《数控编程》课程设计说明书.doc

数控编程课程设计专用纸 机制专业0702班 xx 第一章 设计任务书 1 课程设计概述数控编程课程设计实训是机械设计制造及自动化专业的必修课程之一，它可以提高学生的动手能力，丰富学生的理论知识。是一门理论与实践相结合的综合性专业基础课。通过数控编程课程设计实训的学习，要求学生能够独立设计箱体和型腔壳体类零件，能独立完成零件的实体造型，绘制工程图，并能够合理的选择卡具和加工设备，分析加工工艺，独立完成数控编程，生成nc代码，最终完成零件的加工。本课程设计不仅提高了学生的设计能力，绘图能力，编程能力，还可以锻炼其机床操作能力，对今后的工作和学习打下坚实的基础。2 设计目的通过本次课程设计，了解并掌握利用pro/e软件对零件进行结构设计能力，计算机绘图能力及掌握计算机辅助制造过程和方法，培养自动编程的技能。掌握数控机床进行机械加工的基本方法，巩固数控加工编程的相关知识，将理论知识与实际工作结合起来，并最终达到能够独立从事数控加工程序编制的工作能力。3 设计任务根据本任务书提供的零件图及相关技术要求，用pro/e软件完成零件设计，工程图绘制，零件工艺分析，加工工序卡的编制，用pro/e或mastercam软件进行数控加工程序的编制，最后用华中hnc-21m数控机床加工出所设计工件。课程设计题目不限，但内容需满足设计要求。4 设计要求1) 绘制零件图。了解该零件在部件或总成中的位置和功用，以及部件或总成对该零件提出的技术要求；找出其主要技术要求和技术关键，并在下面拟定工艺规程时予以考虑；对所加工的零件进行结构工艺性分析，分析其结构特点；检查所给零件图的完整性和正确性，完成该零件的实体结构设计并按照机械制图标准绘制其零件图。2) 编制零件数控加工工艺规程。在对零件进行详细分析的基础上，按照数控加工工艺确定原则，确定整个零件的加工工艺规程，确定毛坯，确定加工的工艺基准；拟定零件的工艺路线，包括确定各加工表面的加工方法、正确划分加工阶段、合理安排加工工序的顺序、选择工装、刀具、量具，并对其加工工艺参数进行确定；确定对刀点和换刀点。3) 确定夹具及夹紧方案。对某一道相对复杂的工序，在确定定位装夹方案的基础上，选择一个合适的夹具，完成本工序的加工。该夹具应具有定位可靠，装卸方便、操作安全方便省力、夹紧可靠且适当等特点，适合于数控机床的加工使用。4）确定零件设计原点与加工原点。对将进行数控加工的工序，确定加工零点、换刀方式，确定其编程坐标系，并最终通过绘制数控加工编程坐标系的方式予以明确。标识对刀点和换刀点。5）编制零件加工工艺并编制数控加工程序。参照数控加工编程坐标系图，按照数控加工工艺规程，采用自动编程方式对该工序进行数控程序的编制，生成nc代码，并在数控仿真软件上进行调试。6）现场加工。将已经调试好的零件加工程序导入数控机床，安装好所需刀具，夹紧工件，对刀找到编程原点，进行数控加工。7）编写课程设计说明书。设计说明书需打印：正文：宋体五号，单倍行距；页眉：宋体小五号，内容包括 班级 姓名 数控编程课程设计说明书字样；设计结果包括：设计任务书，设计思路，设计步骤，设计过程的说明和阶段结果，并附有零件实体模型图，工程图，工艺分析方案，刀具和夹具选择方案，现场加工结果。第二章 实体建模2.1 建立新文件启动pre/engineer，单击“文件”“新建”命令，系统弹出“新建”对话框，选择“零件”“实体”类型，取消缺省，确认后选择公制模板，进入实体建模及环境。2.2使用拉伸工具建立模型长方形基体（1）使用拉伸工具建立模型，单击基础特征工具栏上的“拉伸”按钮，选择草绘基准面top面，进入草绘工作环境。画一长方形尺寸为120mm 150mm然后拉伸20mm，再画四个圆30mm，向下拉伸5mm。制作如图模型：（2）点击确定，选择：（3）单击确定按钮，得到实体图：2.2 使用拉伸工具建立正方形凸台（1）用拉伸修改模型，选top面作为基准，画一个正方形的边框，再在边长中点为圆心画40mm的圆去掉交线，然后点击确定，正向拉伸35mm后确定后得到，如图 ：2.3 使用拉伸工具建立正六边形凹槽（1）使用拉伸作图，选择模型凸面为基准面，进入草绘，做边长为20mm的正六边形拉伸5mm，再做边长为15mm的正六边形向下拉伸5mm ：（2）点击确定，选择：（3）再点击确定就有如图模型：2.4使用拉伸工具去除材料建立模型中心孔（1）使用拉伸工具，选择模型正六边形凹槽为基准面，进入草绘，做中心孔如图： （2）点击确定，选择：（3）再点击确定就有如图模型：2.5使用倒圆角工具建立圆角（1）使用倒圆角工具，做倒圆角，得到最后的零件实体图： 平板型单向凸台模型建立完成。第三章 数控加工工艺3.1数控加工的基本过程及工艺描述（1）确定数控加工的内容。（2）进行零件工艺加工的工艺分析。（3）数控加工的工艺设计。（4）工件装夹。（5）后处理工作。3.2 机床的选择（1）数控机床主要的规格的尺寸应与工件的轮廓尺寸相适应，做到设备的合理使用。（2）机床的工作精度与工序要求的加工精度相适应。根据零件的加工精度要求选择机床，如精度要求低的粗加工工序，应选择精度低的机床，精度要求高的精加工工序，应选用精度高的机床。（3）机床的功率与刚度以及机动范围应与工序的性质和最合适的切削用量相适应。如粗加工工序去除的毛呸余量大，切削余量选得大，就要求机床有大的功率和较好的刚度。（4）装夹方便、夹具结构简单也是选择数控设备是需要考虑的一个因素。选择采用卧式数控机床，还是选择立式数控机床，将直接影响所选择的夹具的结构和加工坐标系，直接关系到数控编程的难以程度和数控加工的可靠性。 所以此处选择数控机床为华中数控hnc-21m3.3 确定毛坯尺寸毛坯分为铸件、锻件、型材、焊接件和冷冲压件。铸件适用于形状较复杂的零件，毛坯；锻件适用于强度要求高、形状比较简单的毛坯；型材有热轧和冷拉两种。热轧适用于尺寸较大、精度较低的毛坯。冷拉适用于尺寸较小、精度较高的毛坯；焊接件是根据需要将型材或钢材等焊接而成的毛坯件；冷冲压件可以加工接件成品的工件。 因为本零件形状不复杂而机械性能要求又不高，故选用型材。热加工型材尺寸比较大、精度较低，尺寸公差无要求，表面粗糙度为12.5um-6.3um,适合于各种批量的生产，多用于一般零件的毛坯，适合本零件的使用。故选用热加工型材。由零件图可知，选用硬铝适合。毛坯具体尺寸为：长x宽x高=150mmx120mmx43mm。3.4 刀具的选择3.5 确定夹具及夹紧方案本零件加工需要使用一组夹具，所有加工步骤使用虎钳进行定位加紧，然后进行加工。3.6 加工工艺分析1）该零件为凸台工作台，是一个方块形的零件。图中加工轮廓数据充分，尺寸清晰，无尺寸封闭等缺陷。2）零件尺寸标准注整，轮廓描述清晰，零件结构合理。3）零件材料选取：选用硬铝，无热处理和硬度要求，材料切削加工性能良好。4）无特殊热处理要求。5）本零件为单件生产综合以上，可以简述为：加工部位为上表面，凹槽，上表面有一中心孔。故具体总方案为选一尺寸合适的硬铝毛坯，选用硬铝，在立式数控铣床上加工此平面;然后对此平面进行加工进行挖槽，最后对中心孔进行加工。虽然无特殊表面粗糙度要求，但保证尺寸精度和位置精度要求。3.7 工艺参数计算（见附件3） 计算公式主轴转速n= 1000vc/d 进给速度vf1=fznvc 切削速度 d 刀具直径 f 刀具每齿进给率 z 齿数 n 主轴转数加工工序具体计算见附件三3.8 工序卡零 件 名 称零件材料夹 具使用设备班 级姓 名日 期单向凸台底座ly12虎钳华中数铣0702xx11.28工步号工步内容所选加工方式刀具号刀具规格及名称主轴转速（r/min）进给速度（mm/min）被吃刀量（mm）1铣平面平面铣削t0145mm172122铣内凹槽挖槽t0210mm1146114643铣外凹槽挖槽t0210mm1146114644铣凸台挖槽t0310mm1146114645钻孔钻孔t055mm12613156扩孔钻孔t0610mm630157第四章 加工仿真4.1编制零件加工工艺文件导入mastercam 的加工设置 设置加工原点及毛胚。（1） 平面铣削 平面铣削粗加工和精加工选用同一把刀具。工件上表面宽度为120mm，面宽比较大，拟选用双向来回z形切削。则选用45mm的数控硬质合金可转位面铣刀，选择刀齿数为8。 设面铣刀分二次铣削到指定的高度，粗铣切深为2mm，留下1mm的精加工余量。（2 ）内正六边形凹槽的加工 凹槽的粗加工和精加工都用同一把立铣刀。分析零件可得选用=10mm的三齿立铣刀比较合适。因为余量比较大，要分层铣削。 =10mm的立铣刀，有4 个刀齿。 2 ）外正六边形凹槽的加工 凹槽的粗加工和精加工都用同一把立铣刀。分析零件可得选用=10mm的三齿立铣刀比较合适。因为余量比较大，要分层铣削。 =10mm的立铣刀，有4 个刀齿。加工参数：如图所示。边界在加工：如图所示。分层铣削：加工路线：（3）花型凸台的加工使用“挖槽一般挖槽”加工形式对工件花型内凸台进行铣削加工，10mm的平铣刀（高速钢刀具），背吃刀量4mm，加工深度15mm，采用双向切削方式。（4）零件1/4圆形凹槽铣削使用“挖槽边界再加工”加工形式对工件1/4圆形凹槽进行铣削加工，10mm的平铣刀（高速钢刀具），背吃刀量4mm，加工深度5mm，采用平行环切并清角切削方式。（5） 打中心孔 中心孔选用=5mm的中心钻钻削。因为刀具直径比较小，可以选用比较大的转速，选用主轴转速s=1600r/min,进给速度为f=160mm/min。（6）钻孔 钻中心孔，选用10mm的高速钢麻花钻。进给量为0.1mm/r，切削速度。4.2加工工序总图4.3加工刀轨总图根据华中后处理，生成nc文件。4.4 模拟加工通过mastercam软件生成nc代码（见附件），使用斯沃数控仿真软件进行仿真加工，选择华中数控hnc21m ，设置毛坯120mm80mm33mm的zl412 铝，使用平口虎钳夹并抬高一定安全距离进行装夹，刀具安装顺序与工序卡一致，经过对刀，确定零件设计原点与加工原点（x0，y0，z43），建立加工坐标系，使用nc代码进行仿真加工。加工结果如图：第五章 参考文献数控加工概论，李诚人编著，清华大学出版社，2006年出版。数控加工自动编程，吴明有编著，清华大学出版社，2008年出版。数控加工课程设计指导，张秀珍、冯伟编著，机械工业出版社，2009年出版。第六章 感想为期一周的课程设计结束了，在这一周的学习中，我学到了很多，也现自己身上的很多不足，感受很多，受益匪浅。 从开始的第一天，我就对本次任务进行了规划分析，在以后的几天里，我努力的查阅资料、跟别的同学讨论、请教老师、分析零件图并进行三维建模与数控加工、仿真，比较好完成自己的课程设计任务。这次课程设计是对我们学的数控加工工艺与编程这门课的一次深入学习。平时在课堂上接触的都是纯理论的知识，学的都是课堂上东西，对课堂以的了解得很少，这一次的学习让我们开阔了视野。这次课程设计利用到了pro/e来建模，mastercam 9.0来进行自动编程，斯沃数控仿真系统进行程序的检验。在次过程中，我对这些软件又有了进一步的认识。课程设计中总是会遇到问题，首先是自己独立的进行思考，自己没办法解决就得去请教别人，并通过查阅相关资料来解决问题。在整个过程中，我不但学习到了知识，还提高了自己的学习能力，提高了自己解决问题的能力，学会与人沟通，真是学到很多东西。nc代码%1000n100g0g40g54g49g80g90m6t1n102g0g90x-124.5y-59.998s848m3n104z100.n106z53.n108g1z41.f169.6n110x102.f339.2n112g3y-29.999r15.n114g1x-102.n116g2y0.r15.n118g1x102.n120g3y29.999r15.n122g1x-102.n124g2y59.998r15.n126g1x124.5n128z40.f169.6n130x-102.f339.2n132g3y29.999r15.n134g1x102.n136g2y0.r15.n138g1x-102.n140g3y-29.999r15.n142g1x102.n144g2y-59.998r15.n146g1x-124.5n148g0z100.n150m5n152m01(tool - 2 dia. off. - 2 len. - 2 dia. - 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