AseriesoftextbooksformechanicalinnovationplanninginhighervocationaleducationTask1MachiningofcavitiesCavitymachiningcavityItisacommonpartpatterninactualmachining,andthroughthestudyofthisproject,studentscanunderstandthecharacteristicsandscopeofcavityprocessing.Correctlyidentifythedrawingsandformulatethecorrespondingprocesscards;CorrectlyedittheG-codeprocessingprogram,andprocesstheproductpartsaccordingtotheproductiondrawings;Itcanbeprogrammedindependentlyaccordingtothecavitydrawingsandtheprogramisvalidatedonthemachine.TaskcontentBlanksize60mm×60mm×25mm,madeofaluminum.Makethesize40mm×40mm×5mmsquarecavitywithrecessfilletandR8mmfillet;MissionObjectives1Learnhowtodeterminethepositionofthetooldroppointduringmachining.2Mastertheprogrammingmethodofzigzagcutter.3Thecorrectselectionofthetoolradiuscompensationdirection.MissionpreparationPreparationofMaterials:60mm×60mm×25mmaluminum.EquipmentPreparation:FANUCVDL-600AVerticalCNCMillingMachine.ToolPreparation:φ10mmendmill,hydraulicvise.GagePreparation:Verniercalipers,edgefinders.AuxiliaryTools:Horns,visewrenches,copperrods.KnowledgeLinks1.Toolradiuscompensation(a)Clockwisemachining(b)CounterclockwisemachiningThemethodofselectingthetoolradiuscompensationvalueforthecavityissimilartothatforthecoreKnowledgeLinks2.SelectionofcavitymillingtoolsForcavitygraphicsCNCmillingmachinescannotmachinerightanglesinthecavity,sowhenselectingatool,itisnecessarytoselecttheradiusoftheminimumarcinthepattern.KnowledgeLinks2.SelectionofcavitymillingtoolsInthistask,theminimuminnerarcradiusis8mm,andthetoolcanchooseanendmillofφ16mm;Inthesettingoftheprocessingtechnologyintheactualprocessingandproduction,theactualuseoftoolsisgenerallysmallerthanthatoftheoreticaltools;Forthistask,itisrecommendedtochooseaφ10mmendmillKnowledgeLinks3.ZverticaldownwardknifetypeTheselectionofZ-directionverticalcutterhascertainrequirementsfortoolhardnessandmachiningdepthThecut-downpointisselectedinapositionthathasnoeffectonthesizeinthecavityGenerally,deepgroovemachiningdoesnotchoosethiscuttingmethodGenerally,deepgroovemachiningdoesnotchoosethiscuttingmethodKnowledgeLinks4.DiagonalinsertionlowerknifeTheobliqueinsertionknifeisalsocalledthe"zigzag"knifeThelowerpointisselectedinapositionthathasnoeffectonthesizeinthecavityGenerally,thedeepgrooveismostlylongorsquare,andwhenthemarginsizeislarge,thelowerknifetypeisselected.KnowledgeLinks4.DiagonalinsertionlowerknifeDuringprocessingThedepthofprocessingisoftenrelativelydeep,andthetoolcannotbeprocessedtotheendatonetime.InordertoavoidtheZ-axiscollisionofthetoolintheprocessingprocess,the"zigzag"downwardknifemethodandthespiraldownwardknifemethodareusuallyusedfordeepprocessing."Zigzag"knifemethod,istotakethe"zigzag"routeforlayer-by-layerprocessing,eachprocessingisverysmall,andfinallyreachtherequireddepth.KnowledgeLinks4.DiagonalinsertionlowerknifeProgrammingFormat:NoteWhenmoving,itislinkedtotheZaxisalongtheXaxisorYaxis;01Thedepthofeachcutshouldbesmall,andtrytokeepthelayerdepthconsistenteachtime;02Thiscuttingmethodisestablishedwhentheknifeisnotcompensated,sobecarefultoavoidtheshapewhenselectingthepointontheaxis.03KnowledgeLinks5.SpirallowerknifeTheprincipleofthespiraldownZmethodisthesameasthatofthezigzagmethod,theonlydifferenceisthatthismethodisusedwhenthecavitypatternissmallandthetoolcannotmoveinalargearea.SpiraldownwardknifemethodAsthenamesuggests,theZ-axisdepthisgraduallyreducedduringrotation,sothatthetoolmovementtrajectoryisspiraling.KnowledgeLinks5.SpirallowerknifeProgrammingFormat:NoteWhenmoving,thewholecircleisprogrammed,andthecircleislinkedwiththeZ-axiswhiledrawing;01Thedepthofeachcutshouldbesmall,andtrytokeepthelayerdepthconsistenteachtime;02Thiscuttingmethodisestablishedwhentheknifeisnotcompensated,sobecarefultoavoidtheshapewhenselectingthepointontheaxis.03G02/G03X_Y_I_J_Z-0.2；X_Y_I_J_Z-0.4；X_Y_I_J_Z-0.6；……X_Y_I_J_Z-[DepthRequired];Tasksteps1.StudythedrawingsReadthedrawingsPreliminarycheckofthedimensionsandrequirementsofthedrawingTasksteps2.FormulateprocessingtechnologyEstablishtheworkpiececoordinatesystemaccordingtothedrawingandsimplifiedprogramming;01Tasksteps2.FormulateprocessingtechnologyToolselection,thistaskusesφ10mmendmilltoprocessthecavity;02CutternumberThenameofthecutterSpindlespeedFeedrateT1φ10mmendmillS1000Z：F100；X、Y：F300Accordingtothesizeofthedrawing,thekniferouteisformulated.Thispartisthecavity,thecuttingpointiswithintheworkpiece,theobliqueinsertioncuttingmodeisselected,andthecuttingrouteisestablished;03Tasksteps2.Formulateprocessingtechnologybasispointcalculations;04serialnumberXYremark1’100Knifepoint1-100—2-200—3-2012—4-1220—51220—62012—720-12—812-20—9-12-20—10-20-12—ItcanbeseenthatthispartadoptstheobliqueinsertiontypecuttingmethodSelect1′and1asthecut-downintervalpointsThisdroppointisbuiltbeforetheknifecoverisestablishedTasksteps2.FormulateprocessingtechnologyDeterminetheoriginoftheworkpiececoordinatesystemandthetoolroute,andwhentheprocessingdirectionisclockwise,thetoolpathis1′→1→2→3→4→5→6→7→8→9→10→2→1;05WriteCNCmachiningprograms;06MachiningprogramexegesisO1111；ThenameofthemainprogramG90G17G21G40G49G80；initializeG28G91Z0；TheZ-axisisbacktothereferencepointG54G90G00X0Y0；ThetoolmovesquicklytotheworkpiececenterpointM03S1000；Thespindlerotatesforwardataspeedof1000r/minG00X-10Y0；Thetoolmovesquicklytothe1′pointdownpointZ100；ThetoolmovesquicklytoasafesurfaceZ5；ThetoolisquicklymovedtotheZ5planeG01X-10Z-0.5F100；Straightlineinterpolationto1point,depthZ-0.5Tasksteps2.FormulateprocessingtechnologyMachiningprogramexegesisX10Z-1；Straightinterpolationto1′pointsX-10Z-1.5；Straightlineinterpolationto1pointX10Z-2；Straightinterpolationto1′pointsX-10Z-2.5；Straightlineinterpolationto1pointX10Z-3；Straightinterpolationto1′pointsX-10Z-3.5；Straightlineinterpolationto1pointX10Z-4；Straightinterpolationto1′pointsX-10Z-4.5；Straightlineinterpolationto1pointX10Z-5；Straightinterpolationto1′pointsX-10；Straightinterpolationto1point,millingthebottomsurfaceG01G42D01X-20Y0F300；Establishthetoolradiustotherightcompensationtothe2-pointcoordinateX-20Y12；Straightlineinterpolationto3-pointcoordinatesG02X-12Y20R8；Clockwiseinterpolationto4pointcoordinatesG01X12Y20；Straightinterpolationto5-pointcoordinatesG02X20Y12R8；Clockwiseinterpolationto6pointcoordinatesG01X20Y-12；Straightlineinterpolationto7pointcoordinatesG02X12Y-20R8；Clockwisearcinterpolationtothe8-pointcoordinateTasksteps2.FormulateprocessingtechnologyMachiningprogramexegesisG01X-12Y-20；Straightlineinterpolationto9-pointcoordinatesG02X-20Y-12R8；Clockwisecircularinterpolationto10pointcoordinatesG01X-20Y0；Straightlineinterpolationto2-pointcoordinatesG01G40X-10Y0；Canceltoolradiuscompensationto1pointcoordinateG90G00Z100；ThetoolisquicklymovedtotheheightoftheabsolutecoordinatesZ100M05；ThespindlestopsM30；EndofprogramAftertheendofprocessing,onlythegraphicsrequiredbythedrawingsareprocessed,andtherearestillmoreresidualmaterialsontheinsideofthecavitythathavenotbeenremoved,andtheremainingmaterialscanberemovedmanuallyattheendofprocessing,orthepositionoftheremainingmaterialscanbecalculatedbeforeprocessing,andtheprocessingiscarriedoutbyaddingthenon-toolfillingpoint.07Note:Itisnotpossibletochangethecompensationvalueofthetoolradiusbyremovingtheremainingmaterialfromthecore.Tasksteps3.CNCmachiningUsingtheVDL-600AverticalCNCmillingmachine,themachiningiscarriedoutaccordingtotheCNCmachiningstepsinproject2.Taskevaluationtask

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serialnumberAssessmentitemsDistributionGradingCriteriaMeasuredrecordsscore1Useitintheknifemode1010pointsforcorrectuse,and5pointsformistakes

2Programming2020pointsareawardedforcorrectprogramming,and1pointisdeductedforeacherror

3Toolselection1010pointsareawardedformeetingallre