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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
 

IC646MRD300 Logic PC (HRT) 300 Tag Runtime System

IC800SLCAPM010 Control Cable, SL Servo Terminal Block to APM300, 1 Meter

TGT-AI0V-16-0 Target Analog Module 8 Inputs, 8 Outputs

TGT-S000-1-1 Target series system module with 2 MB RAM

20BC170A0ANNANC0 PowerFlex 700 AC Drive 20B

20DW142A0ENNACANE PowerFlex 700S AC Drive 20D

20G1ABC540JN0NNNNN PowerFlex 755 AC Packaged Drive

2711C-RJ422 PanelView Component Accessory

140CRA21110 Quantum DIO站适配器和电源,115/230VAC,独立,3A

290D-FAP-G1-3 Direct Online Starter

热电偶/PT100输入，继电器输出，3个报警

1492-SPM2B250 MCB Supplementary Protector 25 A

软启动器 3RW30162BB04

电机启动器 3VU16401MQ00

150-F108NBRB SMC Flex Smart Motor Controller

1732D-16CFG1212W Armor WeldBlock 16 Point Block

1771-NT2 1771 Analog Module

193-EC5PB E3 Plus 0.4-2 A Overload Relay

198E-DF14168 Ip66/Nema 4/4X/12 Metal Hinged Enclosure

2090-CPWM6DF-16AA03 TL-Series 3m Standard Power Cable

2094-EN02D-M01-S1 Kinetix 6200/6500 Control Module

DNR240PS24-I FIELD PSU 24VDC 10A

GFK-0870 Host Communications Toolkit for C/C++ Applications User's Manual

IC210EMS001 Modbus RTU slave communications expansion module, 24V DC power source

IC647AUR025 PA Universal Reporting Client 25 pak

IC647PRTEE025C Proficy Portal Enterprise Edition Client Pack 25 Users (M1 Key)

IC693CPU350 CPU 350 Module (32K Bytes user memory, 4K I/O, 8 Racks), no built-in S erial Ports .22msec/K, The battery for the CPU is now included in the CPU backplane box.

IC754VSB06MTD View Basic 6 inch Mono Touch DC

MSI-DEMO-43 Proficy Plant Apps Demo Software-43

SLC/1746 System 1746-RL52 REPLACEMENT OCTAL LABEL KIT FOR CTLG # 1746-OG16

Distributed I/O 1734-FPD FIELD POTENTIAL DISTRIBUTOR

Application-specific products 9307-EM10K3PXENE RSENERYMETRIX 3RD PARTY OPC (65 - 10K METERS)

Operator Interface 2711-NC14 10METER RS232 OPERATING/PROGRAMMING CABLE

Support 9302-HCOR SUPT REINSTATEMENT CONTRACT FOR 9302HCO

Support 9510-PB2500ENR SUPT REINSTATEMENT CONTRACT FOR 9510PB2500EN

DeviceNet Products 1761-NET-DNI DEVICENET INTERFACE (DNI)

RSI Software Products 9301-2SE3350PTE RSVIEW32 RUNTIME 5K (PORTUGUESE)

RSI Software Products 9307-EMRPTENE RSENERGY METRIX REPORTPLUS

Motion Control MPL-B980D-MJ22AA MOTOR,SERVO,162.7NM,2000RPM,MULTI,460V

Silver Series 1398-HMI-001 TOUCHPAD INTERFACE MODULE, ULTRA

HE693ADC816 8 channel, +/- 10VDC HS, 16-bit resolution

IC647CBL704 Cable, Workstation Intf. to Series 90 CPU, Serial, 10 feet (3m)

QPH2D100L2P/B QUICKPANEL 6" MONO LCD HAND HELD BLANK

ST-3802 STXi analog input module 2 Channels, Thermocouple

20BC140A3ANNAEC0 PowerFlex 700 AC Drive 20B

20F1AGC104JN0NNNNN PowerFlex 753 AC Packaged Drive

22A-D4P0N104 PowerFlex 4- 1.5 kW (2 HP) AC Drive

140DAI34000C Quantum 开关量 AC 输入, 16点, 24 VAC, 隔离, CC

284D-FVD1P4B-10-RR-3-DB1-SB-EMI DeviceNet Variable Frequency Drive

CJ1W-DA041 4点模拟量输出单元（1-5V,0-5V,0-10V,-10-10V,4-20MA）分辨率：1/4000

1492-RTB16P 16-Pole Push-In Style Rtb

WinCC 上位监控软件 6GK1901-0DA20-0AA0 BFOC 连接器套件，（20 件）

变送器 3RS17032CD00

1497A-A4-M6-0-N 150VA 240x480-120 60Hz CPT

1606-XLP60EQT AC DC In 24 to 48VDC Out 60W Low Temp PS

1768-KY1 CompactLogix L43/L45 Replacement Key

188-K4C200 Miniature Circuit Breaker 20 A

194R-30-NN 194R30A UL 40A IEC 4th Power Pole Module

2090-CPBM7DF-10AA60 MP-Series 60m Standard Cable

2090-XXNPMP-10S90 MP-Series 90 m Length Power Cable

CBL-13-ED-20 Encoder cable for MTR-1235 or MTR-1300 or MTR-1400 or MTR-1N series stepping motors connected to IMC or S2K. 20 feet

GC647SVW001 Scheduler Desktop View Client

IC200PWR102 POWER SUPPLY WITH EXPANDED 3.3VDC 120/240VAC INPUT

IC646TBLSS150K Proficy Troubleshooter for Intelligent Historian for Hist 150000 Points

IC647NGS000 CIMPLICITY HMI SHARP TCP/IP Communications Driver

IC693ACC300 Input Simulator Module

IC698CRE040 1.8GHz CPU, Ethernet, Redundancy

IC800VMCB1030 Motor power and brake power cable for 1 kW VersaMotion servo motor- 3 meter

SLC/1746 System 1746-IO4 COMBINATION MODULE FOR PROGRAMMABLE CONTROLLER

Industrial Computers 6180W-7P2KH VERSAVIEW 6180W NON-DISPLAY COMPUTER, 7 SLOT

Application-specific products 6556-PA0PM4 CLUTCH/BRAKE KIT W/ARMED CONTINUOUS PUSHBUTTON

Operator Interface 2711-T5A14L1 PV550 MONO TOUCH, MBUS & RS232 PRINT

Support 9301-2SE2200PTS SUPT RENEWAL CONTRACT FOR 93012SE2200PT

Support ABTS-W103S ABT-SW103 PATHFINDER SW SUPPORT RENEWAL

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RSI Software Products 9301-2SE250FRU2R RSVIEW32 WORKS 1500-100K UPGRADE OUT-SUPT (FR)

RSI Software Products 9358-BIZDME2U1R UPGRADE: OUT-SUPT: RSBIZWARE DME TO UNLIMITED

Motion Control MPL-B310P-MK24AA MOTOR,SERVO,1.58 NM,5000RPM,MULTI,460V,BRK

Motion Control 2090-XXNPMP-16S90 CABLE,NON-FLEX,MOTOR POWER,MP/1326AB,16 GAUGE,90M

GC646TDV915 Proficy GlobalCare Complete for Server 1500 I/O Develop/Runtime System

IC641SWP308 LM 90-30/20 ver. 4.02 for NEC 9800 Computer

IMC-313D-X-D IMC-D Series Servo Motor Controller, DeviceNet, 3 Amp

PSPC-DC100/E Prof Shop Floor SPC DC 100 User w/ eSig

20BC011A0AYNADC1 PowerFlex 700 AC Drive 20B

20DJ730N0ENNBNANE PowerFlex 700S AC Drive 730 A 600 Hp 20D

2198-H040-AP-T K5500 FR1,2 AC control conn

2711P-RAAK7 PanelView Plus 7 Series Accessory

280-PWRM35F-M30 ArmorConnect 3-PH Power Media trnk cable

CP1W-CN811 CPM1A扩展单元用IO连接电缆，80CM

1492-MS8X12V1-END Connection Products

模拟量输入/输出模块SM 6ES7 331-7PF01-0AB0 AI/8 电阻，热电阻，光电隔离，40pin 前连接器

行程开关 3SE53220SE21

运行版软件 6AV2105-4FF04-0AE0 SIMATIC WinCC Runtime 专业版 V14 Upgrade WinCC V7.0..V7.3 Runtime 2048 PowerTags -> WinCC Runtime 专业版 2048 PowerTags V14

1585J-M8CBJM-8M5 RJ45 Ethernet Media

1756-RM2K CLX Redundancy Module

188-K1D160 Miniature Circuit Breaker 16 A

194E-Y25M-1756-6N 25 A 194E Load switch

2090-CFBM7E7-CEAF02 2 m Length SpeedTec Extension Cable

2090-UXNFBY-S25 Y-Series 25 m Length Feedback Cable

BC646TRT050 Server 50 I/O RUNTIME SYS with Proficy GlobalCare

GC647IFPLRN00075 GCC iFIX Plus SCADA 75 I/O Run

IC200CBL545 VersaMax CPU001, 9-pin, RS-232 to DataPanel 3x/5x

IC646MPP050 Logic Developer PLC Professional 50 pack

IC647IFPRSRUNLMTK iFIX Profsnl SCADA Unlimited Server (M1 Kit Part)

IC660TSD100 Terminal Assembly for IC660BBD100/101

IC697CPM925RR CPU, 64MHz, 12K Discrete I/O, 1024K RAM, 80486DX2

IC800PCUBC02S030 Powercube flying lead interface cable configured for 200 steps/revolution and power save enabled. 3 meters

ControlLogix/1756 System 1756-OB16E 10-31 VDC ELEC FUSED OUTPUT 16 PTS (20 PIN)

Industrial Computers 6182H-10KEH15B VVCE 1000, KEYPAD, EXT MEM, CNET, AC

Process Control 9358-PBV01ENE RSBIZWARE BATCH FOR PLX VIEW ADDITIONAL CLIENTS

Operator Interface 2711P-RBK15 PV PLUS 1500 KEYPAD REPLACEMENT BEZEL

Support 9355-WAB1CENS SUPT RENEWAL CONTRACT FOR 9355WAB1CEN

Support 9351-SLRSR SUPT REINSTATEMENT CONTRACT FOR 9351SLRS

ControlNet Products 1786-RPFRXL CONTROLNET FIBER RING REPEATER - EXTRA LONG

RSI Software Products 9301-2SE2400ESU1 RSVIEW32 WORKS 1500-32K UPGRADE IN-SUPT (ES)

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Motion Control MPL-A320H-HK24AA MOTOR,SERVO,2.94NM,3500RPM,ENCDR,230V,BRK,5.1KG

Motion Control 2090-DANPT-16S12 CABLE, NON-FLEX, MTR PWR, CABLE-MTD CONN, 16AWG, 1

BC647MQPU01 View for QuickPanel (Upgrade from QuickDesigner) with Proficy GlobalCare Complete and a hardware key

IC5008TAW0000 18" Intelligence Industrial PC, Standard Series Win2000

IC800MCUB12310XD Stepping Motor Cube, 175 oz-in with DeviceNet Option, NEMA 23

OC647IFESGCLNTCDVM iFIX Optn: ESig & ERec iClient Development (M4 Part)

20AD022A3AYYAEG1 PowerFlex 70 AC Drive 22 A at 15 Hp 20A

20DC260A0NYNACANE PowerFlex 700S AC Drive 20D

20G1ANF142JN0NNNNN PowerFlex 755 AC Packaged Drive

25C-E022N104 PowerFlex 527 15kW (20Hp) AC Drive

280-PWRM22B-M10 ArmorStart Three-Phase Power Media

FX1N-422-BD RS422C 通信用适配器

1492-M5X5H21-30 Connection Products

1494H-EA3H2 Heavy Duty Fusible Safety Switch

软启动器 3RW44462BC44

ET 200SP 6ES7193-6BP20-0DA0 基座单元 BU15-P16+A10+2D，类型A0，直插式端子，带有10个AUX端子，用于新负载组，15mm宽

1585D-M4TBJM-0M3 Micro D-Code, QD Style Ethernet Media

1756-ENBTK ControlLogix Communication Module

1794-OF8IH Flex 8 Point Analog Output Module

194E-CA80-P11 194E Load switch

2090-CCMCNDS-48AA03 Kinetix 3 MLX to Drive Cable

2090-DANPT-16S02 TL-Series 2 m Length Power Cable

ABICTDE0000/SER 10.5 inch Color TFT/ TCP Label/ 24VDC/ with HMI-CAB-C52 & HMI-CAB-C83/ UL/ cUL/ CE/ UL1604

GC646PCMS1C GlobalCare Complete for Change Management Electronic Signature Module 100 Pack

HE697THM260 8 channel thermocouple input module for Series 90-70 with 0.1degC resol ution and resistance measurement.

IC630MDL376RR 115/230Vac Isolated Output Module (8 points)

IC647HSTSS75KM-35 Historian v3.5 Standard Server 75000 Points (M4 Key)

IC660BLD022 Cover w/Label for IC660BBD022

IC695CDEM002 RX3i type 2 demo case for Chinese market. Demo includes CPU, power supply, Ethernet, input simulator, output with ESCP, high speed counter, Universal analog and analog output modules. Demo also includes QuickPanel control/view includes thermocouple

IC756WET100E-26 Custom Editor Toolkit, English, v2.6

CompactLogix System 1769-CRR1 1FT (305 MM) RIGHT-TO-RIGHT BUS EXPANSION CABLE

PLC-5/1771 System 9399-RL53GRPT RSLOGIX 5 GETTING RESULTS GUIDE (PORTUGUESE)

Distributed I/O D1794-6.5.8 FLEX I/O ISOLATED ANALOG MOD.USER MANUAL

Operator Interface 2711P-B7C15B1 PV PLUS 700, KEY/TOUCH, CNET, AC PS, STD MEM

Support 6411-SDSCS 6411-SDSC SOFTWARE SUPPORT RENEWAL

Support 9358-PLTM2300R SUPT REINSTATEMENT CONTRACT FOR 9358PLTM2300ENE

Support F1784-KTCX15SERB FIRMWARE UPGRADE FOR 1784-KTCX15 COMMUNICATION MOD

RSI Software Products 9301-2SE2200FRU1 RSVIEW32 WORKS 150-300 UPGRADE IN-SUPT (FR)

RSI Software Products 9701-VWSB000DEU4 SE STATION UNTLD-SE SRV UNTLD DISP+CLIENT (GERMAN)

RSI Software Products 9399-BUTTONUG RSBUTTON USERS GUIDE

Motion Control 2098-IPD-020 DRIVE, 10A/30A, ULTRA5000

ABKSTDN0000/DVN 6" Color STN, TCP Label, 24Vdc, with DeviceNet, No Agency Approvals

IC300ADC010 2 channel Analog Inputs, Voltage (0-5vdc, +/-5vdc, 0-10vdc, +/-10vdc), 12 bit

IC752DPJ003RR Datapanel J+ with Advanced software, 256x64 LCD with EL backlight. Various sizes of text, bitmaps, bar graphs, real time clock. With Real Time Trends & Host Communications. Includes integrated keypad for data entry. No touch capability.

MTR-3S34-G-R-0-E-SRR Servo Motor Nema34 with Seal

ZA06B-6073-K250 Alpha i-series servo SVM amplifier spare control power fuse

20BE062A0AYNAND0 PowerFlex 700 AC Drive 62 A 60 Hp 20B

20G14NF119JA0NNNNN PowerFlex 755 AC Packaged Drive

25-RF018-CL PowerFlex 520 18.3A 480V EMC Filter Kit

2711P-RTFC PanelView Plus 400 600 Mounting Lever

FRN160G11S-4CX 232KVA 304A 160KW 3相AC380V/50Hz/60Hz

1492-JD3-B 2.5 mm Double Level Terminal Block

1492-W10-G IEC Term Blck 8x47.6x41mm Screw

软启动器 3RW40746BB34

CPU 模块 6ES7 672-7AC01-0YA0 CPU 1507S，VERSION 2.0(1 个浮点授权 )，仅能在 SIMATIC IPC 上使用

153H-C85XBD-46 SMC-3 ENCLOSED COMBINATION 85A

1746-C16 SLC 50 inch Interconnect Cable

1786-CTK ControlNet Media Toolkit

193-T1AB10 0.75-1.0 A IEC Bimetallic Overload Relay

20-FI13300 PowerFlex 700S/H Main Fan Assembly

2090-CSBM1DF-10AF20 Kinetix Cable Single DSL 2090-Series

20AC011A3AYYANC1 PowerFlex 70 AC Drive 20A

GA647TDV075 Proficy GlobalCare Assist for CIMPLICITY HMI Server 75 I/O Development and Runtime System

GP647IFPRDV00075 GCP iFIX Profsnl SCADA 75 I/O Dev

IC600BF946RR Loop Management Module (Proloop System)

IC647HSTCS10000KM Historian Enterprise Corporate Server 10,000,000 Points (M4 Key)

IC647TRT075 CIMPLICITY HMI Server 75 I/O Runtime System

IC693PWR321CA Conformal Coated Power Supply 120/240VAC, standard.

IC756MDV001K-98 DV Development - Alpha OpenVMS Addt'l User, Korean, Version 9.8

MicroLogix 1000/1761 System 1761-MMB MICROMENTOR BASICS BOOK FOR PROGRAMMABLE CTRLRS

PLC-5/1771 System 1771-NIS HIGH RESOLUTION ISOLATED ANALOG MODULE

Distributed I/O 1792D-CBFM MAXUM MEDIA BASE FOR KWIKLINK FLAT MEDIA

Communications 9351-SLRS INTERCHANGE FOR SOLARIS

Operator Interface D6190-6.5.28 CONTROLVIEW SCADA OPTION USER MANUAL

Support 9358-B30R SUPT REINSTATEMENT CONTRACT FOR 9358B30ENE

Support 9392-CDRSJPU UPGRADE TO ENGLISH/JAPANESE BUNDLE

RSI Software Products 9310-WE5200E RSLOGIX EMULATE 5

RSI Software Products 9301-2SE3500PTU4 RSVIEW32 RUNTIME 150-100K UPGRADE IN-SUPT (PT)

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Motion Control TL-A2540P-BJ34AA MOTOR, SERVO, 2.9NM, 5000RPM, 17BIT SERIAL FEEDBAC

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IC200CHS012 I/O INTERPOSING BOX STYLE

IC694MDL654 INPUT MODULE 5/12 VDC (TTL) 32 POINT POS/NEG LOGIC

MSI-UNIV-WEB-50 Universal Web Client(RTIP / Dashboard / Web / Excel Addin) 50 Pak

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20BD040A3AYNANC0 PowerFlex 700 AC Drive 40 A at 30 Hp 20B

20G11JF1K4JN0NNNNN PowerFlex 755 AC Packaged Drive

22D-D017N104 PowerFlex 40P- 7.5 kW (10 HP) AC Drive

140NOM21100C Quantum MB+ 网络适配器, 1MB, 1MB+, 单电缆, CC

290E-FAZ-G1 Direct Online Starter

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1492-SPM2C080 MCB Supplementary Protector 8 A

软启动器 3RW30271BB04

电机启动器 3VU16403MG00

150-F201NBDD SMC Flex Smart Motor Controller

1732D-IBDPM12MND ArmorBlock 16 Point Input Block

1771-OR 1771 6 Point Digital Output Module

193-ED1EP E1 Plus 5.4-27 A IEC Overload Relay

199-FSMA2 Industrial Relay R-C Surge Suppressor

2090-CPWM7DF-08AA05 MP-Series 5m Standard Power Cable

2094-XL75S-C2 Kinetix 6000 Line Interface Module

EDS-205 Industrial 5-port Unmanaged 10/100 Switch (-10 to 60 deg c op temp)

GFK-1179 Installation Requirements for Conformance to Standards

IC220ACC002 MODULE LABELS WIDE, QTY 10

IC647BSU010 Batch Server Pak Upgrade (5 to 10 Units)

IC647PRTHE050C Proficy Portal Historian Edition Client Pack 50 Users (M1 Key)

IC693CPU364RR CPU364 Module (240K Bytes configurable user memory), Embedded Ethernet

IC756ADV000J-98 DV Development - AIX Op Sys, Japanese, Version 9.8

MSI-EFF-5 Efficiency Management Clients 5 Pack

SLC/1746 System 1746-RT25C REPLACEMENT TERMINAL BLOCK (ORANGE)

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Application-specific products 9307-RSPRTD RSPOWER RT FOR AB PM1 PM2 POWER MONITORING DEVICES

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