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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
 

MTR-1331-J-N-D-E-S MTR series NEMA 34 splashproof stepping motor with series winding connection

QPJ-ABD-201 Communication Module for 5 inch & 6 inch: AB DataHighway Plus/ UL/ cUL/ CE/ UL 1604

20BC3P5A0AYNADC0 PowerFlex 700 AC Drive 20B

20G14TC770AN0NNNNN PowerFlex 755 AC Packaged Drive

22C-B017F103 PowerFlex 400 3.7 kW (5 Hp) AC Drive

25C-CTMFC1 PowerFlex 527 Control Module Front Cover

2711P-T15C4A9 PanelView Plus Terminal

290D-FBP-G2 Direct Online Starter

NT20S-ST121(B)-ECV3 单色STN LCD 分辨率: 256×128点,4.7英寸

1492-MCBA335 35 A Ul489 Miniature Circuit Breaker

1494V-DN200 NEMA Flange Mtd Rod Switch Disconnect Sw

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运行版软件 6AV2103-4MX04-0AE5 SIMATIC WinCC V7.0..V7.3 RC 65536 ->WinCC 专业版 max. PowerTags V14 Combo 和 WinCC RT 专业版 65536 PowerTags

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1756-L75K ControlLogix 32 MB Controller

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2090-CFBM7DD-CEAA30 MP-Series 30m Servo Feedback Cable

2090-SR040-09 Kinetix 40 Ohm Shunt Resistor

BC646MPS101 Logic Developer PLC Standard with Programming Cable with Proficy GlobalCare Complete

GC647AQC050 GC Quality Client 50 Pak

HMI-COV-204 FRONT SHEET COVER 6 inch (QPK2xxxx-L2P/ -S2P)/ 20 per pack

IC641VPS950 VersaPro Standard Edition 50 Seat Site License - Windows Programming S oftware for Series 90-30 and VersaMax PLCs

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IC697ACC732 Top PWA Cover - CPU77x and CPU78x (Qty 2)

IC756WRT499E-28 DV-Tools Only Runtime License for Windows, Per User, English v2.8

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1494C-DJ622-A4-B-D-E-F-G 200 A Flange Mtd Cable Switch

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1585BT-M8UBBM-5 1585 Ethernet Media Patchcord

1747-DU501 SLC 5/05 Firmware Upgrade Kit

1790D-T8BV8V CompactBlock LDX 16 Point Base Block

194E-A63-1753-6G 63 A 194E Load switch

20-VB00448 FEEDBACK INTERFACE BOARD

2090-CSWM1DE-14AA09 Kinetix Cable Single DSL 2090-Series

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GC646MDB075 Proficy GlobalCare Complete for Logic Developer PC w/Runtime 75 I/O

HE693BZL300 Mounting bezel for full-sized OIUs.

IC600PM548RR High Capacity I/O Rack Power Supply, 125Vdc

IC647HSTESEO30KM eSignature Option for Historian - Enterprise Server 30000 Points (M4 Key)

IC655MDL555RR 12-24Vdc Output, Positive Logic (16 points)

IC694MDL390 Output module 120/240VAC 2 amps 5 point isolated.

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150-FPP480B SMC Flex Renewal Part

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IC693CBL327 Cable, Left Side, One - 24 Pin 90 Degree Connector, 3 Meter

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22B-E1P7N104 PowerFlex 40- 0.75 kW (1 HP) AC Drive

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284E-FVD7P6Z-25-RR-3-DB-SB EtherNet Variable Frequency Drive

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电机启动器 3VU13401NL00

150-C19NBD SMC-3 19A Smart Motor Controller

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1769-SM2 Compact IO To DSI Communication module

193-CBCT2 E3 Plus Ground Fault Current Sensor

194R-R6 Operating Shaft

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2090-XXTPMP-16S25 MP-Series 25 m Length Power Cable

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IC647ADC002 PA Dashboard Client 2 Pak

IC647PCL050 Proficy Process Systems Standard Edition 500 I/O with CIMPLICITY

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Motion Control 9101-0327 CONNECTOR KIT, MOTOR POWER, F/H-6X, STRAIGHT

GQPI3D200E2P QUICKPANEL 9" EL GE LABEL

IC646MRB150 Logic PC 150 Tag Runtime System

MTR-1N42-H-E-A-E-S Steping Motor Nema42, Parallel Wdg, Encoder

SA07-020 MATRIX Basic Training (3.5 days)

20BC056A0AYNACD1 PowerFlex 700 AC Drive 56 A 30 kW 20B

20F11ND096AA0NNNNN PowerFlex 753 AC Packaged Drive

22-RF5P7-AL PowerFlex EMC Filter

2711P-RN6 PV Plus 700 to 1500 DH Plus RIO Module

281D-F12B-10B-CR ArmorStart Direct Online RVSG Starter

C200H-IM212 输入单元,16点, 12 - 24 VAC/DC

1492-PLOTADPT IEC X-Y Plotter Ultra Fine Pen Adapter

定位模块 6ES7 451-3AL00-0AE0 FM451 定位，rapid traverse/creep speed,3 轴

变送器 3RS10301DD20

1497-C-M2-0-N Control Circuit Transformer

1606-XL120E-3 Power Supply XL 120 W Power Supply

1762-IF4 MicroLogix 4 Point Analog Input Module

188-K3C130-N Miniature Circuit Breaker 13 A

194L-G2864R Control Knob Red

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IC800SSI104RS1MOD1 Custom modified 4.3 amp 115/230 VAC S2K servo controller for MTR series motors

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Support 9303-23S0E40S SUPPORT RENEWAL CONTRACT FOR 9303-23S0E40

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