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數(shù)控編程工藝及加工效率的研究

由于后控板塑件在洗衣機上為外觀件，表面光潔度要求較高，所以在模具型腔加工制造過程中必須保證型腔尺寸的公差要求和表面粗糙度要求。對于該模具型腔零件，從內(nèi)向外主要由以下幾部分構(gòu)成：塑件型腔面、分型面、排氣槽、側(cè)抽芯槽、模架面、回程桿墊片槽等。在編制數(shù)控編程工藝時，一般按照整體粗加工、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、型腔局部形狀清角的工藝思路進行編程，并按照分區(qū)域編程的思路，逐漸完成整體零件的編程工作。



圖1 洗衣機后控板模具型腔

2.1 整體粗加工刀具的選擇

在編制粗加工程序時，粗加工刀具型號的選擇直接決定了開粗的加工效率。若開粗刀具選擇過小，致使每刀的下刀量較小，而且刀具的進給速度也較小，最終導(dǎo)致工件的加工效率很低。若開粗刀具選擇過大，表面上看起來粗加工時間很少，但是開粗效果不理想，本應(yīng)開粗到位的區(qū)域沒有開粗到位，需要增加整體中粗程序或大范圍的清角程序，這樣總體的加工時間也會增加。所以在粗加工刀具選擇方面，不但要考慮到工件的整體尺寸大小，還要考慮該零件的材料去除量大小。對于中小型零件來說，原則上把開粗時間 控 制 在 5h 以 內(nèi) ，初 步 選 定 開 粗 刀 具 為 直 徑 為 32mm的牛鼻刀，刀具定義為D32R0.8mm。
2.2 型腔精加工刀具的選擇

在對模具零件型腔進行精加工時，由于模具的型腔面在塑件上為外觀面，表面光潔度要求較高，并考慮到模具的型腔面大部分為曲面，所以在精加工刀具選擇方面，優(yōu)先選擇球頭銑刀進行加工，刀具符號用B及 R 表 示 ，如 直 徑 為 20mm 的 球 頭 刀 定 義 為B20R10mm。本次研究列出了 3 種精加工刀具選擇方案：第 1種方案為大直徑球頭銑刀（B16R8mm）整體精加工、小直徑球頭銑刀（B8R4mm）局部清角的編程加工工藝；第 2 種方案為較大直徑球頭銑刀（B12R6mm）整體光刀、小直徑球頭銑刀（B8R4mm）清角的編程加工工藝；第3種方案為整體用小直徑球頭（B8R4mm）刀一次加工到位，如表 1 所示。然后對以下

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IC647PCM001 Proficy Change Management Server - 1 Concurrent User

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IC754ACC32MEM Expandable User Memory, 32MB for QuickPanel View & Control

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1492-PPJD3 IEC Term Blck 3x80x63 mm Partition Plt

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1497-D-BASX-1-N Control Circuit Transformer

1606-XL240E-3 Power Supply XL 240 W Power Supply

1762-IQ8OW6 MicroLogix 14 Point Digital Comb Module

188-K3C200-N Miniature Circuit Breaker 20 A

194L-G3196 Rect. Front Frame W/ Blank Nameplate

2090-CPBM7DF-04AA12 MP-Series 12 m Length Cable

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GC647PME100 GlobalCare Complete for Proficy Change Management Server Machine Edition Version - 100 Concurrent Users

IC200MDL632 Input 125VDC POS/NEG logic isolated 16 point

IC646PCM003 Proficy Change Management 3 User Pack

IC647MOP001 Logic Developer PC with View for 8000 I/0 Development only with USB Hardware key

IC676CBLPWB050 IP67 Power Cordset - 5 Meters

IC697PCM711MP Modified Series 90-70 PCM for OEMs

IC800SSI107D2 7.2 amp 115/230 VAC Devicenet S2K servo controller for S-series motors

SoftLogix System 1789-STRT1IT SOFTLOGIX 5800 STARTER KIT ITALIAN

Industrial Computers 6189-RDK10C VVCE 1000, KEYPAD DISPLAY MODULE

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Operator Interface 2711-B5A1L3 PV550 MONO KEY&TOUCH, RIO & RS232 PRINT

Support 9303-23S0EFFS SUPPORT RENEWAL CONTRACT FOR 9303-23S0EFF

Support 9371-EWDI3R SUPT REINSTATEMENT CONTRACT FOR 9371EWDI3

ControlNet Products 2706-P42R INVIEW MESSGE DISPLAY. 1 OR 2 LINE, 12 OR 20 CHAR

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RSI Software Products 9358-BANT60U3 UPGRADE: IN-SUPT: RSBATCH ARCHIVER 30 TO 60

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Motion Control 2090-UXNPBMP-16S30 CABLE,460V,NON-FLEX,MOTOR POWER,MP,16 GAUGE,30M

CBL-3T-MB-10 Power/Brake Cable, MTR-3T4x, MTR-3T5x & MTR-3T6x Series Servo Motors, 10 Ft.

IC641CTL972 Upgrade to Add Series 90-70 Target Support to a CIMPLICITY Control License

IC800SLM100N2KE25 1000W, 230VAC SL Servo Motors, 2.5K Quad Encoder

OC647PLSTSENB Proficy Pulse Terminal Server Enabler (can be added to Editor and Viewer)

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2711P-B15C4A9 PanelView Plus Terminal

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CPM1A-10CDT-D-V1 10點主機 DC24V、6點入， 4 點晶體管輸出.漏型

1492-MCEA230 Miniature Circuit Breaker, 30 A

1494V-FS600 Fuse Block

軟啟動器 3RW44652BC46

運行版軟件 6AV2104-0KA04-0AA0 SIMATIC WinCC Runtime Advanced 8192 PowerTags V14

1585J-M4HBJM-10 RJ45 Ethernet Media

1756-OA16IK ControlLogix 16 Point Digital Output

188-K1B160 Miniature Circuit Breaker 16 A

194E-FA63E 194E Load switch

2090-CFBM7DD-CEAF60 60 m Length SpeedTec Flexible Cable

2090-U3CBB-DM44 Ultra 3000 Breakout Board Kit

BC646MSP005 Logic Developer - State Professional with Proficy GlobalCare Complete 5 Pack

GC647ASC100 GC SDK 100 Pak

IC200ACC303 I/O shorting bar quantity 2

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IC647IFPLRN00900C iFIX Plus SCADA 900 I/O Runtime (M1Component Part)

IC660MLA023 Label for IC660BBA023 (Qty 100)

IC697ALG234 Analog Input, Voltage/Current, 8 Channels gold plated terminal. WARNING: The IC697ALG234 module must be matched with IC697ACC775 terminal block ONLY. IC697ACC775 is included with the module.

IC758URM010 iGlobalCare Complete 6-10 Users: DataViews for Unix/Linux

FlexLogix System 1788-CNFR CONTROLNET LOGIX DAUGHTER CARD

GuardPLC Systems 1755-A6 GUARDPLC 2000 - 6 SLOT CHASSIS

Process Control 1757-UPGSIFP UPGRADE MOORE 351,352,353,383 QUICKBUILDER I/F

Operator Interface 2711P-T12C15D2 PV PLUS 1250, TOUCH, CNET, DC PS, EXT MEM

Support 9220-CNA30FR SUPPORT REINSTATEMENT CONTRACT FOR 9220-CNA30F

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RSI Software Products 9399-WAB32UG RSLINX USER GUIDE

Motion Control 8720MC -D097-AN- 97 AMP D CHASSIS DRIVE,OPEN ENCL., LESS OPTIONS

BC646MRA159 View Runtime 1,500 I/O

IC300OCS992 Starter Kit includes IC300OCS052 and IC300OSW232. No simulator. Limited one per customer (DC/DC/Vin/Vout)

IC752WTG572 Display Station 2000 Serires - 15" active matrix XGA (1024x768) resistive touch screen

MTR-3T44-J-R-B-M-0 MTR series metric servo motor with resolver and brake

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20DC015A0EYNANANE PowerFlex 700S AC Drive 20D

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25B-D037N114 PowerFlex 525 18.5kW (25Hp) AC Drive

2715-B15CA PanelView 5500 15 in. Graphic Terminal

FR-A740-0.4K 1.1 KVA 1.5A 0.4KW

1492-LD2 IEC Term Block 3.5x75x43mm Spring Clip

1494F-DX200 Disconnect Switch

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ET 200SP 6ES7155-6AU00-0CN0 IM 155-6 PN 高性能PROFINET接口模塊，不含總線適配器

1585D-D4TBJM-2 Micro D-Code, QD Style Ethernet Media

1747-OS302 SLC 5/03 Firmware Upgrade Kit

1794-AENTR Flex EtherNet/IP Adapter

194E-AA16E-P11-TN 194E Load switch

2080-IF2 Micro800 2 Point Analog Input Plug-In

2090-CSWM1DF-14AA10 Kinetix Cable Single DSL 2090-Series

20AC2P1A3AYNANC0 PowerFlex 70 AC Drive 20A

GC646MODEV10PK Proficy GlobalCare Complete for Motion Developer 10-Pack

HE693IBS323 Discontinued Part. Check with GE IP on migration path.

IC609EXP121RR Series One Jr. Expansion 24Vdc Src In/Relay Out, 115Vac P/S

IC647HSTSC100M Server to Server Collector for Historian - Standard Server 100 Points (M4 Key)

IC660BBA024CA 24/48VDC CUR SCR ALG 4IN/2OUT CONF COAT GENIUS BLOCK

IC694MDL734 Output module 125VDC 1 amp 6 points isolated POS/NEG logic.

IC756WDC009K-99 DV Development Sys VB, Java, C++, Korean, Version 9.9

MicroLogix 1500/1769 System 1769-PB2 PWR SUPPLY 24 VDC INPUT 2 AMP @ 5 VDC OUTPUT

PLC-5/1771 System 1771-DB BASIC MODULE

Distributed I/O 1797-IE8H EX HART ANALOG INPUT MODULE, 16 BIT, 8PT., S.E.

Operator Interface 2711P-K4M3A PV PLUS 400 GRAYSCALE, KEYPAD, DH485, AC PS

Support 9323-MX300ENS SUPT RENEWAL CONTRACT FOR 9323MX300EN

Support 9358-HSTS2300R SUPT REINSTATEMENT CONTRACT FOR 9358HSTS2300

Support F1772-LWPSERC FIRMWARE UPGRADE FOR 1772-LWP PROCESSOR MODULE

RSI Software Products 9324-RLD300NXFRE RSLOGIX 5000 STD., RSNETWORX BUNDLE, FRA

RSI Software Products 9304-WVPR300DU3R UPGRADE: OUT-SUPT: WINVW 128 TO WINVW PRO RT 3000

RSI Software Products 9358-PLTM2600U4R UPGRADE: OUT-SUPT: PLANTMETRICS 50 TO 200 WORKCELL

Motion Control 1756-M02AS 1756 2 AXIS ANALOG/SSI SERVO MODULE

A06B-0116-B175#0008 BM1/4000 Servo Motor, Holding Brake, 32K Serial Encoder

IC200UAL006 23 point; (13) 24VDC In, (9) Relay Out, (1) 24VDC Out, (2) Analog In and (1) Analog Out, AC Power Supply. Battery (IC200ACC403) is required for data retention. Battery not included.

IC752BDT003RR Datapanel 240T with Advanced software, 240x128 LCD with CCFT backlight. 6x8 Matrix Resistive touch screen with text, bitmaps, bar graphs, real time clock. With Real Time Trends & Host Communications.

MTR-1350-N-D-E-S MTR series NEMA 34 splashproof stepping motor with series winding connection

ZA06B-0086-B203 B22/2000HVis servo motor with 128k serial encoder

20BD325A0ANNNNC0 PowerFlex 700 AC Drive 20B

20G11TC650AN0NNNNN PowerFlex 755 AC Packaged Drive

25-PM1-A011 PowerFlex 520 2.2kW (3Hp) Power Module

140XTS00200 Quantum 40點模塊端子條

FRN75F1S-4C 105KVA 139A 75KW 3相AC380V/50Hz/60Hz

1492-SPM3C250 MCB Supplementary Protector 25 A

軟啟動器 3RW40462BB15

數(shù)字量輸出信號板 6ES7 222-1BD30-0XB0 SB 1222 DQ 4 x 24 V DC，200 kHz

150-SC1NBD SMC-50 SOLID STATE MOTOR CONTROLLER 210A

1734-TB3S POINT I/O Terminal Base

1783-NATR Configurable NAT router

193-ESM-VIG-100A-C97 E300/E200 100 Amp Sensing Module

20-750-I1B-E460F460 PowerFlex 750 Replacement Inverter

2090-CPWM7DF-16AA03 MP-Series 3m Servo Power Cable

2099-BM06-S Kinetix 7000 22kW Servo Drive

GA647IFCLNTSRO025 GCA iFIX iClientTS Read Only 50 PK Runtime Version

GP-0602NT-SDP8 GagePort Digital NT 2-port input (for Solartron Digital Probes)

IC5005TBX0030 PanelPC 15 inch Performance Unit Deluxe with Windows XP

IC647HSTAE500M Alarm and Events Option for Historian - Standard Server 500 Points (M4 Key)

IC647SRVSSFQLTY PA SmartStart for Quality

IC693MDL741 12/24 Vdc Output, 0.5 Amp, Negative Logic (16 Points)

IC756HDV010K-97 DV Draw Development on HP/UX Op Sys, Korean, Version 9.7

Pico Controllers 1760-LDFC GFX CPU WITH INTRACONNECT

PLC-5/1771 System 1771-IVN LOW-TRUE INPUT MODULE, 10-30V DC, 32 INPUT

Distributed I/O 1791D-4CMCBL 24 VDC BLOCK I/O RIBBON CABLE, 4CM

Communications 1785-KA DATA HWY/DATA HWY PLUS INTERFACE MODULE

Operator Interface 2706-PCNETM CONTROLNET COMMUNICATION MODULE FOR 2706-P4X

Support 9701-VWMR075AR SUPT REINSTATEMENT CONTRACT FOR 9701VWMR075AENE

Support 9515-RSNHS050S SUPT RENEWAL CONTRACT FOR 9515RSNHS050ENE

EtherNet/IP Products 2711P-K6C20D PV PLUS 600 COLOR, KEYPAD, ETHERNET, DC PS

RSI Software Products 9301-2SE340FRU2R RSVIEW32 RUNTIME 300-32K UPGRADE OUT-SUPT (FR)

RSI Software Products 9356-PRO2300U3R UPGRADE: OUT-SUPT: RSSQL STD.1500 TO PROF.1500 TAG

Motion Control 1326AB-B730E-S2L MOTOR,SERVO,460V,39.0NM,3350RPM,SINGL,IP67

4162-L-1 4162 Continuous Lens Kit. For (1) 4162

HMI-KPN-201 QUICKPANEL KEYPAD FOR 5" & 6"

IC693CPU352 CPU 352 Module (240K Bytes configurable user memory, 4K I/O, 8 Racks, Hardware FLOATING POINT MATH), two built-in Serial Ports .22msec/K

SM1000XTC QUICKMARQUEE CABLE IBM XT PROGRAMMING

TRM-21006689 Servo motor power connector for Target series TGT-3x6l-1-0 modules

20BD011A3AYNAND0 PowerFlex 700 AC Drive 20B

20G11BC1K4JN2NNNNN PowerFlex 755 AC Packaged Drive

22B-V5P0F104 PowerFlex 40 0.75 kW (1 Hp) AC Drive

140XBP00200 Quantum 背板, 2槽

284R-120P1K2-M05 120 Ohm Dynamic Brake Resistor

H5CR-L 100-240VAC,9.999s-9999h 一常開/閉?觸點:5A

1492-SPM1D010-N MCB Supplementary Protector 1 A

通用型變頻器 6SE6 440-2UC27-5DA1 7.5 KW,275 x 520 x 245

電機啟動器 3VU13403MB00

150-C30NBR SMC-3 30A Smart Motor Controller

1609-D600E Uniterruptible Power Supply

1770-XYB PLC-5 Battery

193-EC1GG E3 42-210 A Overload Relay

195-GB01 Auxiliary Contact

2090-CPBM7E7-14AF04 MP-Series 4 m Length Pwr and Brake Cable

2093-PRS2 Kinetix 2000 2 Axis Slim Power Rail

CP9B-0WEB-0140-AZ Shielded motor power cable for B2is/B4is motors (straight connector). 14 meters

GFK-0074 Genius I/O PCIM User's Manual

IC200UEX210-24 Qty of 24, 28 point expansion. (16) 120VAC In, (12) 120VAC Out, 120/2 40VAC Power Supply (includes IC200CBL501)

IC647AHC001 PA Historian Connector

IC647PCMS25 Proficy Change Management Electronic Signature Option - 25 Concurrent Users

IC693CHS391NB Base, CPU, 10 Slots, Use With CPU35x, CPU36x and CPU37x. Base only. No battery included. Battery for CPUs ordered seperately.

IC754CKF15CTD Starter Kit/ 15 inch TFT Ctrl Fully Loaded/ 24VDC

KIT-GFS-344 Proficy ME LD-PLC Workshop Student Kit

SLC/1746 System D1746-6.5 HIGH SPEED COUNTER MODULE USER MANUAL

Distributed I/O 1732P-IB8M8 PROFIBUS 24VDC 8 INPUT W/M8

Application-specific products 1404-M805B-ENT-02 1404-M8 ETHERNET PM3000 CLASS 0.2

Operator Interface 2711-T10C15 PV1000 COLOR TOUCH, CNET & RS232 PRINT

Support 9301-2SE3400JPS SUPT RENEWAL CONTRACT FOR 93012SE3400JP

Support 9381-PA1KENR SUPT REINSTATEMENT CONTRACT FOR 9381PA1KEN

DeviceNet Products 1790-T8BV8VX LDX I/O, 24VDC, 8 UNIV IN/8 SINK OUT EXPN TERM BLK

RSI Software Products 9301-2SE3303 RSVIEW32 RUNTIME 1500 WITH RSLINX