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位置:學(xué)校資訊 > WAM336數(shù)控磨床的技術(shù)改造與工藝編程

WAM336數(shù)控磨床的技術(shù)改造與工藝編程

日期:2008-06-06 08:30:17     瀏覽:210    來源:東莞模具培訓(xùn)網(wǎng)

1 引言


隨著對數(shù)控刀具產(chǎn)品質(zhì)量和經(jīng)濟(jì)效益要求的不斷提高,我廠原有用于加工可轉(zhuǎn)位硬質(zhì)合金刀片的WAM336數(shù)控周邊磨床因電器系統(tǒng)老化、加工工藝落后,已無法滿足對刀具產(chǎn)品尺寸一致性和對稱度公差嚴(yán)格的加工要求。為此,我們對該機(jī)床的電器系統(tǒng)進(jìn)行了技術(shù)改造,并根據(jù)改造后的機(jī)床特點(diǎn)和加工要求重新編制了磨削直線面和圓弧面的加工宏程序。

2 WAM336數(shù)控磨床電器系統(tǒng)技術(shù)改造


WAM336數(shù)控周邊磨床有一個固定主軸和三個進(jìn)給軸。對該數(shù)控磨床的電器系統(tǒng)進(jìn)行技術(shù)改造時(shí),首先必須考慮為三個進(jìn)給軸選擇合適的外部電機(jī)。由于外部電機(jī)與轉(zhuǎn)動軸相連接,整個外部空間的機(jī)械部分無法變更,因此所選電機(jī)的外型尺寸及功率必須與原電器系統(tǒng)相匹配。經(jīng)過考核篩選,西班牙發(fā)格公司FAGOR 8055M電器系統(tǒng)的外部電機(jī)符合要求,且電器系統(tǒng)價(jià)格適中,因此決定采用西班牙FAGOR 8055M電器系統(tǒng)替換原機(jī)床電器系統(tǒng)。FAGOR 8055M電器系統(tǒng)具有控制五坐標(biāo)聯(lián)動功能,由于WAM336數(shù)控磨床只有三個進(jìn)給軸,因此只需連接三個坐標(biāo)伺服板驅(qū)動機(jī)床實(shí)現(xiàn)三坐標(biāo)聯(lián)動,即可滿足WAM336數(shù)控磨床的加工工藝要求,磨削加工形狀復(fù)雜的硬質(zhì)合金刀片。加工實(shí)踐表明,更換后的機(jī)床電器系統(tǒng)操作簡便,加工精度及加工效率均明顯優(yōu)于原系統(tǒng)。

3 加工宏程序的編制


WAM336數(shù)控周邊磨床主要用于磨削各類具有直線面和圓弧面的硬質(zhì)合金可轉(zhuǎn)位銑刀片。根據(jù)改造后的機(jī)床特點(diǎn)和加工要求,我們編制了磨削直線面和圓弧面的工藝宏程序。

  1. 磨削直線面的宏程序
    磨削直線面的宏程序(9011)如下:
    %LINE,MX,
    (SUB 9011)
    (WRITE G54)
    (WRITE G90 G0 XP21)
    (WRITE G90 G0 CP0)
    (WRITE G90 G0 BP11)
    (P25 = P1 + 1)
    (WRITE G90 G0 XP25)
    (P15 = P1 + ORGX54*(1-1 / COS(P11)))
    (WRITE G90 G1 XP15 FP20)
    (WRITE G4 KP23)
    (WRITE G90 G0 XP21)
    (WRITE G91 G0 CP2)
    (WIRTE G90 G0 BP12)
    (P24 = P3 + 1)
    (WRITE G90 G0 XP24)
    (P16 = P3 + ORGX54*(1-1 / COS(P12)))
    (WRITE G90 G1 XP16 FP20)
    (WRITE G4 KP23)
    (WRITE G90 G0XP21)
    (WRITE G91 G0 CP4)
    (WRITE G90 G0 BP13)
    (P22 = P5 + 1)
    (WRITE G90 G0 XP22)
    (P17 = P5 + ORGX*(1-1 / COS(P13)))
    (WRITE G90 G1 XP5 FP20)
    (WRITE G4 KP23)
    (WRITE G90 G0 XP21)
    (WRITE G91 G0 CP6)
    (WRITE G90 G0 BP14)
    (P19 = P7 + 1)
    (WRITE G90 G0 XP19)
    (P17 = P7 + ORGX54*91-1 / COS(P14)))
    (WRITE G90 G1 XP17 FP20)
    (WRITE G4 KP23)
    (P0 = 0,P1 = 0,P2 = 0,P3 = 0,P4 = 0,P5 = 0,P6 = 0,P7 =0,P8 = 0,P9 = 0,P10 = 0,P11 = 0,P12 = 0,P13 = 0,P14 =0,P15 = 0,P16 = 0,P17 = 0,P18 = 0,P19 = 0,P20 = 0,P21= 0,P22 = 0,P23 = 0,P24 = 0,P25 = 0)
    (RET)
    呼叫一次SUB9011 宏程序可完成磨削四個直線面的加工程序編制。在實(shí)際應(yīng)用中,可根據(jù)圖紙和工藝要求,通過在演算子程序中連續(xù)呼叫SUB9011宏程序來完成磨削任意直線面的加工編程。為此,首先需要建立一個演算子程序(即呼叫子程序),然后在該程序中對參數(shù)進(jìn)行賦值,即可完成加工程序的編制。需要賦值的參變量包括:初始上料角度P0,磨床*邊半徑尺寸P1,磨削第二邊外夾角P2,磨削第二邊半徑尺寸P3,磨削第三邊夾角P4,磨削第三邊半徑尺寸P5,磨削第四邊外夾角P6,磨削第四邊半徑尺寸P7,*邊到第四邊的后角P11~P14,磨削速度P20,外接圓半徑P21,空磨時(shí)間P23。

  2. 磨削圓弧面的宏程序
    磨削圓弧面的宏程序(9010)如下:
    %CYCLE,MX,
    (SUB 9010)
    (WRITE M7)
    (WRITE G5)
    (WRITE G90 G1)
    (P24 = P0)
    (P25 = SQRT (P1*P1 + P2*P2))
    (P23 = P7)
    (P19 = P23)
    N10(P20 = P3 - P25)
    (IF P20 GT 0 G0T0 N30)
    (P23 = - P7 - ACOS(P1 / P25))
    (P19 = P23)
    N20(P22 = P25*COS(P23)+ P3)
    (WRITE F10)
    (WRITE XP22)
    (WRITE F100)
    (WRITE CP24)
    N25(P22 = P25*COS(P23)+ P3)
    (WRITE XP22 CP24)
    (P23 = P23 + P12)
    (P24 = P24 + P12)
    (IF P23 LE(P19 + P4)GOTO N25)
    (RET)
    N30(P23 = P7)
    (P19 = P23)
    (P22 = - P25*COS(P23 + P3)
    (WRITE F10)
    (WRITE XP22)
    (P18 = P24 + 90 + P7)
    (WRITE F100)
    (WRITE CP18)
    N35(P22 = - P25*COS(P23)+ P3)
    (WRITE XP22 CP18)
    (P23 = P23 + P12)
    (P18 = P18 = P12)
    (IF P23 LE(P19 + P4)GOTO N35)
    (P0 = 0,P1 = 0,P2 = 0,P3 = 0,P4 = 0,P5 = 0,P6 = 0,P7 =0,P8 = 0,P9 = 0,P10 = 0,P11 = 0,P12 = 0,P13 = 0,P14 =0,P15 = 0,P16 = 0,P17 = 0,P18 = 0,P19 = 0,P20 = 0,P21= 0,P22 = 0,P23 = 0,P24 = 0,P25 = 0)
    (RET)
    通過呼叫SUB9010 宏程序,可實(shí)現(xiàn)磨削任意形狀圓弧面的加工程序編制。使用時(shí),通過對參數(shù)賦值即可完成加工程序編制。需賦值的參變量包括:初始磨圓角P0,X 中心坐標(biāo)P1,Y 中心坐標(biāo)P2,圓弧半徑P3,圓弧轉(zhuǎn)角P4,切線角度P7,圓弧分度P12,圓弧速度P20,外接圓半徑P21。






  3. 加工實(shí)例
    現(xiàn)以磨削加工如圖所示刀片為例,說明如何調(diào)用宏程序SUB9010、SUB9011 和建立演算子程序。
    該刀片需要加工的尺寸包括二個直線面(14mm×7mm)和四個圓弧面(4-R2mm)。根據(jù)工藝要求,首先磨削直線面,再依次磨削圓弧面。刀片初始上料角度為0°。編制演算子程序如下:
    (OPEN P8000,D)
    (WRITE(SUB 8000))
    (PCAL9011,P0 = 0,P1 = 3. 50,P2 = 90°,P3 = 7. 00,P4 =90,P5 = 3. 50,P6 = 90°,P7 = 7. 00,P20 = 8,P21 = 12,P23= 100°)
    (PCALL9010,P0 = 270°,P1 = 5. 00,P2 = 1. 5,P3 = 2,P4 =90°,P7 = 0,P12 = 0.1,P20 = 100,P21 = 12°)
    (PCALL9010,P0 = 360,P1 = 1. 5,P2 = 5,P3 = 2,P4 = 90,P7 = 0,P12 = 0.1,P20 = 100,P21 = 12°)
    (PCALL 9010,P0 = 450°,P1 = 5.00,P2 = 1. 5,P3 = 2,P4 =90°,P7 = 0,P12 = 0.1,P20 = 100,P21 = 12°)
    (PCALL 9010,P0 = 540°,P1 = 1. 5,P2 = 5,P3 = 2,P4 =90°,P7 = 0,P12 = 0.1,P20 = 100,P21 = 12°)
    (WRITE(RET))
    M30
    將編制好的演算子程序在機(jī)床中運(yùn)行,生成一個新的磨削子程序P8000。在實(shí)際加工中,將P8000連接到主程序中即可實(shí)現(xiàn)刀片的磨削。