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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(guò)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(kāi)粗的加工效率。若開(kāi)粗刀具選擇過(guò)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(kāi)粗刀具選擇過(guò)大，表面上看起來(lái)粗加工時(shí)間很少，但是開(kāi)粗效果不理想，本應(yīng)開(kāi)粗到位的區(qū)域沒(méi)有開(kāi)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(lái)說(shuō)，原則上把開(kāi)粗時(shí)間 控 制 在 5h 以 內(nèi) ，初 步 選 定 開(kāi) 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
 

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