1. Clarify the responsibilities of the programmer, and be responsible for the control of processing quality, processing efficiency, cost control, and error rate in the mold CNC manufacturing process.
2. When the programmer receives a new mold, he must understand the requirements of the mold, the rationality of the mold structure, the steel used for the upper and lower molds, the product tolerance requirements, and the plastic material. Clearly distinguish where is the glue position, where is the PL surface, where is the touch-through, rub-through, and where it can be avoided. At the same time, communicate with the technician to determine the content of CNC machining.
3. After the programmer receives the new mold, in principle, the copper material list should be opened as soon as possible. Before filling in the list, the copper male must be disassembled. It can be unfinished, but the size of the palm bottom must be determined, and the copper male code and spark must be determined. bit size.
4. The construction drawings of the copper male and the young male are filled in with two program lists respectively. The workpieces that can be processed on the old machine tool or the workpieces that must be processed by high-speed machining should be explained in words and noted in the blank of “workpiece placement direction”. matter. The copper male is represented by the “TFR-ISO” view in the blank of the “workpiece placement direction”, and the steel material is represented by the “TOP” and “TFR-ISO” views in the blank of the “workpiece placement direction”, and the reference angle is indicated. For workpieces that cannot fully express the placement direction, a “FRONT” or “LEFT” view must be added. The steel material should be compared with the actual workpiece in person to confirm the reference direction, workpiece size and processing surface.
5. When the steel material is rough, the Z cutting amount is 0.5-0.7mm. When the copper material is roughened, the knife amount under Z is 1.0-1.5mm (1.0mm thick on the inside and 1.5mm on the reference edge).
6. When parallel finishing, max×imumstepover is set according to the “parallel finishing optimal contour parameter table”. The remaining amount before fine milling should be kept as small as possible, 0.10-0.2mm for steel material; 0.2–0.5mm for copper material. Do not use the R knife on a flat surface with a large area.
7. Leave a margin of 0.05mm on the rubbing surface or the penetrating surface for FIT molds. For some important rubbing surfaces with small areas, leave a margin of 0.1mm on the penetrating surface, and the surrounding PL surface is processed in place. The larger lower mold PL surface sealing position is 10mm-25mm (standard is 18mm) and can avoid the air by 0.15mm.
8. The approach feed is always 600mm/m when the tool is quickly lowered to a height of 3mm (relative machining depth). The F speed of the Z lower tool with helical lower tool and external feed is always 1000 mm/m. The F speed of the knife is uniformly 300mm/m, and the internal rapid movement (traverse) feed is uniformly 6500mm/m (must go G01).
9. When using Φ63R6, Φ40R6, Φ30R5 flying knife for rough cutting, the margin should be 0.8mm on one side of the side wall and 0.4mm on the bottom. The phenomenon of stepping on the knife cannot occur, and the inner frame with a small processing range of Φ63R6 cannot be used. When using Φ32R0.8, Φ25R0.8, Φ20R0.8, Φ16R0.8 tools for semi-finishing, the larger plane is reprocessed to ensure that 0.15mm margin is left at the bottom, so that the next tool can directly finish the bottom of the workpiece.
10. Before fine milling, a small diameter knife must be used to roughly clear the corner allowance. If the corner cannot be cleared, it must be blocked by a curved surface to avoid damage to the tool due to excessive angular allowance during fine milling. The allowance is uniform during finishing.
11. The tool clamping length does not need to be at the maximum depth or exceeds the maximum depth. When it is necessary to use an extended stub or a tool with a certain length to avoid voids, the data of L, B, and D must be marked in the remarks column of the program list. L—represents the length of the tool clamping, B—represents the clearance length of the tool, and D—represents the diameter of the extended head.
12. When roughing the copper male, add the mold base material to +5mm in the positive direction of Z, and add it to +3mm in the XY direction.
13. When removing the copper male, be sure to check whether the bottom of the palm is enough to avoid the air. Be sure to insert the removed copper male into the workpiece that needs spark machining, and carefully check whether it is enough to avoid the air. The approximately symmetrical copper male should be checked whether it is completely symmetrical and whether the vacant position is the same. Don’t be self-righteous and leave it unchecked.
14. The finished copper male must meet the standard:
⑴ accurate size, tolerance: <±0.01mm;
⑵ no deformation phenomenon;
(3) The knife pattern is clear and there is no particularly rough knife pattern;
⑷ The lines are clear, and the knife is not stepped;
⑸ There is no obvious and difficult to remove the front;
⑹The thickness of the bottom of the palm is guaranteed to be 15-25 mm, and the standard is 20 mm;
⑺ The copper male code is correct;
⑻ The spark position should be reduced around the reference position.
15. Principles to consider when dismantling copper public:
⑴ processing feasibility;
⑵ practical;
⑶ enough strength, no deformation;
⑷ easy to process;
⑸ Copper cost;
⑹ Beautiful appearance;
⑺ The less copper to be removed, the better;
⑻ For symmetrical products, try to make the left and right copper males together, and shift the number of processing.
16. Tool usage guidelines
(1) Use Φ30R5 as much as possible when the general-sized steel is roughened, and Φ63R6 as far as possible for the larger steel;
(2) M16 tool should be used for copper open thickness below 70mm; M20 tool should be used when the height is between 70-85mm; M25 tool should be used between 85-120mm;
(3) Copper male 2D shape light knife, M12 tool is used for the height below 50mm; M16 tool is used for the height between 50-70mm; M20 is used for the height between 70-85mm; M25 is used for the height between 85-120mm; more than 120mm The above are processed with Φ25R0.8, Φ32R0.8 flying knife handle;
⑷ For the flatter surface or the higher profile surface, try to choose Φ20R4, Φ25R5, Φ40R6 as the light knife tool;
17. Workpiece inspection regulations:
(1) The programmer is responsible for the work test results;
(2) The workpiece inspection shall be inspected according to the drawing tolerance;
(3) In principle, the steel material should be checked on the machine tool before it gets off the machine. The steel material processed in the night shift should be arranged to be checked by the programmer in the next morning. Programmer confirms. For large workpieces, the team leader or clerk will notify the technician to pick up the workpiece;
⑷ In principle, Tong Gong is tested in the “to-be-tested area”. After the test is OK, the programmer will place it in the “qualified area” in time. The mold technician is only allowed to take the workpiece in the “qualified area”;
⑸ If the unqualified workpiece is detected, it should be reported to the supervisor of the department, and the supervisor will decide whether to re-process, change the material or accept it according to the qualified workpiece;
⑹ If the head of this department checks and accepts unqualified workpieces as qualified ones, which leads to mold quality accidents, the head of this department shall take the main responsibility.
18. Relevant standards stipulate:
(1) The four sides of the mold material in the upper and lower molds are divided, and the bottom surface is zero;
(2) In the four sides of the original mold base, when the PL surface is a plane, the number of the plane is taken; when the PL surface is not a plane, the number of the bottom surface is taken. Take the number of the reference angle of the non-original mold base (reference angle mark △);
(3) The two sides of the row position are divided, the bottom of the row position touches one side, and the depth hits the bottom to zero;
⑷ Copper male and extra thick are indicated by “T”, thick public “R”, and small public “F”;
⑸ The corner where the mold number is printed on the mold material in the upper and lower molds is the reference angle;
⑹ The shape of the copper plug of the package R is made smaller by 0.08mm to ensure that the product does not scratch the hand;
⑺ The workpiece processing and placement direction, in principle, the X direction is the long dimension, and the Y direction is the short dimension;
⑻ When using “contour shape” and “optimal contour” for finishing, the machining direction should be “climb milling” as much as possible; when using flying cutters for precision milling, “climb milling” must be adopted;
⑼ It is recommended to use the “parallel + equal height” processing method for fine milling of copper male surfaces, with a parallel of 55 degrees and an equal height of 52 degrees; there is an overlap of 2 degrees. The tool used must be the requirement of the depth direction spark position + 0.02mm for the ball knife cutting equal height;
⑽ In principle, one of the four corners of the copper male palm bottom corresponds to the mold reference corner chamfer C6, and the other three corners are rounded to R2; the larger copper male C angle and R angle can be correspondingly larger;
⑾ In principle, it is stipulated that the highest point of the workpiece is Z zero when writing the program. The purpose:
① Prevent forgot to set the safety height and cause knife collision;
② The depth of the lower knife reflects the most conservative length required by the tool;
⑿ When using a white steel knife to process the copper male shape, the spark position parameter should be 0.015mm more negative than the requirement;
⒀ The copper male reference position should be processed to the bottom, leaving 0.2mm at the bottom (the purpose is to prevent the tool from hitting the code plate);
⒁ Tolerance of surface calculated by tool path programming: open rough 0.05mm, rough 0.025mm, smooth knife 0.008mm;
⒂ When using the alloy knife for finishing the straight surface of the steel material, the Z-cutting amount is 1.2mm, and when using the knife handle, the Z-cutting amount is 0.50mm. The straight face must be milled down.
⒃ Copper public material list, in principle, the length should be controlled within 250mm, and the height should be controlled within 100mm as much as possible.
⒄ The processed steel should be coarse or medium, with the remaining amount on the side ≥ 0.3mm and the remaining amount on the bottom ≥ 0.15mm;
⒅ Code board standard M8 20×20 (multiple) M10 30×30 (multiple)
⒆ Solid simulation must be used for all steel processing programs to determine the correctness of the program and reduce processing errors.
19. When opening the copper material, the length and width of the single side should be 2.5mm, and the total height should be 2-3mm, that is, 100 × 60 × 42 should be opened at 105 × 65 × 45. The length and width should be a multiple of 5, the height can be any integer, and the minimum copper male dimension is 40×20×30 (the size after processing is OK).
20. Sparks touch the number of papers to be concise, clear and easy to understand. The lines of the copper map should be thicker, and the size should be marked with integers as much as possible. The reference angle of the copper male should be clearly marked, with the mold number, the copper male number, the copper male 3D drawing, the size of the spark position, and precautions (sequence, shifting processing, rotary processing, processing after removing the insert, and wire cutting of the copper male). etc.), the programmer’s signature is confirmed, and the department supervisor reviews it.
21. The drawings of copper public wire cutting should be concise, clear and easy to understand. The place to be cut should be represented by a section line, including the mold number, copper male number, spark position size, reference position of the computer map, the size of the line cutting slope, precautions, computer map website, programmer’s signature confirmation, department supervisor review.
Post time: Aug-18-2022