模具綜合實驗-模具課程設(shè)計-模具數(shù)控加工實驗

PAGEPAGE28課程設(shè)計課程名稱模具綜合實驗題目名稱人民幣學生學院_材專業(yè)班級學號學生姓名指導教師2012年12月27日目錄一、實驗目的和要求···················································3二、實驗設(shè)備和儀器···················································42.1、模架···························································42.2、原材料、零配件、刃具清單·······································42.3、實驗設(shè)備和儀器·················································4三、實驗項目和內(nèi)容3.1、CAD/CAM/CAE綜合實驗···········································43.2、模具相關(guān)內(nèi)容···················································43.3、模具加工制作具體流程···········································53.4、實驗過程·······················································5四、個人部分4.1、個人產(chǎn)品設(shè)計···················································64.2、模具零件加工的工藝路線·········································74.3、模具制作工藝規(guī)程··············································7五、模具制作組小組部分5.1、小組成員及分工················································85.2、學生實驗配套工具清單··········································95.3、型芯鑲塊的加工工藝路線········································95.4、型腔鑲塊的加工工藝路線········································105.5、工藝規(guī)程······················································105.6、注射部分······················································12六、個人總結(jié)·························································13七、致謝······························································13八、參考資料·························································13一、實驗目的和要求材料成型及控制工程專業(yè)的學生經(jīng)過專業(yè)基礎(chǔ)課和專業(yè)課的學習，基本掌握了高分子材料、金屬材料成型加工的特點，成型模具的結(jié)構(gòu)設(shè)計，各種先進的模具制造技術(shù)等知識。應用所學專業(yè)知識及各種先進計算機軟件（如AutoCAD、Pro/E、UG、MasterCAM）、實驗儀器設(shè)備等進行模具專業(yè)綜合實驗，不但可以提高學生的實踐能力，同時也是一個對專業(yè)課理論知識融會貫通、消化和吸收、提高總結(jié)的過程。在綜合實驗的過程中，不但對理論知識的理解得到提高，最重要的是能夠使學生對專業(yè)知識的綜合運用能力得到提高。通過綜合實驗，能夠提出問題，并運用已掌握的知識分析實際問題，并解決問題，從而使學生解決實際問題的能力得到升華，為今后從事設(shè)計與研究工作奠定良好的基礎(chǔ)。綜合實驗是實踐教學環(huán)節(jié)，有利于培養(yǎng)和提高學生的設(shè)計能力及解決生產(chǎn)技術(shù)問題的能力，初步掌握分析研究解決工程技術(shù)問題的方法。同時，通過實驗也能進一步了解和掌握實驗設(shè)備的結(jié)構(gòu)、工作原理，熟練使用本專業(yè)設(shè)備。在綜合實驗中，要求每個學生利用現(xiàn)有的條件（原材料、工藝設(shè)備等），充分發(fā)揮自己的創(chuàng)新思維和主觀能動性，從制品三維造型設(shè)計、到模具結(jié)構(gòu)設(shè)計、材料選擇、成型加工方法選擇，到實驗工藝路線確定，再到模具的制作與裝配及試模，自行設(shè)計與實施實驗的全過程，最終完成綜合實驗課程的訓練。從而避免驗證性、無自主、無創(chuàng)新的重復實驗。模具專業(yè)綜合實驗是按照生產(chǎn)實際的情況而設(shè)置的實踐環(huán)節(jié)，涉及設(shè)計、采購、外協(xié)聯(lián)系及機械零件的加工制造過程。它為材料成型與控制工程專業(yè)本科學生在專業(yè)知識的應用設(shè)計、加工操作、團體協(xié)作等綜合能力方面提供鍛煉的機會，也提供一個對所學的各門專業(yè)課程知識起到融會貫通、消化和吸收、綜合提高和總結(jié)的實踐環(huán)節(jié)，是一個真刀實槍的實踐平臺。本專業(yè)學生經(jīng)過三年半的學習，系統(tǒng)學習了專業(yè)基礎(chǔ)課程與專業(yè)課程，也進行了相關(guān)課程的實驗，參加過金工實習、認識實習和生產(chǎn)實習，對本專業(yè)所從事的工作有比較深入的了解，有一定的專業(yè)實踐經(jīng)驗，在運用計算機技術(shù)進行產(chǎn)品、工藝與模具的設(shè)計分析、運用數(shù)控加工技術(shù)進行成型模具制造方面具有初步能力。但是，學生對所學的各門專業(yè)課程知識還缺乏大串通、大融合、綜合提高和總結(jié)的實踐鍛煉，因此，在畢業(yè)設(shè)計之前，進行模具專業(yè)綜合性實驗，目的在于學生加深對專業(yè)理論知識的理解，更重要的是可使學生能夠?qū)⒏鏖T課程之間的知識聯(lián)系起來，結(jié)合運用，加強實踐鍛煉，使學生的綜合能力得到提高；目的在于為學生進行畢業(yè)設(shè)計提供掌握專業(yè)實踐經(jīng)驗的學習平臺，為學生走上專業(yè)工作崗位提供一次真刀實槍練兵機會。二、實驗設(shè)備和儀器1、模架龍記大水口AI2015型2、原材料、零配件、刃具清單鋁合金鑲塊毛坯兩塊，130x120x30，130x120x30頂桿Ф4，2根；澆口套定位環(huán)鉆頭Ф4鉆鑲塊螺紋孔用絲錐M5攻鑲塊螺紋鉆頭Ф4鉆鑲塊推桿孔銑刀Ф16，銑鑲塊六平面、粗加工、型腔銑刀Ф4，精加工型芯、型腔3、實驗設(shè)備和儀器ZXK-32B型數(shù)控銑床一臺，ZXK-25A型普通鉆銑床兩臺，ZQ4116臺式鉆床一臺，Aircompressor一臺，CJ80TB塑膠成型注射機一臺，深度游標卡尺一把、樣沖一根，虎頭鉗一座，鐵錘、鋼尺、游標卡尺若干三、實驗項目和內(nèi)容自行設(shè)計一個產(chǎn)品零件，然后根據(jù)實驗室現(xiàn)有的模具模架加工出相應的塑膠塑件。1、CAD/CAM/CAE綜合實驗1）每人根據(jù)所測繪模架的實際尺寸，合理設(shè)計一個無側(cè)孔的塑膠制品；或合理設(shè)計一個沖壓件，并造型設(shè)計其三維結(jié)構(gòu)圖。2）設(shè)計上述產(chǎn)品的注塑模具或沖壓模具，設(shè)計其模具三維結(jié)構(gòu)裝配圖。3）繪制模具的二維裝配圖及零件圖。4）制定模具零件的工藝路線。5）制定模具零件加工工藝規(guī)程。6）模具零件數(shù)控加工刀路生成與加工模擬。選擇合適的加工方式、加工刀具、切削用量和走刀方式，選擇合適的加工工藝其他參數(shù)值，編制數(shù)控加工刀路，并進行加工模擬，再生成數(shù)控NC代碼。（計算機上進行）2、模具相關(guān)內(nèi)容產(chǎn)品CAD計算機輔助設(shè)計。通過所學的知識，運用UG軟件，把塑件圖設(shè)計出來。采購鑲塊、澆口套、頂針及推板固定板粗加工，即用銑床把鑲塊和推板固定板的六個面粗銑一次。把型腔和型芯分別裝配上A、B板，如果配合不夠緊密，則攻螺孔把鑲塊固定。對型腔和型芯進行UG數(shù)控編程。把鑲塊放在數(shù)控加工中心上進行加工。加工頂針使其長度適合，加工推板固定板，動模固定板。加工澆口套，使其剛好到達定模底部。3、模具加工制作具體流程1）模具制作組的確定。根據(jù)實驗的總?cè)藬?shù)分成若干個大組，每個大組加工制作一套模具。2）每個模具制作組進行模架拆裝、結(jié)構(gòu)分析與測繪。3）各人進行CAD/CAM/CAE綜合實驗。4）從本組成員的設(shè)計方案中選擇一套模具圖紙，用于模具加工制作。5）模具制作組分成若干個小組，成員相對分工，指定各小組組長、副組長，指定設(shè)計、采購、編程、加工、裝配負責人。6）對選定方案模具圖紙的審核、零件的工藝路線的可行性分析，零件加工方式、加工刀具的審核。7）模具零配件市場調(diào)研與采購，列出實驗用的材料、零配件、量刃具和夾具清單，并根據(jù)實驗室的具體條件，補充采購實驗用品。8）審核切削用量和走刀方式，選擇相關(guān)的參數(shù)值。9）熟悉儀器設(shè)備的操作使用。10）模具零件數(shù)控加工11）模具零件普通機加工（車、銑、鉆）。12）模具零件電加工（線切割、電火花）。13）檢測加工零件的尺寸精度、形位公差、表面粗糙度等是否達到要求。14）模具鉗工裝配與調(diào)試。15）撰寫實驗報告。16）綜合實驗答辯。4、實驗過程明確綜合實驗內(nèi)容和所提供的實驗條件，認真復習機械制圖、機械制造基礎(chǔ)、數(shù)控加工技術(shù)基礎(chǔ)、模具材料與熱處理、塑膠制品設(shè)計、塑膠成型計算機輔助設(shè)計與制造、塑膠成型工藝與模具設(shè)計、模具制造工藝與模具數(shù)控加工技術(shù)等課程的相關(guān)知識，聯(lián)系起來，綜合運用。了解實驗室所能提供的模具制作的手段，了解和掌握實驗設(shè)備儀器的結(jié)構(gòu)、工作原理、主要技術(shù)參數(shù)、工作特點、注意事項，熟練操作設(shè)備儀器。熟悉量具和刀具的類型、材質(zhì)、尺寸、使用范圍、使用方法，熟悉夾具和鉗工工具的使用方法，掌握機械加工切削用量的選擇。掌握各種基準之間的選擇及相互間尺寸轉(zhuǎn)換。掌握塑膠模具或沖壓模具制造的技術(shù)要求，如尺寸精度、表面形狀和位置精度、粗糙度、硬度，零件間的公差與配合關(guān)系。盡量從日常實用角度出發(fā)，與模架尺寸的大小、綜合實驗時間和提供的加工手段等條件結(jié)合起來，設(shè)計尺寸大小和結(jié)構(gòu)復雜程度合適的塑料件或沖壓件，利用本專業(yè)通用的計算機輔助設(shè)計軟件進行產(chǎn)品造型設(shè)計，進行模具結(jié)構(gòu)設(shè)計，繪制出裝配圖和零件圖，注意到零件間的公差與配合。確定工藝路線，應根據(jù)實驗室的條件選擇合適的零件加工方法。制定詳細的模具制作工藝規(guī)程，工藝規(guī)程內(nèi)容包括：毛坯的種類和尺寸；選擇定位基準和加工方法，擬訂零件加工工藝路線；確定各工序余量、尺寸、公差、技術(shù)要求；確定機床類型，確定零件的加工工序、工步；刀具、夾具的選擇和調(diào)整，工件的定位與裝夾，時間安排；填寫工藝檔。手工編程加工程序時，要對加工軌跡的數(shù)據(jù)進行計算和優(yōu)化。利用本專業(yè)通用的計算機輔助制造軟件進行數(shù)控編程和模擬運行時，應選擇合適加工方式，走刀路徑，選擇合適的加工刀具、切削用量。對生成的刀具路徑進行加工模擬效驗與優(yōu)化，最后生成加工代碼。詳細列出本組完成綜合實驗項目所需物品的清單，要周密考慮，包括毛坯、刀具、夾具、量具、工具等物品，以及其材質(zhì)、類型、尺寸大小、刀具的裝夾尺寸和刀刃有效長度等，與老師一起核對清單并確定需外購物品，獲取采購信息，外購完成實驗用物品。根據(jù)工藝檔，合理安排時間，加工模具零件，裝配和修整模具，按質(zhì)按量完成模具的制作工作。四、個人部分個人產(chǎn)品三視圖對于設(shè)計出來了產(chǎn)品，我們該如何將他們加工出來，在這個過程中我們應該注意哪些問題，都是我們應該考慮的。根據(jù)產(chǎn)品的尺寸和我們實驗室現(xiàn)有的模架，產(chǎn)品注射的使用一模一腔。3D模架圖模具整體三視圖1、模具零件加工的工藝路線模具制造是在一定的工藝條件下，改變模具材料的形狀、尺寸和性質(zhì)，使之成為符合設(shè)計要求的模具零件，再經(jīng)裝配、試模和修整而得到整副模具產(chǎn)品的過程。包括生產(chǎn)技術(shù)準備、模具零件加工和模具裝配等階段。（1）生產(chǎn)技術(shù)準備生產(chǎn)技術(shù)準備階段的主要任務是分析模具圖樣，制訂工藝規(guī)程；編制數(shù)控加工程序；設(shè)計和制造工裝夾具；制定生產(chǎn)計劃，制定并實施工具、材料、標準件等外購和零件外協(xié)加工計劃。各種生產(chǎn)服務活動如生產(chǎn)中原材料、半成品和工具的供應、運輸、保管以及產(chǎn)品的包裝和發(fā)運等。（2）模具零件加工1）傳統(tǒng)的切削加工，如車、鉗、刨、銑、磨等；2）數(shù)控加工，如數(shù)控銑削、加工中心加工等；而我的零件產(chǎn)品加工主要用到的就是這兩種，加工這個零件產(chǎn)品，要先進行平面銑削，使得買回來的模具零件的尺寸精度和表面精度都符合模具零件加工的要求。（3）模具裝配模具裝配是根據(jù)模具裝配圖樣要求的質(zhì)量和精度，將加工好的零件組合在一起構(gòu)成一副完整模具的過程。除此之外，裝配階段的任務還有清洗、修配模具零件，試模及修整等。2、模具制作工藝規(guī)程制定工藝規(guī)程的目的就是為了能有效地指導并控制各工序的加工質(zhì)量，使之能有序地按要求實施，最終能以先進而又可靠的技術(shù)和最低的生產(chǎn)成本、最短的時間制造出品質(zhì)符合用戶要求的模具。（1）工藝規(guī)程的性質(zhì)和作用模具零件機械加工工藝規(guī)程就是以規(guī)范的表格形式和必要的圖文，將模具制造的工藝過程以及各工序的加工順序、內(nèi)容、方法和技術(shù)要求，所配置的設(shè)備和輔助工裝，所需加工工時和加工余量等內(nèi)容，按加工順序，完整有序的編入所形成的模具制造過程的指導性技術(shù)檔。因此，模具制造工藝規(guī)程的作用即是用以組織、指導、管理和控制模具制造的各個工序。（2）制訂工藝規(guī)程的步驟1）首先應對模具的設(shè)計意圖和整體結(jié)構(gòu)、各零部件的相互關(guān)系和功能以及配合要求等有詳盡透徹的了解，即把每個零部件的加工工藝性和裝配性都吃透，方能制訂出切合實際、正確無誤、行之有效的工藝規(guī)程；2）根據(jù)每個零件的數(shù)量確定其采用單件生產(chǎn)還是多件生產(chǎn)方式(多型腔模具)；3）根據(jù)所采用的毛坯類型確定毛坯的下料尺寸；4）根據(jù)圖紙的技術(shù)要求，選定主要加工面的加工方法和定位基準，并確定該零件的加工順序；5）確定各工序的加工余量即各工序尺寸和公差以及技術(shù)要求；6）配置相應的機床、刀具、夾具、工具、量具；7）確定各工序的切削參數(shù)和工時定額；8）填寫并完成工藝過程綜合卡的制訂，經(jīng)審批后下達實施。型腔與型芯五、模具制作組小組部分1、小組成員，本組組長、副組長，各組員負責或參與完成的工作部分。組長：副組長：設(shè)計：整體模具模具實物模具動模部分2、學生實驗配套工具清單：帶鎖便攜式工具箱（含分隔塊6塊）帶表卡尺150X0.02mm直尺300mm百分表塞尺角尺150mm紫銅棒Φ40X200mm黃銅棒Φ10X150mm大平銼（寬30mm）什錦銼一套（10件）內(nèi)六角扳手一套（1.5~10mm共9件）活動扳手300X36固定扳手M16錘子絲攻、板牙（M4-M10）帶扳手一套（M3X0.5,M4X0.7,M5X0.8,M6X1,M7X1,M8X1.25,M9X1.25,M10X1.5,M12X1.75）立銑刀Φ8，Φ10，Φ12，Φ16各1把球頭銑刀R1.5,R2,R3,R4錐銼刀1度，球頭R4,R5各一把雙頭螺栓M12長100、130、150、180、200、250（螺紋長50mm）T型螺母8~10個ME420-10尋邊器1個扁螺絲刀1把，十字刀1把毛刷寬50.8mm的2把，寬38.1mm的2把油石、砂紙一套卷尺3米1個鎖1把3、型腔鑲塊的加工工藝路線粗銑六面體到125.11x90.15x27——精銑六面體到125.01x90.05x26——鑲塊鑲?cè)階板——鉆4個螺釘孔Ф4——攻螺紋M6——取出鑲塊——粗銑型腔——精銑型腔——拋光B板鑲塊A板鑲塊A板鑲塊二維圖B板鑲塊二維圖4、型芯鑲塊的加工工藝路線粗銑六面體到125.11x90.15x25——精銑六面體到125.01x90.05x23.5——鑲塊鑲?cè)隑板——鉆4個推桿孔——鉆4個螺釘孔Ф4——攻螺紋M6——取出鑲塊——粗銑型芯——精銑型芯——拋光5、工藝規(guī)程B板數(shù)控加工圖示（型腔模擬加工）程序清單：%N0010G92X0Y0Z0N0020G91G28Z0.0:0030T00M06N0040G0G90X-.4873Y-.2468S1200M03N0050G43Z.3937H00N0060Z.1181N0070G3X-.4873Y-.2468Z-.0012I-.0073J-.0705K.019F2.N0080X-.5655Y-.3173Z-.033I-.0073J-.0705K.019N0090G1X-.4946M08N0100X-.1583N0110G2X-.0008Y-.4748I0.0J-.1575N0120G1Y-1.0287N0130G3X.0008I.0008J0.0N0140G1Y-.4748N0150G2X.1583Y-.3173I.1575J0.0N0160G1X.8309N0170G3Y-.3157I0.0J.0008N0180G1X.1583N0190G2X.0008Y-.1583I0.0J.1574N0200G1Y.2374N0210G2X.1583Y.3949I.1575J0.0N0220G1X.8309N0230G3Y.3965I0.0J.0008N0240G1X.1833N0250G2X.0719Y.6653I0.0J.1574N0260G1X.3846Y.978N0270G3X.3642Y.9598I.148J-.1867N0280G1X.2233Y.8189N0290G2X-.2233I-.2233J.2232N0300G1X-.3642Y.9598N0310G3X-.3846Y.978I-.1684J-.1685N0320G1X-.0719Y.6653N0330G2X-.1833Y.3965I-.1114J-.1114N0340G1X-.8309N0350G3Y.3949I0.0J-.0008N0360G1X-.1583N0370G2X-.0008Y.2374I0.0J-.1575N0380G1Y-.1583N0390G2X-.1583Y-.3157I-.1575J0.0N0400G1X-.8309N0410G3Y-.3173I0.0J-.0008N0420G1X-.4946N0430Y-.3961N0440X-.1583N0450G2X-.0795Y-.4748I0.0J-.0787N0460G1Y-1.0287N0470G3X.0795I.0795J0.0N0480G1Y-.4748N0490G2X.1583Y-.3961I.0788J0.0N0500G1X.8309N0510G3Y-.237I0.0J.0796N0520G1X.1583N0530G2X.0795Y-.1583I0.0J.0787N0540G1Y.2374N0550G2X.1583Y.3161I.0788J0.0N0560G1X.8309N0570G3Y.4752I0.0J.0796N0580G1X.1833N0590G2X.1276Y.6096I0.0J.0787N0600G1X.6244Y1.1064N0610X.6258Y1.1083N0620X.6253N0630X.5326N0640G3X.3085Y1.0154I0.0J-.317N0650G1X.1676Y.8746N0660G2X-.1676I-.1676J.1675N0670G1X-.3085Y1.0154N0680G3X-.5326Y1.1083I-.2241J-.2241N0690G1X-.6246N0700X-.6249Y1.1069N0710X-.1276Y.6096N0720G2X-.1833Y.4752I-.0557J-.0557N0730G1X-.8309N0740G3Y.3161I0.0J-.0795N0750G1X-.1583N0760G2X-.0795Y.2374I0.0J-.0787N0770G1Y-.1583N0780G2X-.1583Y-.237I-.0788J0.0N0790G1X-.8309N0800G3Y-.3961I0.0J-.0795N0810G1X-.4946N0820Y-.3173N0830Z.0851N0840G0Z.3937N0850X-.4873Y-.2468N0860Z.0851N0870G3X-.4873Y-.2468Z-.0341I-.0073J-.0705K.019N0880X-.5655Y-.3173Z-.0659I-.0073J-.0705K.019N0890G1X-.4946N0900X-.1583N0910G2X-.0008Y-.4748I0.0J-.1575N0920G1Y-1.0287N0930G3X.0008I.0008J0.0N0940G1Y-.4748N0950G2X.1583Y-.3173I.1575J0.0N0960G1X.8309N0970G3Y-.3157I0.0J.0008N0980G1X.1583N0990G2X.0008Y-.1583I0.0J.1574N1000G1Y.2374N1010G2X.1583Y.3949I.1575J0.0N1020G1X.8309N1030G3Y.3965I0.0J.0008N1040G1X.1833N1050G2X.0719Y.6653I0.0J.1574N1060G1X.3846Y.978N1070G3X.3642Y.9598I.148J-.1867N1080G1X.2233Y.8189N1090G2X-.2233I-.2233J.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