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典型零件的數控編程
編制如圖所示零件的加工程序
材料為45鋼,棒直徑為80mm,該零件采用棒料毛坯,由于加工余量大,在外圓精車前采用粗車循環(huán)指令去除大部分毛坯余量,留有單邊0.25mm余量。
1、刀具設置
選擇外圓粗車刀為1號刀,外圓精車刀為2號刀,割槽刀(寬2mm)為3號刀,60度硬質合金螺紋刀為4號刀。
2、 工藝路線
1) 把長軸在車床上找正位置后進行夾緊定位;
2) 用外圓粗車刀從右到左粗車工件各面,分別留0.2mm精車余量;
3) 然后用外圓精車刀從右到左精車各面到尺寸要求;
4) 換螺紋車刀車螺紋;
5) 割退刀槽,并用割槽刀右刀尖倒出C1倒角;
6) 程序結束。
3、 加工程序
程序號O0008;
設置工件坐標系;
返回參考點;
主軸正轉,調用01號粗車刀,打開冷卻液;
快速走到粗車右端面起點(82.0,332.0);
粗車右端面,車削進給速度0.3mm/r;
快速走到外圓粗車循環(huán)起點;
快速定位,靠近工件;
粗車外圓面;
快速退刀;
粗車外圓面;
快速退刀;
粗車外圓面;
快速退刀;
粗車外圓面;
快速退刀;
粗車外圓面;
O0008; N10 G92 X100.0 Z350.0; N15 G28 U0 W0;
N20 S1000 T0101 M03 M08;
N25 G00 X82.0 Z332.0;
N30 G95 G01 X-1.6 W0 F0.3;
N35 G50 X100.0 Z350.0; N40 G00 X42.0 Z332.0; N45 G01 Z34.0;
N50 G00 X37.0 Z332.0;
N55 G00 Z77.0; N60 G00 X32.0 Z332.0;
N65 G00 Z100.5;
N70 G00 X27.0 Z332.0;
N75 G00 Z184.5;
N80 G00 X22.0 Z332.0; N85 G00 Z311.5;
快速退刀;
粗車外圓面;
返回參考點;
快速走到外圓粗車循環(huán)起點;
粗車循環(huán),每次車削深度1.0mm,退刀1.0mm;
留粗車余量X向0.4mm,Z向0.2mm;
快速走到車削起點,精車進給0.15mm/r;
刀具右偏;
精車Φ15外圓面;
精車臺階端面;
精車Φ20外圓面;
精車臺階端面;
精車Φ25外圓面;
精車臺階端面;
精車Φ30外圓面;
精車臺階端面;
精車Φ35外圓面;
精車臺階端面;
精車Φ40外圓面;
精車臺階端面;
取消刀補;
返回參考點;
限制主軸最高轉速為1500r/min;
調用02號精車刀,02號刀補;
粗車后精車;
回退到精車端面快速運動起始點;
快速走到精車端面的工進點;
精車右端面;
返回參考點;
調用03號割槽刀,03號刀補;
刀具快速運動到切槽起點;
切槽;
返回參考點;
刀具快速運動到切槽起點;
切槽;
返回參考點;
刀具快速運動到切槽起點;
切槽;
切槽刀退出;
返回參考點;
N90 G00 X17.0 Z332.0; N95 G00 Z330.0;
N100 G28 U0 W0;
N105 G00 X82.0 Z332.0;
N110 G71 U1.0 R1.0;
N115G71P120Q190U0.4W0.2F0.3S800
N120 G00 X82.0 Z332.0;
N125 G42 G01 X15.0 Z330.0;
N130 W-18.5; N135 X20.0; N140 W-127.0; N145 X25.0;
N150 W-84; N155 X30.0; N160 W-23.5;
N165 X35.0;
N170 W-43.0; N175 X40.0; N180 W-25.0;
N185 X80.0;
N190 G40.0;
N195 G28 U0 W0;
N200 G50 S1500;
N205 G96 S20 T0202; N210 G70 P120Q190;
N215 G00 X82.0 Z332.0;
N220 X17.0;
N225 G01 X-2.0;
N230 G28 U0 W0;
N235 T0303;
N240 G00 X16.0 Z326.5;
N245 G01 X12.0 F0.15;
N250 G28 U0 W0;
N255 G00 X21.0 Z299.5;
N260 G01 X16.0 F0.15;
N265 G28 U0 W0; N270 G00 X21.0 Z189.5;
N275 G01 X16.0 W-5.0 F0.15;
N280 G00 X40;
N285 G28 U0 W0;
取消恒定切削速度,指定主軸轉速,調用04號螺紋車刀;
快速運動到螺紋車削起始點;
復合螺紋加工循環(huán);
復合螺紋加工循環(huán);
返回參考點;
快速運動到螺紋車削起點;
復合螺紋加工循環(huán);
復合螺紋加工循環(huán);
螺紋刀退出;
調用03號割槽刀,03號刀補;
快速運動到倒角起點;
倒角;
返回參考點;
快速運動到倒角起點;
倒角;
返回參考點;
快速運動到倒角起點;
倒角;
返回參考點;
快速運動到倒角起點;
倒角;
返回參考點;
主軸停,關閉冷卻液;
程序結束。
N290 G97 S1500 T0404;
N295 G01 X21.0 Z311.5;
N300 G76 P3 12 60 Q0.1 R0.1; N305G76X16.8W-14.5P1.5Q0.85F2.0;
N310 G28 U0 W0;
N315 G01 X26.0 Z184.5;
N320 G76 P3 12 60 Q0.1 R0.1;
N325G76X16.8W-14.5P2.0Q0.85F2.0;
N330 G00 X42.0;
N335 T0303;
N340 G00 X28.0 Z100.6;
N345 G01 X30.1 Z-1;
N350 G28 U0 W0; N355 G00 X23.0 Z184.6; N360 G01 X25.1 Z-1; N365 G28 U0 W0;
N370 G00 X18.0 Z311.6; N375 G01 X20.1 Z-1; N380 G28 U0 W0;
N385 G00 X13.0 Z330.1;
N390 G01 X15.1 Z-1; N395 G00 X 20.0 Z332.0; N400 G28 U0 W0 M05 M09;
N405 M30;
O0008; N10 G92 X100.0 Z350.0; N15 G28 U0 W0;
N20 S1000 T0101 M03 M08;
N25 G00 X82.0 Z332.0;
N30 G95 G01 X-1.6 W0 F0.3;
N35 G50 X100.0 Z350.0; N40 G00 X42.0 Z332.0; N45 G01 Z34.0;
N50 G00 X37.0 Z332.0;
N55 G00 Z77.0; N60 G00 X32.0 Z332.0;
N65 G00 Z100.5;
N70 G00 X27.0 Z332.0;
N75 G00 Z184.5;
N80 G00 X22.0 Z332.0; N85 G00 Z311.5;
N90 G00 X17.0 Z332.0; N95 G00 Z330.0;
N100 G28 U0 W0;
N105 G00 X82.0 Z332.0;
N110 G71 U1.0 R1.0;
N115G71P120Q190U0.4W0.2F0.3S800
N120 G00 X82.0 Z332.0;
N125 G42 G01 X15.0 Z330.0;
N130 W-18.5; N135 X20.0; N140 W-127.0; N145 X25.0;
N150 W-84; N155 X30.0; N160 W-23.5;
N165 X35.0;
N170 W-43.0; N175 X40.0; N180 W-25.0;
N185 X80.0;
N190 G40.0;
N195 G28 U0 W0;
N200 G50 S1500;
程序號O0008;
設置工件坐標系;
返回參考點;
主軸正轉,調用01號粗車刀,打開冷卻液;
快速走到粗車右端面起點(82.0,332.0);
粗車右端面,車削進給速度0.3mm/r;
快速走到外圓粗車循環(huán)起點;
快速定位,靠近工件;
粗車外圓面;
快速退刀;
粗車外圓面;
快速退刀;
粗車外圓面;
快速退刀;
粗車外圓面;
快速退刀;
粗車外圓面;
快速退刀;
粗車外圓面;
返回參考點;
快速走到外圓粗車循環(huán)起點;
粗車循環(huán),每次車削深度1.0mm,退刀1.0mm;
留粗車余量X向0.4mm,Z向0.2mm;
快速走到車削起點,精車進給0.15mm/r;
刀具右偏;
精車Φ15外圓面;
精車臺階端面;
精車Φ20外圓面;
精車臺階端面;
精車Φ25外圓面;
精車臺階端面;
精車Φ30外圓面;
精車臺階端面;
精車Φ35外圓面;
精車臺階端面;
精車Φ40外圓面;
精車臺階端面;
取消刀補;
返回參考點;
限制主軸最高轉速為1500r/min;
N205 G96 S20 T0202; N210 G70 P120Q190;
N215 G00 X82.0 Z332.0;
N220 X17.0;
N225 G01 X-2.0;
N230 G28 U0 W0;
N235 T0303;
N240 G00 X16.0 Z326.5;
N245 G01 X12.0 F0.15;
N250 G28 U0 W0;
N255 G00 X21.0 Z299.5;
N260 G01 X16.0 F0.15;
N265 G28 U0 W0; N270 G00 X21.0 Z189.5;
N275 G01 X16.0 W-5.0 F0.15;
N280 G00 X40;
N285 G28 U0 W0;
N290 G97 S1500 T0404;
N295 G01 X21.0 Z311.5;
N300 G76 P3 12 60 Q0.1 R0.1; N305 G76X16.8W-14.5P1.5Q0.85F2.0;
N310 G28 U0 W0;
N315 G01 X26.0 Z184.5;
N320 G76 P3 12 60 Q0.1 R0.1;
N325 G76X16.8W-14.5P2.0Q0.85F2.0;
N330 G00 X42.0;
N335 T0303;
N340 G00 X28.0 Z100.6;
N345 G01 X30.1 Z-1;
N350 G28 U0 W0; N355 G00 X23.0 Z184.6; N360 G01 X25.1 Z-1; N365 G28 U0 W0;
N370 G00 X18.0 Z311.6; N375 G01 X20.1 Z-1; N380 G28 U0 W0;
N385 G00 X13.0 Z330.1;
N390 G01 X15.1 Z-1; N395 G00 X 20.0 Z332.0; N400 G28 U0 W0 M05 M09;
N405 M30;
調用02號精車刀,02號刀補;
粗車后精車;
回退到精車端面快速運動起始點;
快速走到精車端面的工進點;
精車右端面;
返回參考點;
調用03號割槽刀,03號刀補;
刀具快速運動到切槽起點;
切槽;
返回參考點;
刀具快速運動到切槽起點;
切槽;
返回參考點;
刀具快速運動到切槽起點;
切槽;
切槽刀退出;
返回參考點;
取消恒定切削速度,指定主軸轉速,調用04號螺紋車刀;
快速運動到螺紋車削起始點;
復合螺紋加工循環(huán);
復合螺紋加工循環(huán);
返回參考點;
快速運動到螺紋車削起點;
復合螺紋加工循環(huán);
復合螺紋加工循環(huán);
螺紋刀退出;
調用03號割槽刀,03號刀補;
快速運動到倒角起點;
倒角;
返回參考點;
快速運動到倒角起點;
倒角;
返回參考點;
快速運動到倒角起點;
倒角;
返回參考點;
快速運動到倒角起點;
倒角;
返回參考點;
主軸停,關閉冷卻液;
程序結束。
湖 南 科 技 大 學
英文文獻翻譯
學 生 姓 名: 王金思
學 院: 機電工程學院
專業(yè)及班級: 機械設計制造及其自動化三班
學 號: 1103010324
指 導 教 師: 萬林林
2015年 5月28日
- 7 -
湖南科技大學本科生畢業(yè)設計(論文)
The Automatic Tool Changer’s main types,characteristics, and the scope of application
1、Auto Rotary Tool
Rotary Tool automatically on the use of CNC machine tool is a simple installation of automatic tool change, the Quartet and 47.60 Turret Tool various forms, such as rotary turret were installed on four, six or more of the Tool , NC instructions by ATC. Rotary Tool has two vertical and horizontal, relatively simple structure, applicable to economic CNC lathe.
Rotary Tool in the structure must have good strength and stiffness, resistance to bear rough Cutting Tool in the cutting force and reduce the role of deformation and improve processing accuracy. Rotating Tool to choose reliable positioning project structure and reasonable position, in order to ensure that each rotary turret to a higher position after 圖1 螺旋升降式四方刀架
repeated positioning accuracy (typically 0.001 to 0.005mm). Figure 2.1 shows the spiral movements of the Quartet Turret.
Auto Rotary Tool in the simplest of ATC, is 180 o rotary ATC devices, as shown in Figure 2 ATC instructions received, the machine control system put ATC spindle control to the designated location at the same time, the tool movement to the appropriate location, ATC, with the rotary axis and at the same time, the knives matching tool; Draw bars from Spindle Cutting Tools rip, ATC, will be the tool from their position removed; ATC, 180 o rotary tool spindle and the tool and tool away; ATC, the Rotary At the same time, the tool refocusing its position to accept Spindle removed from the cutting tool; Next, ATC, will be replaced with the cutter knives were unloaded into the spindle and tool: Finally, back to the original ATC, "standby" position. At this point, ATC completed procedures to continue to run. This ATC, the main advantage of simple structure, the less movement, fast tool change. The main disadvantage is that knives must be kept in parallel with the axis of the plane, and after the home side compared to the tool, chip and liquid-cutting knife into the folder, it is necessary to the tool plus protection. Cone knife folder on the chip will cause ATC error, or even damage knife folders, and the possibility of spindle. Some processing center at the transfer, and the tool side. When the ATC command is called, the transfer-cutter knives will be removed, the machine go forward, and positioning with the ATC, in line with the position. 180 o "Rotary ATC devices can be used horizontal machine, can also be used for vertical machining centers.
圖2 180°回轉式換刀裝置
2 、ATC head-turret installed
With rotating CNC machine tool often used such ATC devices, with a few turret head spindle, each with a spindle on both knives, the first tower interim process can be automatic tool change-realization. The advantage is simple structure, tool change time is short, only about 2 s. However, due to spatial constraints, the number of spindle can not be too much, usually only apply to processes less, not to high precision machine tools, such as the NC drill, such as CNC milling machine. In recent years there has been a mechanical hand and the turret head with a knife for the automatic tool change ATC devices, as shown in Figure 2.3. It is in fact a turret head ATC, and the knife-ATC device combination. The principle is as follows:
圖3 機械手和轉塔頭配合刀庫換刀的自動換刀裝置
5 turret on the first two tool spindle 3 and 4, when using the tool spindle 4 processing tool, the manipulator 2 will be the next step to the need for the tool does not work on the tool spindle 3 until after the completion of this process , the first rotary turret 180 o, ATC completed. ATC most of their time and processing time coincidence, the only real tool change time turret transposition of the first time, this approach mainly used for ATC and NC NC drilling file bed.
3、 Automatic tool changer with tool magazine
Figure 4 shows?the knife and split-type machine to the appearance of CNC machine tool plans.
Figure 5 shows the knife and the whole machine tool CNC machine tools for the appearance of Fig.
At this point, knife storage capacity, a heavier tool can, and often additional transport unit to complete the knife between the spindle and cutting tool transport.
The ATC with tool magazine , the election knives, automatic loading and unloading machine tool and tool exchange institutions (manipulator), composed of four parts, used widely.
Tool Automatic Tool Change the manipulator system, the whole process more complicated ATC. We must first used in the processing of all installed in the standard tool on the knife handle in the machine outside the pre-size, according to a certain way Add to the knife. ATC, selected first in the knife knife, and then from ATC, from the knife from the knife or spindle, exchange, the new knife into the spindle, the old knife back into the knife.
? ATC, as the former two knives to accommodate a limited number can not be too many, can not meet the needs of complex parts machining, CNC machine tool Automatic Tool Changer with tool magazine the use of the automatic tool change devices. The knife has more capacity, both installed in the spindle box side or above. As for the automatic tool change with tool magazine device CNC machine tool spindle box only a spindle, spindle components to high stiffness to meet the machining requirements. The number of establishments in larger knife, which can meet the more complex parts of the machining processes, significantly improving productivity. the automatic tool changer with tool magazine applied to drilling centers and CNC machining centers. The comparison drawn automatic tool changer with tool magazine system is the most promising.
圖4 刀庫與機床為分體式數控機床 圖5 刀庫與機床為整體式數控機床
自動換刀裝置的主要類型、特點和適用范圍
1、自動回轉刀架
自動回轉刀架是數控機床上使用的一種簡單的自動換刀裝置,有四方刀架和六角刀架等多種形式,回轉刀架上分別安裝有四把、六把或更多的刀具,并按數控指令進行換刀。回轉刀架又有立式和臥式兩種,結構比較簡單,適用于經濟數控車床。
回轉刀架在結構上必須具有良好的強度和剛度,以承受粗加工時切削抗力和減少刀架在切削力作用下的變形,提高加工精度?;剞D刀架還要選擇可靠的定位方案和合理的定位結構,以保證回轉刀架在每次轉位之后具有較高的重復定位精度(一般為0.001 ~0.005mm )。圖1所示為螺旋升降式四方刀架。
圖1 螺旋升降式四方刀架
在自動回轉刀架中最簡單的換刀裝置是180o回轉式換刀裝置,如圖2.2所示。接到換刀指令后,機床控制系統(tǒng)便將主軸控制到指定換刀位置;與此同時,刀具庫運動到適當位置,換刀裝置回轉并同時與主軸、刀具庫的刀具相配合;拉桿從主軸刀具上卸掉,換刀裝置將刀具從各自的位置上取下;換刀裝置回轉180o并將主軸刀具與刀具庫刀具帶走;換刀裝置回轉的同時,刀具庫重新調整其位置,以接受從主軸取下的刀具;接下來,換刀裝置將要換上的刀具與卸下的刀具分別裝入主軸和刀具庫:最后,換刀裝置轉回原“待命”位置。至此,換刀完成,程序繼續(xù)運行。這種換刀裝置的主要優(yōu)點是結構簡單、涉及的運動少、換刀快。主要缺點是刀具必須存放在與主軸平行的平面內,與側置后置刀具庫相比,切屑及切削液易進入刀夾,因此必須對刀具另加防護。刀夾錐面上有切屑會造成換刀誤差,甚至有損壞刀夾與主軸的可能。有些加工中心使用了傳遞桿,并將刀具庫側置。當換刀指令被調用時,傳遞桿將刀具庫的刀具取下,轉到機床前方,并定位于與換刀裝置配合的位置。180o“回轉式換刀裝置既可用于臥式機床,也可用于立式機床。
圖2 180°回轉式換刀裝置
2、轉塔頭式換刀裝
帶有旋轉刀具的數控機床常采用此種換刀裝置,轉塔頭上裝有幾個主軸,每個主軸上均裝一把刀具,加工過程中轉塔頭可自動轉位實現換刀。其優(yōu)點是結構簡單,換刀時間短,僅為2s左右。但由于受空間位置的限制,主軸數目不能太多,通常只適用于工序較少、精度要就不高的機床,如數控鉆床、數控銑床等。近年來出現了一種用機械手和轉塔頭配合刀庫進行換刀的自動換刀裝置,如圖3所示。它實際上是轉塔頭換刀裝置和刀庫式換刀裝置的結合。其原理如下:
圖3 機械手和轉塔頭配合刀客換刀的自動換刀裝置
轉塔頭5上有兩個刀具主軸3和4,當用刀具主軸4上的刀具進行加工時,可由機械手2將下一步需要的刀具換至不工作的刀具主軸3上,待本工序完成后,轉塔頭回轉180o,完成換刀。因其換刀時間大部分和加工時間重合,真正換刀時間只需轉塔頭轉位的時間,這種換刀方式主要用于數控鉆床和數控銼床等。
3、帶刀庫的自動換刀系統(tǒng)
圖4所示為刀庫與機床為分體式數控機床的外觀圖。
圖5所示為刀庫與機床為整體式數控機床的外觀圖。
此時,刀庫容量大,刀具可以較重,常常附加運輸裝置來完成刀庫與主軸之間刀具的運輸。
帶刀庫的換刀裝置由刀庫、選刀機構、刀具自動裝卸機械及刀具交換機構(機械手)等四部分組成,應用廣泛。
刀庫機械手自動換刀系統(tǒng),整個換刀過程比較復雜。首先要把加工過程中使用的全部刀具安裝在標準刀柄上,在機外進行尺寸預調后,按一定的方式放入刀庫。換刀時,先在刀庫中選刀,再由換刀裝置從刀庫或主軸上取刀,進行交換,將新刀裝入主軸,舊刀放回刀庫。
由于前兩種換刀裝置容納的刀具數量有限不能太多,不能滿足復雜零件的加工需要,所以自動換刀數控機床多采用帶刀庫的自動換刀裝置。刀庫具有較大容量,既可安裝在主軸箱的側面或上方。由于帶刀庫的自動換刀裝置的數控機床的主軸箱內只有一根主軸,主軸部件的剛度要高,以滿足精密加工要求。刀庫內數量較大,因而能滿足復雜零件的多工序加工,大大提高生產率。帶刀庫的自動換刀系統(tǒng)適用于數控鉆削中心和加工中心。進行比較得出帶刀庫的自動換刀系統(tǒng)是最有發(fā)展前景的。
圖4 刀庫與機床為分體式數控機床 圖5 刀庫與機床為整體式數控機床