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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
 

IC200ALG322 ANALOG OUTPUT 12 BIT VOLTAGE +/-10V 4CH

IC610MDL156RR 24Vdc Sink Output, D Connector, with LEDs (16 points)

IC800SLCFLYV010 Flying Lead Cable, 1-5 kW SL Amplifier I/O to OCS or 3rd Party Controller, 1 Meter

OC647IPWRCLNDVM iPower Option - Dev Client

PXI-5153

DLP-035025

Brooktrout TR1034+P8-8L

COSMO ATIO-32

METEOR2/4

RIO-3309S

1492-MCAA235 35 A Ul489 Miniature Circuit Breaker

1494U-LM31 1494U 100A Multi-port Lugs

軟啟動器 3RW44556BC34

Safety Advanced V14 6ES7833-1FB14-0YE5 STEP 7 Safety Basic V14 SP1 Upgrade

1585D-M4UBDM-7 Ethernet Media M12, Patchord

1756-IV32 ControlLogix 32 Pt 12/24VDC D/I Module

1797-PS2E2 FlexEx Power Supply

194E-E63-1753-6G 63 A 194E Load switch

2090-CFBM6DD-CCAA09 TL-Series 9m Feedback Cable

2090-SCEP10-0 Kinetix 10-10m Fiber Optic Cable

BC646MFC001 FANUC Ladder IIIC for OpenCNC with Proficy GlobalCare Complete

GC647ADC010 GC Dashboard Client 10 Pak

HMI-CAB-C53 CABLE 25 PIN FEMALE COMM

IC641SWP063 Series 90 PCM Support S/W, Term. Emulator/File Transfer (TERMF)

IC647IFCLNTSRO005M iFIX iClientTS Read Only 5 PK (M4 Part)

IC660EBD020 Electronic Assembly for IC660BBD020

IC695PSD140 Multipurpose Power Supply is suitable for use in load-sharing and redund ancy application. It must be installed in a PACsystems RX3i (IC695catalog number) Universal Backplane.

IC756WRE099E-27 Runtime License Windows 50-99 Users English v2.7

FlexLogix System 1794-OB16D 24V DC SOURCE DIAGNOSTIC OUTPUT MODULE, 16PT

PLC-5/1771 System D1785-6.5.2 DH PLUS RS-232-C INTERFACE MDL(1785-KE)USER'S MNL

Process Control 1757-PLXSIFW PLX MA500 QUICKBUILDER INTERFACE

Operator Interface 2711P-K10C4B1 PV PLUS 1000, KEYPAD, ENET, AC PS, STD MEM

Support 9310-WED200S SUPT RENEWAL CONTRACT FOR 9310WED200ENE

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Support F1785-L40C15SERF FIRMWARE UPGRADE FOR 1785-L40C15 PLC5 PROCESSOR MO

RSI Software Products 9301-2SE2300U1R UPGRADE: OUT-SUPT: RSVIEW WORKS 300 TO 1500

RSI Software Products 9701-VWSCWAENE RSVIEW SE CLIENT

RSI Software Products 9399-RL50GRDE RSLOGIX 500 GETTING RESULTS GUIDE (GERMAN)

Motion Control 1394C-AM03 MODULE,AXIS,2KW,3.0A CONT,6.0A PEEK

BC646MDC700 Logic Developer - PC & View Development/Runtime 700 I/O

IC300OCS031 OCS with 2x20 LCD Display and with 16 keypad. Built in I/O no expansion. 8 DC Inputs (12/24vdc), 8 DC Outputs (5/12/24vdc, 0.5A pos. logic with ESCP). No network

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MTR-3T11-G-R-0-M-S MTR series metric servo motor with resolver and shaft seal

PCI-6071E

NBP 20016

PC104-FD-32-DF

WCF681

SBC81610

SHB-960

1492-L2 IEC Term Blck 3.5x51.5x29.5mm Spr Clp

1492-XIM24-16RF Expander Module / 16 Relays 24Vdc Fused

軟啟動器 3RW44243BC36

接口模塊 6ES7 155-5AA00-0AB0 IM 155-5 2PN 接口，PROFINET 接口模塊

1585-C8HB-S100 Cable Spool Ethernet Media

1746-P4 SLC Rack Mounting Power Supply

1790-T0A8X CompactBlock LDX Expansion Block

194E-A100-PE 194E Earthing-Grounding Terminal

20-PP10016 MOTOR CABLE V, PF700H, PF700S

2090-CSBM1DF-18AA20 Kinetix 20m Smartlink Single Cable

20AC037A3AYNANC0 PowerFlex 70 AC Drive 20A

GC-8841-LC-MT SafetyNet Logic Workbench

HE300SFW100 Drive configuration software for GEN100 and RSL100.

IC600KD533RR Amber OptiBasic OIT, Ver 31

IC647HSTES250KM Historian Enterprise Server 250000 Points (M4 Key)

IC650AEL003RR Series Six Controller Board with Faceplate (MAP30) **

IC694APU300 High speed counter module 200KHZ A B and C type.

IC756SDV000K-99 DV Development - Solaris Op Sys, Korean, Version 9.9

MicroLogix 1500/1769 System

PLC-5/1771 System 1771-WF FIELD WIRING ARM, 18 TERMINALS

Distributed I/O 1794-IRT8K CONFORMAL COAT, NON-ISOLATED TC/RTD/MV INPUT, 8 PT

Communications 9399-WAB32UG RSLINX USER GUIDE

Support 6233-52VDLR SUPT REINSTATEMENT CONTRACT FOR 623352VDL

Support 9358-BPC60R SUPT REINSTATEMENT CONTRACT FOR 9358BPC60ENE

Support F1771-IRSERC FIRMWARE UPGRADE FOR 1771-IR I/O MODULE

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Motion Control 8720SM-015S3EAS3 15 KW/33.4 AMP, 750 VDC, AC MOTOR WITH SNS60 ENC.

829-3-0 Thumbwheel Assembly. 3 Digit, 0 True. Dust Seal

IC200MDL635 INPUT 48VDC POS/NEG LOGIC (2 GROUPS OF 8) 16PT

IC697NS1000 NEXT STEP Package 1

MTR-1324-N-A-E-0 MTR series NEMA 34 stepping motor with parallel winding connection

FP-AI-100

IPC-586VF

Dialogic DCB/SC 96-0312-002

PCM-8201

PCA-6114-0B2

WHNC-006A

PCI-7260

1492-SPM3B150 MCB Supplementary Protector 15 A

軟啟動器 3RW40262TB05

主站模塊 6GK7 243-5DX30-0XE0 CM 1243-5 PROFIBUS DP 主站模塊

150-F625NBA SMC Flex Smart Motor Controller

1734-IB4D POINT I/O 4 Point Digital Input Module

1783-BMS20CA Stratix 5700 20 Port Managed Switch

193-EMRA E1 Plus 240V AC Remote Reset Solenoid

20-750-DENC-1 PowerFlex 750 Dual Encoder Option module

2090-CPWM7DF-12AA02 MP-Series 2m Power Cable

2098-DSD-010-SE Ultra 3000 1kW with SERCOS Servo Drive

G-0017 Foot Switch Splitter (for 4-port NT only)

GFK-2098 IC697VRD008, RTD/Strain Bridge Module

IC220PWR013 SEGMENT TERMINAL, FUSED 24VDC W/DIAG (REQUIRES 1 IC220TBK087)

IC647DNP010 "DNP3 Master Protocol for 10,000 points"

IC647S2GC S2G:SECS-II

IC693MDL632LT 125 Vdc Input (8 Points) (LT)

IC756DVE000E-99 EO GECK (Graphical Editor Construction Kit) - Unix, English, Version 9 .9

MSI-QUAL-10-43 Quality Mang Clients 10 Pack-43

PLC-5/1771 System 1771-ASB PLC-2,-3,-5, REMOTE I/O ADAPTER MODULE

Distributed I/O 1790D-0B16 DNET LDX I/O, 24VDC, 16 SOURCE OUT BASE, D-SHELL

Communications 6628-A5 WDLAN-EPR F001 ETHERNET ADAPTER CARD (XT/AT)

Operator Interface 2711E-UK12EK10 PANELVIEW 1200E KEYPAD TO 1000E KEY MIGRATION KIT

Support 9305-RSVADDCPTS SUPT RENEWAL CONTRACT FOR 9305RSVADDCPT

Support 9324-RLDFBDR SUPT REINSTATEMENT CONTRACT FOR 9324RLDFBDEN

DeviceNet Products D1771-6.5.118 DEVICENET SCANNER CONFIGURATION MANUAL

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2225-LV Greyline OS, 4 Line, (20) 4MM Chars, LCD. ASCII /Serial Interface, 10-30 VDC, NEMA 4

HE800ACC512 DIN-rail mount Terminal Block, 12-pin. Compatible with most SmartStack Analog I/O.

IC693ACC318 Connector Kit, 24 Pin, Qty (10), Ribbon Type (For MDL654, 655, 752, 753)

QPK3D200L2P 6" Monochrome, TCP Label, 24Vdc, UL,cUL,CE,UL1604

TGT-000A-4-0RR Target 4-Axis Motion Control Module

SCC-DI01

DS817-03

586ITOX

DAT2000 ISA

M1S2-5500V4H

MTC-610/611

1492-SPM1B500-N MCB Supplementary Protector 50 A

直流電源 6EP1437-3BA00 3 相 400-500VAC 輸入。24VDC/40A 輸出

電機啟動器 3VU13400MG00

1497D-A16-M14-0-N Gen Purpose Transformer

1608G-6F1 I-Grid 6-Channel Subscription Renewal

1769-OB32T CMPLX 32 Pt 24VDC Terminated D/O Module

190S-AND2-CB63C 4.0-6.3 A Compact Comb Starter W/Ckt-Bkr

194R-N60-1753-PBS1 Non-Fused 194R Disconnect Switch

2090-CPBM7DF-16AA20 MP-Series 20m Standard Cable

2090-XXTFMP-S12 MP-Series 12 m Length Feedback Cable

CBL-T7-MP-20 Power cable for MTR-3T10 or MTR-3T20 or MTR-3T40 series servo motors. 20 feet

GF-3093R Connecting FlashCable to Sensotec Pressure Transducer, Keyence LS-5000 .

IC200UDR002 14 point PLC,(8) 24VDC In, (6) Relay Out, 24VDC Power Supply

IC646TPR935 ProServer 35,000 I/O Point Runtime System

IC647PATAXS0 Proficy PAT - Driver For All Axsun Technologies Near-Ir Spectrometers

IC693APU300 High Speed Counter (HSC)

IC752ECD450RR Display Station 1463 - 14 inch VGA (640x480) resistive touch screen/ Penti um 133/ 32MB/ 1.2 Gig hard drive/ expansion slots/ Ethern et/ with CIMP LICITY HMI and Win NT

IFIXONNODE500C iFIX Upgrade to On-Node 500 Tag Standard Edition Historian with Alarm & Event Option, M1 Key

SLC/1746 System 1747-PBASE BASIC DEVELOPMENT SOFTWARE

Industrial Computers 6186-M20ALTR VERSAVIEW 20 INCH MONITOR, RESISTIVE TOUCH SCREEN

Application-specific products 1404-M505A-CNT-02 1404-M5 CONTROLNET PM3000 CLASS 0.2 120/240V P.S.

Operator Interface 2711-K10C10 PV1000 COLOR KEY, DNET & RS232 PRINT

Support 9301-2SE3100S SUPT RENEWAL CONTRACT FOR 93012SE3100

Support 9380-RSBEDRCPR SUPT REINSTATEMENT CONTRACT FOR 9380RSBEDRCP

DeviceNet Products 1738-ADN18P DEVICENET ADAPTER WITH MINI PASS THROUGH

RSI Software Products 9301-2SE3203DEE RSVIEW32 RUNTIME 300 WITH RSLINX (GERMAN)

RSI Software Products 9358-BPCNT60U2R UPGRADE: OUT-SUPT: RSBATCH PC-BASED 10 TO 60

Motion Control MPL-B4520P-SK24AA MOTOR,SERVO,6.1 NM,5000RPM,SINGL,460V,BRK

Motion Control 2090-SCVG200-0 SERCOS FBR CABL,CONN,STNDRD PVC JKT,GLASS,200.0M

GFZ-0043 Genius I/O System Troubleshooting Guide for Series Six PLC

IC646MPC001 Logic Developer - PLC Configuration Tools

MTR-1324-N-D-E-0 Stepping Motor, Nema34, Series Wdg

QPJ-ABD-201 Communication Module for 5 inch & 6 inch: AB DataHighway Plus/ UL/ cUL/ CE/ UL 1604

PXIe-5170R

E2073-66501-3643-02-1999

MATROX MGI PH-P256

PBA75F-12

PEAK 635

KINO-DH810-R10

1492-PDE1142 200 A Enclosed Power Distribution Block

中央處理單元 6ES7417-4XL04-0AB0 CPU417-4，20MB，30ns，電源 24VDC，MPI/PROFIBUS-DP 主站接口，PROFIBUS-DP 主站接口

變送器 3RS17062FE00

1495-N80 Line Side Cover

1585J-M8TBJM-4 RJ45 Ethernet Media

1761-CBL-AS09 MicroLogix Cable

188-K3B200-N Miniature Circuit Breaker 20 A

194L-E16-3254 16 A 194L Load Switch

2090-CPBM4DF-16AF25 MP-Series 25 m Length Cable

2090-XXNFMF-S25 Kinetix Drives 25m Standard Cable

BC647OEM0500B OEM Edge Program - Complete

GC647PATCDI0 Proficy PAT - Driver For CDI - Assist Support

IC200MDD845 Mixed 24VDC POS LOG input group 16 point / isolated 2 amp relay output 8 point.

IC646NRX005 System Sentry - 5 Node

IC647MBL001 Machine Edition Lite Development Suite with USB Hardware key

IC675GSD001 Profibus Station IP67 GSD Configuration Files

IC697MDL740 24/48 Vdc Output, 2 Amp, Positive Logic (16 Points)

IC800SLR003 External regeneration resistor rated 20 ohm 300 Watt for SL and S2K series

ControlLogix/1756 System 1756-BATM CONTROLLOGIX BATTERY MODULE

Industrial Computers 6182H-15BRH15D VVCE 1500, KEY/TOUCH, STD MEM, CNET, DC

Process Control 1757-DNBEXP100 DEVICENET MODULE EXPANSION, 80-100 MAX

Operator Interface 2711P-ST6KC PV PLUS 600 COLOR, KEYPAD STARTER KIT

Support 9326-AD10WDR SUPT REINSTATEMENT CONTRACT FOR 9326AD10WDENE

Support 9371-EDES1S SUPT RENEWAL CONTRACT FOR 9371EDES1

ControlNet Products 1734-EP24DC 24V DC POWER/BUS EXTENSION MODULE

RSI Software Products 9301-2SE240ITU3R RSVIEW32 WORKS 150-32K UPGRADE OUT-SUPT (IT)

RSI Software Products 9358-B60U3R UPGRADE: OUT-SUPT: RSBIZWARE BATCH 30 TO 60

Motion Control MPL-A430P-SK22AA MOTOR,SERVO,5.42 NM,5000RPM,SINGL,230V,6.4KG

Motion Control 2090-UXNFM-S03 CABLE,ULTRA, DRIVE CN2 TO N/C,3M

CBL-1C-ET-20 Encoder Cable, MTR-1216, 1221 & 1231 Stepping Motors, 20 Ft.

IC630MDL303RR 5-12Vdc (TTL) Sink Input Module, D Connector (32 points)

OC647IFSETKTC iFIX Optn: System Extension Toolkit (M1Component Part)

PXI-2569

ROBO-8712VLA

PHILIPS HEALTHCARE SNGBP 459800079641

N2200-PAC-400W

NUPRO-A301 NuPRO-852

4036A H9MSER40XX

1492-MCBA180 80 A UL489 Miniature Circuit Breaker

1494V-DJ622-A-B-D NEMA Flange Mtd Rod Switch Disconnect Sw

軟啟動器 3RW44566BC35

工程組態編程軟件 6AV2103-2DH04-0BD5 SIMATIC WinCC 專業版 Powerpack 512 PowerTags -> 4096 PowerTags V14

1585D-M4UBJM-4 Ethernet Media M12, Patchcord

1756-L72 ControlLogix 4 MB Controller

1799-BRKD Embedded Input/Output DIN Rail Bracket

194E-FA16-P11-PE 194E Load switch

2090-CFBM6DF-CBAA15 TL-Series 15m Feedback Cable

2090-SCNP32-0 Kinetix 32-32m Fiber Optic Cable

BC646MPM001 Logic Developer PLC Nano/Micro with Proficy GlobalCare Complete

GC647AHC001 GC PA Historian Connector

HMI-CAB-ETH 6 feet, Ethernet Cross-over cable for direct connection to CE devices

IC641VPD010 VersaPro Distributor Demo 10 Pack

IC647IFGLBLDPNSRVRM-55 iFIX WebSpace v5.5 Dependent Server

IC660EBD120RR High Speed Counter Electronic Assembly

IC697ACC644 24VDC fan tray for Series 90-70 or RX7i short racks.

IC756WRE499E-27 Runtime License Windows 100+ Users English v2.7

FlexLogix System 1794-IE8 ANALOG INPUT MODULE, 12 BIT, 8 POINT

PLC-5/1771 System D6200-6.4.11RU PLC5 PROG. SW INSTRUCTION REFERENCE MNL (RUSSIAN)

Process Control 1757-PLXSU300 PLX SERVER 100 TO 300 POINT EXPANSION

Operator Interface 2711P-T10C4D1 PV PLUS 1000, TOUCH, ENET, DC PS, STD MEM

Support 6001-A1CS SUPT RENEWAL CONTRACT FOR 6001A1C

Support 2711-END1FRR SUPT REINSTATEMENT CONTRACT FOR 2711END1FR

Support F1785-L46BSERD FIRMWARE UPGRADE FOR 1785-L46B PLC5 PROCESSOR MODU

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