从绿键侠到机械工程师之路
数控编程公开课堂
一件中等复杂度产品加工实例编程详解
首先回顾一下前面的三节课程内容.
第一节讲述数控编程方面的概念,
第二节使用一个简单的编程实例来讲述第一节课内的概念该如何使用.
第三节课总结罗列了fanuc系统所有的车加工G指令.
当前是第四节也是数控编程基础最后一节,本节我们构造了一件中等复杂度的产品进行编程详解,并且应用了一次G52的使用.如果你能够理解这四节课内容,数控加工编程已经可以入门了.后续还会有推出车加工相关的案例进行分享.
首先看一下我们的产品成品图和毛坯图.
分析毛坯和产品加工图面要求.我们可以第一工序先加工工件的左侧,锥度空和内孔的一部分.定位毛坯的左侧,夹持深度90即可.工件夹持找正.程序对刀零点在工件右侧端面.如未特别指定,所有端面内孔刀尖半径R0.8.
第一工序加工尺寸如下所示
第一工序程序如下
O0001(XCP-CC1);
(端面外径)
N1 G21 G99 G97 G40 M3 S350;
T0101;
G0 X300. Z200.0
G0 X260. Z5.0 M8;
G94 Z1.0 X85.0 F0.25;
Z0.0;
G0 X255.0 Z2.0;
G71 U2.0 R2.0;
G71 P11 Q12 F0.25;
N11 G1 X241.0;
Z0.0;
X245.0 W-2.5;
Z-202.0;
X253.0;
X254.0 W-1.5;
N12 Z-207.0;
G0 X300.0 Z200.0
M1;
(内孔粗车)
N2 G99 M3 S350;
T0202 (D32 L155); 这里备注刀杆直径32 安装长度155
G0 X300. Z200.0
G0 X90. Z2.0 M8;
G71 U2.0 R2.0;
G71 P21 Q22 U-0.5 F0.25; 注意看这里我们分配N号的策略,第二程序段N2循环体内的程序段以2开头,这样便于理解和管理.
N21 G1 X120.0;
G1 Z0.0;
G1 X109.8.0 R5.8; 外R+刀尖半径
G1 X100.0 A5.71; 根据锥度比计算出来角度加工
N22 G1 Z-152.0;
G0 X300.0 Z200.0
M1;
(内孔精车)
N3 G99 M3 S350;
T0202 (D32 L155); 这里备注刀杆直径32 安装长度155
G0 X300. Z200.0
G0 X90. Z2.0 M8;
G70 P21 Q22 F0.2;
G0 Z5. M5 M9;
G0 X300.0 Z200.0;
M30;第二加工工序
第二道工序加工右侧端面,精车内孔,前端外径部分.并控制总高度.注意夹持深度,定位稳定性.精修卡爪同心度在0.02.程序对刀零点在工件右侧端面.
第二工序加工尺寸如下图所示.
第二工序程序如下:
O0002(XCP-2);
(端面外径)
N1 G21 G99 G97 G40 M3 S300;
T0101;
G0 X300. Z200.0
G0 X260. Z5.0 M8;
G94 Z1.0 X85.0 F0.25;
Z0.0;
G0 X255.0 Z2.0;
G90 X253.0 Z-98.0 F0.3;
X251.0;
G0 Z2.0;
X245.0;
G1 Z0.0 F0.3;
X250.0 A-45.0 F0.2;
Z-98.0;
G0 U5.0;
Z5.0;
G0 X300.0 Z200.0;
M1;
(外径槽右侧)
N2 G99 M3 S300;
T0202 (反刀SVJCL2525M16);
G0 X300.0 Z50.0;
Z-7.5;
X251.0
G73 U5.0 R10.0;
G73 P21 Q22 U0.2 F0.25;
N21 G1 X250.;
Z-10. A45.0;
G02 X240. R3.2 W-3.2;
G1 Z-50.;
N22 X251. Z-55.0;
G0 Z-7.5;
X251.0;
G70 P21 Q22 F0.2;
G0 X300.;
Z200.0;
M1;
(外径槽左侧)
N3 G99 M3 S300;
T101;
G0 X300. Z50.0;
Z-61.5;
X251.0;
G73 U5.0 R10.0;
G73 P31 Q32 U0.2 F0.25;
N31 G1 X250.;
Z-60. A-45.0;
G03 X240. R3.2 W3.2;
N32 G1 Z-45.;
G0 Z-61.5;
X251.0;
G70 P31 Q32 F0.2;
G0 X300.;
Z200.0;
M1;
(内孔粗车)
N4 G99 M3 S300;
T0303 (D32 L155); 这里备注内孔粗车刀杆直径32 安装长度155
G0 X300. Z200.0
G0 X90. Z2.0 M8;
G71 U2.0 R2.0;
G71 P41 Q42 U-0.5 F0.25;
N41 G1 X185.0;
Z0.0;
X179.7 A30.0;
Z-50.0;
X136.0;
X100.0 A30.0;
N42 Z-152.0;
G0 Z2.0;
G0 X300.0 Z200.0;
M1;
(内孔半精车)
N5 G99 M3 S350;
T0303 (D32 L155);
G0 X300. Z200.0;
G0 X90. Z2.0 M8;
G70 P41 Q42 F0.2;
G0 Z5. M5 M9;
G0 X300.0 Z200.0;
M1;
(内孔精车)
N6 G99 M3 S400; 更换内孔刀杆,二次精车内孔
T0404 (D32 L55); 刀杆直径32,安装长度55
G0 X300. Z200.0;
G0 X180.02 Z2.0 M8;
G1 Z-50.0 F0.2;
U-2.0;
G0 Z2.0;
G0 X300.0 Z200.0;
M1;
(内孔切槽)
N7 G99 M3 S200;
T0505 (D32 L55 W3) ; 备注内孔切槽刀杆直径,安装长度,刀片宽度3.0
G0 X175.0 Z50.0;
Z-48.0;
G1 X180.0 Z-50.0 F0.3;
G75 R0.2;
G75 X186.10 W2.0 P500 Q2500 F0.02;
G0 X179.0;
Z-47.0;
G1 X180.0 F0.25;
G1 U2. Z-48.0 F0.1; 内孔槽部倒角
X186.00;
W-0.8;
G0 X170.0 M9;
Z50.0;
X300. Z200.0;
M1;
M30;第三道加工工序
第三道工序为粗车外径,精修卡爪反夹内孔,尾座顶针辅助,安装刀杆时,注意和尾座顶针之间的间距.程序对刀Z零点在工件左侧端面.对刀小技巧:程序零点设置工件的左侧,即定位端面,对刀Z零点时可以对工件右侧端面Z300.0,由于粗车量较大,粗车过程分多次完成,以便中途更换刀具.相关加工如图所示.
第三工序程序如下:
O0003(XCP-3);
N1 G21 G99 G97 G40 M3 S300;
T0101;
G0 X300. Z302.0; 使用了尾座顶针,注意换刀位置,
G0 X255. M8;
G71 U2.0 R2.0;
G71 P11 Q12 F0.25;
N11 G1 X191.0
Z81.0
X246.0
N12 X251.0 W-2.5;
G0 X300.0 Z302.0 M9;
M1;
N2 G99 M3 S300;
T0101;
G0 X300. Z302.0;
G0 X191.0 M8;
G71 U2.0 R2.0;
G71 P21 Q22 F0.25;
N21 G1 X144.0
X151.0 A-45.0
Z151.0
X190.0
N22 X192.0 W-1.;
G0 X300.0 Z302.0 M9;
M5;
M1;
M30;第四道加工工序
第四工序精加工外径,高度,螺纹,空刀槽.程序编程Z零点在工件出左侧定位端面,对刀小技巧,Z轴可在工件右侧对刀工件总长度Z300.0.
相关图面如下所示.
第四工序加工程序如下:
O0004(XCP-4);
(半精加工)
N1 G21 G99 G97 G40 M3 S300;
T0101;
G0 X350. Z302.0; 使用了尾座顶针,注意换刀位置,
G0 X252.0 Z80.10 M8;
G1 X191.0 F0.25;
W2.0;
G0 U3.0
Z150.2;
G1 X151. F0.25;
W2.0
G0 U2.0;
Z302.0
X141.50
G1 Z300.0 F0.25;
X149.0 A-45.0;
Z260.0;
X149.30;
Z200.0;
X150.6;
Z150.15;
X190.6 C4.0;
Z80.05;
X246.50;
X251.0 A-45.0;
G0 X350.0;
Z302.0;
M1;
(精加工外径高度)
N2 G99 M3 S350;
T0202;
G0 X350. Z302.0 M8;
X150.0;
G1 X141.0 Z300.0 F0.5;
X148.85 A-45.0 F0.2;
Z260.0;
X149.0;
Z200.0;
X150.3;
Z150.1;
X190.3 C4.0;
Z80.0;
X246.0;
X251.0 A-45.0;
G0 X350.0;
Z302.0;
M1;
(5槽宽)
N3 G99 M3 S300;
T303 (w3.0);
G0 X350. Z300.0
Z81.0;
X191.0;
G1 Z80.0 X190.3 F0.1;
G75 R0.3;
G75 X183.9 W2.0 P500 Q2500 F0.05;
G0 X191.0;
Z83.;
G1 X190.3 F0.3;
G1 Z82.0U-2.0 F0.1;
G1 X184.0;
W-0.5;
G0 X191.0;
W2.0;
G0 X350.0;
Z302.0;
M1;
(R3空刀槽 本段程序展示性的使用了G52)
N4 G99 M3 S300;
T404 (刀杆MVQNR2525M16);
G0 X350. Z300.0
G52 Z150.0; 使用G52 设定局部坐标系 Z150.0位置设为Z0.0
G0 Z2.50;
X151.0;
G1 X150.3F0.3;
G1 X148.3F0.1;
G02 Z-1.0 U4. R2. F0.1;
G0 Z3.;
G1 X148.0F0.1;
G02 Z-1.2 U5. R2.5 F0.1;
G1 Z1.0;
G0 Z3.0;
X300.0;
G52 X0. Z0.; 取消G52局部坐标系,返回原坐标系 X300.0 Z153.0
G0 X350.0 Z300.0;
M1;
(M149X2螺纹)
N5 G99 M3 S200;
T505 (16ER2.0);
G0 X350. Z302. M8;
G0 X152.0;
G92 X148.0 Z260. F2.0;
x147.5;
x147.0;
X146.5;
X146.0;
X145.5;
X145.3;
G0 X350.0 M9;
Z302.0 M5;
M1;
M30;本工件是构想出的,程序不一定完全适应,如有错误欢迎提出共同讨论学习.
下一节开始共同学习宏程序的编程.