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1、 . . . 数控加工课程设计说明书一、分析零件图纸,确定总体加工方案一、图纸分析：该图是一复杂轴类零件,零件部分地方较为复杂,部分加工精度较高,采用数控车削加上钻削、滚齿、插齿综合完成。该零件由外圆柱面、孔、倒角、齿轮,齿轮轴、槽、阶梯组成。其中零件最大外径为19mm,长度为104mm.选择毛坯尺寸为114x22mm的棒料。二、精度等级、表面粗糙度分析：考虑到左右两端齿轮齿面粗糙度1.6,滚齿机滚齿后要倒角磨齿；外圆表面粗糙度要求最高为0.8,尺寸精度也易于达到,所以外圆精车即可达到要求。同轴度及各圆跳度都要求要装夹次数减少。所以,外圆以两顶尖定位,一次装夹完成粗精加工。为满足同轴度要求,打
2、孔时应夹外径为13.9的外圆。三、材料和热处理分析：零件材料为31CrMoV9是齿轮钢,预备热处理为调质,回火温度600630 。最终热处理为渗氮,HV900。 四、总体方案：先对毛坯预备热处理调质处理；用数控车床粗精车两端面打中心孔,再以两中心孔定位,粗车外圆轮廓,精车右端外圆轮廓,切槽。再以外径为13.9的槽定位,粗精车左端外圆,钻铰孔、镗孔割槽；最后再滚齿,插齿；最终热处理,再上磨齿机进行磨齿；完成整个零件的加工。 二、确定加工工艺方案一装夹方式及量具选择：数控车床夹具使用三爪卡盘自动定心夹具及顶尖；Y3150E滚齿机使用专用夹具,插齿机使用专用夹具,磨齿机使用专用夹具。量具有游标卡尺,
3、外径千分尺,百分表。二加工顺序：1.备料,下料尺寸22106的棒料,预备热处理2.车,粗精车右端面,钻中心孔3. 粗车,夹左端外圆顶中心孔定位,粗车右端外圆各部,留单边余量0.24、精车,夹左端外圆顶中心孔定位,精车右端外圆各部至图纸所示。5、切1.1mm宽的槽6、用3.5mm切槽刀切3.5mm处,4.6mm处以及12mm处,加之外径为13.9的T型槽至图纸所示。7、掉头夹直径12处外圆,粗精车左端端面及外圆8、钻镗直径为9的孔9、镗直径为12.5的孔。10、割宽5mm的槽。11、钻直径5和4的顶孔。12、铣键槽13、滚齿机滚右端齿14、插齿机插齿轮。15、倒角,倒棱16、最终热处理17、磨齿
4、机磨齿18、终结检验三,切削用量选择镗车削数控车削加工中的切削用量包括：背吃刀量、主轴转速n或切削速度、进给速度或进给量f。这些参数均应在机床给定的允许围选取。车削用量的选择原则是粗车时,首先考虑选择尽可能打的背吃刀量,其次选择较大的进给量f,最后确定一个合适的切削速度v。增大背吃刀量可使走刀次数减少,增大进给量f有利于断屑。精车时,加工精度和表面粗糙度要求较高,加工余量不大且较均匀,因此选择精车的切削用量时,应着重考虑如何保证加工质量,并在此基础上提高加工效率。因此,精车时应选用较小的背吃刀量和进给量f,并选用性能高的刀具材料和合理的几何参数,以尽可能提高切削速度v.(1) 背吃刀量的确定在
5、工艺系统刚度和机床功率允许的情况下,应尽可能选择较大的背吃刀量,以减少进给的次数。当零件精度要求较高时,则应考虑留出精车余量,其所留的精车余量比一般普通车削时所留余量小,常取0.10.5mm。2进给量的确定式中,f进给量,粗车时一般取为0.30.8mm/r,精车时常取0.10.3mm/r,切断时常取0.050.2mm/r。3主轴转速的确定 nr/min1.数控车削a.粗车端面 取 n= 50 m/min f = 0.3 mm/rb.精车端面 取 n = 80m/min f = 0.15 mm/rb.粗车外轮廓,留单面余量0.2mm 取 n = 50 m/min f= 0.3 mm/r ap =
6、 2 mmc.精车外轮廓 取 n= 80 m/min f = 0.15 mm/r ap = 0.2 mmd.切槽取 n = 60m/min f = 0.1 mm/rf.预钻孔8mm及打中心孔 取n = 500 r/min f = 0.2 mm/rg.镗孔取 n =1500 r/min f = 0.2mm/r2.滚齿机滚齿Vc = 0.7 m/sf = 1.5 mm/r（四） 刀具明细表序号刀具名称刀具直径刀补值190端面车刀D01293偏头外圆车刀D0231.15mm割槽刀43.5mm割槽刀54mm割槽刀6高速钢钻头87镗刀8镗刀D0893mm的切槽刀10滚刀D1011插齿刀D11三、数值换算
7、1、公差对称化换算：直径公差带代号公差大小/mm上偏差下偏差对称化后尺寸12g70.018-0.006-0.02411.985100-0.19.9516h70.0180-0.01815.99115.50-0.315.3513.90-0.0313.88516.80-0.116.757.80.0507.82517h80.0180-0.01816.99116.40-0.0416.389H100.0580.05809.02911.50.3011.6530.50.3030.65601060.51.10.101.1590.0509.02511.50-0.111.451.10.101.152、相关节点坐标计
8、算：如图所示：通过坐标标注,各节点坐标清清楚楚。3、刀位点坐标值的计算过程刀位点是指刀具的定位基准点。车刀的刀位点是刀尖或刀尖圆弧中心；钻头的刀位点是钻头顶点。各类数控机床的对刀方法是不完全一样的,这一容将结合各类机床分别讨论。数控车床的刀位点是工件外形轮廓向外偏移一个刀具半径值四、数控的工艺卡片及加工程序O0001车左端面打中心孔加工步骤加工容刀具主轴转速m/min或r/min进给量备注1粗车端面,留精加工余量0.2T01: 90端面车刀500.32精车端面至图纸要求T01800.153打中心孔T02: 直径3.35中心钻5000.2 O0002车外轮廓加工步骤加工容刀具主轴转速m/min或
9、r/min进给量备注1粗车外圆轮廓,留精加工余量0.2T01：93偏头外圆车刀500.3G712精车外圆轮廓至图纸要求T01：93偏头外圆车刀800.15G703切1.1mm宽槽T02：1.1mm割槽刀右刀尖600.14切3.5mm宽槽及4.6mm滚花槽T03：3.5mm割槽刀右刀尖600.15切T型槽及其他槽T04：4mm割槽刀右刀尖600.1 O0003精车左端端面,外圆,钻镗孔加工步骤加工容刀具主轴转速m/min或r/min进给量备注1粗车外圆轮廓,留精加工余量0.2T01：93偏头外圆车刀500.3G712精车外圆轮廓至图纸要求T01：93偏头外圆车刀800.15G703钻底孔T02：
10、直径为8mm高速钢麻花钻5000.24镗孔T03：硬质合金孔车刀5000.25镗直径为12.5mm的孔T04：硬质合金孔车刀15000.26割槽T05：硬质合金切槽刀600.1程序代码如下：O0001N10 G54 F0.3 S800 M03 M07 T0101 ;工艺设定N20 G50 S2000 ；最高转速限制N30 G96 S50 ；恒线速度切削N40 G0 X24 Z0.2 ；快速定位接近工件N50 G1 X-2 ；粗切端面N60 G0 X24 Z1N80 G96 S80 ；精车恒线速度设定N90 Z0N100 G1 X-2 F0.15 ；精车端面N110 G0 X100 Z150 ；
11、返回换刀点N120 T0202 ；换2号刀具N130 G97 S500 ；取消恒线速度,设定转速500r/min。N140 X0 Z5 N150 G1 Z-3.35 ； 钻中心孔N160 G0 Z5N170 X100 Z150N180 M30 ；程序结束O0002N10 G54 F0.3 S800 M03 M07 T0101 ;工艺设定 G50 S2000 ；最高转速限制 G96 S50 ；恒线速度切削G0 X24 Z0.2 ；快速定位接近工件 G1 X-2 ；粗切端面 G0 X24 Z1 G96 S80 ；精车恒线速度设定 Z0G1 X-2 F0.15 ；精车端面N40 G71 U2 R1
12、；G71粗车轮廓循环N50 G71 P60 Q170 U0.4 W0.2 F0.3；粗车轮廓循环参数设定N60 G0 G42 X8 Z2 F0.15 ；循环开始N70 G1 Z0N80 X9.95 Z-0.58N90 Z-15.72N100 G02 X10.36 Z-16.94 R3N110 G01 X11.985 Z-19N120 Z-36.5N130 X15.35N140 X15.991 Z-36.64N150 W-7.825 N160 X19N170 Z-106 ；循环结束N180 G0 X100 Z150N190 G96 S80 ；恒线速度切削N200 G70 P60 Q170 ；G7
13、0循环精车外轮廓N210 G0 X100 Z150 ；返回换刀点N220 T0202 ；换1.1mm切槽刀N230 G96 S60 N240 G0 G40X13 Z-27.5 F0.1；取消刀补,快速定位N250 G1 X11.45N260 G0 X20N270 G0 X100 Z150 N280 T0303 ;换3.5mm切槽刀N290 G0 X17 Z-38.5 ;切3.5mm槽N300 G1 X-15.96N310 G0 X20N320 Z-31.9 ；切4.6mm槽N332 G1 X11.9N340 G0 X14 N345 Z-40.8N350 G1 X11.5 N355 Z-31.9
14、 ；切4.6mm槽结束N360 G0 X20N370 G0 X100 Z150N380 T0404 ；换4mm切槽刀N390 G0 X20 Z-50.35N400 G1 X14.3；粗切直径为13.9的T型槽及宽12mm槽N410 G0 X20 Z-53.5N420 G1 X14.3N430 G0 X20 N435 Z-53.5N440 G1 X14.3N450 G0 X20N451 Z-57N452 G1 X14.3N453 G0 X20N455 Z-60.6N460 G1 X14.3N470 G0 X20 N475 Z-69.5N480 G1 X17.2 ；T型槽粗切结束N490 G0 X
15、20 N495 Z-72N500 G1 X17.2 ；粗切12mm槽N510 G0 X20 N515 Z-75N520 G1 X17.2N530 G0 X20N531 Z-75N532 G1 X17.2N534 G0 X20N535 Z-77.5N540 G1 X17.2 ； 12mm槽粗车结束N550 G0 X20 Z-75N560 Z-45.5N570 G1 X19 ；精车T型槽N580 X14.32 Z-49.55N590 G02 X13.885 Z-50.35 R1.6N600 G01 Z-64.6N610 G2 X14.28 Z-65.35 R1.6N620 G1 X18.22 Z-
16、69.06N630 G3 X17.68 Z-69.5 R0.15 ；精车T型槽结束N640 G1 X16.75 ; 精车12mm槽N645 Z-77.5N650 G0 X100 Z150N660 M30 ;程序结束O0003N10 G54 F0.3 S800 M03 M07 T0101 ;工艺设定N20 G50 S2000 ；最高转速限制N30 G96 S50 ；恒线速度切削N40 G71 U2 R1N50 G71 P60 Q130 U0.4 W0.2 F0.3 ;G71粗车循环N60 G0 G42 X15.2 Z2 F0.15 ；循环开始N70 G1 Z0N80 X16.38 Z-1.39N
17、90 Z-6N100 X16.991N110 Z-21.5N120 X18N130 Z-23 ；循环结束N140 G0 X19 Z2N150 G96 S80N160 G70 P60 Q130 ； G70精车循环N170 G0 X100 Z150 N180 T0202 ；换钻头N190 G0G40X0 Z25 S500 F0.2；钻孔开始,取消刀补N200 G1 Z-10N210 G0 Z2N220 G1 Z-20N230 G0 Z0N240 Z-18N250 G1 Z-35N260 G0 Z0 N270 Z-33N272 Z-50N274 G0 Z0N276 Z-48N280 G1 Z-62N
18、290 P1N300 G0 Z2 ；钻孔结束N310 G0 X100 Z150N320 T0303 ；换铰刀N330 G0 X0 Z5N340 G1 Z-62 ；铰孔N350 P1N360 G0 Z2N370 G0 X100 Z150 N380 T0404 ；换镗刀N390 S1500 F0.2N400 G0 G43X13.5 Z-0.433 ；刀补N405 G1 X12.5 Z-0.433 ；镗孔N410 Z-13N420 X8N430 G0 Z2N440 X100 Z150N450 T0505 ；换切槽刀N460 G0 G40 S60 X8 Z5 F0.1N470 Z-27.65N480
19、G1 X11.1 ；切槽N490 G0 X8N500 W2 N510 G1 X11.1N520 G0 X8N530 Z-24.93N540 G1 X9N550 X11.65 Z-25.65N555 Z-27.65N560 X9 Z-28.37N570 G0 X8N580 Z5N590 G0 X100 Z150N600 M30 ;程序结束五、MASTERCAM仿真1、刀具轨迹图：2、加工后的轮廓图：3、加工后立体图：4、PRO/E制作的三维图：5、MASTERCAM导出的加工程序：15 / 15%O0000G21G0T0101G97S3600M13G0G54X26.Z.5G50S3600G96S
20、295G99G1X-1.6F.2G0Z2.5X26.Z0.G1X-1.6G0Z2.G28U0.W0.M05T0100M01G0T0202G97S3600M13G0G54X18.666Z.5G50S3600G96S295G1Z0.F.3Z-35.436G3X18.687Z-35.6R1.3G1Z-37.845X19.4Z-59.283Z-59.3Z-60.5Z-110.127X22.X24.828Z-108.713G0X26.666Z-35.246X19.394G1X18.687Z-35.6G2X18.4Z-35.006R1.3F.1G1Z-23.3F.3Z-22.3G2X17.4Z-21.43
21、4R1.F.1G1Z-6.8F.3G2X17.2Z-6.364R1.F.1G1Z-2.186F.3G2X16.932Z-1.686R1.F.1G1X15.332Z-.3Z0.F.3X18.16Z1.414G0X19.4Z-22.946X19.107G1X18.4Z-23.3G3X17.712Z-24.055R1.F.1G1X17.2Z-24.277Z-30.209F.3Z-34.425G3X18.687Z-35.6R1.3G1X21.515Z-34.186G0X22.515Z-35.246X19.394G1X18.687Z-35.6G3X18.622Z-35.889R1.3F.1G1X19.0
22、87Z-49.874F.3X21.915Z-48.459G0X22.915Z-60.146X20.107G1X19.4Z-60.5G3X18.712Z-61.255R1.F.1G1X16.4Z-62.26Z-62.8F.3Z-66.3Z-68.156G3X15.733Z-68.901R1.F.1G1Z-110.127F.3X19.8X22.628Z-108.713G0Z-109.773X19.093G1X19.8Z-110.127X12.067F.1Z-86.434F.3X12.279Z-86.142G2X12.4Z-85.8R1.G1Z-77.3Z-76.2Z-72.9Z-70.35X15.
23、712Z-68.91G2X16.133Z-68.655R1.G1X18.962Z-67.24G0Z-68.525X17.099G1X16.133Z-68.655G3X15.712Z-68.91R1.F.1G1X12.4Z-70.35Z-72.9F.3Z-76.2Z-77.3Z-85.8G3X12.279Z-86.142R1.F.1G1X10.641Z-88.392G2X10.4Z-89.076R2.G1Z-104.223F.3G3X9.712Z-104.977R1.F.1G1X8.4Z-105.548Z-110.127F.3X12.467X15.295Z-108.713G0X22.Z.083X
24、15.244G1X14.986Z-.4X16.586Z-1.786G3X16.8Z-2.186R.8G1Z-6.413G3X17.Z-6.8R.8G1Z-21.558G3X18.Z-22.3R.8G1Z-23.3G3X17.45Z-23.904R.8G1X16.8Z-24.186Z-30.209Z-34.559G3X18.287Z-35.6R1.1X18.221Z-35.867R1.1G1X19.Z-59.287Z-59.3Z-60.5G3X18.45Z-61.104R.8G1X16.Z-62.169Z-62.8Z-66.3Z-68.156G3X15.45Z-68.759R.8G1X12.Z-
25、70.259Z-72.9Z-76.2Z-77.3Z-85.8G3X11.904Z-86.074R.8G1X10.265Z-88.324G2X10.Z-89.076R2.2G1Z-104.223G3X9.45Z-104.826R.8G1X8.Z-105.457Z-110.327X10.828Z-108.913G0X21.6G28U0.W0.M05T0200M01G0T0404G97S1592M13G0G54X23.Z-44.966G50S3600G96S115G1X14.3F.1G0X23.Z-46.963G1X14.3X14.699Z-46.763G0X23.Z-42.969G1X14.3X1
26、4.699Z-43.169G0X23.Z-48.96G1X14.3X14.699Z-48.76G0X23.Z-40.972G1X14.3X14.699Z-41.172G0X23.Z-50.956G1X14.708X15.107Z-50.757G0X23.Z-38.975G1X14.382X14.781Z-39.175G0X23.Z-52.953G1X17.014X17.413Z-52.753G0X23.Z-36.979G1X16.423X16.822Z-37.178G0X23.Z-33.474X21.022G1X18.193Z-34.888X14.251Z-38.595G2X13.9Z-39.
27、299R1.5G1Z-50.255G2X14.302Z-51.005R1.5G1X18.973Z-55.05G0X21.802G28U0.W0.M05T0400M01G0T0303G97S1695M13G0G54X21.6Z-76.3G50S3600G96S115X16.G1X11.5F.1G0X16.Z-77.914X14.828G1X12.Z-76.5X11.5G0X14.828Z-74.986G1X12.Z-76.4X11.5Z-76.5G0X14.828X21.6G28U0.W0.M05T0300M01G0T0404G97S1592M13G0G54X23.Z-60.5G50S3600G
28、96S115G1X16.4F.1G0X23.Z-60.G1X16.4X16.5Z-60.05G0X23.Z-59.9G1X16.4X16.5Z-59.95G0X23.Z-61.G1X16.4X16.5Z-60.95G0X23.Z-61.5G1X16.4X16.5Z-61.45G0X23.Z-57.086X21.828G1X19.Z-58.5Z-59.6G3X18.8Z-59.7R.1G1X16.Z-61.9G3X15.93Z-61.976R.1G0X18.758X21.6G28U0.W0.M05T0400M01G0T0303G97S1642M13G0G54X22.287Z-17.967G50S
29、3600G96S115G1X17.4F.1G0X22.287Z-18.067G1X17.4X17.42Z-18.057G0X22.287Z-17.868G1X17.4X17.42Z-17.878G0X22.287Z-18.167G1X17.4X17.42Z-18.157G0X22.287Z-17.768G1X17.4X17.42Z-17.778G0X22.287Z-18.267G1X17.4X17.42Z-18.257G0X22.287Z-17.668G1X17.4X17.42Z-17.678G0X22.287Z-18.367G1X17.4X17.42Z-18.357G0X22.287Z-17
30、.568G1X17.4X17.42Z-17.578G0X22.287Z-18.466G1X17.4X17.42Z-18.456G0X22.287Z-17.468G1X17.4X17.42Z-17.478G0X22.287Z-18.566G1X17.4X17.42Z-18.556G0X22.287Z-17.368G1X17.4X17.42Z-17.378G0X22.287Z-18.666G1X17.4X17.42Z-18.656G0X22.287Z-17.269G1X17.4X17.42Z-17.279G0X22.287Z-18.766G1X17.4X17.42Z-18.756G0X22.287
31、Z-17.169G1X17.4X17.42Z-17.179G0X22.287Z-18.866G1X17.4X17.42Z-18.856G0X22.287Z-17.069G1X17.4X17.42Z-17.079G0X22.287Z-18.966G1X17.4X17.42Z-18.956G0X22.287Z-16.969G1X17.4X17.42Z-16.979G0X22.287Z-19.065G1X17.4X17.42Z-19.055G0X22.287Z-16.869G1X17.4X17.42Z-16.879G0X22.287Z-19.165G1X17.4X17.42Z-19.155G0X22
32、.287Z-16.77G1X17.4X17.42Z-16.78G0X22.287Z-19.265G1X17.4X17.42Z-19.255G0X22.287Z-16.67G1X17.4X17.42Z-16.68G0X22.287Z-19.365G1X17.4X17.42Z-19.355G0X22.287Z-16.57G1X17.4X17.42Z-16.58G0X22.287Z-19.465G1X17.4X17.42Z-19.455G0X22.287Z-16.47G1X17.4X17.42Z-16.48G0X22.287Z-19.564G1X17.4X17.42Z-19.555G0X22.287
33、Z-16.37G1X17.4X17.42Z-16.38G0X22.287Z-19.664G1X17.4G0G54X21.6Z-69.3G50S3600G96S115X16.032G1X11.9F.1G0X16.032Z-69.4X16.004G1X11.9X11.92Z-69.39G0X16.006X16.086Z-69.2G1X11.9X11.92Z-69.21G0X16.079Z-69.5X16.G1X11.9X11.92Z-69.49G0X16.X16.17Z-69.1G1X11.9X11.92Z-69.11G0X16.16Z-69.6X16.G1X11.9X11.92Z-69.59G0
34、X16.X16.289Z-69.Z-68.G1X11.9X11.92Z-68.01G0X18.495Z-70.7X16.G1X11.9X11.92Z-70.69G0X16.X18.748Z-67.9G1X11.9X11.92Z-67.91G0X18.725Z-70.8X16.G1X11.9X11.92Z-70.79G0X16.X18.978Z-67.8G1X11.9X11.92Z-67.81G0X18.955Z-70.9X16.G1X11.9X11.92Z-70.89G0X16.X19.208Z-67.7G1X11.9X11.92Z-67.71G0X19.185Z-72.514X14.828G
35、1X12.Z-71.1X11.5X12.Z-70.85G0X18.496X18.6Z-66.086X18.496G1X15.668Z-67.5X11.5Z-71.1X12.Z-70.85X11.23Z-29.787G0X8.Z-29.897G1X11.25X11.23Z-29.887G0X8.Z-29.997G1X11.25X11.23Z-29.987G0X8.Z-30.097G1X11.25X11.23Z-30.087G0X8.Z-30.197G1X11.25X11.23Z-30.187G0X8.Z-30.296G1X11.25X11.23Z-30.286G0X8.Z-30.396G1X11
36、.25X11.23Z-30.386G0X8.Z-30.496G1X11.25X11.23Z-30.486G0X8.Z-30.596G1X11.012X10.992Z-30.586G0X8.Z-30.695G1X10.645X10.625Z-30.685X CENTER - WIDE INSERT - N151.2-600-4EG0T0404G97S1695M13G0G54X21.6Z-104.G50S3600G96S115X12.G1X-.2F.1G0X12.X21.6G28U0.W0.M05T0400M30六、课程设计小结时光匆匆,两周的数控课程设计转眼入尾声。过程是艰辛的,但回顾起来却处处甘甜。本次课程设计分了五个大组,每组八人,每组共两个图,一个简单的另一个复杂的,作为组长,我根据同学们的能力及兼顾考研的同学,根据图纸,将八人分成两组,然后有问题的大家公开讨论,大家都很乐意。我自觉选择复杂的图,然后尽量将进度拉在最前,让组员们能够有所参考,然后
