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數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，從內向外主要由以下幾部分構成：塑件型腔面、分型面、排氣槽、側抽芯槽、模架面、回程桿墊片槽等。在編制數控編程工藝時，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，本應開粗到位的區域沒有開粗到位，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 ，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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1734-IR2E POINT I/O 2 Point RTD Input Module

1788-ENBT FlexLogix/DriveLogix ENet/IP Comms Card

194E-Y16-1753-4A 16 A 194E Load switch

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IC800SSI107RS1 7.2 amp 115/230 VAC S2K servo controller for MTR series motors

SLC/1746 System 1747-L30A 30 I/O FIXED HARDWARE STYLE

Industrial Computers 6189-RPEH VVCE LOGIC MODULE, 256MB FLASH, 256MB RAM

Process Control 9399-SAPRG RSBATCH SERVER API REFERENCE GUIDE

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IC647HSTCC100KM Calculation Collector for Historian - Standard Server 100000 Points (M4 Key)

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