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1、一、零件铣削加工工艺分析1. 零件工艺分析 零件材料为硬铝LY12,毛坯已加工好，尺寸（长宽高）为140mm140 mm30 mm，单件生产零件材料为硬铝，切削加工性能良好。加工分粗、精加工两个阶段进行，以保证尺寸公差及表面粗糙度的要求。同时用底面定位，以保证垂直度要求。2. 确定装夹方案该零件外形规则，因此在加工各表面及孔时选用平口虎钳夹紧。以底面和侧面定位，用等高垫铁垫起，注意垫块应避开孔的位置，在平口虎钳的旁边安置一个定位挡块，以起工件定位作用。3. 确定加工顺序及走刀路线加工顺序按先面后孔、先粗后精的原则确定。先加工凸台轮廓，再加工孔，然后加工凹槽。为了保证加工精度，各轮廓表面的粗、精
2、加工应分开。走刀路线包括平面进给和深度进给两部分。平面进给时，外轮廓切削刀具从轮廓外延切线方向切入、切出，内凹槽轮廓从过渡圆弧切入切出。为了保证表面质量，均采用顺铣方式分层环形铣削。深度进给采用螺旋下刀方式达到既定深度。4.刀具的选择根据零件的材料和结构特点，采用高速钢立铣刀。所选刀具及其加工表面见表1-1数控加工刀具卡片表1 零件数控加工刀具卡片序号刀具号刀具加工表面备注 规格名称数量刀长/mm1T0112mm高速钢立铣刀190粗加工凸台2T0212mm高速钢立铣刀190精加工凸台5.切削用量的选择凸台、凹槽的粗加工在平面进给和深度进给方向都应分层铣削，铣削时每层的侧吃刀量和背吃刀量都选为3
3、mm，各轮廓表面的精加工留0.3mm的铣削余量。选择主轴转速与进给速度是，先查切削用量手册，确定切削速度与每齿进给量，然后计算进给速度与主轴转速，具体数值详见加工工序卡片。6.填写数控加工工序卡片将各工步的加工内容、所用刀具和切削用量填入表2的数控加工工序卡片中。表2 数控加工工序卡片夹具名称使用设备平口虎钳XK5034工步号工步内容刀具号刀具规格/mm主轴转速/(rmin -1)进给速度/(mmmin-1 )背吃刀量/mm备注1粗加工凸台T011263010042精加工凸台T0212900600.3二、零件的加工1.加工前的准备工作1.1生成加工模型图1 加工模型1.2设定加工毛坯选择“加工
4、”“定义毛坯”命令，弹出“定义毛坯”对话框。选择参照模型方式，其它参数如图所示，单击“确定”按钮，完成毛坯的定义。图2 “定义毛坯”对话框1.3后置设置(1) 选择“加工” “后置处理” “后置设置”命令，弹出“机床后置”对话框，如图。(2) 增加机床设置。选择当前机床类型。(3) 后置处理设置。选择“后置设置”选项卡，根据当前的机床，设置各参数，如图。图3 “机床后置”对话框图4 机床后置设置对话框2.粗加工等高线粗加工单击“加工” “粗加工” “等高线粗加工”或单击按钮，弹出“等高线粗加工”对话框。在“加工参数”选项中按表3设置各项参数 表3 等高线粗加工参数表加工参数切削用量加工方向顺铣
5、主轴转速1000层高3慢速下刀速度100行距3切入切出速度800切削模式环切切削速度1000行间连接方式直线退刀速度100加工顺序Z优先下刀方式加工精度0.1安全高度50加工余量0.5慢速下刀距离10区域切削类型仅切削退刀距离10起始点坐标X=0,Y=0,Z=50切入方式垂直毛坯类型参照模型零件类型轮廓型实体刀具参数其他参数不设定刀具名12立铣刀加工边界刀具半径6最小最大-55/0刀角半径图5 等高线粗加工轨迹3.精加工等高线精加工（1）粗加工的刀具轨迹隐藏掉（2）击“加工” “精加工” “等高线精加工”，弹出“等高线精加工”对话框，在加工参数选项中按表4设置各项参数。表4 等高线精加工参数表
6、加工参数切削用量加工方向顺铣主轴转速2000最小层间距0.1慢速下刀速度100加工顺序Z优先切入切出速度800删除面积系数0.1切削速度1500删除长度系数0.1退刀速度800恢复公差长度0.001下刀方式行距6安全高度50走刀方式环切慢速下刀距离10加工精度0.01退刀距离10加工余量0切入方式垂直起始点坐标X=0,Y=0,Z=50刀具参数毛坯类型铸件刀具名12立铣刀零件类型轮廓型实体刀具半径6其他参数不设定刀角半径图6 等高线精加工轨迹4.轨迹仿真（1）单击“线面可见”按钮，显示所有以生成的加工轨迹，然后拾取粗加工轨迹，单击鼠标右键确认。（2）选择“加工” “实体仿真”命令。拾取粗加工/精
7、加工的刀具轨迹，单击鼠标右键结束。系统弹出“轨迹仿真”界面。（3）单击“仿真加工”按钮，系统将立即进行仿真加工，并弹出仿真加工对话框如图。仿真加工过程中系统显示走刀过程如图。图7 “仿真加工”对话框图8 仿真加工过程5.生成G代码（1）选择“加工” “后置处理” “生成G代码”命令，弹出“选择后置文件”对话框，填写加工代码文件名“零件粗加工”，单击“保存”按钮。（2）状态栏提示“拾取刀具轨迹”，选择以上生成的粗加工轨迹，单击鼠标右键，弹出记事本文件，内容为生成的G代码程序。见附表1（3）同样的方法生成精加工的G代码程序。见附表26.生成工序单选择加工工艺清单命令，弹出工艺清单对话框，如图。填写
8、加工零件名称“零件加工”，单击“拾取轨迹”按钮，返回工作界面，拾取粗、精加工轨迹后，单击鼠标右键，返回“工艺清单”对话框；单击“生成清单”按钮。弹出“CAXA工艺清单”界面，如图。工艺清单共有general(NC数据检查表)、function(功能参数)、tool(工具)、path(刀具路径)、ncdata(NC数据)5个NC数据检查表文件。至此，零件的造型、生成加工轨迹、加工轨迹仿真检查、生成G代码程序、生成加工工艺清单的工作全部做完。图9 “工艺清单”对话框图10 CAXA工艺清单界面项目关键字结果备注加工策略顺序号CAXAMEFUNCNO1加工策略名称CAXAMEFUNCNAME等高线粗
9、加工标签文本CAXAMEFUNCBOOKMARK加工策略说明CAXAMEFUNCCOMMENT加工策略参数CAXAMEFUNCPARA加工方向:顺铣角度0.加工顺序:Z向优先删除面积系数:0.1删除长度系数:0.1行间连接方式:直线添加拐角半径:否执行平坦区域识别:否HTML代码XY向切入类型(行距/残留)CAXAMEFUNCXYPITCHTYPE行距XY向行距CAXAMEFUNCXYPITCH3.XY向残留高度CAXAMEFUNCXYCUSP-Z向切入类型(层高/残留)CAXAMEFUNCZPITCHTYPE层高Z向层高CAXAMEFUNCZPITCH3.Z向残留高度CAXAMEFUNCZC
10、USP-主轴转速CAXAMEFEEDRATESPINDLE3000 慢速下刀速度CAXAMEFEEDRATESLOWPLUNGE100.切入切出连接速度CAXAMEFEEDRATELINK800.切削速度CAXAMEFEEDRATE1000退刀速度CAXAMEFEEDRATEBACK100.安全高度CAXAMEAIRCLEARANCE100.安全高度模式CAXAMEAIRCLEARANCEMODE绝对加工余量CAXAMESTOCKALLOWANCE0.加工精度CAXAMETOLERANCE0.1起始点CAXAMEFUNCHOMEPOSITION(0.,0.,100.)加工坐标系CAXAMEFU
11、NCWCS.sys.图11 功能参数表(粗加工)N10G90G54G00Z100.000N12S3000M03N14X0.000Y0.000Z100.000N16X-75.000Y-82.500N18Z35.744N20G01Z25.744F100N22Y-75.000F600N24Y75.000F800N26X75.000N28Y-75.000N30X-75.000N32X-72.000Y-72.000F600N34Y72.000F800N36X72.000N38Y-72.000N40X-72.000N42X-69.000Y-69.000F600N44Y69.000F800N46X69.00
12、0N48Y-69.000N50X-69.000N52X-66.000Y-66.000F600N54Y66.000F800N56X66.000N58Y-66.000N60X-66.000N62X-63.000Y-63.000F600N64Y63.000F800N66X63.000N68Y-63.000N70X-63.000N72X-60.000Y-60.000F600N74Y60.000F800N76X60.000N78Y-60.000N80X-60.000N82X-57.000Y-57.000F600N84Y57.000F800N86X57.000N88Y-57.000N90X-57.000N
13、92X-54.000Y-54.000F600N94Y54.000F800N96X54.000N98Y-54.000N100X-54.000N102X-51.000Y-51.000F600N104Y51.000F800N106X51.000N108Y-51.000N110X-51.000N112X-48.000Y-48.000F600N114Y48.000F800N116X48.000N118Y-48.000N120X-48.000N122X-45.000Y-45.000F600N124Y45.000F800N126X45.000N128Y-45.000N130X-45.000N132X-42.
14、000Y-42.000F600N134Y42.000F800N136X42.000N138Y-42.000N140X-42.000N142X-39.000Y-39.000F600N144Y39.000F800N146X39.000N148Y-39.000N150X-39.000N152X-36.000Y-36.000F600N154Y36.000F800N156X36.000N158Y-36.000N160X-36.000N162X-33.000Y-33.000F600N164Y33.000F800N166X33.000N168Y-33.000N170X-33.000N172X-30.000Y
15、-30.000F600N174Y30.000F800N176X30.000N178Y-30.000N180X-30.000N182X-27.000Y-27.000F600N184Y27.000F800N186X27.000N188Y-27.000N190X-27.000N192X-24.000Y-24.000F600N194Y24.000F800N196X24.000N198Y-24.000N200X-24.000N202X-21.000Y-21.000F600N204Y21.000F800N206X21.000N208Y-21.000N210X-21.000N212X-18.000Y-18.
16、000F600N214Y18.000F800N216X18.000N218Y-18.000N220X-18.000N222X-15.000Y-15.000F600N224Y15.000F800N226X15.000N228Y-15.000N230X-15.000N232X-12.000Y-12.000F600N234Y12.000F800N236X12.000N238Y-12.000N240X-12.000N242X-9.000Y-9.000F600N244Y9.000F800N246X9.000N248Y-9.000N250X-9.000N252X-6.000Y-6.000F600N254Y
17、6.000F800N256X6.000N258Y-6.000N260X-6.000N262X-3.000Y-3.000F600N264Y3.000F800N266X3.000N268Y-3.000N270X-3.000N272X-1.000Y-1.000F600N274Y1.000F800N276X1.000N278Y-1.000N280X-1.000N282Z35.744F100N284G00Z40.000N286X-75.000Y-82.500N288Z33.744N290G01Z23.744F100N292Y-75.000F600N294Y75.000F800N296X75.000N29
18、8Y-75.000N300X-75.000N302X-74.966Y-74.966F600N304X-75.000Y-74.932F800N306Y74.913N308X-74.913Y75.000N310X74.932N312X75.000Y74.932N314Y-74.920N316X74.920Y-75.000N318X-74.932N320X-74.966Y-74.966N322X-72.844Y-72.845F600N324G02X-75.000Y-70.623I72.820J72.803F800N326G01Y70.604N328G02X-73.305Y72.363I74.881J
19、-70.489N330G02X-70.604Y75.000I73.328J-72.387N332G01X70.624N334G02X72.362Y73.325I-70.256J-74.642N336G01X72.377Y73.309N338X72.381Y73.306N340X72.399Y73.288Z23.743N342G02X75.000Y70.622I-72.586J-73.420N344G01Y-70.611N346G02X70.610Y-75.000I-74.920J70.547N348G01X-70.623N350G02X-72.361Y-73.325I69.841J74.216
20、N352G01X-72.367Y-73.320N354X-72.382Y-73.305N356G02X-72.844Y-72.845I81.270J82.209N358G01X-70.723Y-70.724F600N360G02X-75.000Y-66.170I70.705J70.690F800N362G01Y66.151N364G02X-71.170Y70.255I75.033J-66.183N366G02X-66.151Y75.000I71.151J-70.234N368G01X66.170N370G02X70.255Y71.189I-66.143J-74.992N372G01X70.27
21、0Y71.175N374X70.273Y71.171N376X70.290Y71.154N378G02X75.000Y66.168I-70.358J-71.170N380G01Y-66.159N382G02X66.157Y-75.000I-75.009J66.185N384G01X-66.170N386G02X-70.254Y-71.190I66.179J75.040N388G01X-70.260Y-71.184N390X-70.274Y-71.170N392G02X-70.723Y-70.724I66.328J67.178N394G01X-68.601Y-68.603F600N396G02X
22、-75.000Y-61.541I68.626J68.606F800N398G01Y61.522N400G02X-69.035Y68.147I75.004J-61.525N402G02X-61.522Y75.000I69.045J-68.157N404G01X61.541N406G02X68.148Y69.054I-61.549J-75.028N408G01X68.162Y69.040N410X68.165Y69.037N412X68.181Y69.021N414G02X75.000Y61.537I-68.261J-69.048N416G01Y-61.531N418G02X61.527Y-75.
23、000I-75.010J61.557N420G01X-61.540N422G02X-68.147Y-69.054I61.517J75.005N424G01X-68.153Y-69.049N426X-68.166Y-69.036Z23.742N428G02X-68.601Y-68.603I72.069J72.954N430G01X-66.480Y-66.482F600N432G02X-75.000Y-56.693I66.488J66.472F800N434G01Y56.674N436G02X-66.900Y66.040I74.997J-56.673N438G02X-56.674Y75.000I6
24、6.908J-66.047N440G01X56.693N442G02X66.041Y66.918I-56.687J-75.015N444G01X66.054Y66.905N446X66.057Y66.902N448X66.072Y66.887N450G02X75.000Y56.688I-66.128J-66.893N452G01Y-56.684N454G02X56.679Y-75.000I-75.009J56.709N456G01X-56.692N458G02X-66.040Y-66.919I56.680J75.016N460G01X-66.045Y-66.914N462X-66.058Y-6
25、6.901N464G02X-66.480Y-66.482I62.776J63.588N466G01X-64.358Y-64.361F600N468G02X-75.000Y-51.564I64.376J64.358F800N470G01Y51.545N472G02X-64.765Y63.932I75.014J-51.558N474G02X-51.545Y75.000I64.769J-63.935N476G01X51.564N478G02X63.934Y64.783I-51.555J-75.010N480G01X63.946Y64.771N482X63.949Y64.767N484X63.963Y
26、64.754N486G02X75.000Y51.558I-64.023J-64.764N488G01Y-51.557N490G02X51.550Y-75.000I-75.006J51.579N492G01X-51.563N494G02X-63.933Y-64.783I51.562J75.029N496G01X-63.938Y-64.778N498X-63.950Y-64.767N500G02X-64.358Y-64.361I74.931J75.801N502G01X-62.237Y-62.240F600N504G02X-75.000Y-46.061I62.244J62.228F800N506G
27、01Y46.042N508G02X-62.630Y61.825I75.007J-46.050N510G02X-46.042Y75.000I62.640J-61.835N512G01X46.062N514G02X61.827Y62.647I-46.059J-75.018N516G01X61.838Y62.636N518X61.841Y62.633N520X61.854Y62.620N522G02X75.000Y46.054I-61.908J-62.626N524G01Y-46.057N526G02X46.046Y-75.000I-75.008J46.081N528G01X-46.059N530G
28、02X-61.826Y-62.648I46.059J75.031N532G01X-61.831Y-62.643N534X-61.841Y-62.633N536G02X-62.237Y-62.240I55.047J55.779N538G01X-60.115Y-60.119F600N540G02X-75.000Y-40.030I60.127J60.111F800N542G01Y40.011N544G02X-60.495Y59.717I75.012J-40.022N546G02X-40.011Y75.000I60.505J-59.728N548G01X40.031N550G02X59.720Y60.
29、511I-40.021J-75.009N552G01X59.730Y60.502Z23.744N554X59.733Y60.498Z23.744N556X59.745Y60.487N558G02X75.000Y40.021I-59.807J-60.498N560G01Y-40.029N562G02X40.014Y-75.000I-75.006J40.052N564G01X-40.027N566G02X-59.719Y-60.512I40.017J75.018N568G01X-59.724Y-60.508N570X-59.733Y-60.498N572G02X-60.115Y-60.119I59
30、.913J60.674N574G01X-57.993Y-57.998F600N576G02X-75.000Y-33.184I58.002J57.988F800N578G01Y33.165N580G02X-58.360Y57.610I75.010J-33.175N582G02X-33.165Y75.000I58.369J-57.617N584G01X33.184N586G02X57.613Y58.376I-33.175J-75.009N588G01X57.622Y58.367N590X57.625Y58.364N592X57.635Y58.353N594G02X75.000Y33.172I-57
31、.696J-58.363N596G01Y-33.188N598G02X33.167Y-75.000I-75.006J33.210N600G01X-33.180N602G02X-57.612Y-58.377I33.174J75.023N604G01X-57.617Y-58.372N606X-57.625Y-58.364N608G02X-57.993Y-57.998I55.796J56.500N610G01X-55.872Y-55.877F600N612G02X-75.000Y-24.858I55.883J55.868F800N614G01Y24.839N616G02X-56.225Y55.502
32、I75.009J-24.848N618G02X-24.839Y75.000I56.234J-55.510N620G01X24.858N622G02X55.506Y56.240I-24.849J-75.010N624G01X55.514Y56.232N626X55.517Y56.229N628X55.526Y56.220N630G02X75.000Y24.842I-55.586J-56.230N632G01Y-24.862N634G02X73.221Y-29.701I-75.025J24.840N636G01X73.216Y-29.713N638X73.214Y-29.717N640X73.21
33、0Y-29.728N642G02X24.839Y-75.000I-73.216J29.751N644G01X-24.852N646G02X-55.505Y-56.241I24.846J75.023N648G01X-55.510Y-56.237N650X-55.517Y-56.229N652G02X-55.872Y-55.877I56.487J57.178N654G01X-53.750Y-53.756F600N656G02X-75.000Y-12.352I53.759J53.746F800N658G01Y12.333N660G02X-54.090Y53.395I75.009J-12.342N66
34、2G02X-12.333Y75.000I54.100J-53.404N664G01X12.353N666G02X53.399Y54.105I-12.343J-75.010N668G01X53.406Y54.098N670X53.409Y54.094N672X53.417Y54.087N674G02X75.000Y12.328I-53.477J-54.096N676G01Y-12.348N678G02X70.440Y-28.575I-75.055J12.336N680G01X70.436Y-28.584N682X70.434Y-28.589N684X70.430Y-28.599N686G02X1
35、2.327Y-75.000I-70.437J28.622N688G01X-12.340N690G02X-53.398Y-54.105I12.334J75.023N692G01X-53.402Y-54.101N694X-53.409Y-54.095N696G02X-53.750Y-53.756I63.888J64.625N698G01X-51.629Y-51.635F600N700G02X-51.955Y51.287I51.638J51.625F800N702G02X51.292Y51.969I51.965J-51.296N704G01X51.298Y51.963N706X51.301Y51.9
36、60N708X51.308Y51.953N710G02X67.660Y-27.448I-51.369J-51.963N712G01X67.656Y-27.457N714X67.654Y-27.461N716X67.651Y-27.470N718G02X-51.291Y-51.970I-67.657J27.493N720G01X-51.295Y-51.966N722X-51.301Y-51.960N724G02X-51.629Y-51.635I44.199J44.799N726G01X-49.507Y-49.514F600N728G02X-49.820Y49.179I49.517J49.504F
37、800N730G02X49.185Y49.834I49.830J-49.189N732G01X49.190Y49.829N734X49.194Y49.825N736X49.199Y49.820N738G02X64.879Y-26.322I-49.260J-49.829N740G01X64.876Y-26.329N742X64.875Y-26.333N744X64.872Y-26.340N746G02X-49.184Y-49.834I-64.878J26.363N748G01X-49.188Y-49.831N750X-49.193Y-49.826N752G02X-49.507Y-49.514I5
38、4.245J54.889N754G01X-47.386Y-47.392F600N756G02X-47.685Y47.072I47.395J47.383F800N758G02X47.078Y47.698I47.695J-47.081N760G01X47.082Y47.694N762X47.086Y47.691N764X47.090Y47.686N766G02X62.099Y-25.195I-47.151J-47.696N768G01X62.097Y-25.201N770X62.095Y-25.205N772X62.092Y-25.211N774G02X-47.077Y-47.699I-62.09
39、9J25.234N776G01X-47.081Y-47.695N778X-47.085Y-47.691N780G02X-47.385Y-47.393I44.658J45.228N782G01X-45.264Y-45.271F600N784G02X-45.550Y44.964I45.274J45.262F800N786G02X44.971Y45.562I45.560J-44.974N788G01X44.974Y45.559N790X44.978Y45.556N792X44.981Y45.553N794G02X59.318Y-24.069I-45.042J-45.562N796G01X59.317
40、Y-24.073N798X59.315Y-24.077N800X59.313Y-24.082N802G02X-44.970Y-45.563I-59.320J24.104N804G01X-44.974Y-45.560N806X-44.977Y-45.557N808G02X-45.264Y-45.271I45.322J45.879N810G01X-43.142Y-43.150F600N812G02X-43.415Y42.857I43.152J43.141F800N814G02X42.864Y43.427I43.425J-42.866N816G01X42.866Y43.425N818X42.870Y
41、43.421N820X42.872Y43.419N822G02X56.538Y-22.942I-42.932J-43.429N824G01X56.537Y-22.945N826X56.535Y-22.949N828X56.534Y-22.952N830G02X-42.864Y-43.427I-56.540J22.975N832G01X-42.866Y-43.425N834X-42.868Y-43.423N836G02X-43.142Y-43.150I33.637J34.121N838G01X-41.021Y-41.029F600N840G02X-58.009Y-0.009I41.029J41.
42、019F800N842G02X-41.280Y40.749I58.019J-0.000N844G02X40.757Y41.291I41.290J-40.759N846G01X40.758Y41.290N848X40.762Y41.287N850X40.763Y41.286N852G02X53.757Y-21.815I-40.823J-41.296N854G01Y-21.817N856X53.755Y-21.822N858X53.755Y-21.823N860G02X-40.757Y-41.292I-53.761J21.846N862G01X-40.759Y-41.289N864X-40.760
43、Y-41.288N866G02X-41.021Y-41.029I41.860J42.380N868G01X-38.899Y-38.908F600N870G02X-55.009Y-0.009I38.908J38.899F800N872G02X-39.145Y38.642I55.018J0.000N874G02X38.650Y39.156I39.155J-38.651N876G01X38.654Y39.152N878G02X50.977Y-20.689I-38.714J-39.162N880G01X50.975Y-20.694N882G02X-38.650Y-39.156I-50.982J20.7
44、16N884G01X-38.652Y-39.154N886G02X-38.899Y-38.908I37.680J38.142N888G01Z33.744F100N890G00Z40.000N892X-75.000Y-82.500N894Z31.744N896G01Z21.744F100N898Y-75.000F600N900Y75.000F800N902X75.000N904Y-75.000N906X-75.000N908X-73.167Y-73.167F600N910X-73.269Y-73.064F800N912G02X-75.000Y-71.287I73.358J73.150N914G01Y71.284N916G02X-73.065Y73.266I75
