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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(jī)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(duì)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(shí)，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(jìn)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(jī)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(shí)，粗加工刀具型號(hào)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(jìn)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(shí)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(shí)間也會(huì)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(duì)于中小型零件來說，原則上把開粗時(shí)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(duì)模具零件型腔進(jìn)行精加工時(shí)，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(jìn)行加工，刀具符號(hào)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(duì)以下
 

150-F108NBD SMC Flex Smart Motor Controller

1738-8CFGM8 ArmorPoint 8 Point Combination Module

1797-RPA FlexEx Repeater Adaptor

193-ESM-I-60A-E3T E300/E200 60 Amp Sensing Module

2085-IRT4 Micro800 4 Channel TC/RTD Input Module

2090-CPBM7E7-16AF25 MP-Series 25 m Length Cable

2098-DSD-020-DN Ultra 3000 Servo Drive

GC646MOSS99 QuickPanel Control Development Software - Site License with Proficy GlobalCare Complete

GF-0207 Connecting FlashCable to Fowler Ultra Cal II, Ultra Height II.

IC200TBX220 Tool box, Micro 20, operator interface and software. Includes (IC200UDD020) 24VDC In/24VDC Out, requires 24VDC power, (IC200USB001) RS-232 option board with (2) 0 -10VDC analog in with VersaMax DataPanel DP 45 (IC200DTX450) with Proficy programming

IC646TBSPMPS800 Smart Process Monitoring Process+ server 800 loops

IC647NSL001 Proficy SQL 2005 - 1 Client Access License (order as separate item, not an option)

IC693ACC334 Faceplate provides a 24 pin fale Fujitsu connector for cable connection. Faceplate replaces I/O module terminal block (20 screw terminal connector).

IC752CBT000RR Datapanel 320T MB (Mono Base): 320x240 1/4 VGA Monochrome LCD with 803 86SX/40 PC processor. Analog touch screen with text, bitmaps, bar gra phs, real time clock.

IC800VMCP1200 Power cable for 1 kW VersaMotion servo motor- 20 meter

SLC/1746 System 1746-FIO4I (2) FAST ANALOG INPUTS, (2) ANALOG CURRENT OUPUTS

Industrial Computers 6189V-CDROM CD-ROM DRIVE

Application-specific products 1402-LS51 LINE SYNCHRONIZATION MODULE (LSM)

Operator Interface 2711-B6C5 PV600 COLOR KEY&TOUCH, RS232 (DH485)

Support 9301-2SE2400FRR SUPT REINSTATEMENT CONTRACT FOR 93012SE2400FR

Support 9307-EMCHTS SUPT RENEWAL CONTRACT FOR 9307EMCHTENE

DeviceNet Products 1734-IB8 24V DC 8 CHANNEL SINK INPUT MODULE

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Motion Control MPL-B330P-RK22AA MOTOR,SERVO,4.18 NM,5000RPM,RSLVR,460V

Motion Control 2090-U3BK-D4409 BREAKOUT BOARD KIT,CONTROL,CN1,ULTRA 3000,9M

GFK-0726 90-30 PLC State Logic Processor User's Guide

IC646FXMU01 Proficy Change Management 1 User System

MSCPX-425606NT Marathon Exp CPU,850 MHz CPU, 128M, 6G, Win NT, 2 PCI/ISA, 1 PCI, 1 ISA

PSPC-DC50/EL Prof Shop Floor SPC DC 50 User w/ eSig

20BC015A3AYNAEC0 PowerFlex 700 AC Drive 20B

20F11FC104JA0NNNNN PowerFlex 753 AC Packaged Drive

2198-KITCON-P070 Kinetix 5700 55mm Bus Supply Connectors

2711P-RBT10 PanelView Plus 1000 Touch Screen Bezel

280-RA35 M35 To M22 Reducing Adapter

CQM1-0C222 輸出16點(diǎn).繼電器 250V AC/24V DC 2A

1492-N38 TERM BLCK 2 Pole Uninsulated Jumper

接口模塊 6ES7360-3AA01-0AA0 IM360,接口模塊，用于主機(jī)架，可擴(kuò)展 3 個(gè)機(jī)架

行程開關(guān) 3SE53223SG23

TIA 博途 WinCC 選件 6AV2107-2KK00-0BD0 SIMATIC WinCC WebNavigator for Runtime Professional Powerpack 25 -> 50 Clients

1585J-M8HBJM-78 RJ45 Ethernet Media

1760-L12AWA-NC Pico 12 Point AC Controller

188-K2C020 Miniature Circuit Breaker 2 A

194L-A16-1753 16 A 194L Load Switch

2090-CHBP8S8-12AAP5 Kinetix 6000M IDM Hybrid Cable

2090-UXTBMP-18S20 MP-Series 20 m Length Brake Cable

BC647MPS001 Logic Developer PLC Standard with Proficy GlobalCare Complete with USB Hardware key

GC647IFSTDV00300 GCC iFIX Std HMI 300 I/O Dev

IC200CHS121 I/O interposing fuse style 16 point

IC646MSS005 Logic Developer State Standard 5 Pack

IC647IFSTRN00150K iFIX Standard HMI 150 I/O Runtime (M1 Kit Part)

IC670CHS102 I/O Base, Box Style, Hot Insertion obsolete. Recommended replacement is IC670CHS101 I/O Base, Barrier Style.

IC697GDH701 CIMPLICITY 70 Graphic Display Hardware Package (Repeat Systems)

IC800SKCPVL050 Power cable for SLM350 or SDM500 or SLM500 S-series servo motor to an S2K. 5 meters

ControlLogix/1756 System 1756-HSC 2 CHANNEL / 4 OUTPUT HIGH SPEED COUNTER (36 PIN)

Industrial Computers 6182H-12BEH4D VVCE 1250, KEY/TOUCH, EXT MEM, ENET, DC

Process Control 1757-PE1400RED2 PLX BACKUP SERVER ON DELL PE1400

Operator Interface 2711P-RGT7 PV PLUS/VVCE PROTECTIVE ANTIGLARE OVERLAYS QTY 3

Support 9355-WABOEMFRR SUPT REINSTATEMENT CONTRACT FOR 9355WABOEMFR

Support 9354-SS105S 9354-SS105 SOFTWARE SUPPORT CONTRACT RENEWAL

ControlNet Products 1734-IA2 120 VAC 2 CHANNEL INPUT MODULE

RSI Software Products 9301-2SE2400PTU3 RSVIEW32 WORKS 150-32K UPGRADE IN-SUPT (PT)

RSI Software Products 9357-ANETMDAD3E RSNETWORX MD FOR CNET,DNET,ENET ADD-ON

Motion Control MPL-A330P-MK22AA MOTOR,SERVO,4.18 NM,5000RPM,MULTI,230V,5.0KG

Motion Control 2090-UXNBMP-18S15 CABLE,ULTRA,NON-FLEX,MOTOR BRAKE,MP 15 MTR.

CBL-136 Cable. Mitsubishi A Series Prog. Port (RS-422)

IC600RR551RR RPU Rack With Power Supply, 115-230Vac

IC800SKCEZ050 Encoder Cable, S2K to 200-750W S-Series Servo Motors, 5 Meters

OC647IFESGSR00150C iFIX Optn: ESig & ERec 150 I/O Server (M1Component Part)

20AD052F3AYNANC0 PowerFlex 70 AC Drive 52 A at 40 Hp 20A

20DC5P0A3EYYAEASE PowerFlex 700S AC Drive 20D

20P21AD010RA0NNN PowerFlex 10 A DC Drive

2711-CBL-PM05 PanelView 300 5 m Operate and Prog Cable

280-PWRM22E-M6 ArmorConnect 3-PH Power Media drop cable

FX2N-4AD-PT 4通道熱電阻模擬量輸入模塊PT100

1492-M7X12 IEC 7 x 12 mm Marker Card

1494U-C313 1494U 30A-100A 3' Cable Mechanism

軟啟動(dòng)器 3RW44532BC45

SIMATIC STEP 7 V14 6ES7822-1AA04-0YA7 SIMATIC STEP 7 專業(yè)版 V14 試用授權(quán)

1585D-M4UBDE-60 1585D Ethernet Media Patchcord

1756-IB32K ControlLogix 32 Point Digital Input

1794-TB3TSK Flex Terminal Base

194E-E16-1753-4N 16 A 194E Load switch

2090-CFBM4DF-CDAF04 MP-Series 4m Feedback Cable

2090-KFBM6-AA TL-Series Feedback Connector Kit

BC-FDT-DTM-SW2 FDT-DTM Software for use in FDT frame applications (NV project version). extension of the existing DTM, enhanced to better support E thernet.

GC646TDV999 Proficy GlobalCare Complete for Viewer Development System

HMI-BEZ-201 Stainless Steel Bezel: 5 inch Color & Mono (QPJ2xxxx-L2P/ -S2P)/ NEMA 4X

IC640WMI910RR Series 90 XT/AT Parallel/Serial Interface Card

IC647I3EC I3E:IEEE 488.2

IC660CBB902RR Series Six Genius I/O Bus Controller w/Diagnostics (Ph B)

IC695FTB001 Fiber Optic Terminal Board for PMM335

IC756WRE024E-99 DataViews Runtime for Windows 1-24, Per User, English, Version 9.9

FlexLogix System 1794-ACN15K CONFORMAL COATED, SINGLE MEDIA ADAPTER, CONTROLNET

PLC-5/1771 System D1771-6.5.76 RTD INPUT MODULE(1771-IR/B)USER MANUAL

Process Control 1757-PLXNW OPEN DATA ACCESS - 10 USER

Operator Interface 2711P-T7C15B2 PV PLUS 700, TOUCH, CNET, AC PS, EXT MEM

Support 6626-PLPR 6626-PLP SOFTWARE SUPPORT REINSTATEMENT

Support 8520-ODSS SUPT RENEWAL CONTRACT FOR 8520ODS

Support F1785-L20C15SERE FIRMWARE UPGRADE FOR 1785-L20C15 PLC5 PROCESSOR MO

RSI Software Products 9301-2SE220JPU1R RSVIEW32 WORKS 150-300 UPGRADE OUT-SUPT (JP)

RSI Software Products 9701-VWSB100ENU1 RSVIEW SE STATION 25 - 100 DISPLAY UPGRADE

RSI Software Products 9399-HDWAREREFPT HARDWARE INTERFACE CONFIG. USER GUIDE (PORTUGUESE)

Motion Control 2098-DSD-HV150-DN HIGH VOLTAGE DRIVE, 34A/68A, ULTRA3000 W/DNET

BC646CSCEMK ControlStation CE Development Software with 1 year SAFE

IC300DIQ627 8 AC Input (120 VAC) , 8 AC Output (250 VAC max, 2A)

IC752MNH899 Monitor -- 18" flat panel LCD active matrix monitor. No touch.

MTR-3S46-H-R-0-E-SRR Servo Motor with Seal

ZA06B-6110-K210 AHVi Amplifier CXA2A/B Connector

20BP205A0ANNANC0 PowerFlex 700 AC Drive 20B

20G14TF500JN0NNNNN PowerFlex 755 AC Packaged Drive

25A-B032N104 PowerFlex 523 7.5kW (10Hp) AC Drive

2711P-T12W22A9P PanelView Plus 7 Graphic Terminal

OPC-G11S-DEV(通訊卡)

1492-JG16 16 square mm Ground Terminal Block

1492-WFB424 IEC Term Blck 8x47.6x41mm Screw

軟啟動(dòng)器 3RW44223BC44

性能信號(hào)模塊 6ES7 522-1BF00-0AB0 DQ 8：數(shù)字量輸出模塊，高性能 DQ 8x 24VDC/ 2A HF, 35mm 模塊，不含前連接器

156-B32CB3 32 A Contactor

1746-N3 SLC Mating Connector

1786-TPYS ControlNet Coaxial Straight Y-Tap

193-T1DC60 45-60 A IEC Bimetallic Overload Relay

20-IP20DR-600 PowerFlex 700H/S Door Kit

2090-CSBM1DF-14AF07 Kinetix Cable Single DSL 2090-Series

20AC022A3AYNANC0 PowerFlex 70 AC Drive 22 A at 11 kW 20A

GA647TRT915 Proficy GlobalCare Assist for CIMPLICITY HMI Server 1500 I/O Runtime System

GPA-602-F LVDT Expansion Unit (Full Bridge), includes G-0602 connecting cable.

IC600CM548RR 8K CMOS Logic Memory Module (for use in Model 600 or 6000)

IC647HSTCSEO1500KM eSignature Option for Historian - Enterprise Corporate Server 1,500,000 Points (M4 Key)

IC647WFL001 Proficy Workflow - 1 User License

IC694ACC300 Input simulator module, 16 points.

IC756RDV001K-98 DV Development - Irix Op Sys Addt'l User, Korean, Version 9.8

MicroLogix 1200 System 1762-L40BXB MICROLOGIX 1200, 40 PT.

PLC-5/1771 System 1771-LC4B LOOP CONTROLLER W/RTD OPTION,240V AC SUPPLY

Distributed I/O 1794-IM8 220V AC INPUT MOD, 8 PT.

Communications 9355-WABOEMFRE RSLINX OEM - FRENCH

Operator Interface D6195-6.5.3DE CONTROLVIEW BUILDER SOFTWARE USER MANUAL (GERMAN)

Support 9358-BEPB60S SUPT RENEWAL CONTRACT FOR 9358BEPBNT60ENE

Support F1770-KF2SERB FIRMWARE UPGRADE FOR 1770-KF2 COMMUNICATION MODULE

RSI Software Products 9324-RL0300NXENE RSLOGIX 500 STANDARD; RSNETWORX FOR CONTROLNET

RSI Software Products 9301-2SE350DEU1R RSVIEW32 RUNTIME 32K-100K UPGRADE OUT-SUPT (DE)

RSI Software Products 9358-HSTS2300U2 UPGRADE: IN-SUPT: HISTORIAN 300 TO 1500 TAG

Motion Control W-4030-P-H00AA MOTOR,SERVO,WASHDOWN,AF,2.8 NM,3000RPM,12.0KG

601 Numeric Keypad, Flat Membrane keys. NEMA 4

IC200MDD840LT MIXED 24VDC POS LOG INPUT GRP 20PT / OUTPUT RELAY 2.0A PER PT GRP 12PT (LT)

IC695PSD040 Power supply 24VDC 40 watts occupies one slot on system base

MTR-1220-E-D-E-0 MTR series NEMA 23 stepping motor with series winding connection and encoder

VSPCSE-SF50 VisualSPC SE ShopFloor includes Attribute Data Collection, Measurement Systems Analysis and A-681 interface cable. 50 license pack.

20BD077A0ANNAND0 PowerFlex 700 AC Drive 77 A 60 Hp 20B

20G11NC011JA0NNNNN PowerFlex 755 AC Packaged Drive

22F-A8P0N113 PowerFlex 4M- 1.5 kW (2 HP) AC Drive

990NAD21110 Quantum MB+ 站電纜,2.4M

291E-FBZ-G1 Direct Online Reversing Starte

PF113A-E 導(dǎo)軌安裝型，MK3P-I

1492-SPM2D300 MCB Supplementary Protector 30 A

軟啟動(dòng)器 3RW30472BB14

電機(jī)啟動(dòng)器 3VU16401CN00

150-F361NBD SMC Flex Smart Motor Controller

1732E-IT4IM12R ARMORBLOCK 4 POINT TC INPUT

1771-WC FIELD WIRING ARM 10 TRMLS GOLD PLATED

193-EELG E1 Plus 100-500 A IEC Overload Relay

20-750-ACTE1-F6 PowerFlex 750 AC Terminal Extension Kit

2090-CPWM7DF-10AA04 MP-Series 4m Servo Power Cable

2097-V32PR0-LM Kinetix 350 400W Servo Drive

ET-GT-3ES-2SC 2 RJ45 Ports, 1 Multimode Fiber Port Ethernet Switch

GFK-1886 ViewStation/ControlStation CE Iix (10 inch) HW User's Guide

IC220MDD840 HIGH SPEED COUNTER INPUT, 1IN/1OUT 24VDC (REQUIRES 1 IC220TBK203)

IC647CSPR025 Proficy Cause+ for Intelligent HMI/SCADA Runtime Server - 25X monitored KPIs

IC647PSF025 Proficy Process Systems 250 I/O with iFIX

IC693MDL231LT 240 Vac Isolated Input (8 Points) (LT)

IC756CDV000J-97 DV Development - Compaq True64 Op Sys, Japanese, Version 9.7

MSI-MGMT-5-43 Production Mang Clients 5 Pack-43

PLC-5/1771 System 1785-L40C15 PLC-5/40C FOR CONTROLNET PHASE 1.5

Distributed I/O 1738-ADN12 DEVICENET ADAPTER M12

Communications 1787-TCABL T-STYLE CABLE FOR 1770-KFD 6 FT (1.82 METERS)

Operator Interface 2711-NR4 19-INCH RACK MOUNT KIT

Support 9304-WVD256R SUPT REINSTATEMENT CONTRACT FOR 9304WVD256

Support 9324-RLD25U6ENE RSLOGIX 5000 LITE ENGLISH TO FULL UPGRADE

DeviceNet Products 2711-K5A10 PV550 MONOCHROME KEY, DNET & RS232 PRINT

RSI Software Products 9301-2SE335KOU3R RSVIEW32 RUNTIME 1500-5K UPGRADE OUT-SUPT (KO)

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Motion Control MPG-B025-031M22 MOTOR,SERVO,GEAR RATIO 31,100NM,156RPM,MULTI,460V

Silver Series 2711-T14C1 PV1400 COLOR TOUCH, RIO & RS232 PRINT

HE693STP101 same as STP100E w/optical isolation, independent accel/decel

IC670MDL233 120VAC 8 PT Isolated Input

QPI-PSL-201 Communication Adaptor Module for 7.5", 10", 12" QP4's

ST-7241 STXi Expansion Field Power Distribution module, 5, 24, 48, AC 10 Amp no LED status

20BC292A0ANNNNC0 PowerFlex 700 AC Drive 20B

20F1ANC302AN0NNNNN PowerFlex 753 AC Packaged Drive

22B-B033H204 PowerFlex 40 7.5 kW (10 Hp) AC Drive

140DAO84210 Quantum 開關(guān)量AC輸出,16點(diǎn),110-230VAC,隔離,4組

284D-FVD6P0Z-25-CR-3 DeviceNet Variable Frequency Drive

E3F3-R81 2m反射式，暗通，PNP晶體管輸出100mA電源：10-30VDC直徑18mm,需另配反射板

1492-SPM1B050 MCB Supplementary Protector 5 A

6ED1055-1CB00-0BA0 LOGO!DM8 24，4DI/4DO

6ES73325HB014AB2

1497B-A9-M15-0-N Control Power Transformer

1606-XLSBAT1 1606 7 Ah UPS Battery Power Supply

1769-IT6 CompactLogix 6 Pt Thermocouple Module

190-PB Circuit-Breaker Disconnect Accessory

194R-J30-1753-PYS1 194R Disconnect Switch

2090-CPBM7DF-14AA60 MP-Series 60m Standard Cable

2090-XXNPMP-8S60 MP-Series 60 m Length Power Cable

CBL-3C-RD-30 Resolver cable for MTR-3S or MTR-3N series servo motors. 30 feet

GF-0800-3 Connecting FlashCable to DataMyte 518 Gap & Flushness, GSE, RS Technol ogies.

IC200UAA003 14 point PLC, (8) 120VAC In, (6) 120VAC Out, 120V/240VAC Power Supply

IC646TBSPMSW005 Smart Process Monitoring SPC+ Web Clients 5 Pack

IC647NUU000 CIMPLICITY HMI Upgrade Process Fee

IC693ALG221 Analog Input, Current, 4 Channels

IC752CGE202 SNP CMM cable for DataPanel 150/160/240

IC800VMM04LBKSE25 400 W VersaMotion servo motor with 24 VDC holding brake (1.27 Nm)

SLC/1746 System 1746-NR8 8 CHANNEL RTD INPUT MODULE

Industrial Computers 6189V-DVICBL5 DIGITAL VIDEO CABLE 6186 5M

Application-specific products 1403-LM01B MASTER MODULE FOR POWERMONITOR

Operator Interface 2711-K6C16 PV600 COLOR KEY, DF1 & RS232 PRINT

Support 9301-2SE2500ESR SUPT REINSTATEMENT CONTRACT FOR 93012SE2500ES

Support 9380-RSB10000S SUPT RENEWAL CONTRACT FOR 9380RSB10000

DeviceNet Products 1734-IE2C 24V DC 2 CHANNEL ANALOG CURRENT INPUT MODULE

RSI Software Products 9301-2SE3103FRE RSVIEW32 RUNTIME 150 WITH RSLINX (FRENCH)

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Motion Control 2090-S-BLHD SERCOS FIBER CABLE BULKHEAD ADAPTOR 2 PER

GFK-0846 Pro-Log GRI Genius I/O Interface for the Allen-Bradley PLC Reference Manual

IC646MDB159 Logic Developer 1500 Tag Runtime & Development System

MSDIS-1211 Discontiuned, Marathon 12", HiBrite Display, Keypad and Touch

PSPC-MONITOR50 Prof Shop Floor SPC Monitor 50 User

20BC022A0NYNANC0 PowerFlex 700 AC Drive 22 A at 11 kW 20B

20F11GC060AA0NNNNN PowerFlex 753 AC Packaged Drive

2198-S130-ERS3 Kinetix 5700 Single Axis Inverter

2711P-RDB7CK PanelView Plus Display Module

280D-F12Z-10C-CRW-3 ArmorStart Direct Online Starter