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1、如何设定加工参数如何设定加工参数何謂何謂.金屬切削金屬切削?精密精密把工件中不需要的部份把工件中不需要的部份切除切除.不多不少地不多不少地.Evaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.第二撕剪區第二撕剪區第二撕剪區第二撕剪區Secondary Shear Zone刀具移動，高溫鐵屑與刀刃的前削角表面摩擦刀刃刀刃工件工件Evaluation only.Created with Aspose.Slides for.NE
2、T 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.第三撕剪區第三撕剪區第三撕剪區第三撕剪區Tertiary Shear Zone材料被刀刃擠壓，逃出刀尖的材料在刀刃後的間隙角(clearance angle)作彈性回復(spring back)彈性回復的材料與刀刃的間隙角表面摩擦，對刀尖及刀刃的後削面構成磨損刀刃刀刃工件工件Evaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011
3、Aspose Pty Ltd.高速切削的奧妙高速切削的奧妙第一撕剪區第一撕剪區Primary Shear Zone分子高速互相摩擦，在第一撕剪區產生極高溫度高速切削使用的刀具將切削時所產生的溫度集中到鐵屑去受到高溫熱能的幫助，切削材料能夠在高溫塑化下進入回火狀態所以切削阻力可以減低刀刃刀刃工件工件Evaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.Evaluation only.Created with Aspose.Sl
4、ides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.Evaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.ASSAB 8407 在不同線速度下加工出來的鐵屑Evaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright
5、 2004-2011 Aspose Pty Ltd.-KU JASSAB 8407在不同溫度下的抗衝擊值Evaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.ASSAB 8407回火曲線圖奧氏體化溫度1060 (1940 F)1020(1870 F)Evaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2
6、004-2011 Aspose Pty Ltd.高速切削熱力的消散分佈高速切削熱力的消散分佈 75%由鐵屑和油霧氣流帶走由鐵屑和油霧氣流帶走由刀具帶走由刀具帶走5%被工件吸收被工件吸收20%Evaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.高效率加工透過高速切削參數提高切削效率高效率加工透過高速切削參數提高切削效率,來達到更低來達到更低成本成本,更高準確度更高準確度,及更節省工序時間及更節省工序時間.低成本低成本高效率加
7、工高效率加工節省工序時間節省工序時間高準確度高準確度主軸轉速快主軸轉速快走刀速度高走刀速度高合理及進取合理及進取之切面面績之切面面績高效率加工之定義高效率加工之定義Evaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.高效率加工目標高效率加工目標開粗開粗最短時間切削最多材料最短時間切削最多材料,造成工件的初造成工件的初型型.中光中光繼續切削使光刀餘量平均繼續切削使光刀餘量平均,令光刀的刀令光刀的刀具損耗減至最少具損耗減至最少
8、.光刀光刀最短時間走最長的刀路最短時間走最長的刀路,令工件符合光令工件符合光潔度及準確度的要求潔度及準確度的要求.Evaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.順銑順銑?逆銑逆銑?A:順銑順銑B:逆銑逆銑A:順銑順銑B:逆銑逆銑Evaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-201
9、1 Aspose Pty Ltd.銑刀會銑刀會由外至內由外至內切削工件切削工件.每刃中每刃中,碎削厚度由厚至薄碎削厚度由厚至薄,而刀具所承受切削力由大而刀具所承受切削力由大漸降漸降.因此因此切削力切削力,切削量會由多至少切削量會由多至少.多用於多用於CNC及高速加工及高速加工何謂順銑何謂順銑(DOWN CUT)Evaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.切削力鐵屑厚度時間時間順銑情況Evaluation only.
10、Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.銑刀會銑刀會由內至外由內至外切削工件切削工件.每刃中每刃中,碎削厚度由薄至厚碎削厚度由薄至厚,而刀具所承受切削力由小漸大而刀具所承受切削力由小漸大.因因此此切削力切削力,切削量會由少至多切削量會由少至多.多用於切削黑皮多用於切削黑皮,手動銑床手動銑床.何謂逆銑何謂逆銑(UP CUT)Evaluation only.Created with Aspose.Slides for.NET 3.5 Client
11、 Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.切削力鐵屑厚度時間時間逆銑情況Evaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.順銑和逆銑與刀具壽命之關係順銑和逆銑與刀具壽命之關係 逆銑逆銑(Up cut)逆銑會導致較大逆銑會導致較大震動及磨損震動及磨損,損害切口損害切口,因而因而縮短刀具壽縮短刀具壽命命.順銑順銑(Down cut)由於在開始嚙合時產生較大的沖擊力
12、由於在開始嚙合時產生較大的沖擊力,因此需要剛性較因此需要剛性較強的刀具，夾具及機床強的刀具，夾具及機床.順銑會導致較小順銑會導致較小震動及磨損震動及磨損,因而因而有較長刀具壽命有較長刀具壽命.Evaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.加工難度低高 (硬度)低高 (韌性)快慢 (傳熱速度)低高 (磨損性)工件材料特性和加工難度的關係工件材料特性和加工難度的關係Evaluation only.Created with
13、 Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.銅,鋁銅,鋁8407,S136SKD61,H132344,20832510,D2SKD11ASP23,ASP30ASP60不同材料和線速度的關係不同材料和線速度的關係Evaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.D:刀具直徑(mm)S:機床主軸轉速(
14、RPM)V:線速度(m/min)F:走刀速度(mm/min)f:每刃切削量(mm/tooth)Z:刃數CNC加工常用公式加工常用公式Evaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.線速度示意圖Evaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.主軸
15、轉速快慢和刀具壽命之關係主軸轉速快慢和刀具壽命之關係Evaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.10mm 四刃高速鋼平底刀,切削HRC40 的鋼材.Evaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.切削速度增加可提高切削溫度切削速度增加可提高
16、切削溫度,令工件軟化而易於切削令工件軟化而易於切削.但如果溫度太高也會使刀具塗層損耗但如果溫度太高也會使刀具塗層損耗,令刀具壽命縮短令刀具壽命縮短.Evaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.走刀速度與刃切量的關係w走刀速度(F)w=刃切量(f)x刃數(Z)x轉速(S)Evaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.
17、0.0.Copyright 2004-2011 Aspose Pty Ltd.金屬切削區金屬切削區刀刃刀刃工件工件刀尖軌跡刀尖軌跡走刀方向走刀方向以順銑為例以順銑為例切削方向切削方向Evaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.則刃加工時(Side milling)刀具直徑與每刃切削量的關係Evaluation only.Created with Aspose.Slides for.NET 3.5 Client Pr
18、ofile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.不同顏色和形狀的切屑不同顏色和形狀的切屑Evaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.Evaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.每刃切削量
19、每刃切削量(f,feed per tooth)刀具切口與切口之間進刀距離刀具切口與切口之間進刀距離(unit:mm/tooth)F=f x Z x S F:走刀速度走刀速度S:機床主軸轉速機床主軸轉速z:刀具切口數目刀具切口數目何謂每刃切削量及如何設定走刀速何謂每刃切削量及如何設定走刀速度度 Evaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.切削實例切削實例切削物料切削物料切削物料切削物料SKD 61SKD 61硬度硬度
20、硬度硬度HRC 50HRC 50刀具刀具刀具刀具VC-2MS(VC-2MS(1 1)2)2刃刃刃刃主軸轉速主軸轉速主軸轉速主軸轉速20000rpm20000rpm切削深度切削深度切削深度切削深度0.1mm(0.1D)0.1mm(0.1D)走刀速度走刀速度走刀速度走刀速度A=100mm/minA=100mm/minB=200mm/minB=200mm/minC=400mm/minC=400mm/minD=800mm/minD=800mm/minE=1200mm/minE=1200mm/minEvaluation only.Created with Aspose.Slides for.NET 3.
21、5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.走刀速度走刀速度 mm/min每刃切削量每刃切削量 mm刀具與工件接刀具與工件接觸次數觸次數(10mm)A1000.00254000B2000.0052000C4000.011000D8000.02500E12000.03333A,B:刀具與工件接觸次數過多刀具與工件接觸次數過多,令刀具損耗增加令刀具損耗增加,縮短刀具壽命縮短刀具壽命.D,E:每刃切削量過大每刃切削量過大,使刀具負荷過大使刀具負荷過大.C:不會有刀具與工件接觸次數過多，或刀具超出負荷的情況出不會有刀具與工件接
22、觸次數過多，或刀具超出負荷的情況出現現,所以刀具壽命最長所以刀具壽命最長,是最合適的走刀速度。是最合適的走刀速度。Evaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.Evaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.切削實例切削實例切削物料切削物料切
23、削物料切削物料NAK 80NAK 80硬度硬度硬度硬度HRc 40HRc 40刀具刀具刀具刀具YC-4MC/VC-MD(YC-4MC/VC-MD(1010)假設刀具可切削假設刀具可切削假設刀具可切削假設刀具可切削長度為長度為長度為長度為240 m240 mEvaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.常見加工方法常見加工方法方法一方法二Evaluation only.Created with Aspose.Slide
24、s for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.S=3000 rpmV=94 m/minAd=0.5 mmF=1000 mm/minRd=6 mmf=0.083mm/tooth方法一方法一:一般加工方法一般加工方法切削速率切削速率=Ad*Rd*F =0.5*6*1000 =3000 mm3/min (3 cc/min)每件工件生產時間每件工件生產時間=(100*20*6)mm3/3000mm3/min=4 min刀路總長刀路總長=刀路長刀路長*行數行數 =100mm*(20/0.5)=4000 mm
25、 (4 m)生產工件總數生產工件總數=240m/4m=60件件 如刀具可切削長度為如刀具可切削長度為如刀具可切削長度為如刀具可切削長度為240 m240 mEvaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.S=6400 rpmV=200 m/minAd=20 mm(2D)F=1536 mm/minRd=1 mm(0.1D)f=0.06mm/tooth方法二方法二:見議高效率加工方法見議高效率加工方法如刀具可切削長度為如刀
26、具可切削長度為如刀具可切削長度為如刀具可切削長度為240 m240 m切削速率切削速率=Ad*Rd*F =20*1*1536 =30720 mm3/min (30.72 cc/min)每件工件生產時間每件工件生產時間=(100*20*6)mm3/30720mm3/min=0.39 min刀路總長刀路總長=刀路長刀路長*行數行數 =100mm*(6/1)=600 mm (0.6 m)生產工件總數生產工件總數=240m/0.6m=400件件 Evaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.C
27、opyright 2004-2011 Aspose Pty Ltd.S=10000 rpmV=314 m/minAd=20 mm(2D)F=6000 mm/minRd=0.5 mm(0.1D)f=0.1mm/tooth方法三方法三:見議高速見議高速,高效率加工方法高效率加工方法如刀具可切削長度為如刀具可切削長度為如刀具可切削長度為如刀具可切削長度為600 m600 m切削速率切削速率=Ad*Rd*F =20*0.5*6000 =60000 mm3/min (60 cc/min)每件工件生產時間每件工件生產時間=(100*20*6)mm3/60000mm3/min=0.2 min=12 sec刀
28、路總長刀路總長=刀路長刀路長*行數行數 =100mm*(6/0.5)=1200 mm (1.2 m)生產工件總數生產工件總數=600m/1.2m=500件件 Evaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.刀刃溫度時間溫度不斷上升溫度不斷上升刀刃溫度保持低溫保持低溫時間刀具切削溫度情況刀具切削溫度情況Evaluation only.Created with Aspose.Slides for.NET 3.5 Clien
29、t Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.一般加工方法一般加工方法方法一方法一(a)方法二方法二方法三方法三切削速率切削速率,Q(cc/min)330.72(10.24a)60(20a)每件工件生產時間每件工件生產時間(min)40.39(0.0975a)0.2(0.05a)切削面積切削面積(mm2)6 0.5 20 1(6.67a)20 0.5(3.33a)走刀速度走刀速度,F(mm/min)10001536(1.536a)6000(6a)工序切削長度工序切削長度,Tp(m)4 0.6(0.15a)1.2(0.3a)生產工件總數
30、生產工件總數(件件)60400(6.67a)500(8.33a)比較結果比較結果Evaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.Example:VC-4MCBottom cutSide millingEvaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Lt
31、d.Example:VC-4MC 6mmBottom CutSide millingEvaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.Example:VC-4MC 10mmBottom CutSide millingEvaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose
32、 Pty Ltd.Example:VC-MD(Side milling)Evaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.Example:VC-2SBEvaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.Example:VC-2SBEvaluation only.Created with Aspose.Slides for.NET 3.5 Client Profile 5.2.0.0.Copyright 2004-2011 Aspose Pty Ltd.