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text-justify:inter-ideograph;text-indent:22.0pt;line-height:10.5pt;mso-line-height-rule: exactly;mso-list:l0 level1 lfo1;background:transparent"><!--[if !supportLists]--><span style="font-size: 10.5pt; font-family: Garamond;">1.<span style="font-weight: normal; font-stretch: normal; font-size: 7pt; line-height: normal; font-family: 'Times New Roman';"> </span></span><!--[endif]--><span class="90">问题分析</span></p> <p class="3631" style="text-align:justify;text-justify:inter-ideograph; text-indent:22.0pt;line-height:16.3pt;mso-line-height-rule:exactly;background: transparent"><span class="3630">如图1所示为余姚市麦斯特 电子科技有限公司生产的超长异 型薄壁不锈钢产品全剖视图，材 料为304不锈钢，该产品总长度为 5 </span><span class="3630"><span style="font-family: SimSun;">430</span></span><span class="363Garamond"><span lang="EN-US" style="font-size: 10pt;">mm</span></span><span class="3630"><span lang="EN-US">，</span></span><span class="3630">总宽为</span><span class="3630"><span style="font-family: SimSun;">88.1</span></span><span class="363Garamond"><span lang="EN-US" style="font-size: 10pt;">mm</span></span><span class="3630"><span lang="EN-US">，</span></span><span class="3630">总高 为 </span><span class="3630"><span style="font-family: SimSun;">58.36</span></span><span class="363Garamond"><span lang="EN-US" style="font-size: 10pt;">mm</span></span><span class="3630"><sub><span style="font-family: SimSun;">0</span></sub></span></p> <p class="3631" align="left" style="text-indent: 22pt; line-height: 16.55pt; background: transparent;"><span class="3630">由图1可见，产品最薄处厚度 为</span><span class="3630"><span style="font-family: SimSun;">3</span></span><span class="363Garamond"><span lang="EN-US" style="font-size: 10pt;">mm</span></span><span class="3630"><span lang="EN-US">，</span></span><span class="3630">且不镑钢具有塑性大、 韧性高和导热率低的特点，易形 成刀具高温，从而产生切屑瘤， 使切削阻力变大，薄壁处容易产 生变形现象。产品还具有较高的形位公差要求。对于长条型不锈 钢产品的加工，难免会出现整体 变形现象。要使总长5 <span style="font-family: SimSun;">430</span></span><span class="363Garamond"><span lang="EN-US" style="font-size: 10pt;">mm</span></span><span class="3630">的 长不锈钢工件加工出来的形位公 差在要求的公差范围之内，其工 装的合理设计成了能否加工出合 格产品的关键；其次，产品有一 条宽</span><span class="3630"><span style="font-family: SimSun;">30</span></span><span class="363Garamond"><span lang="EN-US" style="font-size: 10pt;">mm</span></span><span class="3630">的贯穿的斜槽和直径 为</span><span class="3630"><span style="font-family: SimSun;">8</span></span><span class="363Garamond"><span lang="EN-US" style="font-size: 10pt;">mm</span></span><span class="3630">的通孔，人们的第一反应 往往会考虑使用五轴数控机床进 行加工。如果使用三轴机床能够 完成图样的加工要求，那就会给 客户带来巨大的经济效益。</span></p> <div class="Section1"> <p class="91" style="margin:0cm;margin-bottom:.0001pt;text-indent:21.0pt; line-height:16.55pt;mso-line-height-rule:exactly;mso-list:l0 level1 lfo1; background:transparent"><!--[if !supportLists]--><b><span style="font-size: 10.5pt; font-family: Garamond;">1.<span style="font-weight: normal; font-stretch: normal; font-size: 7pt; line-height: normal; font-family: 'Times New Roman';"> </span></span></b><!--[endif]--><span class="91pt1">相应的加工方案（包括 </span><span class="90">工装设计）</span></p> <p class="3631" style="margin-left:0cm;text-align:justify;text-justify:inter-ideograph; text-indent:27.0pt;line-height:16.8pt;mso-line-height-rule:exactly;mso-list: l1 level1 lfo2;background:transparent"><!--[if !supportLists]--><span style="font-family: SimSun;">(1)<span style="font-stretch: normal; font-size: 7pt; line-height: normal; font-family: 'Times New Roman';"> </span></span><!--[endif]--><span class="3630">工序1:利用万向角度 铣头（见图</span><span class="3630"><span style="font-family: SimSun;">2)</span></span><span class="3630">加工上方斜面与 斜孔。</span></p> </div> <p class="3631" align="left" style="text-indent: 22pt; line-height: 16.55pt; background: transparent;"> </p> <p class="3631" align="left" style="margin-bottom: 11.55pt; text-indent: 21pt; line-height: 16.55pt; background: transparent;"><span class="3630">工件材料为长条型304不锈 钢，先加工上方斜面与斜孔，斜 面均为规则角度斜面，可用万向 角度头加工，一次加工到位。角 度头加工斜面主要有以下特点： ①效率高。角度头输出端可夹持 </span><span class="363Garamond"><span lang="EN-US" style="font-size: 10pt;">BT</span></span><span class="3630">锥度刀柄，根据不同的加工要 求可随意更换不同类型的刀具， 无论斜面或者侧面加工均可一次 加工成型，大大节省了传统斜面 爬面的加工时间。②表面粗糙度</span><span class="3660pt" style="line-height: 16.55pt; text-align: justify; background-color: transparent;">质量高。与传统的加工斜面方式 相比，角度头铣斜面具有无接刀 痕的优点，因此加工出的斜面表 面粗糙度质量也相对比较高。③ 可斜面钻孔和刚性攻牙。以此工 件为例，要想在普通三轴加工中 心上加工</span><span class="3660pt" style="line-height: 16.55pt; text-align: justify; background-color: transparent;"><span style="font-family: SimSun;">0 8</span></span><span class="366Garamond" style="line-height: 16.55pt; text-align: justify; background-color: transparent;"><span lang="EN-US" style="font-size: 9.5pt;">mm</span></span><span class="3660pt" style="line-height: 16.55pt; text-align: justify; background-color: transparent;">斜孔，就必须 利用分度头或者制作相对应的角 度工装，而分度头根本无法装夹 一个总长5 </span><span class="3660pt" style="line-height: 16.55pt; text-align: justify; background-color: transparent;"><span style="font-family: SimSun;">430</span></span><span class="366Garamond" style="line-height: 16.55pt; text-align: justify; background-color: transparent;"><span lang="EN-US" style="font-size: 9.5pt;">mm</span></span><span class="3660pt" style="line-height: 16.55pt; text-align: justify; background-color: transparent;">的工件。如果 制作工装的话，投入成本过大， 而且所加工出来的孔中心角度未 必能达到要求。角度铣头可在 ±120。内任意一度一调调角度， 并且角度定位方式为插销定位 式，不但定位刚性足，且其定位 的角度误差可控制在万分之一度 以内，大大提高了孔位与工件的 位置公差。</span></p> <p class="3631" align="left" style="margin-bottom: 11.55pt; text-indent: 21pt; line-height: 16.55pt; background: transparent;"><span class="3660pt"><span style="font-size: 8pt;">工序2:利用工装（见 图</span></span><span class="3660pt"><span style="font-size: 8pt; font-family: SimSun;">3)</span></span><span class="3660pt"><span style="font-size: 8pt;">加工下方平面与圆弧面。 此工装由数个专用垫块组成，都</span></span><span style="line-height: 16.55pt; text-align: justify; background-color: transparent;">是由线切割加工，所以成本较 低，而且一致性非常好，每个垫 块在线切割时都有轮廓单边偏移</span></p> <p class="3660" style="margin-left:0cm;text-indent:0cm;line-height:16.55pt; mso-line-height-rule:exactly;mso-list:l0 level1 lfo1;background:transparent"><!--[if !supportLists]--><span style="font-family: SimSun; letter-spacing: 0.5pt;">0.<span style="font-stretch: normal; font-size: 7pt; line-height: normal; font-family: 'Times New Roman';"> </span></span><!--[endif]--><span class="3660pt"><span style="font-family: SimSun;">01</span></span><span class="366Garamond"><span lang="EN-US" style="font-size: 9.5pt;">mm</span></span><span class="3660pt"><span style="font-family: SimSun;">,</span></span><span class="3660pt">能够与精加工后的工件 过度配合。垫块间距为</span><span class="3660pt"><span style="font-family: SimSun;">200</span></span><span class="366Garamond"><span lang="EN-US" style="font-size: 9.5pt;">mm</span></span><span class="3660pt"><span style="font-family: SimSun;">, </span></span><span class="3660pt">能保证在加工中的平稳性，使工 件加工表面粗糙度质量提高。图4 所示为加工实况图，图5所示为加 工出的成品。</span></p> <!--[if !supportTextWrap]--> <!--[endif]--> <!--[if !supportTextWrap]--> <!--[endif]--> <p class="111" align="left" style="margin: 0cm 0cm 0.0001pt 17pt; text-indent: 0cm; line-height: 10pt; background: transparent;"><a name="bookmark1"><!--[if !supportLists]--><span style="font-family: SimSun;">3.<span style="font-stretch: normal; font-size: 7pt; line-height: normal; font-family: 'Times New Roman';"> </span></span><!--[endif]--><span class="110">结语</span></a></p> <p class="3660" style="text-align:justify;text-justify:inter-ideograph; text-indent:17.0pt;line-height:16.3pt;mso-line-height-rule:exactly;background: transparent"><span class="3660pt">此加工案例中利用万向角度 铣头和巧妙的工装设计，解决了 长条型带斜面的不锈钢产品在三 轴加工中心上加工的问题，大大 提高了加工效率和加工精度，并 且大大降低了加工成本。所加工 出来的斜面表面质量都非常好， 得到了客户的好评与肯定，也为 客户带来了良好的经济效益。</span></p> <p class="3660" style="text-align:justify;text-justify:inter-ideograph; text-indent:17.0pt;line-height:16.3pt;mso-line-height-rule:exactly;background: transparent"> </p> <p class="3660" style="text-align:justify;text-justify:inter-ideograph; text-indent:17.0pt;line-height:16.3pt;mso-line-height-rule:exactly;background: transparent"> </p> <p class="MsoNormal"><span style="font-size:9.0pt;font-family:宋体;mso-ascii-font-family: "Times New Roman";mso-hansi-font-family:"Times New Roman"">本文由伯特利数控整理发表文章均来自网络仅供学习参考，转载请注明！</span><span style="font-size:9.0pt"> <span lang="EN-US"><o:p></o:p></span></span></p></div> <div class="blank30"></div> <!-- tag --> <div class="blank10"></div> 标签： <a href='/index.php?case=tag&act=show&tag=%E5%8A%A0%E5%B7%A5%E4%B8%AD%E5%BF%83' target='_blank'>加工中心</a> <a href='/index.php?case=tag&act=show&tag=%E6%95%B0%E6%8E%A7%E5%8A%A0%E5%B7%A5%E4%B8%AD%E5%BF%83' target='_blank'>数控加工中心</a> <a href='/index.php?case=tag&act=show&tag=CNC%E5%8A%A0%E5%B7%A5%E4%B8%AD%E5%BF%83' target='_blank'>CNC加工中心</a> <a href='/index.php?case=tag&act=show&tag=%E6%95%B0%E6%8E%A7%E6%9C%BA%E5%BA%8A' target='_blank'>数控机床</a> <a 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