數控加工課程設計說明書一、分析零件圖紙,擬定總體加工方案（一）、圖紙分析:該圖是一復雜軸類零件,零件部分地方較為復雜,部分加工精度較高,采用數控車削加上鉆削、滾齒、插齒綜合完畢。該零件由外圓柱面、孔、倒角、內齒輪,齒輪軸、槽、階梯組成。其中零件最大外徑為19mm,長度為104mm.選擇毛坯尺寸為114x22mm的棒料。（二）、精度等級、表面粗糙度分析:考慮到左右兩端齒輪齒面粗糙度1.6,滾齒機滾齒后要倒角磨齒；外圓表面粗糙度規定最高為0.8,尺寸精度也易于達成,所以外圓精車即可達成規定。同軸度及各圓跳度都規定要裝夾次數減少。所以,外圓以兩頂尖定位,一次裝夾完畢粗精加工。為滿足同軸度規定,打孔時應夾外徑為13.9的外圓。（三）、材料和熱解決分析:零件材料為31CrMoV9是齒輪鋼,預備熱解決為調質,回火溫度600℃——630℃。最終熱解決為滲氮,HV900。（四）、總體方案:先對毛坯預備熱解決（調質解決）；用數控車床粗精車兩端面打中心孔,再以兩中心孔定位,粗車外圓輪廓,精車右端外圓輪廓,切槽。再以外徑為13.9的槽定位,粗精車左端外圓,鉆鉸孔、鏜孔割內槽；最后再滾齒,插齒；最終熱解決,再上磨齒機進行磨齒；完畢整個零件的加工。二、擬定加工工藝方案（一）裝夾方式及量具選擇:數控車床夾具使用三爪卡盤自動定心夾具及頂尖；Y3150E滾齒機使用專用夾具,插齒機使用專用夾具,磨齒機使用專用夾具。量具有游標卡尺,外徑千分尺,百分表。（二）加工順序:1.備料,下料尺寸ф22×106的棒料,預備熱解決2.車,粗精車右端面,鉆中心孔3.粗車，夾左端外圓頂中心孔定位，粗車右端外圓各部，留單邊余量0.24、精車,夾左端外圓頂中心孔定位,精車右端外圓各部至圖紙所示。5.切1.1mm寬的槽6、用3.5mm切槽刀切3.5mm處,4.6mm處以及12mm處,加之外徑為13.9的T型槽至圖紙所示。7、掉頭夾直徑12處外圓,粗精車左端端面及外圓8、鉆鏜直徑為9的孔9、鏜直徑為12.5的孔。10、割寬5mm的內槽。11.鉆直徑5和4的頂孔。12.銑鍵槽13.滾齒機滾右端齒14.插齒機插內齒輪。15、倒角,倒棱16.最終熱解決17、磨齒機磨齒18、終結檢查（三）,切削用量選擇（鏜車削）數控車削加工中的切削用量涉及：背吃刀量
、主軸轉速n或切削速度
、進給速度
或進給量f。這些參數均應在機床給定的允許范圍內選取。車削用量的選擇原則是粗車時,一方面考慮選擇盡也許打的背吃刀量
,另一方面選擇較大的進給量f,最后擬定一個合適的切削速度v。增大背吃刀量可使走刀次數減少,增大進給量f有助于斷屑。精車時,加工精度和表面粗糙度規定較高,加工余量不大且較均勻,因此選擇精車的切削用量時,應著重考慮如何保證加工質量,并在此基礎上提高加工效率。因此,精車時應選用較小的背吃刀量
和進給量f,并選用性能高的刀具材料和合理的幾何參數,以盡也許提高切削速度v.背吃刀量的擬定在工藝系統剛度和機床功率允許的情況下,應盡也許選擇較大的背吃刀量,以減少進給的次數。當零件精度規定較高時,則應考慮留出精車余量,其所留的精車余量比一般普通車削時所留余量小,常取0.1~0.5mm。（2）進給量的擬定

式中,f進給量,粗車時一般取為0.3~0.8mm/r,精車時常取0.1~0.3mm/r,切斷時常取0.05~0.2mm/r。（3）主軸轉速的擬定n（r/min）1.數控車削a.粗車端面取n=50m/minf=0.3mm/rb.精車端面取n=80m/minf=0.15mm/rb.粗車外輪廓,留單面余量0.2mm取n=50m/minf=0.3mm/rap=2mmc.精車外輪廓取n=80m/minf=0.15mm/rap=0.2mmd.切槽取n=60m/minf=0.1mm/rf.預鉆孔Ф8mm及打中心孔取n=500r/minf=0.2mm/rg.鏜孔取n=1500r/minf=0.2mm/r2.滾齒機滾齒Vc=0.7m/sf=1.5mm/r刀具明細表序號刀具名稱刀具直徑刀補值190°端面車刀D01293°偏頭外圓車刀D0231.15mm割槽刀43.5mm割槽刀54mm割槽刀6高速鋼鉆頭87鏜刀8鏜刀D0893mm的內切槽刀10滾刀D1011插齒刀D11三、數值換算1.公差對稱化換算:直徑公差帶代號公差大小/mm上偏差下偏差對稱化后尺寸12g70.018-0.006-0.02411.985100-0.19.9516h70.0180-0.01815.99115.50-0.315.3513.90-0.0313.88516.80-0.116.757.80.0507.82517h80.0180-0.01816.99116.40-0.0416.389H100.0580.05809.02911.50.3011.6530.50.3030.65601001.1590.0509.02511.50-0.111.452.相關節點坐標計算:如圖所示:通過坐標標注,各節點坐標清清楚楚。3.刀位點坐標值的計算過程刀位點是指刀具的定位基準點。車刀的刀位點是刀尖或刀尖圓弧中心；鉆頭的刀位點是鉆頭頂點。各類數控機床的對刀方法是不完全同樣的,這一內容將結合各類機床分別討論。數控車床的刀位點是工件外形輪廓向外偏移一個刀具半徑值四、數控的工藝卡片及加工程序O0001——車左端面打中心孔加工環節加工內容刀具主軸轉速（m/min或r/min）進給量備注1粗車端面,留精加工余量0.2T01:90°端面車刀500.32精車端面至圖紙規定T01800.153打中心孔T02:直徑3.35中心鉆5000.2O0002——車外輪廓加工環節加工內容刀具主軸轉速（m/min或r/min）進給量備注1粗車外圓輪廓,留精加工余量0.2T01:93°偏頭外圓車刀500.3G712精車外圓輪廓至圖紙規定T01:93°偏頭外圓車刀800.15G703切1.1mm寬槽T02:1.1mm割槽刀（右刀尖）600.14切3.5mm寬槽及4.6mm滾花槽T03:3.5mm割槽刀（右刀尖）600.15切T型槽及其他槽T04:4mm割槽刀（右刀尖）600.1O0003——精車左端端面,外圓,鉆鏜孔加工環節加工內容刀具主軸轉速（m/min或r/min）進給量備注1粗車外圓輪廓,留精加工余量0.2T01:93°偏頭外圓車刀500.3G712精車外圓輪廓至圖紙規定T01:93°偏頭外圓車刀800.15G703鉆底孔T02:直徑為8mm高速鋼麻花鉆5000.24鏜孔T03:硬質合金內孔車刀5000.25鏜直徑為12.5mm的孔T04:硬質合金內孔車刀15000.26割內槽T05:硬質合金內切槽刀600.1程序代碼如下:O0001N10G54F0.3S800M03M07T0101;工藝設定N20G50S2023；最高轉速限制N30G96S50；恒線速度切削N40G0X24Z0.2；快速定位接近工件N50G1X-2；粗切端面N60G0X24Z1N80G96S80；精車恒線速度設定N90Z0N100G1X-2F0.15；精車端面N110G0X100Z150；返回換刀點N120T0202；換2號刀具N130G97S500；取消恒線速度,設定轉速500r/min。N140X0Z5N150G1Z-3.35；鉆中心孔N160G0Z5N170X100Z150N180M30；程序結束O0002N10G54F0.3S800M03M07T0101;工藝設定G50S2023；最高轉速限制G96S50；恒線速度切削G0X24Z0.2；快速定位接近工件G1X-2；粗切端面G0X24Z1G96S80；精車恒線速度設定Z0G1X-2F0.15；精車端面N40G71U2R1；G71粗車輪廓循環N50G71P60Q170U0.4W0.2F0.3；粗車輪廓循環參數設定N60G0G42X8Z2F0.15；循環開始N70G1Z0N80X9.95Z-0.58N90Z-15.72N100G02X10.36Z-16.94R3N110G01X11.985Z-19N120Z-36.5N130X15.35N140X15.991Z-36.64N150W-7.825N160X19N170Z-106；循環結束N180G0X100Z150N190G96S80；恒線速度切削N200G70P60Q170；G70循環精車外輪廓N210G0X100Z150；返回換刀點N220T0202；換1.1mm切槽刀N230G96S60N240G0G40X13Z-27.5F0.1；取消刀補,快速定位N250G1X11.45N260G0X20N270G0X100Z150N280T0303;換3.5mm切槽刀N290G0X17Z-38.5;切3.5mm槽N300G1X-15.96N310G0X20N320Z-31.9；切4.6mm槽N332G1X11.9N340G0X14N345Z-40.8N350G1X11.5N355Z-31.9；切4.6mm槽結束N360G0X20N370G0X100Z150N380T0404；換4mm切槽刀N390G0X20Z-50.35N400G1X14.3；粗切直徑為13.9的T型槽及寬12mm槽N410G0X20Z-53.5N420G1X14.3N430G0X20N435Z-53.5N440G1X14.3N450G0X20N451Z-57N452G1X14.3N453G0X20N455Z-60.6N460G1X14.3N470G0X20N475Z-69.5N480G1X17.2 ；T型槽粗切結束N490G0X20N495Z-72N500G1X17.2；粗切12mm槽N510G0X20N515Z-75N520G1X17.2N530G0X20N531Z-75N532G1X17.2N534G0X20N535Z-77.5N540G1X17.2；12mm槽粗車結束N550G0X20Z-75N560Z-45.5N570G1X19；精車T型槽N580X14.32Z-49.55N590G02X13.885Z-50.35R1.6N600G01Z-64.6N610G2X14.28Z-65.35R1.6N620G1X18.22Z-69.06N630G3X17.68Z-69.5R0.15；精車T型槽結束N640G1X16.75;精車12mm槽N645Z-77.5N650G0X100Z150N660M30;程序結束O0003N10G54F0.3S800M03M07T0101;工藝設定N20G50S2023；最高轉速限制N30G96S50；恒線速度切削N40G71U2R1N50G71P60Q130U0.4W0.2F0.3;G71粗車循環N60G0G42X15.2Z2F0.15；循環開始N70G1Z0N80X16.38Z-1.39N90Z-6N100X16.991N110Z-21.5N120X18N130Z-23；循環結束N140G0X19Z2N150G96S80N160G70P60Q130；G70精車循環N170G0X100Z150N180T0202；換鉆頭N190G0G40X0Z25S500F0.2；鉆孔開始,取消刀補N200G1Z-10N210G0Z2N220G1Z-20N230G0Z0N240Z-18N250G1Z-35N260G0Z0N270Z-33N272Z-50N274G0Z0N276Z-48N280G1Z-62N290P1N300G0Z2；鉆孔結束N310G0X100Z150N320T0303；換鉸刀N330G0X0Z5N340G1Z-62；鉸孔N350P1N360G0Z2N370G0X100Z150N380T0404；換鏜刀N390S1500F0.2N400G0G43X13.5Z-0.433；刀補N405G1X12.5Z-0.433；鏜孔N410Z-13N420X8N430G0Z2N440X100Z150N450T0505；換內切槽刀N460G0G40S60X8Z5F0.1N470Z-27.65N480G1X11.1；切內槽N490G0X8N500W2N510G1X11.1N520G0X8N530Z-24.93N540G1X9N550X11.65Z-25.65N555Z-27.65N560X9Z-28.37N570G0X8N580Z5N590G0X100Z150N600M30;程序結束五、MASTERCAM仿真1.刀具軌跡圖:2.加工后的輪廓圖:3.加工后立體圖:4.PRO/E制作的三維圖:5.MASTERCAM導出的加工程序:%O0000G21(PROGRAMNAME-MYMASTER22DATE=DD-MM-YY-20-11-11TIME=HH:MM-16:31)(TOOL-1OFFSET-1)(LFACEODROUGHRIGHT-80DEG.INSERT-CNMG120408)G0T0101G97S3600M13G0G54X26.Z.5G50S3600G96S295G99G1X-1.6F.2G0Z2.5X26.Z0.G1X-1.6G0Z2.G28U0.W0.M05T0100M01(TOOL-2OFFSET-2)(LROUGHODFINISHRIGHT-35DEG.INSERT-VNMG160408)G0T0202G97S3600M13G0G54X18.666Z.5G50S3600G96S295G1Z0.F.3Z-35.436G3X18.687Z-35.6R1.3G1Z-37.845X19.4Z-59.283Z-59.3Z-60.5Z-110.127X22.X24.828Z-108.713G0X26.666Z-35.246X19.394G1X18.687Z-35.6G2X18.4Z-35.006R1.3F.1G1Z-23.3F.3Z-22.3G2X17.4Z-21.434R1.F.1G1Z-6.8F.3G2X17.2Z-6.364R1.F.1G1Z-2.186F.3G2X16.932Z-1.686R1.F.1G1X15.332Z-.3Z0.F.3X18.16Z1.414G0X19.4Z-22.946X19.107G1X18.4Z-23.3G3X17.712Z-24.055R1.F.1G1X17.2Z-24.277Z-30.209F.3Z-34.425G3X18.687Z-35.6R1.3G1X21.515Z-34.186G0X22.515Z-35.246X19.394G1X18.687Z-35.6G3X18.622Z-35.889R1.3F.1G1X19.087Z-49.874F.3X21.915Z-48.459G0X22.915Z-60.146X20.107G1X19.4Z-60.5G3X18.712Z-61.255R1.F.1G1X16.4Z-62.26Z-62.8F.3Z-66.3Z-68.156G3X15.733Z-68.901R1.F.1G1Z-110.127F.3X19.8X22.628Z-108.713G0Z-109.773X19.093G1X19.8Z-110.127X12.067F.1Z-86.434F.3X12.279Z-86.142G2X12.4Z-85.8R1.G1Z-77.3Z-76.2Z-72.9Z-70.35X15.712Z-68.91G2X16.133Z-68.655R1.G1X18.962Z-67.24G0Z-68.525X17.099G1X16.133Z-68.655G3X15.712Z-68.91R1.F.1G1X12.4Z-70.35Z-72.9F.3Z-76.2Z-77.3Z-85.8G3X12.279Z-86.142R1.F.1G1X10.641Z-88.392G2X10.4Z-89.076R2.G1Z-104.223F.3G3X9.712Z-104.977R1.F.1G1X8.4Z-105.548Z-110.127F.3X12.467X15.295Z-108.713G0X22.Z.083X15.244G1X14.986Z-.4X16.586Z-1.786G3X16.8Z-2.186R.8G1Z-6.413G3X17.Z-6.8R.8G1Z-21.558G3X18.Z-22.3R.8G1Z-23.3G3X17.45Z-23.904R.8G1X16.8Z-24.186Z-30.209Z-34.559G3X18.287Z-35.6R1.1X18.221Z-35.867R1.1G1X19.Z-59.287Z-59.3Z-60.5G3X18.45Z-61.104R.8G1X16.Z-62.169Z-62.8Z-66.3Z-68.156G3X15.45Z-68.759R.8G1X12.Z-70.259Z-72.9Z-76.2Z-77.3Z-85.8G3X11.904Z-86.074R.8G1X10.265Z-88.324G2X10.Z-89.076R2.2G1Z-104.223G3X9.45Z-104.826R.8G1X8.Z-105.457Z-110.327X10.828Z-108.913G0X21.6G28U0.W0.M05T0200M01(TOOL-4OFFSET-4)(LFINISHODGROOVECENTER-WIDEINSERT-N151.2-600-4E)G0T0404G97S1592M13G0G54X23.Z-44.966G50S3600G96S115G1X14.3F.1G0X23.Z-46.963G1X14.3X14.699Z-46.763G0X23.Z-42.969G1X14.3X14.699Z-43.169G0X23.Z-48.96G1X14.3X14.699Z-48.76G0X23.Z-40.972G1X14.3X14.699Z-41.172G0X23.Z-50.956G1X14.708X15.107Z-50.757G0X23.Z-38.975G1X14.382X14.781Z-39.175G0X23.Z-52.953G1X17.014X17.413Z-52.753G0X23.Z-36.979G1X16.423X16.822Z-37.178G0X23.Z-33.474X21.022G1X18.193Z-34.888X14.251Z-38.595G2X13.9Z-39.299R1.5G1Z-50.255G2X14.302Z-51.005R1.5G1X18.973Z-55.05G0X21.802G28U0.W0.M05T0400M01(TOOL-3OFFSET-3)(LFINISHODGROOVECENTER-NARROWINSERT-N151.2-185-20-5G)G0T0303G97S1695M13G0G54X21.6Z-76.3G50S3600G96S115X16.G1X11.5F.1G0X16.Z-77.914X14.828G1X12.Z-76.5X11.5G0X14.828Z-74.986G1X12.Z-76.4X11.5Z-76.5G0X14.828X21.6G28U0.W0.M05T0300M01(TOOL-4OFFSET-4)(LFINISHODGROOVECENTER-WIDEINSERT-N151.2-600-4E)G0T0404G97S1592M13G0G54X23.Z-60.5G50S3600G96S115G1X16.4F.1G0X23.Z-60.G1X16.4X16.5Z-60.05G0X23.Z-59.9G1X16.4X16.5Z-59.95G0X23.Z-61.G1X16.4X16.5Z-60.95G0X23.Z-61.5G1X16.4X16.5Z-61.45G0X23.Z-57.086X21.828G1X19.Z-58.5Z-59.6G3X18.8Z-59.7R.1G1X16.Z-61.9G3X15.93Z-61.976R.1G0X18.758X21.6G28U0.W0.M05T0400M01(TOOL-3OFFSET-3)(LFINISHODGROOVECENTER-NARROWINSERT-N151.2-185-20-5G)G0T0303G97S1642M13G0G54X22.287Z-17.967G50S3600G96S115G1X17.4F.1G0X22.287Z-18.067G1X17.4X17.42Z-18.057G0X22.287Z-17.868G1X17.4X17.42Z-17.878G0X22.287Z-18.167G1X17.4X17.42Z-18.157G0X22.287Z-17.768G1X17.4X17.42Z-17.778G0X22.287Z-18.267G1X17.4X17.42Z-18.257G0X22.287Z-17.668G1X17.4X17.42Z-17.678G0X22.287Z-18.367G1X17.4X17.42Z-18.357G0X22.287Z-17.568G1X17.4X17.42Z-17.578G0X22.287Z-18.466G1X17.4X17.42Z-18.456G0X22.287Z-17.468G1X17.4X17.42Z-17.478G0X22.287Z-18.566G1X17.4X17.42Z-18.556G0X22.287Z-17.368G1X17.4X17.42Z-17.378G0X22.287Z-18.666G1X17.4X17.42Z-18.656G0X22.287Z-17.269G1X17.4X17.42Z-17.279G0X22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