轴类零件数控车削工艺分析 实例一
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<TD align=middle colSpan=4 height=1><B><FONT color=#000080>轴类零件数控车削工艺分析 实例一</FONT></B></TD></TR>
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<TD align=middle bgColor=#00468c colSpan=4 height=16><FONT color=#ffffff>NEWS.C-CNC.COM 2007-5-18 来源： 阅读：
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<DIV><FONT face=Courier> 典型轴类零件如图1所示，零件材料为45钢，无热处理和硬度要求，试对该零件进行数控车削工艺分析。</FONT></DIV>
<DIV align=center><STRONG><IMG src="http://www.chmcw.com/upload/news/RCL/13220_z0j6eb200751893314.jpg"></STRONG></DIV>
<DIV align=center><STRONG>图1 典型轴类零件</STRONG></DIV>
<DIV><BR> （1）零件图工艺分析</DIV>
<DIV>该零件表面由圆柱、圆锥、顺圆弧、逆圆弧及螺纹等表面组成。其中多个直径尺寸有较严的尺寸精度和表面粗糙度等要求；球面Sφ50㎜的尺寸公差还兼有控制该球面形状（线轮廓）误差的作用。尺寸标注完整，轮廓描述清楚。零件材料为45钢，无热处理和硬度要求。</DIV>
<DIV>通过上述分析，可采用以下几点工艺措施。</DIV>
<DIV>①对图样上给定的几个精度要求较高的尺寸，因其公差数值较小，故编程时不必取平均值，而全部取其基本尺寸即可。</DIV>
<DIV>②在轮廓曲线上，有三处为圆弧，其中两处为既过象限又改变进给方向的轮廓曲线，因此在加工时应进行机械间隙补偿，以保证轮廓曲线的准确性。</DIV>
<DIV>③为便于装夹，坯件左端应预先车出夹持部分（双点画线部分），右端面也应先粗车出并钻好中心孔。毛坯选φ60㎜棒料。</DIV>
<DIV>（2）选择设备 </DIV>
<DIV>根据被加工零件的外形和材料等条件，选用TND360数控车床。</DIV>
<DIV>（3）确定零件的定位基准和装夹方式 </DIV>
<DIV>①定位基准 确定坯料轴线和左端大端面（设计基准）为定位基准。</DIV>
<DIV>②装夹方法 左端采用三爪自定心卡盘定心夹紧，右端采用活动顶尖支承的装夹方式。</DIV>
<DIV>（4）确定加工顺序及进给路线 </DIV>
<DIV>加工顺序按由粗到精、由近到远（由右到左）的原则确定。即先从右到左进行粗车（留0.25㎜精车余量），然后从右到左进行精车，最后车削螺纹。</DIV>
<DIV>TND360数控车床具有粗车循环和车螺纹循环功能，只要正确使用编程指令，机床数控系统就会自动确定其进给路线，因此，该零件的粗车循环和车螺纹循环不需要人为确定其进给路线（但精车的进给路线需要人为确定）。该零件从右到左沿零件表面轮廓精车进给，如图2所示。</DIV>
<DIV align=center><STRONG><IMG src="http://www.chmcw.com/upload/news/RCL/13220_qxcza520075189342.jpg"></STRONG></DIV>
<DIV align=center><STRONG>图2 精车轮廓进给路线</STRONG></DIV>
<DIV>（5）刀具选择 </DIV>
<DIV>①选用φ5㎜中心钻钻削中心孔。</DIV>
<DIV>②粗车及平端面选用900硬质合金右偏刀，为防止副后刀面与工件轮廓干涉（可用作图法检验），副偏角不宜太小，选κ=35 0。</DIV>
<DIV>③精车选用900硬质合金右偏刀，车螺纹选用硬质合金600外螺纹车刀，刀尖圆弧半径应小于轮廓最小圆角半径，取rε=0.15～0.2㎜。</DIV>
<DIV>将所选定的刀具参数填入数控加工刀具卡片中（见表1），以便编程和操作管理。</DIV><FONT face=Courier>
<DIV align=center><STRONG>表1 数控加工刀具卡片</STRONG></DIV>
<P>
<TABLE id=table8 cellSpacing=0 cellPadding=0 border=1>
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<TD vAlign=top width=98 colSpan=3>
<DIV align=center><FONT size=2>产品名称或代号</FONT></DIV></TD>
<TD vAlign=top width=120 colSpan=3>
<DIV align=center><FONT size=2>×××</FONT></DIV></TD>
<TD vAlign=top width=60 colSpan=2>
<DIV align=center><FONT size=2>零件名称</FONT></DIV></TD>
<TD vAlign=top width=84 colSpan=2>
<DIV align=center><FONT size=2>典型轴</FONT></DIV></TD>
<TD vAlign=top width=96>
<DIV align=center><FONT size=2>零件图号</FONT></DIV></TD>
<TD vAlign=top width=59>
<DIV align=center><FONT size=2>×××</FONT></DIV></TD></TR>
<TR>
<TD vAlign=top width=38>
<DIV align=center><FONT size=2>序号</FONT></DIV></TD>
<TD vAlign=top width=48>
<DIV align=center><FONT size=2>刀具号</FONT></DIV></TD>
<TD vAlign=top width=132 colSpan=4>
<DIV align=center><FONT size=2>刀具规格名称</FONT></DIV></TD>
<TD vAlign=top width=36>
<DIV align=center><FONT size=2>数量</FONT></DIV></TD>
<TD vAlign=top width=204 colSpan=4>
<DIV align=center><FONT size=2>加工表面</FONT></DIV></TD>
<TD vAlign=top width=59>
<DIV align=center><FONT size=2>备注</FONT></DIV></TD></TR>
<TR>
<TD vAlign=top width=38>
<DIV align=center><FONT size=2>1</FONT></DIV></TD>
<TD vAlign=top width=48>
<DIV align=center><FONT size=2>T01</FONT></DIV></TD>
<TD vAlign=top width=132 colSpan=4>
<DIV align=center><FONT size=2>φ5中心钻</FONT></DIV></TD>
<TD vAlign=top width=36>
<DIV align=center><FONT size=2>1</FONT></DIV></TD>
<TD vAlign=top width=204 colSpan=4>
<DIV align=center><FONT size=2>钻φ5 mm中心孔</FONT></DIV></TD>
<TD vAlign=top width=59>
<DIV align=center><FONT size=2></FONT> </DIV></TD></TR>
<TR>
<TD vAlign=top width=38>
<DIV align=center><FONT size=2>2</FONT></DIV></TD>
<TD vAlign=top width=48>
<DIV align=center><FONT size=2>T02</FONT></DIV></TD>
<TD vAlign=top width=132 colSpan=4>
<DIV align=center><FONT size=2>硬质合金90<SUP>0</SUP>外圆车刀</FONT></DIV></TD>
<TD vAlign=top width=36>
<DIV align=center><FONT size=2>1</FONT></DIV></TD>
<TD vAlign=top width=204 colSpan=4>
<DIV align=center><FONT size=2>车端面及粗车轮廓</FONT></DIV></TD>
<TD vAlign=top width=59>
<DIV align=center><FONT size=2>右偏刀</FONT></DIV></TD></TR>
<TR>
<TD vAlign=top width=38>
<DIV align=center><FONT size=2>2</FONT></DIV></TD>
<TD vAlign=top width=48>
<DIV align=center><FONT size=2>T03</FONT></DIV></TD>
<TD vAlign=top width=132 colSpan=4>
<DIV align=center><FONT size=2>硬质合金90<SUP>0</SUP>外圆车刀</FONT></DIV></TD>
<TD vAlign=top width=36>
<DIV align=center><FONT size=2>1</FONT></DIV></TD>
<TD vAlign=top width=204 colSpan=4>
<DIV align=center><FONT size=2>精车轮廓</FONT></DIV></TD>
<TD vAlign=top width=59>
<DIV align=center><FONT size=2>右偏刀</FONT></DIV></TD></TR>
<TR>
<TD vAlign=top width=38>
<DIV align=center><FONT size=2>3</FONT></DIV></TD>
<TD vAlign=top width=48>
<DIV align=center><FONT size=2>T04</FONT></DIV></TD>
<TD vAlign=top width=132 colSpan=4>
<DIV align=center><FONT size=2>硬质合金60<SUP>0</SUP>外螺纹车刀</FONT></DIV></TD>
<TD vAlign=top width=36>
<DIV align=center><FONT size=2>1</FONT></DIV></TD>
<TD vAlign=top width=204 colSpan=4>
<DIV align=center><FONT size=2>车螺纹</FONT></DIV></TD>
<TD vAlign=top width=59>
<DIV align=center><FONT size=2></FONT> </DIV></TD></TR>
<TR>
<TD vAlign=top width=86 colSpan=2>
<DIV align=center><FONT size=2>编制</FONT></DIV></TD>
<TD vAlign=top width=69 colSpan=2>
<DIV align=center><FONT size=2>×××</FONT></DIV></TD>
<TD vAlign=top width=39>
<DIV align=center><FONT size=2>审核</FONT></DIV></TD>
<TD vAlign=top width=60 colSpan=2>
<DIV align=center><FONT size=2>×××</FONT></DIV></TD>
<TD vAlign=top width=54 colSpan=2>
<DIV align=center><FONT size=2>批准</FONT></DIV></TD>
<TD vAlign=top width=54>
<DIV align=center><FONT size=2>×××</FONT></DIV></TD>
<TD vAlign=top width=96>
<DIV align=center><FONT size=2>共 页</FONT></DIV></TD>
<TD vAlign=top width=59>
<DIV align=center><FONT size=2>第 页</FONT></DIV></TD></TR>
<TR height=0>
<TD width=38><FONT size=2> </FONT></TD>
<TD width=48><FONT size=2> </FONT></TD>
<TD width=12><FONT size=2> </FONT></TD>
<TD width=57><FONT size=2> </FONT></TD>
<TD width=39><FONT size=2> </FONT></TD>
<TD width=24><FONT size=2> </FONT></TD>
<TD width=36><FONT size=2> </FONT></TD>
<TD width=24><FONT size=2> </FONT></TD>
<TD width=30><FONT size=2> </FONT></TD>
<TD width=54><FONT size=2> </FONT></TD>
<TD width=96><FONT size=2> </FONT></TD>
<TD width=59><FONT size=2> </FONT></TD></TR></TBODY></TABLE> （6）切削用量选择 </P>
<DIV>①背吃刀量的选择 轮廓粗车循环时选a<SUB>p</SUB>=3 ㎜，精车a<SUB>p</SUB>=0.25㎜；螺纹粗车时选a<SUB>p</SUB>= 0.4 ㎜，逐刀减少，精车a<SUB>p</SUB>=0.1㎜。</DIV>
<DIV>②主轴转速的选择 车直线和圆弧时，选粗车切削速度<I>v<SUB>c</SUB></I>=90m/min、精车切削速度<I>v<SUB>c</SUB></I>=120m/min，然后利用公式<I>v<SUB>c</SUB></I>=<I>πdn</I>/1000计算主轴转速<I>n</I>（粗车直径<I>D</I>=60 ㎜，精车工件直径取平均值）：粗车500r/min、精车1200 r/min。车螺纹时，参照式（5-1）计算主轴转速<I>n </I>=320 r/min.</DIV>
<DIV>③进给速度的选择 选择粗车、精车每转进给量，再根据加工的实际情况确定粗车每转进给量为0.4㎜/r，精车每转进给量为0.15㎜/r，最后根据公式<I>v<SUB>f </SUB>= nf</I>计算粗车、精车进给速度分别为200 ㎜ /min和180 ㎜/min。</DIV>
<DIV>综合前面分析的各项内容，并将其填入表2所示的数控加工工艺卡片。此表是编制加工程序的主要依据和操作人员配合数控程序进行数控加工的指导性文件。主要内容包括：工步顺序、工步内容、各工步所用的刀具及切削用量等。</DIV>
<DIV align=center><STRONG>表2 典型轴类零件数控加工工艺卡片</STRONG></DIV>
<TABLE id=table9 cellSpacing=0 cellPadding=0 border=1>
<TBODY>
<TR>
<TD width=76 colSpan=3 rowSpan=2>
<DIV align=center><FONT size=2>单位名称</FONT></DIV></TD>
<TD width=61 colSpan=2 rowSpan=2>
<DIV align=center><FONT size=2>×××</FONT></DIV></TD>
<TD width=155 colSpan=4>
<DIV align=center><FONT size=2>产品名称或代号</FONT></DIV></TD>
<TD width=150 colSpan=2>
<DIV align=center><FONT size=2>零件名称</FONT></DIV></TD>
<TD width=136 colSpan=2>
<DIV align=center><FONT size=2>零件图号</FONT></DIV></TD></TR>
<TR>
<TD width=155 colSpan=4>
<DIV align=center><FONT size=2>×××</FONT></DIV></TD>
<TD width=150 colSpan=2>
<DIV align=center><FONT size=2>典型轴</FONT></DIV></TD>
<TD width=136 colSpan=2>
<DIV align=center><FONT size=2>×××</FONT></DIV></TD></TR>
<TR>
<TD width=76 colSpan=3>
<DIV align=center><FONT size=2>工序号</FONT></DIV></TD>
<TD width=61 colSpan=2>
<DIV align=center><FONT size=2>程序编号</FONT></DIV></TD>
<TD width=155 colSpan=4>
<DIV align=center><FONT size=2>夹具名称</FONT></DIV></TD>
<TD width=150 colSpan=2>
<DIV align=center><FONT size=2>使用设备</FONT></DIV></TD>
<TD width=136 colSpan=2>
<DIV align=center><FONT size=2>车间</FONT></DIV></TD></TR>
<TR>
<TD width=76 colSpan=3>
<DIV align=center><FONT size=2>001</FONT></DIV></TD>
<TD width=61 colSpan=2>
<DIV align=center><FONT size=2>×××</FONT></DIV></TD>
<TD width=155 colSpan=4>
<DIV align=center><FONT size=2>三爪卡盘和活动顶尖</FONT></DIV></TD>
<TD width=150 colSpan=2>
<DIV align=center><FONT size=2>TND360数控车床</FONT></DIV></TD>
<TD width=136 colSpan=2>
<DIV align=center><FONT size=2>数控中心</FONT></DIV></TD></TR>
<TR>
<TD width=31>
<DIV align=center><FONT size=2>工步号</FONT></DIV></TD>
<TD width=168 colSpan=6>
<DIV align=center><FONT size=2>工步内容</FONT></DIV></TD>
<TD width=35>
<DIV align=center><FONT size=2>刀具号</FONT></DIV></TD>
<TD width=57>
<DIV align=center><FONT size=2>刀具规格</FONT></DIV>
<DIV align=center><FONT size=2>/ mm</FONT></DIV></TD>
<TD width=71>
<DIV align=center><FONT size=2>主轴转速</FONT></DIV>
<DIV align=center><FONT size=2>/r.min<SUP>－1</SUP> </FONT></DIV></TD>
<TD width=78>
<DIV align=center><FONT size=2>进给速度</FONT></DIV>
<DIV align=center><FONT size=2>/mm. min<SUP>－1</SUP></FONT></DIV></TD>
<TD width=68>
<DIV align=center><FONT size=2>背吃刀量</FONT></DIV>
<DIV align=center><FONT size=2>/ mm</FONT></DIV></TD>
<TD width=68>
<DIV align=center><FONT size=2>备注</FONT></DIV></TD></TR>
<TR>
<TD width=31>
<DIV align=center><FONT size=2>1</FONT></DIV></TD>
<TD width=168 colSpan=6>
<DIV align=center><FONT size=2>平端面</FONT></DIV></TD>
<TD width=35>
<DIV align=center><FONT size=2>T02</FONT></DIV></TD>
<TD width=57>
<DIV align=center><FONT size=2>25×25</FONT></DIV></TD>
<TD width=71>
<DIV align=center><FONT size=2>500</FONT></DIV></TD>
<TD width=78>
<DIV align=center><FONT size=2></FONT> </DIV></TD>
<TD width=68>
<DIV align=center><FONT size=2></FONT> </DIV></TD>
<TD width=68>
<DIV align=center><FONT size=2>手动</FONT></DIV></TD></TR>
<TR>
<TD width=31>
<DIV align=center><FONT size=2>2</FONT></DIV></TD>
<TD width=168 colSpan=6>
<DIV align=center><FONT size=2>钻中心孔</FONT></DIV></TD>
<TD width=35>
<DIV align=center><FONT size=2>T01</FONT></DIV></TD>
<TD width=57>
<DIV align=center><FONT size=2>φ5</FONT></DIV></TD>
<TD width=71>
<DIV align=center><FONT size=2>950</FONT></DIV></TD>
<TD width=78>
<DIV align=center><FONT size=2></FONT> </DIV></TD>
<TD width=68>
<DIV align=center><FONT size=2></FONT> </DIV></TD>
<TD width=68>
<DIV align=center><FONT size=2>手动</FONT></DIV></TD></TR>
<TR>
<TD width=31>
<DIV align=center><FONT size=2>3</FONT></DIV></TD>
<TD width=168 colSpan=6>
<DIV align=center><FONT size=2>粗车轮廓</FONT></DIV></TD>
<TD width=35>
<DIV align=center><FONT size=2>T02</FONT></DIV></TD>
<TD width=57>
<DIV align=center><FONT size=2>25×25</FONT></DIV></TD>
<TD width=71>
<DIV align=center><FONT size=2>500</FONT></DIV></TD>
<TD width=78>
<DIV align=center><FONT size=2>200</FONT></DIV></TD></TR></TBODY></TABLE></FONT></TD></TR></TBODY></TABLE></TD></TR></TBODY></TABLE></TD></TR></TBODY></TABLE></TD></TR></TBODY></TABLE>
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