊“安裝夾具”指令后,彈出對(duì)話框如圖2-4,選擇毛坯2,夾具選擇工藝板。圖2-42.4.4打開菜單“零件”單擊“安裝零件”指令后,彈出對(duì)話框,選擇毛坯2,點(diǎn)擊安裝零件,如圖2-5。點(diǎn)擊上下左右鍵移動(dòng)夾具到合適位置,如圖2-6。圖2-5圖2-62.4.5點(diǎn)擊“急停按鈕”使其由變成狀態(tài)。點(diǎn)擊按鈕,按+X,直到變成。同樣的操作使變成。此時(shí)CRT顯示屏如圖2-7所示。圖2-72.4.打開菜單“機(jī)床/選擇刀具”選擇刀具并確認(rèn)如圖2-8所示:圖2-82.4.(1)X和Y方向?qū)Φ饵c(diǎn)擊菜單“機(jī)床/基準(zhǔn)工具””按鈕,選擇彈性棒,如圖2-9;點(diǎn)擊按鈕,使其指示燈亮,再利用按鈕進(jìn)行手動(dòng)操作;直到工具和工件較為接近,選擇厚度為的塞尺檢驗(yàn),如圖2-10所示;點(diǎn)擊按鈕,使其指示燈亮,再按,顯示手輪,進(jìn)行微調(diào),直到塞尺檢驗(yàn)合適,如圖2-11所示。點(diǎn)擊“測(cè)量/剖面圖測(cè)量”,在“選擇測(cè)量平面”中選擇“Y-Z”此時(shí),系統(tǒng)自動(dòng)測(cè)出X軸坐標(biāo),如圖2-12。同樣操作可得Y方向的對(duì)刀值,如圖2-13.。圖2-9圖2-10圖2-112-12圖2-13(2)Z方向?qū)Φ恫鸪鶞?zhǔn)工具,將01號(hào)刀添加到主軸上,類似X對(duì)刀方式,并用厚度為的塞尺檢驗(yàn),直到提示信息顯示“塞尺檢驗(yàn)結(jié)果:合適”;點(diǎn)擊“測(cè)量/剖面圖測(cè)量”,在“選擇測(cè)量平面”中選擇“X-Y”此時(shí),系統(tǒng)自動(dòng)測(cè)出Z軸坐標(biāo),如圖2-14。圖2-142.4.8在控制面板上點(diǎn)擊進(jìn)入子頁(yè)面,如圖2-15,點(diǎn)擊,依次輸入X軸、Y軸、Z軸的坐標(biāo)值X-570,Y-465,Z-378,并分別摁輸入,顯示界面如圖2-16。返回并摁下,輸入G54,如圖2-17。圖2-16圖2-172.4.點(diǎn)擊,選擇路徑如圖2-18,點(diǎn)擊確認(rèn)。圖2-18點(diǎn)擊按鈕,并點(diǎn)擊,加工結(jié)果如圖2-19。圖2-193字母的數(shù)控銑削編程加工3.1零件圖的分析3.1.1圖3-1加工零件如圖3-1,是字母的加工,由直線插補(bǔ)插補(bǔ)完成,材料為10低碳鋼,毛坯尺寸為:,采用銑床加工。3.1.2加工的內(nèi)壁面有粗糙度為的要求,對(duì)于粗糙度要求,主要是通過(guò)選用合適的刀具及其幾何參數(shù),正確的加工路線,合適的切削用量及冷卻液等措施來(lái)保證。3.2工藝分析及確定工藝路線,選擇數(shù)控機(jī)床設(shè)備3.2.1由于毛坯為長(zhǎng)方形,用工藝板夾緊定位。由于工件結(jié)構(gòu)簡(jiǎn)單,換算容易,故編程原點(diǎn)選為毛坯的上端面左前頂點(diǎn)。3.2.2根據(jù)工件的形狀及加工要求,選用數(shù)控銑床加工。數(shù)控系統(tǒng)選用華中世紀(jì)星數(shù)控銑床。確定加工工藝路線為:從左向右。3.2.3選擇的刀具直徑尺寸應(yīng)為的平底立銑刀。刀具為硬質(zhì)合金涂層刀具。銑削深度為2mm。3.2.4主軸轉(zhuǎn)速(n):硬質(zhì)合金材料的刀具切削低碳鋼工件時(shí)切削速度,但由于刀具直徑較小,根據(jù)經(jīng)驗(yàn)及查資料取v,根據(jù)公式,主軸轉(zhuǎn)速取3.2.5表3-1零件的加工工藝表3-1零件的加工工藝卡工步號(hào)加工內(nèi)容刀具S(主軸轉(zhuǎn)速)r/minF(進(jìn)給量)mm/min1直線插補(bǔ)T011000502孔加工T01100050圓弧插補(bǔ),加工圓T011000503.3編寫加工程序采用絕對(duì)值編程,絕對(duì)值坐標(biāo)用X`、Y地址表示,且坐標(biāo)尺寸采用小數(shù)點(diǎn)編程。加工程序如表3-2所示。表3-2加工程序表3-2加工程序O003編程系統(tǒng)華中世紀(jì)星程序簡(jiǎn)要說(shuō)明%003;N10G90G54;N20M03S1000;N30G90G00X13Y17;N40G43Z10H01M07;N50G01Z-2F50;N60X33Y47;N70G00Z6;N80X13;N90G01Z-2;N100X33Y17;N110G00Z6;N120X38Y47;N130G01Z-2;N140X48Y32;N150Y17;N160G00Z6;N170X58Y47;N180G01Z-2;N190X48Y32;N200G00Z6;N210X63Y47;N220G01Z-2;N230X83;N240X63Y17;N250X83;N260G00Z6;N270X23Y10;N280G01Z-2;N290G00Z6;N300X48Y10;N310G01Z-2;N320G00Z6;N330X73Y10;N340G01Z-2;N350G00Z6;N360X12Y32;N370G01Z-2N380G03X12Y32R-4F50;N390G00Z6;N400X92Y32;N410G01Z-2N420G03X92Y32R-4F50;N430G00G49Z0;N440M09M05;N450G91G28X0Y0Z0;N460M02;程序名絕對(duì)方式編程,G54工件坐標(biāo)系主軸正轉(zhuǎn),1000r/min快速定位到點(diǎn)(13,17,0)Z軸快速定位,調(diào)用1號(hào)長(zhǎng)度補(bǔ)償,切削液開Z向進(jìn)給刀具切削至點(diǎn)(33,47,-2)快速抬刀快速定位到點(diǎn)(13,47,6)Z向進(jìn)給刀具切削至點(diǎn)(33,17,-2)快速抬刀快速定位到點(diǎn)(38,47,6)Z向進(jìn)給刀具切削至點(diǎn)(48,32,-2)Y向進(jìn)給快速抬刀快速定位到點(diǎn)(58,47,6)Z向進(jìn)給刀具切削至點(diǎn)(48,32,-2)快速抬刀快速定位到點(diǎn)(63,47,6)Z向進(jìn)給X向進(jìn)給刀具切削至點(diǎn)(63,17,-2)X向進(jìn)給快速抬刀快速定位到點(diǎn)(23,10,6)Z向進(jìn)給快速抬刀快速定位到點(diǎn)(48,10,6)Z向進(jìn)給快速抬刀快速定位到點(diǎn)(73,10,6)Z向進(jìn)給快速抬刀快速定位到點(diǎn)(12,32,6)Z向進(jìn)給逆時(shí)針圓弧插補(bǔ),加工整圓快速抬刀快速定位到點(diǎn)(92,32,6)Z向進(jìn)給逆時(shí)針圓弧插補(bǔ),加工整圓取消刀具補(bǔ)償,Z軸快速回到機(jī)械原點(diǎn)切削液關(guān),主軸停止返回到機(jī)床原點(diǎn)程序停止3.4使用仿真軟件經(jīng)行仿真加工3.4.1選擇機(jī)床打開菜單“機(jī)床/選擇機(jī)床”指令后,選擇控制系統(tǒng)類型和相應(yīng)的機(jī)床,并按“確定”按鈕。這里所選控制
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