1. Clarify the responsibilities of programmers, and be responsible for the control of processing quality, processing efficiency, cost control, and error rate in the mold CNC manufacturing process.
2. When a 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, product tolerance requirements, and beer plastic materials. Clearly distinguish where is the glue position, where is the PL surface, where is punctured, rubbed through, and where can be avoided. At the same time, communicate with the technician to determine the content of CNC machining.
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3. After the programmer receives the new mold, in principle, he will open the copper material list as soon as possible. Before filling in the list, the copper male must be disassembled.
4. The construction drawings of Tong Gong and Tong Gong should be filled in with 2 program lists respectively. The workpieces that can be machined on the old machine tool or the workpieces that must be processed by high-speed machining should be explained in words and matters needing attention in the blank space of "Workpiece placement direction". Tonggong is represented by “TFR-ISO” view in the blank space of “Workpiece Placement Direction”, steel material is represented by “TOP” and “TFR-ISO” views in the blank space of “Workpiece Placement Direction”, and the reference angle is indicated. For workpieces that cannot fully express the direction of placement, the "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 roughing the steel material, the Z cutting amount is 0.5-0.7mm. When the copper material is roughed, the Z cutting amount is 1.0-1.5mm (the internal roughing is 1.0mm, and the reference side is roughed at 1.5mm).
6. During parallel finish milling, max×imumstepover is set according to the “Parallel Best Contour Parameter Table for Finish Machining”. The remaining amount before fine milling should be as small as possible, steel material 0.10-0.2mm; copper material 0.2-0.5mm. Do not use the R knife to finish the plane with a large area.
7. Leave a margin of 0.05mm for the wear-through surface or the bump-through surface for FIT molding. For some important wear-through surfaces with small areas, leave a margin of 0.1mm for the bump-through surface, and the surrounding PL surface is processed in place. The PL surface sealant of the larger lower mold is 10mm-25mm (standard is 18mm) and the space can be avoided by 0.15mm.
8. The approach feed rate of the rapid down to 3mm height (relative to the processing depth) is 600mm/m, the F speed of the Z down knife with the spiral down knife and the external infeed is 1000 mm/m, the F speed of the Z down knife with the stepping knife is 300mm/m, and the internal rapid movement (traverse) feed is 6500mm/m (G01 must be used).
9. When using Φ63R6, Φ40R6, Φ30R5 flying cutters for roughing, the margin is 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, and Φ16R0.8 tools for semi-finishing, the larger plane is reprocessed to ensure a 0.15mm margin at the bottom, so that the next tool can directly finish the bottom of the workpiece.
10. Before finishing milling, you must use a smaller diameter tool to roughly clear the corner allowance. Where the corner cannot be cleared, you must make a curved surface to block it, so as to avoid excessive corner allowance during finish milling and cause damage to the tool. Ensure that the allowance during finish milling is uniform.
11. The clamping length of the tool does not need to be the maximum depth or exceed the maximum depth. When it is necessary to use an extended nozzle or a tool with a certain clearance length, the data of L, B, and D must be indicated in the remarks column of the program list. L—indicates the clamping length of the tool, B—indicates the clearance length of the tool, and D—indicates the diameter of the lengthening head.
12. During the rough machining of the copper male, add the mold base material to +5mm in the positive direction of Z, and +3mm on one side 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 put the dismantled copper male into the workpiece that needs spark processing, and carefully check whether it is enough to avoid the air. For approximately symmetrical copper males, it is necessary to check whether they are completely symmetrical and whether the avoidance positions are all the same. Don't be presumptuous and leave it unchecked.
14. The finished copper must meet the standard:
⑴ Accurate size, tolerance: <±0.01mm;
⑵ no deformation;
⑶ The knife pattern is clear and there is no particularly rough knife pattern;
⑷ The lines are clear, and there is no step at the knife joint;
(5) There is no obvious cloak that is difficult to remove;
⑹The thickness of the sole of the palm is guaranteed to be 15-25 mm, and the standard is 20mm;
⑺ Copper code is correct;
⑻Sparks should be reduced around the reference position.
15. Consideration principles for dismantling copper:
⑴ processing feasibility;
⑵ Practical;
⑶ strong enough, no deformation;
⑷ Convenient processing;
⑸ Copper cost;
⑹ beautiful appearance;
⑺ The less copper to remove, the better;
⑻ For symmetrical products, try to process the left and right copper males together, and shift the number of processing.
16. Guidelines for Tool Use
⑴ Try to choose Φ30R5 when roughing steel materials of general size, and choose Φ63R6 for larger steel materials;
⑵ M16 cutters are used for copper open thickness below 70mm; M20 cutters are used for heights between 70-85mm; M25 cutters are used for heights between 85-120mm; Φ25R0.8 and Φ32R0.8 flying knife handles are used for more than 120mm;
⑶ Tonggong 2D shape light knife, choose M12 tool if the height is less than 50mm; choose M16 tool when the height is between 50-70mm; choose M20 if the height is between 70-85mm;
⑷ Try to choose Φ20R4, Φ25R5, Φ40R6 as the light knife tool for the flat surface or the high shape surface;
17. Workpiece detection regulations:
⑴ The programmer is responsible for the work test results;
⑵ Workpiece detection is carried out according to the drawing tolerance;
⑶ In principle, the steel material should be tested on the machine tool before getting off the machine. The steel material processed on the night shift should not be off the machine until the programmer checks it in the next morning. The workpiece that must be off the machine in the middle of the night will be tested by the operator team leader and confirmed by the programmer the next day. For large workpieces, the team leader or clerk will notify the technician to pick up the workpieces;
⑷ In principle, Tonggong is tested in the "to-be-tested area". After the test is OK, the programmer will place it in the "qualified area" in time, and the mold technician is only allowed to take away the workpiece in the "qualified area";
⑸ Unqualified workpieces should be reported to the supervisor of the department, and the supervisor will decide whether to reprocess, refuel or accept qualified workpieces;
⑹ If the supervisor of the department checks the unqualified workpieces as qualified workpieces and causes mold quality accidents, the supervisor of the department shall bear the main responsibility.
18. Relevant standards stipulate:
⑴ The four sides of the inner mold material of the upper and lower molds are centered, and the bottom surface is zero;
⑵ The four sides of the original mold base are centered. 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. The reference angle of the non-original mold base (the reference angle sign △);
(3) The two sides of the row position are divided into centers, the bottom of the row position touches one side, and the depth is zero when it touches the bottom;
⑷ Copper, special and coarse are represented by "T", coarse public is represented by "R", and small public is represented by "F";
⑸ The corner with the mold number printed on the inner mold material of the upper and lower molds is the reference angle;
⑹ The shape of the stop copper male with R is made smaller by 0.08mm to ensure that the product does not scratch hands;
⑺ The workpiece processing placement direction, in principle, the X direction is the long dimension, and the Y direction is the short dimension;
⑻ When using the "contour shape" and "best contour" methods for finishing, the processing direction should be "climb milling" as much as possible; when using flying cutters for finishing milling, "climb milling" must be adopted;
⑼ It is recommended to use the "parallel + equal height" processing method for cutting when the copper male surface is finely milled, the parallel is 55 degrees, and the equal height is 52 degrees; there is 2 degrees of overlap. The tool used must be the requirement of the spark position in the depth direction of the ball knife cutting equal height +0.02mm;
⑽ In principle, of the four corners of the palm bottom of the copper male, one corner corresponds to the chamfer angle C6 of the mold reference angle, and the other three corners are rounded R2; the C angle and the R angle of the larger copper male 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 is:
① Prevent collision with the knife caused by forgetting to set the safety height;
② The depth of the cutting tool 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 touching the code plate);
⒁ Compile and calculate the surface tolerance of the tool path: open rough 0.05mm, rough finish 0.025mm, smooth knife 0.008mm;
⒂ When using an alloy knife for the straight surface of the steel material, the Z cutting distance is 1.2mm, and when using the knife handle, the Z cutting distance is 0.50mm. The straight face must be milled along;
⒃ Copper public bill of materials, in principle, the length is controlled within 250mm, and the height is controlled within 100mm as much as possible.
⒄ The processed steel material is rough and medium thick, the remaining amount on the side is ≥0.3mm, and the remaining amount on the bottom is ≥0.15mm;
⒅ Code board standard M8 20x20 (multiple) M10 30x30 (multiple)
⒆ Physical simulation must be used for the processing formulas of all steel materials to confirm the correctness of the programs and reduce processing errors.
19. When opening the copper material, the length and width of the unilateral residual volume is 2.5mm, and the total residual volume of the height is 2-3mm, that is, 100×60×42 should be opened to 105×65×45. If the length and width are multiples of 5, the height can be any integer, and the minimum copper outer dimension is 40×20×30 (the size after processing OK).
20. The paper of sparks touch number is required to be concise, clear and easy to understand. The lines of the copper map should be thicker, and the dimensions should be marked with integers as much as possible. The reference angle of the copper male shall be clearly marked, and there shall be mold number, copper male number, copper male 3D map, spark position size, precautions (sequencing, shifting processing, rotary processing, post-insert processing, copper male wire cutting, etc.), programmer’s signature confirmation, and department supervisor’s review.
21. Copper male wire cutting drawings are required to be concise, clear and easy to understand. The place to be wire-cut should be indicated by a section line, and it must have the mold number, copper male number, spark position size, computer diagram reference position, wire cutting slope size, precautions, computer diagram website, programmer's signature confirmation, and department supervisor review.
