驱动轴机械加工工艺和铣键槽专用夹具设计
驱动轴机械加工工艺和铣键槽专用夹具设计,驱动,机械,加工,工艺,键槽,专用,夹具,设计
无锡职业技术学院毕业设计开题报告(2011届)题 目WIA8.310.0001驱动轴工艺及铣键槽夹具设计指导教师张铮院 系机械班 级数控10871学 号1060087106姓 名金贤二一一年一月八日一、选题的意义此次毕业设计是对我们三年学习的一次综合检验,也是检验我们是不是一个合格的毕业生的最好方式。在完成毕业设计的同时,也培养了我们正确使用技术资料,国家标准的有关手册,图册等工具书,设计计算,编写技术文件等方面的工作能力,也为我们以后的工作打下了坚实的基础,我们要认真对待这次综合能力运用的机会!二、研究的主要内容,拟解决的主要问题(阐述的主要观点)此次研究的主要内容是WIA8.310.0001驱动轴工艺及铣键槽夹具设计。轴类零件是机械加工中常见的机械零件。要求参考机械设计资料并根据所学的知识设计拟定出合理加工工艺方案并完成相应的工艺卡片及设计说明书。拟定解决的主要问题:驱动轴工艺及铣键槽夹具设计三、研究(工作)步骤、方法及措施(思路) 1. 参阅机械制造工艺学中的基本知识和理论,结合生产实习中的实践知识,独立地分析和解决工艺问题。2. 根据所学知识绘制零件图,设计出零件的工艺规程。3. 确定铣键槽的定位方式及夹具设计。4. 完成工艺卡片、主要工序的工序卡。5编写设计说明书一份。四、毕业论文(设计)提纲第一章 绪论第二章 驱动轴加工工艺过程第三章 驱动轴工序设计第四章 铣键槽夹具的设计第五章 回顾总结五、主要参考文献1艾兴、肖诗纲,切削用量简明手册+第3版机械工艺出版社。2. 陈文亮,机械加工工艺师手册机械工业出版社。 3薄宵,魔攻实用技术手册江苏科学技术出版社。4. 彭林中,机械切削工艺参数速查手册化学工业出版社。5. 倪森寿,机械制造工艺与装备化学工艺出版社。6. 殷国富 、徐雷 、胡晓兵、 数字化手册编委会,机床夹具设计手册软件版1.0机械工业出版社。7.赵汝嘉、数字化手册编委会编,机械加工工艺手册(软件版)1.0机械工业出版社。指导教师意见:签名:2010年 月 日系毕业设计(论文)工作指导小组意见:同 意 实 施 签名:年 月 日二级学院(直属系)毕业设计(论文)工作领导小组意见:同 意签名:年 月 日答辩人答辩人:金贤:金贤WIA8.310.0001驱动轴工驱动轴工艺及铣键槽夹具设计艺及铣键槽夹具设计WIA8.310.0001驱动轴驱动轴二维图二维图工艺路线工艺路线夹具设计夹具设计英语翻译英语翻译课程设计课程设计说明书说明书课程设计课程设计工艺路线工艺路线工艺过程工艺过程设计设计工序设计工序设计夹具设计夹具设计铣键槽夹铣键槽夹具设计具设计铣键槽夹具铣键槽夹具定位方案分析定位误差分析计算夹紧力及加紧元件确定夹具总装图工序设计工序设计车削加工钻削加工螺纹加工键槽铣削研顶尖孔外圆磨削工艺过程工艺过程毛坯的设计工艺过程设计机床、刀、夹、量具的选择谢谢观赏谢谢观赏答辩人:金贤答辩人:金贤B64114EN/01PROGRAMMING8. COORDINATE VALUE AND DIMENSION298.3DECIMAL POINT PROGRAMMINGExplanationsExamplesNumerical values can be entered with a decimal point. A decimal point can be used when entering a distance, time, or speed. Decimal points can be specified with the following addresses:X, Y, Z, U, V, W, A, B, C, I, J, K, R, and F.There are two types of decimal point notation: calculatortype notation and standard notation.When calculatortype decimal notation is used, a value without decimal point is considered to be specified in millimeters. When standard decimal notation is used, such a value is considered to be specified in least input increments. Select either calculatortype or standard decimal notation by using the DPI bit (bit 0 of parameter 3401).Values can be specified both with and without decimal point in a single program.Program commandPocket calculator type decimal point programmingStandard type decimal point programmingX1000Command value with- out decimal point1000mmUnit : mm1mmUnit : Least input increment(0.001 mm)X1000.0Command value with decimal point1000mmUnit : mm1000mmUnit : mmWARNINGIn a single block, specify a G code before entering a value. The position of decimal point may depend on the command.Examples:G20;Input in inchesX1.0 G04;X1.0 is considered to be a distance and processed as X10000. This command is equivalent to G04 X10000. The tool dwells for 10 seconds.G04 X1.0;Equivalent to G04 X1000. The tool dwells for one second.NOTE1 Fractions less than the least input increment are truncated.Examples:X1.23456;Truncated to X1.234 when the least input increment is 0.001 mm.Processed as X1.2345 when the least input increment is 0.0001 inch.2 When more than eight digits are specified, an alarm occurs. If a value is entered with a decimal point, the number of digits is also checked after the value is converted to an integer according to the least input increment.Examples:X1.23456789; P/S alarm 003 occurs because more than eight digits are specified.X123456.7;If the least input increment is 0.001 mm, the value is converted to integer123456700. Because the integer has more than eight digits, an P/S alarm 003 occurs.B-64114CM/01编程8. 坐标值和尺寸8.3小数点编程数值可以用小数点输入。距离、时间或速度的输入可使用小数点。下列地 址可用小数点:X,Y,Z,U,V,W,A,B,C,I,J,K,R和F。说明有两种类型的小数点表示法:计算器型表示法和标准表示法。当用计算 器型表示法时,不带小数点的值的单位认为是mm。当用标准表示法时,这样的值以最小输入增量为单位指定。小数点表示法的选择由3401号参数 的第0位(DPI)确定。带小数点和不带小数点的值可在一个程序中指定。例程序指令袖珍计算器型 小数点编程标准型小 数点编程X1000不带小数 点指令值1000mm单位:mm1mm单位:最小输入增量单位(0.001mm)X1000.0 带小数 点指令值1000mm单位:mm1000mm单位:mm警告在一个单独的程序段中,输入数值之前指定G20/G21代码。小数点的位置取决于指令。 例如:G20;英输入X1.0 G04;X1.0被当做距离并且被处理为X10000.该指令等效于G04X10000.刀具暂停10秒G04X1.0;等效于G04 X1000.刀具暂停1秒注1. 小于最小输入增量单位的小数被舍去 例如: X1.23456;当最小输入增量单位是0.001mm时,处理为X1.234,当最小输入增量单位是0.0001inch时,处理成X1.23452. 当指定多于8位数时,产生报警。如果输入带小数点的值,将该值按照最小输入增量单位转换为整数后 也要检查其位数。例如: X1.23456789;产生003号P/S报警,因为指定了多于8位的数。 X123456.7;如果最小输入增量单位是0.001mm,该值转换为整数是123456700。因为整数超过8位,产生003号P/S报警8. COORDINATE VALUE AND DIMENSIONPROGRAMMINGB64114EN/018.4DIAMETER AND RADIUS PROGRAMMINGSince the work cross section is usually circular in CNC lathe control programming, its dimensions can be specified in two ways :Diameter and RadiusWhen the diameter is specified, it is called diameter programming and when the radius is specified, it is called radius programming.ABR2R1D1D2X axisD1, D2 : Diameter programmingR1, R2 : Radius programmingZ axisExplanationsNotes on diameter programming/radius programming for each commandRadius programming or diameter programming can be specified by parameter DIA (No.1006#3). When using diameter programming, note the conditions listed in the table 8.4.Table 8.4 Notes on specifying diameter valueItemNotesX axis commandSpecified with a diameter valueIncremental commandSpecified with a diameter valueIn the above figure, specifies D2 minus D1 for tool path B to A.Coordinate system setting (G50)Specifies a coordinate value with a diame- ter valueComponent of tool offset valueParameter (No.5004#1) determines either diameter or radius valueParameters in canned cycle, such as cutting depth along X axis. (R)Specifies a radius valueRadius designation in circular in- terpolation (R, I, K, and etc.)Specifies a radius valueFeedrate along axisSpecifies change of radius/rev. or change of radius/min.Display of axis positionDisplayed as diameter valueB-64114CM/01编程8. 坐标值和尺寸8.4 直径编程和 半径编程因为在CNC车床控制程序中工件横截面通常是圆,所以其尺寸可用两种方 法指令:直径和半径 当用直径指令时,叫做直径编程;当用半径指令时,叫做半径编程。说明 关于直径编程/半径编程半径编程或直径编程由1006号参数的第3位(DIA)设定。使用直径编程 注意事项时,注意表8.4中所列的条件。表8.4 关于指令直径值的注意事项项目注释X轴指令用直径值指定增量指令用直径值指定。在上图中,对刀具轨迹B到A用D2减D1指定坐标系设定(G50)用直径值指定坐标值刀偏值分量由5004号参数的第1位决定是直径值或半径 值固定循环参数,如沿X轴切深(R)指定半径值圆弧插补中的半径(R,1,K等)指定半径值沿轴进给速度指定半径的变化/转或半径的变化/分轴位置显示按直径值显示B64114EN/01PROGRAMMING9. SPINDLE SPEED FUNCTION9SPINDLE SPEED FUNCTIONThe spindle speed can be controlled by specifying a value following address S.In addition, the spindle can be rotated by a specified angle. This chapter contains the following topics.9.1 SPECIFYING THE SPINDLE SPEED WITH A CODE9.2 SPECIFYING THE SPINDLE SPEED VALUE DIRECTLY (S5DIGIT COMMAND)9.3 CONSTANT SURFACE SPEED CONTROL (G96, G97)9.4 SPINDLE SPEED FLUCTUATION DETECTION FUNCTION (G25, G26)9.5 SPINDLE POSITIONING FUNCTIONB-64114CM/01编程9. 主轴速度功能9 主轴速度功能用地址 S 及其后面的数值指令主轴速度。 此外,主轴还可以按指定角度回转。 本章包括下列内容:9.1 用代码指定主轴速度9.2 直接指定主轴速度值(S5 位数指令)9.3 恒表面切削速度控制(G96、G97)9.4 主轴速度波动检测功能(G25,G26)9.5 主轴定位功能9. SPINDLE SPEED FUNCTIONPROGRAMMINGB64114EN/019.1SPECIFYING THE SPINDLE SPEED WITH A CODE9.2SPECIFYING THE SPINDLE SPEED VALUE DIRECTLY (S5DIGIT COMMAND)Specifying a value following address S sends code and strobe signals to the machine. On the machine, the signals are used to control the spindle speed. A block can contain only one S code. Refer to the appropriate manual provided by the machine tool builder for details such as the number of digits in an S code or the execution order when a move command and an S code command are in the same block.The spindle speed can be specified directly by address S followed by a fivedigit value (min1). The unit for specifying the spindle speed may vary depending on the machine tool builder. Refer to the appropriate manual provided by the machine tool builder for details.B-64114CM/01编程9. 主轴速度功能9.1 用代码指定主轴速度9.2直接指定主轴速度值(S5 位数指令)主轴速度代码为地址 S 及其后面的数值。代码信号和选通信号送到机床。 在机床上,该信号用于控制主轴速度。一个程序段只能包含一个 S 代码。 至于更详细的情况,如 S 代码后跟几位数,或当运动指令和 S 代码指令在 同一个程序段中执行次序等,请见机床制造商的说明书。S 后可指令 5 位数(min-1)以直接指定主轴速度。主轴速度的指令单位取决 于机床的设定。详见机床制造商的说明书。B64114EN/01PROGRAMMING9. SPINDLE SPEED FUNCTION9.3CONSTANT SURFACE SPEED CONTROL(G96, G97)FormatConstant surface speed control commandConstant surface speed control cancel commandClamp of maximum spindle speedSpecify the surface speed (relative speed between the tool and workpiece) following S. The spindle is rotated so that the surface speed is constant regardless of the position of the tool.G96 S;Surface speed (m/min or feet/min)Note : This surface speed unit may change according to machine tool builders specification.G97 S;Spindle speed (min1)Note : This surface speed unit may change according to machine tool builders specification.G50 S_ ;The maximum spindle speed (min1) follows S.B-64114CM/01编程9. 主轴速度功能在 S 后指定表面速度(刀具与工件间的相对速度)。主轴回转而表面速度保持恒定,与刀具位置无关。93恒表面切削速度控制(G96,G97)指令格式 恒表面速度切 削的控制指令G96 S ;表面速度(米/分或英尺/分)注:此表面速度的单位根据制造商的设定而变化 恒表面切削 速度控制的取消指令G97 S ;主轴速度(min-1) 最大主轴 速度箝制G50 S_; S 后跟最大主轴速度值(min-1)9. SPINDLE SPEED FUNCTIONPROGRAMMINGB64114EN/01ExplanationsConstant surface speed control command (G96)G96 (constant surface speed control command) is a modal G code. After a G96 command is specified, the program enters the constant surface speed control mode (G96 mode) and specified S values are assumed as a surface speed. A G96 command must specify the axis along which constant surface speed control is applied. A G97 command cancels the G96 mode.When constant surface speed control is applied, a spindle speed higher than the value specified in G50S_; (maximum spindle speed) is clamped at the maximum spindle speed. When the power is turned on, the maximum spindle speed is not yet set and the speed is not clamped.S (surface speed) commands in the G96 mode are assumed as S= 0 (the surface speed is 0) until M03 (rotating the spindle in the positive direction) or M04 (rotating the spindle in the negative direction) appears in the program.Fig. 9.3 (a) Relation between workpiece radius, and surface speedSpindle speed (min1)The spindle speed (min1) almost coincides with the surface speed (m/min) at approx. 160 mm (radius).spindle speedSetting the workpiece coordinate system for constant surface speed controlTo execute the constant surface speed control, it is necessary to set the work coordinate system , Z axis, (axis to which the constant surface speed control applies) becomes zero.X Z0Fig. 9.3 (b) Example of the workpiece coordinate system for constant surface speed controlB-64114CM/01编程9. 主轴速度功能说明 恒表面切削速度控制指 令(G96)G96(恒表面切削速度控制指令)是模态 G 代码。在指定 G96 指令后,程序 进入恒表面速度控制方式(G96 方式)且以指定 S 值作为表面速度。G96 指 令必须指定恒表面切削速度控制应用那个轴。G97 指令取消 G96 方式。在 用恒表面切削速度控制时,主轴速度若高于 G50S_;(最大主轴速度)中规 定的值,就被箝在最大主轴速度。若通电时尚未指定最大主轴速度,则主 轴速度不被箝制。在 G96 程序段的 S(表面速度)指令被当作 S=0(表面速度是 0),直到程序中出现 M03(主轴正转)或 M04(主轴反转)。 图 9.3(a) 工件半径、主轴速度和表面速度之间的关系 为恒表面切削速度控制设定 工件坐标系为执行恒表面切削速度控制,必须设定工件坐标系。使 X 轴(用恒表面切 削速度控制的轴)的中心坐标值为 0。图9.3(b) 恒表面切削速度控制的工件坐标系B64114EN/01PROGRAMMING9. SPINDLE SPEED FUNCTIONSurface speed specified in the G96 modeG96 modeG97 modeSpecify the surface speed in m/min(or feet/min)G97 commandStore the surface speed in m/min(or feet/min)SpecifiedCommand for the spindle speedThe specified spindle speed (min1) is usedNot specifiedThe surface speed (m/min or feet/min) is converted to the spindle speed (min1)Commands other than G96SpecifiedG96 commandThe specified surfacespeed is usedCommand for the surface speedNot specifiedThe stored surface speed (m/min or feet/min) is used. If no surface speed is stored, 0 is assumed.RestrictionsConstant surface speed control for threadingThe constant surface speed control is also effective during threading. Accordingly, it is recommended that the constant surface speed control be invalidated with G97 command before starting the scroll threading and taper threading, because the response problem in the servo system may not be considered when the spindle speed changes.B-64114CM/01编程9. 主轴速度功能 G96方式中指定 的表面速度限制 螺纹切削时的 恒表面切削速度恒表面切削速度控制在切削螺纹时也有效。因此,建议在开始涡形螺纹和 锥螺纹加工前用 G97 指令取消恒表面速度控制,因为可不考虑主轴速度变 化时伺服系统的响应问题。9. SPINDLE SPEED FUNCTIONPROGRAMMINGB64114EN/01Constant surface speed control for rapid traverse (G00)In a rapid traverse block specified by G00, the constant surface speed control is not made by calculating the surface speed to a transient change of the tool position, but is made by calculating the surface speed based on the position at the end point of the rapid traverse block, on the condition that cutting is not executed at rapid traverse.Radius valueProgrammed pathXTool path after offset1N16N16N15N15N14N142 4N113N11700675600500400375300200100f600Z300 400 500 600 700 800 900 1000 1100 1200 1300 1400 150014751050ExampleN8 G00 X1000.0Z1400.0 ; N9 T33;N11 X400.0Z1050.0;N12 G50S3000 ; (Designation of max. spindle speed)N13 G96S200 ; (Surface speed 200m/min)N14 G01 Z 700.0F1000 ; N15 X600.0Z 400.0;N16 Z ;The CNC calculates the spindle speed which is proportional to the specified surface speed at the position of the programmed coordinate value on the X axis. This is not the value calculated according to the X axis coordinate after offset when offset is valid. At the end point N15 in the example above, the speed at 600 dia. (Which is not the turret center but the tool nose) is 200 m/min. If X axis coordinate value is negative, the CNC uses the absolute value.B-64114CM/01编程9. 主轴速度功能 快速移动时的恒表面切削速度控制(G00)在指定的快速移动 G00 的程序段中,恒表面切削速度控制不是根据刀具 位置的瞬间变化计算表面速度,而是根据该段的终点计算的表面速度实现控制的。因为快速移动时不切削。例N8 G00 X1000.0Z1400.0;N9 T33;N11 X400.0Z1050.0;N12 G50S3000;(最大主轴速度给定) N13 G96S200;(表面速度 200 m/min) N14 G01 Z 700.0F1000;N15 X600.0Z 400.0;N16 Z.;CNC 计算主轴速度,它正比于 X 轴上程编坐标值指定的位置处的表面速 度。但这并不是根据偏置后的 X 坐标值计算出来的值。在上例 N15 的终 点即直径为 600 处(不是转塔中心而是刀尖)的速度是 200m/min。如果 X 轴 坐标值是负的,CNC 使用绝对值。B64114EN/01PROGRAMMING9. SPINDLE SPEED FUNCTION9.4SPINDLE SPEED FLUCTUATION DETECTION FUNCTION(G25, G26)FormatWith this function, an overheat alarm (No. 704) is raised when the spindle speed deviates from the specified speed due to machine conditions.This function is useful, for example, for preventing the seizure of the guide bushing.G26 enables spindle speed fluctuation detection. G25 disables spindle speed fluctuation detection.G26 Pp Qq Rr ;G25 ;Spindle fluctuation detection onSpindle fluctuation detection offp : Time (in ms) from the issue of a new spindle rotation command (S command) to the start of checking whether the actual spindle speed is so fast that an overheat can occur.When a specified speed is reached within the time period of P, spindle speed is checked at that time.q : Tolerance (%) of a specified spindle speedq = 1actual spindle speed 100 specified spindle speedIf a specified spindle speed lies within this range, it is regarded as having reached the specified value. Then, an actual spindle speed is checked.r : Spindle speed fluctuation (%) at which the actual spindle speed is so fast that an overheat can occurr= 1speed that can cause overheat 100specified spindle speedG26 enables the spindle speed fluctuation detection function, and G25 disables the spindle speed fluctuation detection.Even if G25 is specified, p, q, and r are not cleared. 主轴速度功能编程B-64114CM/019.4 主轴速度波 动检测功能(G25,G26)指令格式使用此功能,当主轴速度由于机床的原因而偏离指定的速度时,产生 704号过热报警。此功能是有用的,例如,防止轴瓦卡住。G26 使主轴速度波动检测功能生效G25 取消主轴速度波动检测功能G26PpQqRr;主轴波动检测功能生效G25;主轴波动检测取消p:从发出主轴回转指令(S 指令)到开始检查发生过热时的主轴速度(即从 发出 S 指令到检查开始)的时间,以 ms 为单位。如果在 p 期间内到达指定的速度,就在此刻检查主轴速度。q:指令的主轴速度的容差(%)q = 1 实际的主轴度 指定的主轴速度100如果速度处于此范围内,就认为已经到达了指定值。于是,进行实际 主轴速度的检查。r:主轴速度的波动范围(%),在此范围内将出现过热。r = 1 能引起过热的度 指定的主轴速度100G26 使主轴速度波动检测功能生效,G25 取消主轴速度波动检测功能。 即使指令了 G25,p、q 和 r 也不被清除。9. SPINDLE SPEED FUNCTIONPROGRAMMINGB64114EN/01ExplanationsThe fluctuation of the spindle speed is detected as follows:1. When an alarm is issued after a specified spindle speed is reachedSpindle speedrq d SpecifiedqdspeedrActual speedCheckNo checkCheckSpecification of another speedStart of checkAlarmTime2. When an alarm is issued before a specified spindle speed is reachedSpindle speedrq d Specifiedq d speedrpActual speedCheckNo checkCheckSpecification of another speedStart of checkAlarmTimeSpecified speed :(Speed specified by address S and fivedigit value) (spindle override)Actual speed : Speed detected with a position coderp : Time elapses since the specified speed changes until a check starts.q : (Percentage tolerance for a check to start) (specified speed)r : (Percentage fluctuation detected as an alarm condition) (specified speed)d : Fluctuation detected as an alarm (specified in parameter 4913)An alarm is issued when the difference between the specified speed and the actual speed exceeds both r and d.B-64114CM/01编程9. 主轴速度功能说明主轴速度的波动检测如下:1. 报警发生在指定的主轴速度到达以后指定的 速度指定另外的速度2. 报警发生在到达指定的主轴指定的速度0指定的速度:(由地址 S 和 5 位数指定的速度)(主轴倍率) 实际速度:用位置编码器检测的速度p:从指定的速度改变起到检查开始的时间 q:(开始检查的容差百分比)(指定的速度) r:(检测报警条件的波动百分比)(指定的速度) d:检测报警的波动(由 4913 号参数设定) 当指定的速度和实际速度之差超过 r 和 d 时发出报警。B64114EN/01PROGRAMMING9. SPINDLE SPEED FUNCTIONNOTE1 When an alarm is issued in automatic operation, a singleblock stop occurs. The spindle overheat alarm is indicated on the CRT screen, and the alarm signal “SPAL” is output (set to 1 for the presence of an alarm). This signal is clearedby resetting.2 Even when reset operation is performed after an alarm occurs, the alarm is issued again unless the cause of the alarm is corrected.3 No check is made during spindle stop state (*SSTP = 0).4 By setting the parameter (No. 4913), an allowable range of speed fluctuations can be set which suppresses theoccurrence of an alarm. However, an alarm is issued one second later if the actual speed is found to be 0 min1.5 The values of p, q, and r specified in the G26 block are setin the following parameters. If the specification of p, q, or r is omitted, the value set in the corresponding parameter is referenced.p : Parameter No. 4914 q : Parameter No. 4911 r : Parameter No. 49126 Bit 0 (FLR) of parameter No. 4900 can be used to specify0.1% as the units of the specified q and r values.B-64114CM/01编程9. 主轴速度功能注1在自动运行中发出报警时,出现单程序段停止。主轴过热报警显 示在 CRT 屏幕上,同时输出报警信号 SPAL(报警信号出现时置为1)。此信号由复位清除。2在报警出现后即使进行复位操作,报警仍再出现,除非正确地排 除了故障,报警才清除。3在主轴停止状态不进行检查(*SSTP = 0)。44913 号参数可以设定抑制报警的速度波动允许范围。但是如果实 际的主轴速度为 0min-1,则在 1 秒后会出现报警。5在 G26 程序段中可以指定 p,q 和 r 的值被设定在下列参数中。如果 p,q 或 r 被省略的话,可以参考参数中的值。P:参数 4914Q:参数 4911R:参数 4912 6参数 4900 的第 0 位(FLR)可以用来指定 0.1%为 p 和 q 值的单位。9. SPINDLE SPEED FUNCTIONPROGRAMMINGB64114EN/019.5SPINDLE POSITIONING FUNCTION9.5.1Spindle Orientation9.5.2Spindle PositioningPositioning with a semifixed angle specified by an M codeIn turning, the spindle connected to the spindle motor is rotated at a certain speed to rotate the workpiece mounted
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