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PCA-6144S,

PCA-6144S

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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
 

194E-AA63E 194E Load switch

194R-N30-1753 Non-Fused 194R Disconnect Switch

2090-CPBM7E7-08AF09 9 m Length SpeedTec Extension Cable

2094-BNINV-2 Kinetix 6000 Connector Set

GA647IFESGRN00900 GCA iFIX Optn: ESig & ERec 900 I/O Run

HMI-CAB-C116 CABLE UNI-TELWAY

IC220TBK082 I/O TERMINAL STRIP, 8 POSITION SPRING STYLE, QTY 10

IC647HSTSC1KM Server to Server Collector for Historian - Standard Server 1000 Points (M4 Key)

IC647NSP000 CIMPLICITY HMI SPC (Statistical Process Control) Option

IC693ACC338 CPU364 FACEPLATE KIT CONTAINS 5 EACH FRONT PLASTIC AND LABELS

IC752CBT020RR Datapanel 320T MEG (Mono Expansion w/ Genius): 320x240 1/4 VGA Monochr ome LCD with 80386SX/40 PC processor. Analog touch screen with text, bitmaps, bar graphs, real time clock. With 2M memory. With Genius PC/1 04.

IC800VMCP2100 Power cable for 2 kW VersaMotion servo motors- 10 meter

SLC/1746 System 1746-NI16V (16) ANALOG INPUT MODULE, +/- 10V DC

Industrial Computers 6189V-CPUPFM3 PERFORMANCE SBC (W/CPU AND COOLER) (700R)

Application-specific products 1403-CF003 2 X 3 M F LINK FOR POWERMONITOR

Operator Interface 2711-B6C9 PV600 COLOR KEY&TOUCH, RS232 (DH485) & RS232 PRINT

Support 9301-2SE2400JPR SUPT REINSTATEMENT CONTRACT FOR 93012SE2400JP

Support 9307-EMRTS SUPT RENEWAL CONTRACT FOR 9307EMRTENE

DeviceNet Products 1734-OA2 120/230 VAC 2 CHANNEL OUTPUT MODULE

RSI Software Products 9301-2SE3100ESE RSVIEW32 RUNTIME 150 (SPANISH)

RSI Software Products 9358-BNTK10U1R UPGRADE: OUT-SUPT: RSBATCH BACK-UP KEY 03 TO 10

Motion Control MPL-B330P-SK22AA MOTOR,SERVO,4.18 NM,5000RPM,SINGL,460V

Motion Control 2090-U5EK-DN KIT,EXPANSION,ULTRA5000 DEVICE NET

GFK-0732 ECLiPS (State Logic) Programming for Series 90-30 PLC User's Guide

IC646FXMU20 Proficy Change Management 20 Users System

MSC-RTD-V Obsolete - 100W PT (-200 to 850C) in / 0-10 V out

PSPC-MONITOR Prof Shop Floor SPC Monitor 1 User

20BC015A3AYNANN0 PowerFlex 700 AC Drive 20B

20F11FD022AA0NNNNN PowerFlex 753 AC Packaged Drive

2198-KITCON-S160 Kinetix 5700 100mm Single Axis Conectors

2711P-RC3 PanelView Plus 256MB Ext Memory Card

280A-EXTCABLE ArmorStart ArmorPoint Extension Cable

CQM1-OD214 输出16点.晶体管PNP 24V DC 300mA

1492-N45 TERM BLCK Marking Cards CA1 CA2 CAM

连接电缆 6ES7368-3BC51-0AA0 IM360/361 连接电缆， 2.5m

变送器 3RS18001BW00

TIA 博途 WinCC 选件 6AV2107-0LD00-0BB0 SIMATIC WinCC DataMonitor for Runtime Professional 3 Clients

1585J-M8PBJM-0M3 RJ45 Ethernet Media

1760-L12BWB Pico 12 Point DC Controller

188-K2C080 Miniature Circuit Breaker 8 A

194L-A25-1751 25 A 194L Load Switch

2090-CNSRPRS-AA04 Kinetix 6000M Network Cable

2090-UXTBMP-18S60 MP-Series 60 m Length Brake Cable

BC647MQPU01 Machine Edition View for Quick Panel 1 user Upgrade from QuickDesigner with Proficy GlobalCare Complete with USB Hardware key

GC647IFSTRN00150 GCC iFIX Std HMI 150 I/O Run

IC200CPU001LT CPU 12K USER PROG 1.80MSEC/K BOOLEAN ONE RS232 AND ONE RS485 SERIAL PO RTS (LT)

IC646MXN001 Max-ON RX3i Hot Standby Redundancy Software

IC647IFSTRN00300M iFIX Standard HMI 300 I/O Runtime (M4 Part)

IC670GBI102 120Vac/125Vdc Powered Genius Bus Interface Unit

IC697LBR701 90-70 Documentation Library (paper manuals covering most options)

IC800SKCS030 S2K to PC controller serial communications cable. 3 meters

ControlLogix/1756 System 1756-M02AS 1756 2 AXIS ANALOG/SSI SERVO MODULE

Industrial Computers 6182H-12BRH15D VVCE 1250, KEY/TOUCH, STD MEM, CNET, DC

Process Control 1757-PFBEXP003 PROFIBUS INTERFACE MODULE EXPANSION

Operator Interface 2711P-RN1 SRIO NETWORK COMM MODULE. FOR PVPLUS 400/600

Support 9355-WABSNR SUPT REINSTATEMENT CONTRACT FOR 9355WABSNEN

Support 9354-SS505S 9354-SS505 SOFTWARE SUPPORT CONTRACT RENEWAL

ControlNet Products 1734-IM2 230 VAC 2 CHANNEL INPUT MODULE

RSI Software Products 9301-2SE2400U2 UPGRADE: IN-SUPT: RSVIEW WORKS 300 TO 32K

RSI Software Products 9357-DNETL3 RSNETWORX FOR DEVICENET

Motion Control MPL-A330P-SK22AA MOTOR,SERVO,4.18 NM,5000RPM,SINGL,230V,5.0KG

Motion Control 2090-UXNFBMP-S01 CABLE,ULGRF50ON-FLEX,MOTOR FEEDBACK,MP,1M

CBL-138-3 Cable. SIMATIC T.I.545,555 Port 1 (RS-232)

IC600WD010 I/O Cable, 10 feet (3m)

IC800SKCI010 Interface Cable, S2K Aux. I/O Connector to 44A726268-001 Terminal Block, 1 Meter

OC647IFESGSR00900C iFIX Optn: ESig & ERec 900 I/O Server (M1Component Part)

20AD065A0NYNANC0 PowerFlex 70 AC Drive 65 A at 50 Hp 20A

20DC730A0ENNBNANE PowerFlex 700S AC Drive 730 A 400 kW 20D

20P21AD035RA0NNN PowerFlex 35 A DC Drive

2711-NC14 PanelView 10 m Operate Comms Print Cable

280-PWRM22F-M3 ArmorStart Three-Phase Power Media

FX-485PC-IF RS232/RS485

1492-MC5X5 IEC 5 x 5 mm Marker Card

1494U-D30 1494U 30A Switch and Mechanism

软启动器 3RW44536BC35

SIMATIC STEP 7 V14 6ES7822-1AA04-0YE5 Upgrade SIMATIC STEP 7 专业版 V11..V13 -> V14 orV11..V13/2010 Combo -> V14/2010 Combo 浮动授权

1585D-M4UBDF-15 Micro D-Code, QD Style Ethernet Media

1756-IF6CIS ControlLogix 6 Point A/I Module

1794-VHSC Flex 2 Point High Speed Counter Module

194E-E16-TN Neutral Terminal

2090-CFBM4DF-CDAF15 MP-Series 15m Feedback Cable

2090-KPBE7-12AA MP-Series Power and Brake Connector Kit

BC641VPN999 VersaPro Nano/Micro Edition Unlimited Seat Site License - Windows Prog ramming Software for VersaMax Nano/Micro PLCs

GC646TRT075 Proficy GlobalCare Complete for Server 75 I/O Runtime System

HMI-BEZ-403 Stainless Steel Bezel: 10.5 inch (QPICxxx0000)/ NEMA 4X

IC641CTL970 Control 90-70 Programmer with CD Documentation Library

IC647IEC010 IEC 61850 Client - 10,000 points

IC660EBA021 Electronic Assembly for IC660BBA021

IC695HSC304 RX3i High Speed Counter, 4 channels. 8 configurable inputs and 7 configurable ESCP outputs. Module supports high speed counting, input interrupts and programmable limit switch.

IC756WRE024J-99 DataViews Runtime for Windows 1-24, Per User, Japanese, Version 9.9

FlexLogix System 1794-ASBK CONFORMALLY COATED, REMOTE I/O ADAPTER

PLC-5/1771 System D1771-6.5.86 PLASTICS MOLDING MODULE INJECT AND CLAMP MODE MNL

Process Control 1757-PLXS100 PROCESSLOGIX 100 POINT SERVER LICENSE

Operator Interface 2711P-T7C4D1 PV PLUS 700, TOUCH, ENET, DC PS, STD MEM

Support 9307-RSE32R SUPT REINSTATEMENT CONTRACT FOR 9307RSE32

Support GML-DAS SUPT RENEWAL CONTRACT FOR GMLDA

Support F1785-L20CSERE FIRMWARE UPGRADE FOR 1785-L20C PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE2300 RSVIEW32 WORKS 1500

RSI Software Products 9701-VWSB100JPU1 RSV SE STATION 25 - 100 DISPLAY UPGRADE (JAPANESE)

RSI Software Products 9399-INTDOSUG INTERCHANGE FOR DOS USERS GUIDE

Motion Control 2098-IPD-005-DN DRIVE, 2.5A/7.5A, ULTRA5000, DEVICENET

BC646MBPS99 ME Professional Dev. Suite Site License

IC300DIQ722 14 AC Inputs / 10 Outputs, 120 - 160 VAC Sink or source, Relay Out, 3 amps. isolated, 2 per common

IC752MNL003 Mature. Datapanel 1000 Series Operator's Manual

MTR-3S63-G-R-B-E-S MTR series servo motor with resolver and brake and shaft seal

ZA06B-6114-K213#E AHVis and AHVi Motor Brake Connector Kit (90 Deg)

20BP730N0NNNNNC0 PowerFlex 700 AC Drive 730 A 400 kW. 20B

20G1ABC540JN0NNNNN PowerFlex 755 AC Packaged Drive

25A-B2P5N104 PowerFlex 523 0.4kW (0.5Hp) AC Drive

2711P-T15C21D8S PanelView Plus 7 Standard 1500

OPC-F1-RS(RS485通信)

1492-JG3TW IEC 1-Ckt Feed-Thru Grd Blk 3 Conn Pts

1492-WG4 IEC Term Blck 8x47.6x41mm Screw

软启动器 3RW44223BC46

性能信号模块 6ES7 531-7NF10-0AB0 AI 8：模拟量输入模块，高速，AI 8x U/I HS, 35mm 模块，不含前连接器

156-B50CA1 50 A Contactor

1746-NIO4I SLC 4 point Analog Current Comb Module

1787-USADPTR U.S. P/S ADAPTER FOR 1770-KFD

193-T1DC90P 72-90 A IEC Bimetallic Overload Relay

20-MAINSTND PowerFlex Maintenance Stand

2090-CSBM1DF-14AF11 Kinetix Cable Single DSL 2090-Series

20AC022C0NYNANC0 PowerFlex 70 AC Drive 22 A at 11 kW 20A

GA647WFL005 Proficy GlobalAssist Complete for Proficy Workflow - 5 User License

GPA-602-F4 LVDT Expansion Unit (Full Bridge for Solartron), includes G-0602 conne cting cable.

IC600CP612RR 13 inch Series Six Plus CPU 24Vdc Power Supply (8 Slots)

IC647HSTCSEO2000KM eSignature Option for Historian - Enterprise Corporate Server 2,000,000 Points (M4 Key)

IC647WFL025 Proficy Workflow - 25 User License

IC694ALG220CA Conformal Coated Analog Input Voltage module, 4 channels.

IC756RDV010E-99 DV Draw Development on IRIX Op Sys, English, Version 9.9

MicroLogix 1200 System 1762-IA8 8 POINT 120 VAC INPUT MODULE

PLC-5/1771 System 1771-LIA2 ADVANCED LOOP CONTROLLER INTERFACE

Distributed I/O 1794-OA8I 85-132V AC OUTPUT MODULE (ISOLATED), 8 POINT

Communications 9355-WABSNENE RSLINX SINGLE NODE

Operator Interface D6195-6.5.5 CONTROLVIEW BUILDER GETTING STARTED MANUAL

Support 9358-BERP02S SUPT RENEWAL CONTRACT FOR 9358BERP02ENE

Support F1771-ACNR15SERB FIRMWARE UPGRADE FOR 1771-ACNR15 PROCESSOR

RSI Software Products 9324-RL03U7ENR RSLOGIX 500 STD TO PRO UPGRADE, EXP SUP >90

RSI Software Products 9301-2SE350DEU5R RSVIEW32 RUNTIME 5K-100K UPGRADE OUT-SUPT (DE)

RSI Software Products 9358-HSTS2350U1R UPGRADE: OUT-SUPT: HISTORIAN 150 TO 5K TAG

Motion Control W-4075-R-H00AA MOTOR,SERVO,WASHDOWN,AF,7.2 NM,3000RPM,17.2KG

612A-FT-SO-N4 Numeric Keypad Entry, 4 Digit LED DISP., Full Travel Keys. Sourcing Output, NEMA 4

IC200MDD843 MIXED 24VDC POS LOG INPUT GRP 10PT / OUTPUT RELAY 2.0A PER PT GRP 6PT

IC695STK003 RX3i Power PACkage 3 Starter Kit includes RX3i/ motion module (Servo andAmplifier sold seperately) and QuickPanel View 6 inch STD wi th software

MTR-1220-N-D-E-0 MTR series NEMA 23 stepping motor with series winding connection

Z44A718031-G12 Alpha i-series servo bus bar kit for 150 mm wide module

20BD077A3ANNACA0 PowerFlex 700 AC Drive 77 A 60 Hp 20B

20G11NC022JA0NNNNN PowerFlex 755 AC Packaged Drive

22F-B033N104 PowerFlex 4M- 7.5 kW (10 HP) AC Drive

990NAD23011 Quantum RUGGEDIZED MBUS+ TAP TERM

29340-127-07-R M12 X 1.75 HEX NUT

Y92A-48B 硬塑料面板罩

1492-SPM2D630 MCB Supplementary Protector 63 A

软启动器 3RW40242TB04

电机启动器 3VU16402CG00

150-F361NCDB SMC Flex Smart Motor Controller

1732E-OF4M12R ARMORBLOCK 4 POINT ANALOG OUTPUT

1771-WHFB 1771 Field Wiring Arm

193-EEQD E1 Plus 11-55 A IEC Overload Relay

20-750-BUS2-F8 PF755 FR8,IP00,AC IN,INPUT TERMINATION

2090-CPWM7DF-10AA15 MP-Series 15m Servo Power Cable

2097-V33PR1 Kinetix 300 Servo Drive

ET-GT-5ES-2SC 4 RJ45 Ports, 1 Multimode Fiber Port Ethernet Switch

GFK-1997 Control Station CE II QuickStart

IC220MDL230 INPUT, 230VAC, 1 PT (REQUIRES 1 IC220TBK083)

IC647CTRAN3 Trane Tracer XT Central Cooling Plant Plus - For ordering by Trane Only

IC647PSF500 Proficy Process Systems 5000 I/O with iFIX

IC693MDL240RR 120 Vac Input (16 Points)

IC756CDV000K-99 DV Development - Compaq True64 Op Sys, Korean, Version 9.9

MSI-MGMT-UNL Unltd Site Clients - Production Mgmt

PLC-5/1771 System 1785-L60B PLC-5/60 CONTROLLER, 64K WORD SRAM

Distributed I/O 1738-ACNR CONTROLNET REDUNDANT ADAPTER

Communications 1784-KTCS ISA BUS PC CARD WITH CONTROLNET SCANNER

Operator Interface 2711-NR7T ADAPTOR TO MOUNT PANELVIEW 1000/1000E/6182 TOUCH

Support 9304-WVPD300S SUPT RENEWAL CONTRACT FOR 9304WVPD300

Support 9324-RLD25U7DEE RSLOGIX 5000 LITE GERMAN TO PRO UPGRADE

DeviceNet Products 2711-B6C10 PV600 COLOR KEY&TOUCH, DNET & RS232 PRINT

RSI Software Products 9301-2SE335ZHU2R RSVIEW32 RUNTIME 300-5K UPGRADE OUT-SUPT (ZH)

RSI Software Products 9371-EDESI2U5 UPGRADE: IN-SUPT: RSWIRE DET IEC/ACAD TO DES IEC/A

Motion Control MPG-B025-091M24 MOTOR,SERVO,GEAR RATIO 91,100NM,65RPM,MULTI,BRK

Silver Series 2711-T14C15 PV1400 COLOR TOUCH, CNET & RS232 PRINT

HE693STP113 One axis stepper positioning module for Series 90-30 with incremental encoder feedback, optical isolation, independent acceleration/deceleration and indexed moves.

IC670MDL331 120VAC 2A Output 8 Pt. Isolated

QPJ2D100S2P QUICKPANEL JR. COLOR 5" STN

ST-7518 STXi Potential Distribution module module for 24VDC, 10 A, with module ID type with status LEDs

20BC2P1A0AYYANC0 PowerFlex 700 AC Drive 20B

20F1ANC367AN0NNNNN PowerFlex 753 AC Packaged Drive

22B-B2P3H204 PowerFlex 40 0.4 kW (0.5 Hp) AC Drive

140DAO85300 Quantum 开关量AC输出,32点,24-240VAC,4组隔离

284D-FVD7P6B-25-RRN-3-DB1-SB-EMI DeviceNet Variable Frequency Drive

E3F3-R61 2m反射式，暗通，NPN晶体管输出100mA电源：10-30VDC直径18mm,需另配反射板

1492-SPM1B070 MCB Supplementary Protector 7 A

6ED1055-1MA00-0BA0 LOGO!AM2

6ES73325HF004AB2

1497D-A11-M11-0-2 1EN PURPOSE TRANSFORMER

1606-XLSBATASSY2 1606 Power Supply

1769-L19ER-BB1B CompactLogix L19 1MB Memory Controller

190E-AND2-CB16X 1.0-1.6 A Economy Starter W/Ckt-Bkr

194R-J30-1753S-PYS1 194R Disconnect Switch

2090-CPBM7DF-14AF04 MP-Series 4 m Length Pwr and Brake Cable

2090-XXNPT-16S03 Kinetix Drives 03m Standard Cable

CBL-3T-MB-10 Power/brake cable for MTR-3T50 or MTR-3T60 series servo motors. 10 feet

GF-0903R Connecting FlashCable to Fischerscope, Mahr, Metronics, OGP, RAM, Sens otec, Weightronix.

IC200UAL004 23 point PLC, (13) 12VDC In, (10) Relay Out, (2) Analog In and (1) Ana log Out, 12VDC Power Supply, Battery (IC200ACC403) is required for lon g term data rentntion and Real Time Clock. Battery not included.

IC646TDV000 Unlimited I/O Point Development System

IC647NWV000 CIMPLICITY HMI WebView

IC693ALG222 Analog Input, Voltage 16 Single/8 Differential Channels

IC752CMO201 Modicon 984 9 pin cable for DataPanel 150/160/240

IC800VMM10LBKSE25 1 kW VersaMotion servo motor with 24 VDC holding brake (3.18 Nm)

SLC/1746 System 1746-BTM BARREL TEMPERATURE MODULE FOR PROGRAMMABLE CTRLR

Industrial Computers 6189V-FD144 FLOPPY DISK DRIVE

Application-specific products 1403-MM01B MASTER MODULE FOR POWERMONITOR

Operator Interface 2711-K6C20 PV600 COLOR KEY, ENET & RS232 PRINT

Support 9301-2SE2500ITR SUPT REINSTATEMENT CONTRACT FOR 93012SE2500IT

Support 9380-RSB2500S SUPT RENEWAL CONTRACT FOR 9380RSB2500

DeviceNet Products 1734-OE2C 24V DC 2 CHANNEL ANALOG CURRENT OUTPUT MODULE

RSI Software Products 9301-2SE3103PTE RSVIEW32 RUNTIME 150 WITH RSLINX (PORTUGUESE)

RSI Software Products 9358-BPC30U1R UPGRADE: OUT-SUPT: RSBIZWARE PC PHASES 03 TO 30

Motion Control MPL-B430P-MJ22AA MOTOR,SERVO,6.55 NM,5000RPM,MULTI,460V,6.4KG

Motion Control 2090-SCEP10-0 SERCOS FBR CABL,CONN,ENCLOSURE ONLY PLASTIC,10.0M

GFK-1004 TCP/IP Ethernet Communications for the Series 90-70 User's Manual

IC646MDC075 Logic Developer - PC & View 75 Tag Runtime & Development System

MSF Obsolete - CONFIGURATION SOFTWARE WITH CABLE

QDA-EDT-001 QuickDesigner Advance (includes download cable)

20BC022A3AYNADC0 PowerFlex 700 AC Drive 22 A at 11 kW 20B

20F11GC2P1JA0NNNNN PowerFlex 753 AC Packaged Drive

21G11PC1K0JN0NNNNN-HD-L1-P3-P20 PowerFlex Air Cooled 755 Packaged Drive

2711P-RDK12CK PanelView Plus Display Module

280D-F23B-25D-RR-3 ArmorStart Direct Online Starter

C200HE-CPU11-E CPU单元 内存3.2K最大I/O点数:640点

1492-PBC4 Power Distribution Block Accessory

微存储卡 6ES7953-8LP11-0AA0 MMC 微存储卡 8M 用于 S7-300/C7/ET200S IM151 CPU,3.3V NFLASH