WAM336數(shù)控磨床的技術(shù)改造與工藝編程
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,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。 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,磨床第一邊半徑尺寸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,第一邊到第四邊的后角P11~P14,磨削速度P20,外接圓半徑P21,空磨時間P23。 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,可實現(xiàn)磨削任意形狀圓弧面的加工程序編制。使用時,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 |