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数控编程工艺及加工效率的研究

由于后控板塑件在洗衣机上为外观件，表面光洁度要求较高，所以在模具型腔加工制造过程中必须保证型腔尺寸的公差要求和表面粗糙度要求。对于该模具型腔零件，从内向外主要由以下几部分构成：塑件型腔面、分型面、排气槽、侧抽芯槽、模架面、回程杆垫片槽等。在编制数控编程工艺时，一般按照整体粗加工、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、型腔局部形状清角的工艺思路进行编程，并按照分区域编程的思路，逐渐完成整体零件的编程工作。



图1 洗衣机后控板模具型腔

2.1 整体粗加工刀具的选择

在编制粗加工程序时，粗加工刀具型号的选择直接决定了开粗的加工效率。若开粗刀具选择过小，致使每刀的下刀量较小，而且刀具的进给速度也较小，最终导致工件的加工效率很低。若开粗刀具选择过大，表面上看起来粗加工时间很少，但是开粗效果不理想，本应开粗到位的区域没有开粗到位，需要增加整体中粗程序或大范围的清角程序，这样总体的加工时间也会增加。所以在粗加工刀具选择方面，不但要考虑到工件的整体尺寸大小，还要考虑该零件的材料去除量大小。对于中小型零件来说，原则上把开粗时间 控 制 在 5h 以 内 ，初 步 选 定 开 粗 刀 具 为 直 径 为 32mm的牛鼻刀，刀具定义为D32R0.8mm。
2.2 型腔精加工刀具的选择

在对模具零件型腔进行精加工时，由于模具的型腔面在塑件上为外观面，表面光洁度要求较高，并考虑到模具的型腔面大部分为曲面，所以在精加工刀具选择方面，优先选择球头铣刀进行加工，刀具符号用B及 R 表 示 ，如 直 径 为 20mm 的 球 头 刀 定 义 为B20R10mm。本次研究列出了 3 种精加工刀具选择方案：第 1种方案为大直径球头铣刀（B16R8mm）整体精加工、小直径球头铣刀（B8R4mm）局部清角的编程加工工艺；第 2 种方案为较大直径球头铣刀（B12R6mm）整体光刀、小直径球头铣刀（B8R4mm）清角的编程加工工艺；第3种方案为整体用小直径球头（B8R4mm）刀一次加工到位，如表 1 所示。然后对以下
 

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