Ana amfani da masu yankan kusurwa akai-akai a cikin injinan ƙananan filaye da ingantattun abubuwan da ke cikin masana'antu daban-daban. Suna da tasiri musamman ga ayyuka kamar chamfering da deburring workpieces.
Ana iya yin bayanin aikace-aikacen ƙirƙirar masu yankan kusurwa ta hanyar ka'idodin trigonometric. A ƙasa, muna gabatar da misalai da yawa na shirye-shirye don tsarin CNC gama gari.
1. Gabatarwa
A cikin masana'antu na ainihi, sau da yawa ya zama dole don chamfer gefuna da sasanninta na samfurori. Ana iya cika wannan yawanci ta amfani da dabarun sarrafawa guda uku: shirye-shiryen ƙarshen niƙa Layer, shirye-shiryen abun yankan ƙwallon ball, ko shirye-shiryen yankan kwane-kwane. Tare da shirye-shirye na ƙarshen niƙa, tip ɗin kayan aiki yana ƙoƙarin yin lalacewa da sauri, yana haifar da raguwar rayuwar kayan aiki [1]. A gefe guda kuma, shirye-shiryen saman ƙwallon ƙwallon ba shi da inganci, kuma duka hanyoyin injin niƙa da na ƙwallon ƙwallon suna buƙatar shirye-shiryen macro na hannu, wanda ke buƙatar takamaiman matakin fasaha daga ma’aikacin.
Sabanin haka, shirye-shirye na milling cutter contour kawai yana buƙatar daidaitawa ga tsawon kayan aikin diyya da ƙimar diyya a cikin shirin gamawa na kwane-kwane. Wannan ya sa ɓangarorin milling cutter contour programming hanya mafi inganci tsakanin ukun. Koyaya, masu aiki galibi suna dogara da yanke gwaji don daidaita kayan aikin. Suna ƙayyade tsawon kayan aiki ta amfani da hanyar yanke gwajin aikin aikin Z-direction bayan ɗaukar diamita kayan aiki. Wannan dabarar tana aiki ne kawai ga samfur guda ɗaya, yana buƙatar sake daidaitawa yayin canzawa zuwa samfurin daban. Don haka, akwai buqatar ingantawa a cikin tsarin daidaita kayan aiki da hanyoyin shirye-shirye.
2. Gabatar da abubuwan da aka saba amfani da su na kafa masu yankan kusurwa
Hoto na 1 yana nuna haɗe-haɗen kayan aikin carbide chamfering, wanda aka saba amfani dashi don ɓarna da ɓata gefuna na sassa. Ƙididdigar gama gari sune 60°, 90° da 120°.
Hoto 1: Abun yankan carbide chamfering guda ɗaya
Hoto na 2 yana nuna haɗaɗɗen injin ƙarshen kusurwa, wanda galibi ana amfani dashi don aiwatar da ƙananan filaye masu tsayi tare da kafaffen kusurwoyi a cikin sassan mating na sassa. Babban kusurwar tip ɗin kayan aiki da aka saba amfani da shi bai wuce 30° ba.
Hoto na 3 yana nuna babban mai yanke niƙa na kusurwa mai girman diamita tare da abubuwan da za a iya ƙididdige su, wanda galibi ana amfani da shi don aiwatar da manyan sassa na sassa. The kayan aiki tip kusurwa ne 15 ° zuwa 75 ° kuma za a iya musamman.
3. Ƙayyade hanyar saitin kayan aiki
Nau'o'in kayan aikin guda uku da aka ambata a sama suna amfani da saman ƙasa na kayan aiki azaman wurin tunani don saiti. An kafa axis Z a matsayin sifili akan kayan aikin injin. Hoto na 4 yana kwatanta saitin saitin kayan aiki a cikin hanyar Z.
Wannan tsarin saitin kayan aiki yana taimakawa kiyaye daidaitaccen tsayin kayan aiki a cikin injin, rage girman sauye-sauye da yuwuwar kurakuran ɗan adam da ke da alaƙa da yanke gwajin aikin.
4. Binciken Ka'ida
Yanke ya haɗa da cire rarar kayan aiki daga kayan aiki don ƙirƙirar kwakwalwan kwamfuta, yana haifar da aikin aiki tare da ƙayyadaddun siffar geometric, girman, da ƙarewar saman. Mataki na farko a cikin aikin injin shine don tabbatar da cewa kayan aikin yana hulɗa tare da kayan aikin a cikin hanyar da aka yi niyya, kamar yadda aka kwatanta a hoto na 5.
Hoto 5 Chamfering abun yanka a lamba tare da workpiece
Hoto na 5 yana nuna cewa don ba da damar kayan aiki don yin hulɗa tare da kayan aiki, dole ne a sanya takamaiman matsayi zuwa tip ɗin kayan aiki. Wannan matsayi yana wakilta ta hanyar daidaitawa a kwance da kuma tsaye a kan jirgin sama, da kuma diamita na kayan aiki da haɗin gwiwar Z-axis a wurin lamba.
Rushewar girman kayan aikin chamfering a lamba tare da ɓangaren ana nuna shi a cikin Hoto 6. Ma'ana A yana nuna matsayin da ake buƙata. Tsawon layin BC an tsara shi azaman LBC, yayin da tsayin layin AB ana kiransa LAB. Anan, LAB yana wakiltar daidaitawar axis Z na kayan aiki, kuma LBC yana nuna radius na kayan aiki a wurin tuntuɓar.
A cikin ingantattun mashin ɗin, radius na kayan aikin ko haɗin gwiwar Z za a iya saita shi da farko. Ganin cewa kusurwar tip kayan aiki an gyara shi, sanin ɗaya daga cikin ƙimar da aka saita yana ba da damar lissafin ɗayan ta amfani da ka'idodin trigonometric [3]. Manufofin sune kamar haka: LBC = LAB * tan (kusurwar tip angle / 2) da LAB = LBC / tan (kusurwar tip / 2).
Misali, ta yin amfani da abin yankan carbide chamfering yanki guda ɗaya, idan muka ɗauka cewa haɗin gwiwar kayan aikin shine -2, zamu iya ƙayyade radius na kayan aiki daban-daban guda uku: radius na lamba don 60° chamfering cutter shine 2 * tan (30° = 1.155 mm, don 90 ° chamfering abun yanka shi ne 2 * tan (45 °) = 2 mm, kuma ga 120 ° Chamfering abun yanka shi ne 2 * tan (60°) = 3.464 mm.
Sabanin haka, idan muka ɗauka radius lamba na kayan aiki shine 4.5 mm, zamu iya ƙididdige daidaitawar Z don kayan aikin guda uku: daidaitawar Z don 60 ° chamfer milling cutter shine 4.5 / tan (30 °) = 7.794, don 90 ° chamfer. Milling abun yanka shi ne 4.5 / tan (45°) = 4.5, kuma ga 120 ° chamfer milling. abun yanka shi ne 4.5 / tan (60°) = 2.598.
Hoto na 7 yana kwatanta ɓarkewar girma na injin ƙarshen kusurwa guda ɗaya a cikin hulɗa da ɓangaren. Ba kamar na'urar yankan carbide chamfer guda ɗaya ba, injin ƙarshen kusurwa guda ɗaya yana da ƙaramin diamita a ƙarshen, kuma radius lamba na kayan aiki yakamata a lissafta shi azaman (LBC + ƙaramin diamita / 2). Hanyar ƙididdiga ta musamman an yi dalla-dalla a ƙasa.
Tsarin ƙididdige radiyon tuntuɓar kayan aiki ya ƙunshi amfani da tsayin (L), kwana (A), faɗin (B), da tangent na rabin kusurwar tip kayan aiki, wanda aka taƙaita tare da rabin ƙaramin diamita. Sabanin haka, samun haɗin gwiwar axis na Z-axis ya haɗa da cire rabin ƙananan diamita daga radius lamba na kayan aiki da rarraba sakamakon da tangent na rabin kusurwar tip kayan aiki. Misali, ta amfani da injin ƙarshen kusurwa mai haɗaɗɗiya tare da takamaiman girma, kamar daidaitawar axis Z-2 da ƙaramin diamita na 2mm, zai samar da radiyo daban-daban don masu yankan katako a kusurwoyi daban-daban: mai yankan 20° yana haifar da radius. na 1.352mm, mai yankan 15 ° yana ba da 1.263mm, kuma mai yankan 10 ° yana ba da 1.175mm.
Idan muka yi la'akari da wani labari inda aka saita radius lamba na kayan aiki a 2.5mm, daidaitattun daidaitawar Z-axis don masu yankan katako na digiri daban-daban za a iya fitar da su kamar haka: don mai yankan 20 °, yana ƙididdige zuwa 8.506, don 15 °. mai yankan zuwa 11.394, kuma ga mai yankan 10 °, babban 17.145.
Wannan dabarar tana aiki akai-akai a cikin adadi ko misalai daban-daban, tana mai nuna matakin farko na tantance ainihin diamita na kayan aiki. Lokacin ƙayyadeInjin CNCdabarun, yanke shawara tsakanin fifikon radius na kayan aiki da aka saita ko daidaitawar axis Z yana tasiri ta hanyarbangaren aluminum's zane. A cikin al'amuran da sashin ke nuna siffa mai tako, guje wa tsangwama tare da kayan aikin ta hanyar daidaita daidaitawar Z ya zama wajibi. Sabanin haka, ga sassan da ba su da siffofi masu tako, zaɓin babban radius na tuntuɓar kayan aiki yana da fa'ida, haɓaka mafi kyawun ƙarewa ko ingantaccen aikin injina.
Shawarwari game da daidaita radius na kayan aiki tare da haɓaka ƙimar ciyarwar Z sun dogara ne akan takamaiman buƙatu na chamfer da nisa da aka nuna akan tsarin ɓangaren.
5. Misalan Shirye-shiryen
Daga nazarin ka'idodin lissafin kayan aikin tuntuɓar kayan aiki, ya bayyana a fili cewa lokacin da ake amfani da injin milling na kusurwa don sarrafa saman saman, ya isa ya kafa kusurwar tip kayan aiki, ƙaramin radius na kayan aiki, ko dai Z-axis. ƙimar saitin kayan aiki ko saitaccen radius na kayan aiki.
Sashe na gaba yana zayyana madaidaicin ayyuka don FANUC #1, #2, Siemens CNC tsarin R1, R2, Okuma CNC tsarin VC1, VC2, da tsarin Heidenhain Q1, Q2, Q3. Yana nuna yadda ake tsara takamaiman abubuwan haɗin gwiwa ta amfani da hanyar shigar da siga mai shirye-shirye na kowane tsarin CNC. Tsarin shigarwa don sigogin shirye-shirye na FANUC, Siemens, Okuma, da tsarin Heidenhain CNC an yi dalla-dalla a cikin Tables 1 zuwa 4.
Lura:P yana nuna lambar diyya na kayan aiki, yayin da R ke nuna ƙimar kayan aiki a cikin cikakkiyar yanayin umarni (G90).
Wannan labarin yana amfani da hanyoyin shirye-shirye guda biyu: lambar jeri 2 da lambar jeri 3. Haɗin gwiwar Z-axis yana amfani da tsarin biyan diyya na tsawon kayan aiki, yayin da radius lamba na kayan aiki yana amfani da hanyar biyan diyya ta radius na lissafi.
Lura:A cikin tsarin koyarwa, "2" yana nufin lambar kayan aiki, yayin da "1" ke nuna lambar gefen kayan aiki.
Wannan labarin yana amfani da hanyoyin shirye-shirye guda biyu, musamman lambar serial lamba 2 da lambar serial lamba 3, tare da haɗin gwiwar Z-axis da hanyoyin biyan diyya na radius na kayan aiki da suka rage daidai da waɗanda aka ambata a baya.
Tsarin Heidenhain CNC yana ba da damar daidaitawa kai tsaye zuwa tsayin kayan aiki da radius bayan an zaɓi kayan aiki. DL1 yana wakiltar tsayin kayan aikin da aka ƙaru da 1mm, yayin da DL-1 ke nuna tsayin kayan aikin ya ragu da 1mm. Ka'idar amfani da DR ta yi daidai da hanyoyin da aka ambata.
Don dalilai na nunawa, duk tsarin CNC za su yi amfani da da'irar φ40mm a matsayin misali don shirye-shiryen kwane-kwane. An bayar da misalin shirye-shirye a ƙasa.
5.1 Fanuc CNC tsarin shirye-shirye misali
Lokacin da aka saita #1 zuwa ƙimar da aka saita a cikin jagorar Z, #2 = #1*tan (ƙaramar tip angle/2) + (ƙananan radius), kuma shirin shine kamar haka.
G10L11P (lambar diyya kayan aiki mai tsayi) R-#1
G10L12P (lambar ramuwa kayan aikin radius) R#2
G0X25Y10G43H (lambar diyya kayan aiki mai tsayi) Z0G01
G41D (lambar ramuwa kayan aikin radius) X20F1000
Y0
G02X20Y0 I-20
G01Y-10
G0Z50
Lokacin da aka saita #1 zuwa radius na lamba, #2 = [lambar lamba - ƙananan radius]/tan (kusurwar tip / 2), kuma shirin shine kamar haka.
G10L11P (lambar diyya kayan aiki mai tsayi) R-#2
G10L12P (lambar ramuwa kayan aikin radius) R#1
G0X25Y10G43H (lambar diyya kayan aiki mai tsayi) Z0
G01G41D (lambar ramuwa kayan aikin radius) X20F1000
Y0
Saukewa: G02X20Y0I-20
G01Y-10
G0Z50
A cikin shirin, lokacin da aka yi alama tsawon tsayin sashin da aka karkata a cikin hanyar Z, R a cikin sashin shirin G10L11 shine “-# 1-tsawon tsayin saman Z-direction”; lokacin da aka yi alama tsayin saman da aka karkata a kwance, R a cikin sashin shirin G10L12 shine “+# 1-inclined surface a kwance tsayin”.
5.2 Siemens CNC tsarin shirye-shirye misali
Lokacin da R1 = Z ƙimar saiti, R2 = R1tan (kayan kayan aiki / 2) + (ƙaramin radius), shirin shine kamar haka.
TC_DP12[lambar kayan aiki, lambar gefen kayan aiki] = -R1
TC_DP6[lambar kayan aiki, lambar gefen kayan aiki] = R2
G0X25Y10
Z0
G01G41D(lambar ramuwa kayan aikin radius)X20F1000
Y0
Saukewa: G02X20Y0I-20
G01Y-10
G0Z50
Lokacin da R1 = lamba radius, R2 = [R1-aramin radius]/tan (kayan tip angle/2), shirin shine kamar haka.
TC_DP12[lambar kayan aiki, lambar yanka] = -R2
TC_DP6[lambar kayan aiki, lambar yankan] = R1
G0X25Y10
Z0
G01G41D (lambar ramuwa kayan aikin radius) X20F1000Y0
Saukewa: G02X20Y0I-20
G01Y-10
G0Z50
A cikin shirin, lokacin da aka yi alama tsawon ɓangaren bevel a cikin hanyar Z, sashin shirin TC_DP12 shine "-R1-bevel Z-direction length"; lokacin da aka yi alama tsawon ɓangaren bevel a cikin madaidaiciyar hanya, sashin shirin TC_DP6 shine "+ R1-bevel horizontal length".
5.3 Okuma CNC tsarin shirye-shirye misali Lokacin VC1 = Z saiti darajar, VC2 = VC1tan (tool tip angle / 2) + (ƙananan radius), shirin shine kamar haka.
VTOFH [lambar diyya na kayan aiki] = -VC1
VTOFD [lambar diyya na kayan aiki] = VC2
G0X25Y10
G56Z0
G01G41D (lambar ramuwa kayan aikin radius) X20F1000
Y0
Saukewa: G02X20Y0I-20
G01Y-10
G0Z50
Lokacin da VC1 = lamba radius, VC2 = (VC1-minor radius) / tan (kayan aikin tip / 2), shirin shine kamar haka.
VTOFH (lambar diyya na kayan aiki) = -VC2
VTOFD (lambar diyya na kayan aiki) = VC1
G0X25Y10
G56Z0
G01G41D (lambar ramuwa kayan aikin radius) X20F1000
Y0
Saukewa: G02X20Y0I-20
G01Y-10
G0Z50
A cikin shirin, lokacin da aka yi alamar tsayin ɓangaren bevel a cikin hanyar Z, sashin shirin VTOFH shine "-VC1-bevel Z-direction length"; lokacin da aka yi alamar tsayin ɓangaren bevel a cikin madaidaiciyar hanya, sashin shirin VTOFD shine "+ VC1-bevel horizontal length".
5.4 Misalin shirye-shirye na tsarin Heidenhain CNC
Lokacin da Q1 = Z ƙimar saiti, Q2 = Q1tan (ƙaramar tip kusurwa / 2) + (ƙananan radius), Q3 = Q2-radius, shirin shine kamar haka.
TOOL "Lambar kayan aiki / sunan kayan aiki" DL-Q1 DR Q3
Saukewa: LX25Y10FMAX
L Z0 FMAXL X20 R
L F1000
L Y0
Farashin CC0Y0
C X20Y0 R
L Y-10
L Z50 FMAX
Lokacin da Q1 = lamba radius, Q2 = (VC1-ƙananan radius) / tan (kayan kayan aiki / 2), Q3 = Q1-radius radius, shirin shine kamar haka.
TOOL "Lambar kayan aiki / sunan kayan aiki" DL-Q2 DR Q3
Saukewa: LX25Y10FMAX
LZ0 FMAX
Saukewa: LX20RL F1000
L Y0
Farashin CC0Y0
C X20Y0 R
L Y-10
L Z50 FMAX
A cikin shirin, lokacin da aka yi alama tsawon ɓangaren bevel a cikin hanyar Z, DL shine "-Q1-bevel Z-direction tsawon"; lokacin da tsayin ɓangaren bevel ɗin aka yi alama a cikin madaidaiciyar hanya, DR shine "+ Q3-bevel horizontal length".
6. Kwatanta lokacin sarrafawa
Ana nuna zane-zane da kwatancen sigogin hanyoyin sarrafawa guda uku a cikin Tebur na 5. Ana iya ganin cewa yin amfani da abin yankan niƙa na kusurwa don tsara shirye-shiryen kwane-kwane yana haifar da ɗan gajeren lokacin sarrafawa da ingantaccen inganci.
Yin amfani da ƙwanƙolin milling na kusurwa yana magance ƙalubalen da ake fuskanta a cikin shirye-shirye na ƙarshen niƙa da shirye-shiryen wasan ƙwallon ƙwallon ƙwallon ƙafa, gami da buƙatar ƙwararrun ƙwararrun masu aiki, rage tsawon rayuwar kayan aiki, da ƙarancin sarrafawa. Ta hanyar aiwatar da ingantaccen saitin kayan aiki da dabarun shirye-shirye, an rage lokacin shirye-shiryen samarwa, wanda ke haifar da haɓaka haɓakar samarwa.
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