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font-family: 宋體;">隨著工業技術的飛速發展，數控加工技術也以它強有力的生命力在現代機械加工中領居著不可替代的位置。數控加工作為一種新形式的加工理念，它使操作者從煩瑣而勞累的體力勞動中解脫出來，也使很多以前靠搖動手柄不能加工的產品變為了現實。所以我個人認為，數控加工是現代加工業的一大革命。它不但能減輕操作者的勞動強度、</span><span style="text-indent: 21pt;"> </span><span style="text-indent: 21pt; font-family: 宋體;">獲得高質量的加工產品。而在效率就是生命力的現代社會里，數控加工的出現，為企業、也為操作者贏得了第二次生命。</span></p> <p class="MsoNormal" style="text-indent:21.0pt;mso-char-indent-count:2.0"><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">雖然說數控加工作為一種新形式、高效率、高質量的加工方式，</span> <span style="font-family: 宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family:"Times New Roman"">能有效的獲得較高的生產效率和更好的加工質量。但它也受著很多因素的影響，如刀具的合理選擇與刃磨、</span> <span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">切削用量的選擇以及程序的合理編制等，這對操作者來說，無疑是一新的挑戰和對操作者更高技能的要求。下面以加工一內球面為例，試述自己在球面加工中刀具選擇及程序編制的一點體會。</span></p> <p class="MsoNormal" style="text-indent:21.0pt;mso-char-indent-count:2.0"><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">如圖</span><span lang="EN-US">1</span><span style="font-family: 宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family:"Times New Roman"">所示為一</span><span lang="EN-US">SR20</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman"; mso-hansi-font-family:"Times New Roman"">內球面的加工</span><span lang="EN-US">,</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">其球面形狀度要求為</span><span lang="EN-US">0.05mm,</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">表面粗糙度為</span><span lang="EN-US">0.8mm</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">。刀具的選擇及刃磨。</span></p> <p class="MsoNormal" style="text-indent:21.0pt;mso-char-indent-count:2.0"><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">機械加工中</span><span lang="EN-US">,</span><span style="font-family: 宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family:"Times New Roman"">刀具的選擇及刃磨卻是影響加工質量的重要因素</span><span lang="EN-US">,</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman"; mso-hansi-font-family:"Times New Roman"">在該零件的加工中</span><span lang="EN-US">,</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">為能達到設計要求和粗糙度要求</span><span lang="EN-US">,</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">切削刃必須過球心</span><span lang="EN-US">,</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">且切削時又不能使刀具與工件發生干涉</span><span lang="EN-US">,</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">所以只能將車刀的主偏角</span><span lang="EN-US">Kr </span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">刃磨到盡可能的大的角度。而我們由刀尖角ε</span><span lang="EN-US">r =1800-(Kr + Kr</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">′</span><span lang="EN-US">) </span><span style="font-family: 宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family:"Times New Roman"">（</span><span lang="EN-US">Kr</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman"; mso-hansi-font-family:"Times New Roman"">′為副偏角</span><span lang="EN-US">)</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">可知</span><span lang="EN-US">,</span><span style="font-family: 宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family:"Times New Roman"">當主偏角</span><span lang="EN-US">Kr</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman"; mso-hansi-font-family:"Times New Roman"">增大時</span><span lang="EN-US">(</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">副偏角</span><span lang="EN-US">Kr</span><span style="font-family: 宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family:"Times New Roman"">′沒有改變</span><span lang="EN-US">),</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman"; mso-hansi-font-family:"Times New Roman"">刀尖角ε</span><span lang="EN-US">r</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">就會減少。而我們都知道</span><span lang="EN-US">,</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">刀尖角的減小必然導致刀尖強度降低</span><span lang="EN-US">,</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">同時刀具本身的散熱面積也隨之減少，從而加劇了刀尖的磨損，也極易造成“崩刃”現象，這大大影響和降低了刀具的耐用度及其壽命。</span></p> <p class="MsoNormal" style="text-indent:21.0pt;mso-char-indent-count:2.0"><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">同時從切削原理分析我們知道</span><span lang="EN-US">,</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">主偏角的增大，將直接影響切削層厚度及斷屑的效果，在背吃刀量和進給量一定時，主偏角的增大將使切削厚度增大</span><span lang="EN-US">,</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman"; mso-hansi-font-family:"Times New Roman"">而切削寬度則會減少，這雖有利于斷屑</span><span lang="EN-US">,</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman"; mso-hansi-font-family:"Times New Roman"">但切削刃在單位長度上的負荷將會增大</span><span lang="EN-US">,</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman"; mso-hansi-font-family:"Times New Roman"">這就使得加工過程極不平穩及殘留高度不均而導致加工表面的粗糙度降低。</span></p> <p class="MsoNormal" style="text-indent:21.0pt;mso-char-indent-count:2.0"><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">在該球面體的切削加工中，為了既使刀具不與工件發生干涉又提高刀具壽命以及排屑的順暢，我選用了與被加工圓弧直徑的</span><span lang="EN-US">1/10</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman"; mso-hansi-font-family:"Times New Roman"">即</span><span lang="EN-US">R4 </span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">的圓弧刀進行加工</span><span lang="EN-US">,</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">為了提高切削的表面質量和精度</span><span lang="EN-US">, </span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">將圓弧刀的前角γ</span><span lang="EN-US">0</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">刃磨成</span><span lang="EN-US">40</span><span style="font-family: 宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family:"Times New Roman"">～</span><span lang="EN-US">60</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman"; mso-hansi-font-family:"Times New Roman"">，后角α</span><span lang="EN-US">0</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">則刃磨成雙重或多重角，以增大刀具的強度和壽命。由于</span><span lang="EN-US">R</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">刀刀刃的圓度誤差將會直接復映到加工工件上，</span> <span style="font-family:宋體; mso-ascii-font-family:"Times New Roman";mso-hansi-font-family:"Times New Roman"">所以在刃磨后需要用油石仔細的研磨、修整刀刃，以獲得較好的輪廓度以及較好的表面粗糙度</span> <span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">（車刀精度必須高于被加工工件的精度要求）</span><span lang="EN-US"> ,</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">以保證切削質量。</span></p> <p class="MsoNormal" style="text-indent:21.0pt;mso-char-indent-count:2.0"><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">我們從圖</span><span lang="EN-US">2 </span><span style="font-family: 宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family:"Times New Roman"">可以看出</span><span lang="EN-US">,</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman"; mso-hansi-font-family:"Times New Roman"">圓弧車刀在整個切削過程中刀尖始終與工件表面成相切狀態。加工中刀具角度也不會隨切削而發生改變</span><span lang="EN-US">,</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman"; mso-hansi-font-family:"Times New Roman"">所以切削變得平穩。</span> <span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">同時由于切削刃的增大，</span> <span style="font-family:宋體;mso-ascii-font-family: "Times New Roman";mso-hansi-font-family:"Times New Roman"">極大的改善了散熱條件，減少了殘留面積，</span> <span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">大大提高了表面粗糙度質量及刀具壽命。</span></p> <p class="MsoNormal" style="text-indent:21.0pt;mso-char-indent-count:2.0"><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">加工程序的編制。</span></p> <p class="MsoNormal" style="text-indent:21.0pt;mso-char-indent-count:2.0"><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">數控加工程序的合理編制，也是加工質量的重要保證之一，程序編制的關鍵是盡可能的讓刀具走一個與被加工圖樣相符且最為簡捷而合理的軌跡，而這個理想軌跡的起始點、運動路線及距離尺寸均是由刀尖來確定的。而用</span><span lang="EN-US">R </span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman"; mso-hansi-font-family:"Times New Roman"">刀車削內球面時，其切削點是在不斷的變化著的，如把每個點都視為有一個刀尖，勢必就會有很多的刀尖，而且每個刀尖在切削過程中與工件圓弧軌跡的距離是在不斷變化的，所以不宜用參加切削的刀刃進行編程。眾所周知，兩圓相切，無論以何種方式相切于何處，兩圓心與切點的距離始終保持不變，其值等于半徑。所以在整個切削過程中，圓弧車刀上只有刀刃圓心始終與工件球面保持不變的距離即</span><span lang="EN-US">4mm</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman"; mso-hansi-font-family:"Times New Roman"">，明白了這一點，編程的編制就顯得容易多了：我們就將該點（圓弧車刀的圓心）視為刀尖進行編程，讓其走一圓弧軌跡，這樣既簡化了程序的編制，又提高了切削效率。</span> <span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">（但該圓弧軌跡的尺寸必須減去一個</span><span lang="EN-US">R</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">刀的直徑尺寸）程序編制如下：</span></p> <p class="MsoNormal" style="text-indent:21.0pt;mso-char-indent-count:2.0"><span lang="EN-US">*</span></p> <p class="MsoNormal" style="text-indent:21.0pt;mso-char-indent-count:2.0"><span lang="EN-US">NXX</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman"; mso-hansi-font-family:"Times New Roman""> </span><span lang="EN-US">T33;</span></p> <p class="MsoNormal" style="text-indent:21.0pt;mso-char-indent-count:2.0"><span lang="EN-US">NXX</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman"; mso-hansi-font-family:"Times New Roman""> </span><span lang="EN-US">M6;</span></p> <p class="MsoNormal" style="text-indent:21.0pt;mso-char-indent-count:2.0"><span lang="EN-US">NXX</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman"; mso-hansi-font-family:"Times New Roman""> </span><span lang="EN-US">G00 X36. Z6. M08</span></p> <p class="MsoNormal" style="text-indent:21.0pt;mso-char-indent-count:2.0"><span lang="EN-US">NXX</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman"; mso-hansi-font-family:"Times New Roman""> </span><span lang="EN-US">G01 Z-10. F300</span></p> <p class="MsoNormal" style="text-indent:21.0pt;mso-char-indent-count:2.0"><span lang="EN-US">NXX</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman"; mso-hansi-font-family:"Times New Roman""> </span><span lang="EN-US">G02 X0 Z-26. I20. K0F300</span></p> <p class="MsoNormal" style="text-indent:21.0pt;mso-char-indent-count:2.0"><span lang="EN-US">NXX</span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman"; mso-hansi-font-family:"Times New Roman""> </span><span lang="EN-US">G00 Z6.</span></p> <p class="MsoNormal" style="text-indent:21.0pt;mso-char-indent-count:2.0"><span lang="EN-US">*</span></p> <p class="MsoNormal" style="text-indent:21.0pt;mso-char-indent-count:2.0"><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family: "Times New Roman"">生產實踐證明，該刀具的選擇及編程方式的選擇是合理可行的，而且在同類產品的加工中（包括外球面）得以廣泛而成功的應用，均取得了良好效果。</span></p> <p class="MsoNormal" align="center" style="margin-top:4.5pt;margin-right:0cm; margin-bottom:7.5pt;margin-left:0cm;text-align:center;line-height:13.5pt; mso-pagination:widow-orphan;mso-outline-level:1"><b><span style="mso-bidi-font-size: 10.5pt;font-family:宋體;mso-bidi-font-family:宋體;color:#666666;mso-font-kerning: 0pt">本文由<span lang="EN-US"> <a ><span 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