模具設(shè)計與制造實驗報告

PAGE75/NUMPAGES75課程名稱：模具設(shè)計與制造院系：機械工程系學(xué)號：20107150姓名：龔華德指導(dǎo)教師：雷代明西南交通大學(xué)峨眉校區(qū)實驗一Mastercam9.0模具加工基礎(chǔ)一個產(chǎn)品試制成功后，要進行批量生產(chǎn)，首要程序是進行模具的設(shè)計與制造，而那個程序也是決定生產(chǎn)出來的產(chǎn)品是否符合客戶、設(shè)計人員初始設(shè)想的關(guān)鍵因素。在CAD／CAM技術(shù)尚未廣泛應(yīng)用之前，模具的設(shè)計與制造皆依靠于老師傅的手藝和經(jīng)驗，導(dǎo)致模具設(shè)計與制造的差異性大，同時帶來產(chǎn)品修改難、技術(shù)連續(xù)難等一系列問題。CAD／CAM技術(shù)在模具行業(yè)中的應(yīng)用，極大地提高了模具設(shè)計與制造的精度、效率和相容性。而Mastercam模具設(shè)計與制造一體化軟件在我國的模具行業(yè)中擁有龐大的用戶群。Mastercam模具設(shè)計加工的一般流程Mastercam是一套被模具行業(yè)廣泛采納的CAD／CAM系統(tǒng)，其強大的CAD部分足以應(yīng)付任何復(fù)雜的模具設(shè)計，而CAM部分則提供完整的二軸、三軸、四軸和五軸銑削加工。利用Mastercam的CAD部分對產(chǎn)品建立模型后，就能夠通過其CAM部分選擇加工方式、加工刀具、設(shè)定加工參數(shù)、計算NC刀具路徑、實體切削模擬結(jié)果等步驟，在檢驗一切無誤后，選擇對應(yīng)的后處理器將刀具路徑轉(zhuǎn)換成數(shù)控機床所能同意的NC代碼，再利用DNC方式傳輸給CNC操縱器進行加工。下面介紹Mastercam模具設(shè)計加工的一般流程。自己設(shè)計一簡單二維零件，規(guī)劃好該零件的刀具路徑，進行模擬加工，并將處理后的程序打印出來。1.繪制設(shè)計圖圖1-1零件設(shè)計圖圖1-2零件清晰圖2.規(guī)劃零件刀具路徑2.1挖槽圖2-1選擇挖槽加工方式圖2-2選擇加工刀具參數(shù)圖2-3設(shè)定加工參數(shù)圖2-4設(shè)定加工參數(shù)圖2-5設(shè)定加工參數(shù)圖2-6設(shè)定加工參數(shù)圖2-7設(shè)定加工參數(shù)圖2-8設(shè)定加工參數(shù)2.2鉆孔圖2-9選擇鉆孔加工方式圖2-10選擇加工刀具參數(shù)圖2-11設(shè)定加工參數(shù)圖2-12設(shè)定加工參數(shù)2.3鉆孔圖2-13選擇鉆孔加工方式圖2-14設(shè)定加工刀具參數(shù)圖2-15設(shè)定加工參數(shù)圖2-16設(shè)定加工參數(shù)圖2-17設(shè)定工件參2.4銑削外形圖2-18選擇加工方式圖2-19設(shè)定加工刀具參數(shù)圖2-20設(shè)定加工參數(shù)圖2-21設(shè)定加工參數(shù)圖2-22設(shè)定加工參數(shù)圖2-23設(shè)定加工參數(shù)圖2-24設(shè)定加工參數(shù)圖2-25生成加工刀具路徑圖2-26實體加工模擬程序%O0000(13-3)(DATE=DD-MM-YY-12-11-13TIME=HH:MM-17:28)(MCXFILE-C:\USERS\LENOVO\DESKTOP\13-3.MCX-5)(NCFILE-C:\USERS\LENOVO\DESKTOP\13-3.NC)(MATERIAL-ALUMINUMMM-2024)(T1|12.FLATENDMILL|H1)(T2|20.DRILL|H2)(T3|12.DRILL|H3)N100G21N102G0G17G40G49G80G90N104T1M6N106G0G90G54X38.542Y-8.999A0.S1500M3N108G43H1Z50.N110Z3.N112G1Z1.F159.1N114X49.948Z.402N116X37.948Z-.227N118X49.948Z-.856N120X37.948Z-1.484N122X49.948Z-2.113N124X37.948Z-2.742N126X49.948Z-3.371N128X37.948Z-4.N130X29.553Y-7.F800.N132X33.002Y-4.75N134X34.657Y-2.5N136X35.345Y.5N138X34.647Y2.75N140X31.535Y5.75N142X28.329Y6.5N144X20.873Y2.N146X10.32Y-.25N148X-10.32N150X-21.16Y.5N152X-39.339Y-.25N154X-34.155Y.5N156X-27.353Y-1.N158X-23.498N160X-12.794Y.5N162X12.248N164X16.926Y-.25N166X29.553Y-7.N168X26.132Y-15.25N170X32.52N172X36.12Y-13.75N174X40.869Y-10.N176X44.042Y-4.N178X44.466Y2.N180X42.31Y8.N182X38.089Y12.5N184X31.584Y15.5N186X27.067N188X24.672Y14.75N190X15.984Y9.5N192X7.416Y6.5N194X-7.416N196X-13.452Y8.N198X-24.055Y9.5N200X-33.678Y8.75N202X-45.004Y5.75N204X-57.289Y-.25N206X-43.596Y-6.25N208X-29.991Y-9.25N210X-20.923N212X-5.833Y-6.25N214X5.833N216X12.037Y-7.75N218X20.228Y-12.25N220X26.132Y-15.25N222X14.968Y-18.604N224G3X43.684Y18.604R23.5N226X14.968R23.5N228G2X-6.779Y14.457R24.5N230G3X-62.068Y6.301R67.501N232Y-6.301R7.5N234X-6.779Y-14.457R67.5N236G2X14.968Y-18.604R24.5N238G0Z25.N240X-44.041Y6.651N242Z3.N244G1Z-4.F159.1N246X-45.792Y-5.22F800.N248G3X-35.672Y-18.843R11.999N250X-6.088Y-16.859R70.N252G2X13.441Y-20.583R22.N254G3X45.211Y20.583R26.N256X13.441R26.N258G2X-6.088Y16.859R22.N260G3X-63.424Y8.401R70.N262Y-8.401R10.N264X-35.672Y-18.843R70.N266X-22.049Y-8.722R12.N268G1X-20.298Y3.149N270G0Z25.N272X38.542Y-8.999N274Z-1.N276G1Z-3.F159.1N278X49.948Z-3.598N280X37.948Z-4.227N282X49.948Z-4.856N284X37.948Z-5.484N286X49.948Z-6.113N288X37.948Z-6.742N290X49.948Z-7.371N292X37.948Z-8.N294X29.553Y-7.F800.N296X33.002Y-4.75N298X34.657Y-2.5N300X35.345Y.5N302X34.647Y2.75N304X31.535Y5.75N306X28.329Y6.5N308X20.873Y2.N310X10.32Y-.25N312X-10.32N314X-21.16Y.5N316X-39.339Y-.25N318X-34.155Y.5N320X-27.353Y-1.N322X-23.498N324X-12.794Y.5N326X12.248N328X16.926Y-.25N330X29.553Y-7.N332X26.132Y-15.25N334X32.52N336X36.12Y-13.75N338X40.869Y-10.N340X44.042Y-4.N342X44.466Y2.N344X42.31Y8.N346X38.089Y12.5N348X31.584Y15.5N350X27.067N352X24.672Y14.75N354X15.984Y9.5N356X7.416Y6.5N358X-7.416N360X-13.452Y8.N362X-24.055Y9.5N364X-33.678Y8.75N366X-45.004Y5.75N368X-57.289Y-.25N370X-43.596Y-6.25N372X-29.991Y-9.25N374X-20.923N376X-5.833Y-6.25N378X5.833N380X12.037Y-7.75N382X20.228Y-12.25N384X26.132Y-15.25N386X14.968Y-18.604N388G3X43.684Y18.604R23.5N390X14.968R23.5N392G2X-6.779Y14.457R24.5N394G3X-62.068Y6.301R67.501N396Y-6.301R7.5N398X-6.779Y-14.457R67.5N400G2X14.968Y-18.604R24.5N402G0Z25.N404X-44.041Y6.651N406Z-1.N408G1Z-8.F159.1N410X-45.792Y-5.22F800.N412G3X-35.672Y-18.843R11.999N414X-6.088Y-16.859R70.N416G2X13.441Y-20.583R22.N418G3X45.211Y20.583R26.N420X13.441R26.N422G2X-6.088Y16.859R22.N424G3X-63.424Y8.401R70.N426Y-8.401R10.N428X-35.672Y-18.843R70.N430X-22.049Y-8.722R12.N432G1X-20.298Y3.149N434G0Z25.N436X38.542Y-8.999N438Z-5.N440G1Z-7.F159.1N442X49.948Z-7.598N444X37.948Z-8.227N446X49.948Z-8.856N448X37.948Z-9.484N450X49.948Z-10.113N452X37.948Z-10.742N454X49.948Z-11.371N456X37.948Z-12.N458X29.553Y-7.F800.N460X33.002Y-4.75N462X34.657Y-2.5N464X35.345Y.5N466X34.647Y2.75N468X31.535Y5.75N470X28.329Y6.5N472X20.873Y2.N474X10.32Y-.25N476X-10.32N478X-21.16Y.5N480X-39.339Y-.25N482X-34.155Y.5N484X-27.353Y-1.N486X-23.498N488X-12.794Y.5N490X12.248N492X16.926Y-.25N494X29.553Y-7.N496X26.132Y-15.25N498X32.52N500X36.12Y-13.75N502X40.869Y-10.N504X44.042Y-4.N506X44.466Y2.N508X42.31Y8.N510X38.089Y12.5N512X31.584Y15.5N514X27.067N516X24.672Y14.75N518X15.984Y9.5N520X7.416Y6.5N522X-7.416N524X-13.452Y8.N526X-24.055Y9.5N528X-33.678Y8.75N530X-45.004Y5.75N532X-57.289Y-.25N534X-43.596Y-6.25N536X-29.991Y-9.25N538X-20.923N540X-5.833Y-6.25N542X5.833N544X12.037Y-7.75N546X20.228Y-12.25N548X26.132Y-15.25N550X14.968Y-18.604N552G3X43.684Y18.604R23.5N554X14.968R23.5N556G2X-6.779Y14.457R24.5N558G3X-62.068Y6.301R67.501N560Y-6.301R7.5N562X-6.779Y-14.457R67.5N564G2X14.968Y-18.604R24.5N566G0Z25.N568X-44.041Y6.651N570Z-5.N572G1Z-12.F159.1N574X-45.792Y-5.22F800.N576G3X-35.672Y-18.843R11.999N578X-6.088Y-16.859R70.N580G2X13.441Y-20.583R22.N582G3X45.211Y20.583R26.N584X13.441R26.N586G2X-6.088Y16.859R22.N588G3X-63.424Y8.401R70.N590Y-8.401R10.N592X-35.672Y-18.843R70.N594X-22.049Y-8.722R12.N596G1X-20.298Y3.149N598G0Z50.N600M5N602G91G28Z0.N604A0.N606M01N608T2M6N610G0G90G54X-58.Y0.A0.S1000M3N612G43H2Z100.N614G98G82Z-30.R3.P1.F300.N616X38.N618G80N620M5N622G91G28Z0.N624A0.N626M01N628T3M6N630G0G90G54X-62.Y38.A0.S1000M3N632G43H3Z100.N634G98G82Z-25.R3.P1.F200.N636X0.N638X62.N640Y-38.N642X0.N644X-62.N646G80N648M5N650G91G28Z0.N652G28X0.Y0.A0.N654M30%實驗二凸凹模具設(shè)計造型自己設(shè)計一簡單零件，將該零件的凸凹模設(shè)計出來并打印。利用凸模扒出凹模創(chuàng)建一個凸模，實體旋轉(zhuǎn)造型1）創(chuàng)建一條100mm直線。2）點曲線-手動畫曲線，用鼠標捕捉直線端點，任意幾點，形成封閉曲線，如圖1-1。3）點擊實體-實體旋轉(zhuǎn)，利用之前畫出的曲線形成旋轉(zhuǎn)體，如圖1-2。圖1-1圖1-22、創(chuàng)建凹模實體1）創(chuàng)建立方體，如圖2-1所示；2）選Length輸入長200；3）選Width輸入寬100；4）選Height,輸入高50；5）選擇把凸模與創(chuàng)建成的長方體進行實體-布爾運算-切割，圖2-2，結(jié)果如圖2-3所示： 圖2-1圖2-2圖2-3圖2-4成型凸凹模3、保存：file凹模.MCX-5實驗三銑削加工——復(fù)雜零件輪廓加工一、實驗?zāi)康耐ㄟ^較復(fù)雜零件輪廓的加工，進一步熟悉和掌握數(shù)控系統(tǒng)常用指令的編程與加工工藝，加深對數(shù)控銑床工作原理的了解。二、實訓(xùn)儀器與設(shè)備(1)配備三菱加工中心一臺。(2)毛坯一件(材料為石蠟)，90×83×30如圖4—4所示。(3)Φ12立銑刀一把，Φ6麻花鉆一根。三、相關(guān)知識概述數(shù)控銑床的要緊加工對象為平面類零件、箱體類零件和曲面類零件。假如換上孔加工刀具，還能進行數(shù)控鉆、鏜、锪、鉸及攻螺紋等孔加工操作。由于數(shù)控銑床沒有刀具庫，不具有自動換刀功能，因此其加工程序的編制比較簡單；通常數(shù)值計算量不大的平面輪廓加工程序或孔加工程序可直接通過手工編程完成。編程時選擇合適的坐標位置編程方式可使程序簡化，減少數(shù)值計算工作量。坐標位置編程方式有絕對指令方式和相對指令方式兩種，要緊依照圖紙上尺寸的標注方式來選擇。當加工尺寸由一個固定基準給定時，采納絕對指令方式編程較為方便。當加工尺寸是以輪廓o頂點之間的間距給出時，采納相對指令方式編程較為方便。(1)絕對值編程指令(G90)和相對值編程指令(G91)。格式：式中，G90為絕對值編程指令，每個坐標軸上的編程值是相關(guān)于程序原點的；G91為·相對值編程指令，每個坐標軸上的編程值是相關(guān)于前一位置而言的，該值等于沿坐標軸移動的距離。G90、G91為模態(tài)功能指令，G90為缺省值。(2)固定循環(huán)指令(G98，G99)固定循環(huán)指令的程序格式包括數(shù)據(jù)形式、返回點平面、孔加工方式、孔位置數(shù)據(jù)、孔加工數(shù)據(jù)和循環(huán)次數(shù)。數(shù)據(jù)形式(G90或G91)，在程序開始時就已指定，因此，在固定循環(huán)指令的程序格式中可不注出。格式圖6—1G73指令動作圖圖6—2G74指令動作圖式中，第一個G代碼(G98或者G99)為返回點平面G代碼，G98為返回初始平面，G99為返回R點平面；第二個G代碼為孔加工方式，即固定循環(huán)代碼G73(高速深孔加工指令)，G74，G76和G81～G89中的任一個(G73、G74指令動作圖，如圖6—l、圖6—2所示)；X、Y為孔位數(shù)據(jù)，指被加工孔的坐標位置；Z為R點到孔底的距離(G9l時)或孔底坐標(G90時)；R為初始點到R點的距離(G91時)或R點的坐標值(G90時)；Q為每次進給深度(G73或G83時)，增量值，Q<0；K為每次退刀(G73或G83：、時)刀具的位移增量，K>0；I、J為刀尖向反方向的移動量(分不在X、y軸向上)；P為刀具在孔底的暫停時刻；F為刀具切削進給速度；L為固定循環(huán)的次數(shù)。四、實驗內(nèi)容(1)依照數(shù)控系統(tǒng)的程序格式，編制如圖1-1所示零件的加工程序。圖1-1加工零件圖(2)依照上述加工零件制定加工工藝。1)工藝分析①技術(shù)要求本實驗加工零件的毛坯如圖1-2所示，毛坯的大平面通過預(yù)先銑削加工，材料為石蠟。圖1-2零件毛坯圖②加工工藝的確定加工方式：由零件圖和毛坯圖可知，該零件需要進行銑削和鉆削加工。裝夾定位的確定：為了在一次裝夾后完成所有的加工，所預(yù)備的毛坯增加了一個工藝厚度，能夠利用它將其裝夾在乎口鉗上，在加工完零件形狀后再設(shè)法去除。③加工刀具的確定，平銑刀(Φ12、Φ6)各1把，麻花鉆(Φ16)一把。④切削用量：主軸轉(zhuǎn)速300r／min，進給速度150mm／min。、2)數(shù)學(xué)計算。①建立工件坐標系。②依照零件圖中的尺寸標注，程序中有些基點的絕對坐標位置可直接讀出，另外些基點間的相對位置也可直接讀出，因此在編程時可用絕對坐標位置和相對坐標位置這兩種坐標值方式。3）加工結(jié)果，如圖1-3：圖1-3零件加工完成圖4）程序%O0000(MACHINE_GROUP_1)(DATE=DD-MM-YY-12-11-13TIME=HH:MM-18:27)(MCXFILE-C:\USERS\LENOVO\DESKTOP\3.MCX-5)(NCFILE-C:\USERS\LENOVO\DESKTOP\MACHINE_GROUP_1.NC)(MATERIAL-ALUMINUMMM-2024)(T1|12.FLATENDMILL|H1)(T2|6.FLATENDMILL|H2)(T3|16.DRILL|H3)N100G21N102G0G17G40G49G80G90N104T1M6N106G0G90G54X-36.324Y-56.595A0.S2200M3N108G43H1Z50.N110Z3.N112G1Z-2.F500.N114X-26.172Y-50.197F800.N116G3X-22.419Y-33.646R12.N118G1X-43.343Y-.447N120G2X-43.767Y20.711R20.5N122X43.767R50.5N124X43.343Y-.447R20.501N126G1X22.419Y-33.646N128G2X-22.419R26.5N130G3X-38.969Y-29.893R12.N132G1X-49.121Y-36.291N134X-35.901Y-56.328N136X-25.749Y-49.93N138G3X-21.996Y-33.38R12.N140G1X-42.92Y-.181N142G2X-43.333Y20.461R20.N144X43.333R50.N146X42.92Y-.181R20.N148G1X21.996Y-33.38N150G2X-21.996R26.N152G3X-38.546Y-29.626R12.N154G1X-48.698Y-36.024N156X-36.324Y-56.595N158Z-4.F500.N160X-26.172Y-50.197F800.N162G3X-22.419Y-33.646R12.N164G1X-43.343Y-.447N166G2X-43.767Y20.711R20.5N168X43.767R50.5N170X43.343Y-.447R20.501N172G1X22.419Y-33.646N174G2X-22.419R26.5N176G3X-38.969Y-29.893R12.N178G1X-49.121Y-36.291N180X-35.901Y-56.328N182X-25.749Y-49.93N184G3X-21.996Y-33.38R12.N186G1X-42.92Y-.181N188G2X-43.333Y20.461R20.N190X43.333R50.N192X42.92Y-.181R20.N194G1X21.996Y-33.38N196G2X-21.996R26.N198G3X-38.546Y-29.626R12.N200G1X-48.698Y-36.024N202X-36.324Y-56.595N204Z-6.F500.N206X-26.172Y-50.197F800.N208G3X-22.419Y-33.646R12.N210G1X-43.343Y-.447N212G2X-43.767Y20.711R20.5N214X43.767R50.5N216X43.343Y-.447R20.501N218G1X22.419Y-33.646N220G2X-22.419R26.5N222G3X-38.969Y-29.893R12.N224G1X-49.121Y-36.291N226X-35.901Y-56.328N228X-25.749Y-49.93N230G3X-21.996Y-33.38R12.N232G1X-42.92Y-.181N234G2X-43.333Y20.461R20.N236X43.333R50.N238X42.92Y-.181R20.N240G1X21.996Y-33.38N242G2X-21.996R26.N244G3X-38.546Y-29.626R12.N246G1X-48.698Y-36.024N248X-36.324Y-56.595N250Z-8.F500.N252X-26.172Y-50.197F800.N254G3X-22.419Y-33.646R12.N256G1X-43.343Y-.447N258G2X-43.767Y20.711R20.5N260X43.767R50.5N262X43.343Y-.447R20.501N264G1X22.419Y-33.646N266G2X-22.419R26.5N268G3X-38.969Y-29.893R12.N270G1X-49.121Y-36.291N272X-35.901Y-56.328N274X-25.749Y-49.93N276G3X-21.996Y-33.38R12.N278G1X-42.92Y-.181N280G2X-43.333Y20.461R20.N282X43.333R50.N284X42.92Y-.181R20.N286G1X21.996Y-33.38N288G2X-21.996R26.N290G3X-38.546Y-29.626R12.N292G1X-48.698Y-36.024N294X-36.324Y-56.595N296Z-10.F500.N298X-26.172Y-50.197F800.N300G3X-22.419Y-33.646R12.N302G1X-43.343Y-.447N304G2X-43.767Y20.711R20.5N306X43.767R50.5N308X43.343Y-.447R20.501N310G1X22.419Y-33.646N312G2X-22.419R26.5N314G3X-38.969Y-29.893R12.N316G1X-49.121Y-36.291N318X-35.901Y-56.328N320X-25.749Y-49.93N322G3X-21.996Y-33.38R12.N324G1X-42.92Y-.181N326G2X-43.333Y20.461R20.N328X43.333R50.N330X42.92Y-.181R20.N332G1X21.996Y-33.38N334G2X-21.996R26.N336G3X-38.546Y-29.626R12.N338G1X-48.698Y-36.024N340G0Z50.N342M5N344G91G28Z0.N346A0.N348M01N350T2M6N352G0G90G54X14.598Y-6.799A0.S2500M3N354G43H2Z50.N356Z3.N358G1Z1.F400.N360G2X12.92Y-3.615Z.704I0.J0.N362X14.598Y-6.799Z.407I0.J0.N364X12.92Y-3.615Z.111I0.J0.N366X14.598Y-6.799Z-.185I0.J0.N368X12.92Y-3.615Z-.481I0.J0.N370X14.598Y-6.799Z-.778I0.J0.N372X11.974Y-5.436Z-.96I0.J0.N374G1X.474Y-6.917F600.N376X1.119Y-6.317N378X.389Y-5.417N380X.8Y-2.717N382X-.225Y-5.117N384X-1.144Y-6.317N386X-.494Y-6.917N388X.726Y-9.017N390X0.N392Y-16.517N394X-.262N396X5.22Y-7.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