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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
 

Motion Control MPL-B420P-MJ24AA MOTOR,SERVO,4.74 NM,5000RPM,MULTI,460V,BRK,6.8KG

Motion Control 2094-PRS2 POWER RAIL, SLIM, 230V OR 460V, 2 AXIS

BC5005TAW0000 15 Inch Inbligence Industrial Computer - Bundled - Standard Series - w/ Windows 2000

IC300OSW001 Cscape PDA Software with Handspring Visor/Visor Deluxe/Prism Cable

IC800SSD107RS1 7.2A, 115/230V, S2K Servo Drive for MTR Series Motors

MSI-SDK-50-43 SDK Connections 50 Pack-43

STXPBS432 STXi Profibus with 16 24VDC sink (Positive Logic) b and 16 24VDC source output, expandable to 8 additional modules.

20BC011A3AYNANC0 PowerFlex 700 AC Drive 20B

20BD248A0ANNAND0 PowerFlex 700 AC Drive 20B

20G11RC8P7AA0NNNNN PowerFlex 755 AC Packaged Drive

25-FAN1-70C PowerFlex 520 Fr A-D Control Module Fan

140XTS10206 Quantum CABLEFAST电缆, 大电流, 带 I/O 端子, 1.8M

294E-FD4P2Z-G2-3-SB Variable Frequency Drive

D4MC-2020 触点:1开/1闭,10A 250VAC机械寿命:1000万次?下压式合页式滚珠短摆杆型

1492-SPM3C070 MCB Supplementary Protector 7 A

软启动器 3RW40361BB04

数字量输入 / 直流输出模块 6ES7 223-1BL32-0XB0 M 1223DI 16×24 V DC，DQ16×24 V DC

150-PB Start/Stop Metal Push Button Kit

1734-OV2E POINT I/O 2 Point Digital Output Module

1783-IMS28NAC Stratix 5410 28 Port Managed Switch

193-ESM-I-60A-T E300/E200 60 Amp Sensing Module

20-750-I1-C460D430 PowerFlex 750 Inverter Assembly Kit

2090-CPWM7DF-14AF05 MP-Series 5 m Length Power Cable

2098-DSD-HV100 Ultra 3000 Servo Drive

GA646PME005 GlobalCare Assist for PCM Machine Edition Version 5 User

GP-0602NT-F4 GagePort LVDT NT (Full Bridge for Solartron)

IC5002TAX0130 PanelPC 12 inch Standard Unit Deluxe with Windows XP and Stainless Steel Bezel

IC647HSTAE1500KM Alarm and Events Option for Historian - Standard Server 1,500,000 Points (M4 Key)

IC647SMK001 Scheduler Desktop Pro 1 user

IC693MDL731 12/24 Vdc Output, 2 Amp, Negative Logic (8 Points)

IC756HDV001E-99 DV Development - HP/UX Op Sys Addt'l User, English, Version 9.9

MSI-SDK-2-43 SDK Connections 2 Pack-43

PLC-5/1771 System 1771-IDK CONFORMALLY COATED, ISOLATED INPUT MODULE

Distributed I/O 1790D-T8A0 DNET LDX , 120V AC, 8 INPUT BASE, TERMINAL BLOCK

Communications 1784-KTS ISA BUS PC CARD WITH RIO SCANNER

Operator Interface 2706-P22R INVIEW PANEL MOUNT DISPLAY

Support 9305-RSVADSESS SUPT RENEWAL CONTRACT FOR 9305RSVADSES

Support 9515-RSEOL040R SUPT REINSTATEMENT CONTRACT FOR 9515RSEOL040ENE

EtherNet/IP Products 2711-B6C20L1 PV600 COLOR KEY&TOUCH, ENET & RS232 PRINT

RSI Software Products 9301-2SE3403FRE RSVIEW32 RUNTIME 32K WITH RSLINX (FRENCH)

RSI Software Products 9356-PRO2100U1 UPGRADE: IN-SUPT: RSSQL STD.150 TO PROF.150 TAG

Motion Control 1326AB-B530E-M2K5L MOTOR,SERVO,460V,18.0NM,3000RPM,MULTI,BRK,IP67

4161-4-5-N4 BCD To 7 SEG Display . 4 Digit, 5VDC. NEMA 4

HMI-CCT-201 BACKLIGHT TUBE 10.5"

IC693CMM302 Communication Module, Genius (1 Kbyte) GCM+

QSK3D200C2P QUICKSTART KIT 6" TFT COLOR

TRM-21006672 4 point screw terminal motor power connector for 7.2 amp 460 VAC S2K

20BC8P7A3AYYANC0 PowerFlex 700 AC Drive 8.7 A 4 kW 20B

20F1ANF142JA0NNNNN PowerFlex 753 AC Packaged Drive

22B-E4P2C104 PowerFlex 40 2.2 kW (3 Hp) AC Drive

140AMM09000 Quantum 模拟量混合模块, 4通道输入, 2通道输出

284E-FVD7P6Z-25-RRN-3-DB-SB-EMI-OC EtherNet Variable Frequency Drive

E2E-X10Y1 10mm,电感式,二线,常开 300mA 电源:24-240VAC圆M30

1492-SPM1C250-N MCB Supplementary Protector 25 A

通用型变频器 6SE6 430-2UD41-1FB0 110 KW,326 x 1400 x 356

电机启动器 3VU13402ME00

150-C201NBR SMC-3 201A Smart Motor Controller

1608P-BP110A480V3 ProDySC 110 Amp Bypass

1770-CD3 Data Highway 300-300 ft Length Cable

193-DNCT-BZ1 DeviceNet Door Mount Bezel Kit

194R-S1 194R Standard Length Operating Shaft

2090-CPBM7E7-08AF20 20 m Length SpeedTec Extension Cable

2090-XXTPMP-16S90 MP-Series 90 m Length Power Cable

CP5B-0WEB-0070-AZ Shielded motor power cable for B12is motor(straight connector). 7 meters

GF-965012 Connecting FlashCable to Mitutoyo Indicator (543-11x/543-13x/543-14x/5 43-18x/543-17x).

IC200UEX010-24 Qty of 24, 14 point expansion. (8) 120VAC In, (6) 120VAC Out, 120/240 VAC Power Supply (includes IC200CBL501)

IC647ADC050 PA Dashboard Client 50 Pak

IC647PCL500 Proficy Process Systems Standard Edition 5000 I/O with CIMPLICITY

IC693CBL319 I/O cable for DSM324 24V I/O or APM I/O to the 44A726268-001 terminal block. 1 meter

IC754ACC15MNT Mounting Clips and PWR Conn 15in QP

IMC-316P-X-DRR IMC-D Series Servo Motor Controller, Enhanced, DeviceNet

SLC/1746 System 9399-RL50GRDE RSLOGIX 500 GETTING RESULTS GUIDE (GERMAN)

Open Automation Systems 1770-XYV PLC-5 VME PROCESSOR BATTERY (1785VXXX)

Application-specific products 1404-M805A-DNT-02 MASTER MODULE-PQ DNET COM-120/240V P/S-CLASS0.2

Operator Interface 2711-K10G20L1 PV1000 GRAYSCALE KEY, ENET & RS232 PRINT

Support 9301-2SE3300S SUPT RENEWAL CONTRACT FOR 93012SE3300

Support 9381-P250ENR SUPT REINSTATEMENT CONTRACT FOR 9381P250EN

DeviceNet Products 1790-0V16X LDX I/O, 24 VDC, 16 SINK OUT EXPANSION, D-SHELL

RSI Software Products 9301-2SE3300JPU2 RSVIEW32 RUNTIME 150-1500 UPGRADE IN-SUPT (JP)

RSI Software Products 9358-EP60U2 UPGRADE: IN-SUPT: RSBIZWARE EPROCEDURE 10 TO 60

Motion Control MPL-B4540F-RK24AA MOTOR,SERVO,10.2NM,3000RPM,RSLVR,460V,BRKKE

Motion Control 9101-0398 CONNECTOR KIT, MOTOR POWER, H-2X/3X, 90 DEG

GQPI-DEM-E02 QUICKPANEL DEMO 9" EL GE LABEL

IC646MRC000 Logic PC & View Runtime 8,000 I/O

MTR-3T12-G-R-0-M-S MTR-Series Servo Motor, Resolver, Metric, Seal

SFW-CCSP-6 CCS for Windows software version 6.0 package with serial cable and manual

20BC056A0AYNAND0 PowerFlex 700 AC Drive 56 A 30 kW 20B

20F11ND8P0AA0NNNNN PowerFlex 753 AC Packaged Drive

22-RFD036 PowerFlex EMC Filter

140CPU11302C Quantum CPU256K,8K用户逻辑,10K寄存器,1MB和1MB+,C

281D-F12Z-10A-CR ArmorStart Direct Online RVSG Starter

C200H-0C224 输出单元, 8点, 继电器独立接点 同上

1492-PPJD3 IEC Term Blck 3x80x63 mm Partition Plt

接口模块 6ES7460-1BA01-0AB0 IM460-1 发送器接口模块，用于集中式连接，最大1.5m，有 5V 电源

变送器 3RS10302DD20

1497-D-BASX-1-N Control Circuit Transber

1606-XL240E-3 Power Supply XL 240 W Power Supply

1762-IQ8OW6 MicroLogix 14 Point Digital Comb Module

188-K3C200-N Miniature Circuit Breaker 20 A

194L-G3196 Rect. Front Frame W/ Blank Nameplate

2090-CPBM7DF-04AA12 MP-Series 12 m Length Cable

2090-XXNFY-S02 Y-Series 2 m Length Feedback Cable

BC647PSF500 Proficy Process Systems 5000 I/O with iFIX with Global Care

GC647PME050 GlobalCare Complete for Proficy Change Management Server Machine Edition Version - 50 Concurrent Users

IC200MDL631 Input 125VDC POS/NEG logic isolated 8 point

IC646PCM001 Proficy Change Management 1 user

IC647MODEV Motion Developer for S2K Series Amplifiers/Controllers with USB Hardware key

IC676CBLPWB020 IP67 Power Cordset - 2 Meters

IC697PCM711 Programmable Coprocessor

IC800SSI104S1RR 4.3A, 115/230V, S2K Servo Controller for S-Series Motors

SoftLogix System 1789-STRT1FR SOFTLOGIX 5800 STARTER KIT FRENCH

Industrial Computers 6189-RDB7C VVCE 700, KEY/TOUCH DISPLAY MODULE

Process Control 9399-RSBEEUG RSBATCH EQUIPMENT EDITOR USER'S GUIDE

Operator Interface 2711-B5A1L2 PV550 MONO KEY&TOUCH, RIO & RS232 PRINT

Support 9303-23S0EFFR SUPPORT REINSTATEMENT CONTRACT FOR 9303-23S0EFF

Support 9371-ETBP3S SUPT RENEWAL CONTRACT FOR 9371ETBP3

ControlNet Products 2706-P42C INVIEWW MESSAGE DISPLAY. 1 OR 2 LINE

RSI Software Products 9301-2SE2500FRU1 RSVIEW32 WORKS 32K-100K UPGRADE IN-SUPT (FR)

RSI Software Products 9358-BANT60U2R UPGRADE: OUT-SUPT: RSBATCH ARCHIVER 10 TO 60

Motion Control MPL-A4530F-MK22AA MOTOR,SERVO,8.36 NM,2800RPM,MULTI,230V,8.2KG

Motion Control 2090-UXNPBMP-16S15 CABLE,460V,NON-FLEX,MOTOR POWER,MP,16 GAUGE,15M

CBL-3P-MP-30 Power Cable, MTR-3S6x-H Series Servo Motors, 30 Ft.

IC641CTL971 CIMPLICITY Control 90-70 Programmer with Paper Documentation Library

IC800SLM075N2XE25 750W, 230 VAC SL Servo Motor, Holding Brake, 2.5K Quad Encoder

OC647IPWRTSUSBSEM iPower Option - TS Base

20AE032A0AYNNNC0 PowerFlex 70 AC Drive 32 A at 30 Hp 20A

20DD077A3EYNANASE PowerFlex 700S AC Drive 77 A 60 Hp 20D

20P41AD996RA0NNN PowerFlex DC Drive 996 A

2711P-B15C4A8 PanelView Plus Terminal

280-PWRM35A-M10 ArmorConnect 10 Meter M35 Patchcord

CPM1A-10CDR-D-V1 10点主机 DC24V、6点入， 4 点继电器输出

1492-MCEA225 Miniature Circuit Breaker, 25 A

1494V-FS60 Fuse Block

软启动器 3RW44652BC36

运行版软件 6AV2104-0HA04-0AA0 SIMATIC WinCC Runtime Advanced 4096 PowerTags V14

1585J-M4HBJM-1 RJ45 Ethernet Media

1756-OA16I ControlLogix 16 Point D/O Module

188-K1B130-N Miniature Circuit Breaker 13 A

194E-FA63-P11 194E Load switch

2090-CFBM7DD-CEAF50 50 m Length SpeedTec Flexible Cable

2090-U3CBB-DM12 Ultra 3000 Breakout Board Kit

BC646MSP001 Logic Developer State Professional with Proficy GlobalCare Complete

GC647ASC050 GC SDK 50 Pak

IC200ACC302 I/O b simulator

IC646CSPC001 Proficy Cause+ for Inbligent HMI/SCADA Client Enabler - 1X CAL

IC647IFPLRN00300M iFIX Plus SCADA 300 I/O Runtime (M4 Part)

IC660MLA021 Label for IC660BBA021 (Qty 100)

IC697ALG230RR Analog Input, Voltage/Current, 8 Channels

IC758DCH000 Consulting per hour

FlexLogix System 1788-CNF CONTROLNET LOGIX DAUGHTER CARD

GuardPLC Systems 1753-OB16 GUARDPLC DISTRIBUTED I/O - 16 OUT, GUARDPLC ENET

Process Control 1757-UPGSIFO UPGRADE MOORE APACS QUICKBUILDER INTERFACE

Operator Interface 2711P-T12C15D1 PV PLUS 1250, TOUCH, CNET, DC PS, STD MEM

Support 9220-CCS SUPT RENEWAL CONTRACT FOR 9220CC

Support 2098-UWCPRGR SUPT REINSTATEMENT CONTRACT FOR 2098UWCPRG

Support F1785-L86BSERE FIRMWARE UPGRADE FOR 1785-L86B PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE2350ITU1 RSVIEW32 WORKS 150-5K UPGRADE IN-SUPT (IT)

RSI Software Products 9701-VWSS250LENE RSVIEW SE SERVER 250 W/RSLINX ENTERPRISE

RSI Software Products 9399-WAB32UG RSLINX USER GUIDE

Motion Control 8720MC -D097-AN- 97 AMP D CHASSIS DRIVE,OPEN ENCL., LESS OPTIONS

BC646MRA159 View Runtime 1,500 I/O

IC300OCS992 Starter Kit includes IC300OCS052 and IC300OSW232. No simulator. Limited one per customer (DC/DC/Vin/Vout)

IC752WTG572 Display Station 2000 Serires - 15" active matrix XGA (1024x768) resistive touch screen

MTR-3T44-J-R-B-M-0 MTR series metric servo motor with resolver and brake

20AC8P7A0AYYNDC0 PowerFlex 70 AC Drive 8.7 A at 4 kW 20A

20DC015A0EYNANANE PowerFlex 700S AC Drive 20D

20G1ALD740AN0NNNNN PowerFlex 755 AC Packaged Drive

25B-D037N114 PowerFlex 525 18.5kW (25Hp) AC Drive

2715-B15CA PanelView 5500 15 in. Graphic Terminal

FR-A740-0.4K 1.1 KVA 1.5A 0.4KW

1492-LD2 IEC Term Block 3.5x75x43mm Spring Clip

1494F-DX200 Disconnect Switch

软启动器 3RW44346BC35

ET 200SP 6ES7155-6AU00-0CN0 IM 155-6 PN 高性能PROFINET接口模块，不含总线适配器

1585D-D4TBJM-2 Micro D-Code, QD Style Ethernet Media

1747-OS302 SLC 5/03 Firmware Upgrade Kit

1794-AENTR Flex EtherNet/IP Adapter

194E-AA16E-P11-TN 194E Load switch

2080-IF2 Micro800 2 Point Analog Input Plug-In

2090-CSWM1DF-14AA10 Kinetix Cable Single DSL 2090-Series

20AC2P1A3AYNANC0 PowerFlex 70 AC Drive 20A

GC646MODEV10PK Proficy GlobalCare Complete for Motion Developer 10-Pack

HE693IBS323 Discontinued Part. Check with GE IP on migration path.

IC609EXP121RR Series One Jr. Expansion 24Vdc Src In/Relay Out, 115Vac P/S

IC647HSTSC100M Server to Server Collector for Historian - Standard Server 100 Points (M4 Key)

IC660BBA024CA 24/48VDC CUR SCR ALG 4IN/2OUT CONF COAT GENIUS BLOCK

IC694MDL734 Output module 125VDC 1 amp 6 points isolated POS/NEG logic.

IC756WDC009K-99 DV Development Sys VB, Java, C++, Korean, Version 9.9

MicroLogix 1500/1769 System 1769-PB2 PWR SUPPLY 24 VDC INPUT 2 AMP @ 5 VDC OUTPUT

PLC-5/1771 System 1771-DA ASCII I/O MODULE

Distributed I/O 1797-IE8 EX ANALOG INPUT MODULE, 16 BIT, 8 PT., S.E.

Operator Interface 2711P-K4M20D PV PLUS 400 GRAYSCALE, KEYPAD, ETHERNET, DC PS

Support 9323-MX300ENR SUPT REINSTATEMENT CONTRACT FOR 9323MX300EN

Support 9358-HSTS2200S SUPT RENEWAL CONTRACT FOR 9358HSTS2200

Support F1772-LWPSERB FIRMWARE UPGRADE FOR 1772-LWP PROCESSOR MODULE

RSI Software Products 9324-RLD300NXESE RSLOGIX 5000 STD., RSNETWORX BUNDLE, ESP

RSI Software Products 9304-WVPR300DU3 UPGRADE: IN-SUPT: WINVW 128 TO WINVW PRO RT 3000

RSI Software Products 9358-PLTM2600U4 UPGRADE: IN-SUPT: PLANTMETRICS 50 TO 200 WORKCELL

Motion Control 1756-M02AE 2-AX SERVO,ANALOG/ENC-ICP

A06B-0116-B075#0008 BM1/4000 Servo Motor, 32K Serial Encoder

IC200UAL005-24 Qty of 24, 23 point PLC, (13) 24VDC In, (1) 24VDC Out, (9) Relay Out, (2) Analog In & (1) Analog Out, 24VDC Power Supply. Battery (IC200ACC403) is required for long-term data retention & Real Time Clock

IC752BDT000RR Datapanel 240T, 240x128 LCD with CCFT backlight. 6x8 Matrix Resistive touch screen with text, bitmaps, bar graphs, real time clock.

MTR-1350-N-D-E-0RR Stepping Motor Nema34

ZA06B-0085-B503#0100 B22/2000is Servo Motor with Straight Shaft, Key, Brake and IP67 Sealing

20BD2P1A3NYNAEC1 PowerFlex 700 AC Drive 2.1 A at 1 Hp 20B

20G11TC567JN0NNNNN PowerFlex 755 AC Packaged Drive

25-MAP-FB PowerFlex 520 Frame B Adaptor Plate

140XTS00100 Quantum 40点模块端子条, IP20

FRN55F1S-4C 77 KVA 105A 55KW 3相AC380V/50Hz/60Hz

H5S-B 外形:72×72mm最小设定时间:1分?控制输出:AC250V 15A 1开2路

1492-SPM3C200-N MCB Supplementary Protector 20 A

软启动器 3RW40471BB14

数字量输入信号板 6ES7 221-3AD30-0XB0 SB 1221 DI 4 x 5 V DC，200 kHz

150-SB4NUR SMC-50 SOLID STATE MOTOR CONTROLLER 180A

1734-TB3 POINT I/O Terminal Base

1783-MX08T Stratix 8000 Copper 8 Port Exp. Module

193-ESM-SA-100 E300/E200 Screw Mounting Adapter

20-750-I1B-E395F370 PowerFlex 750 Replacement Inverter

2090-CPWM7DF-16AA02 MP-Series 2m Servo Power Cable

2098-UWCPRGM UltraWARE Programming MED Software

GA647IFCLNTSRO010 GCA iFIX iClientTS Read Only 25 PK Runtime Version

GP-0602NT-SDP16SB GagePort Digital NT 2-port b (for Solartron Digital Probes) - Sale s BOM.

IC5005TBX0010 PanelPC 15 inch Perbance Unit with Windows XP

IC647HSTAE500KM Alarm and Events Option for Historian - Standard Server 500,000 Points (M4 Key)

IC647SRVSSFPRD PA SmartStart for Production

IC693MDL740RR 12/24 Vdc Output, 05 Amp, Positive Logic (16 Points)

IC756HDV010J-99 DV Draw Development on HP/UX Op Sys, Japanese, Version 9.9

Pico Controllers 1760-LDF GFX CPU STANDARD

PLC-5/1771 System 1771-IV DRIVER LOGIC INPUT MODULE, 12-24V DC, 8 INPUT

Distributed I/O 1791D-16V0X 24VDC COMPACTBLOCK I/O EXPANSION, 16 IN SOURCE

Communications 1784-PKTXD PCI BUS CARD W/DH+,DH485,RIO SCANNER