- Define the responsibilities of the programmer — take full responsibility for the processing quality, processing efficiency, cost control and error control in the whole CNC manufacturing process of the mold.
- When receiving the new die, the programmer must understand the requirements of the die, the rationality of the die structure, the steel used in the front and rear dies, the product tolerance requirements, and the plastic materials. Distinguish where is the glue position, where is the PL surface, where is the touch through, rub through, where can be avoided.
- After receiving the new die, the programmer should open the list of copper materials at the first time in principle. Before filling in the list, the copper male must be removed. It can be that it is not repaired, but it should have the size of palm base, and determine the code of copper male and the size of spark position. The first batch of copper materials must be opened within 2 days, and all copper materials can be opened within 10 days, which can be divided into 4 times of BOM.
- The construction drawings of tonggong and Yougong shall be filled in with two construction drawings respectively, and the spark position must be filled in the designated place. For the workpieces that can be processed in the old machine tool, please tick “√” with the corresponding machine tool in the machine tool column of the construction drawing, and the workpieces that must be processed in the high speed machine tool should be indicated in the remarks column. For the workpiece that can’t express clearly the placement direction in the CNC construction drawing, it must be attached with the printed orientation diagram, which can make it clear at a glance. The steel material shall confirm the datum direction, workpiece size and processing surface by comparing with the actual workpiece.
- When the steel is roughened, the Z cutting amount is 0.5-0.7mm. When the copper material is roughened, the Z cutting amount is 1.0-1.5mm (the inner roughening is 1.0 mm, and the base edge roughening is 1.5 mm).
- In parallel finish milling, Ma × imum Stepover is set according to the “table of best contour parameters of parallel finish milling”. Before finish milling, the remaining amount should be kept as small as possible, and the steel material should be 0.10-0.2mm. Copper 0.2-0.5mm. Don’t use r-knife to finish the plane with large area.
- Leave 0.05mm allowance on the rubbing through surface or touching through surface for fit mold. For some important rubbing through surfaces with small area, leave 0.1mm allowance on the touching through surface, and process the peripheral PL surface in place. The larger back mold PL surface sealing glue position is 18mm away, and the voidable one is 0.10mm away (determined by the department head).
- Fast cutting to 3mm height, use F-speed cutting (relative processing depth), normal cutting F-speed is 300 mm / m, spiral cutting and external feeding z-cutting F-speed is 900 mm / m, stepping z-cutting F-speed is 150 mm / m, internal fast moving F-speed is 6500 mm / M (must go G01).
- When using Φ 63r6, Φ 40r6, and Φ 30r5 flying cutter for roughening, the allowance shall be 0.8mm on one side, and the phenomenon of stepping on the cutter shall not occur. The inner frame with smaller machining range of Φ 63r6 shall not be used for grooving. After roughening, the larger plane shall be machined again with the same cutter to ensure that the allowance of 0.2mm is left at the bottom, so that the next cutter can directly finish the bottom of the workpiece.
- Before finishing milling, the corner allowance must be roughly cleared with a small diameter tool. Where it is impossible to clear the corner, the surface must be used to block it, so as to avoid tool damage caused by excessive corner allowance during finishing milling.
- The length of the cutting tool cannot be accurately determined. When it is necessary to use a lengthened nozzle or a small knife with a conical head, it must be noted “please use lengthened nozzle” on the construction drawing. The length of tool extension, tool straight position and the total length of shank + tool extension must be clearly stated.
- In rough machining, multi curved surface slotting is not used as far as possible to improve machining efficiency, and multi curved surface contour cutting is preferred.
- When removing the copper joint, it is necessary to check whether the palm bottom is empty enough. It is necessary to insert the removed copper joint into the workpiece to be machined by spark machining, and color it carefully to check whether it is empty enough. If the copper is approximately symmetrical, it is necessary to check whether it is completely symmetrical and whether the void avoidance positions are the same. Don’t be self righteous and don’t check.
- The finished copper alloy must meet the following standards:
(1) the dimensions are accurate with tolerance of ± 0.02mm for young and ± 0.04mm for coarse;
(2) there is no deformation;
(3) the knife pattern is clear, and there is no particularly rough knife pattern;
(4) the line is clear, and there is no step at the cutting point;
(5) there is no obvious drape front which is difficult to remove;
(6) the thickness of palmar floor should be 15-25 mm, and the standard is 20 mm;
(7) the copper code is correct;
(8) reduce the spark level around the reference level.
- Consideration principle of dismantling Copper Company:
(1) processing feasibility;
(2) practical;
(3) enough strength without deformation;
(4) convenient processing;
(5) copper cost;
(6) beautiful appearance;
(7) the less copper is removed, the better;
(8) for symmetrical products, the left and right copper male should be processed together as far as possible, and the number shifting processing should be used.
- Tool use guidelines
(1) when roughening the general size steel, try to choose Φ 30r5, and when roughening the larger size steel, try to choose Φ 63r6;
(2) the M16 tool is selected for the height of copper surface below 70mm; the M20 tool is selected for the height between 70-85mm; the M25 tool is selected for the height between 85-120mm; the Φ 25r0.8 and Φ 32r0.8 flying tool handles are selected for the height above 120mm; the parts that must be removed in the middle of the night are inspected by the programmer tomorrow morning and confirmed by the programmer the next day. For large workpieces, the team leader or clerk shall inform the technician to collect the workpieces
(3) the copper male 2D shape light knife, the height below 50 mm, select the M12 tool; the height is 50-70 mm
M16 tool is selected for the height between 70-85mm, M20 tool is selected for the height between 85-120mm
M25 is used when the diameter is more than 120mm, and Φ 25r0.8 and Φ 32r0.8 flying tools are used when the diameter is more than 120mm;
(4) for flat surface or higher surface, try to choose Φ 20r4, Φ 25r5 and Φ 40r6
As a light knife tool;
(5) the specific processing parameters are shown in the table of rough and finish processing parameters.
- Workpiece inspection regulations:
(1) the programmer is responsible for the test results;
(2) workpiece inspection shall be conducted according to the seven requirements of Article 14;
(3) in principle, the steel material will not be removed from the machine until it is tested on the machine tool, and the steel material processed in the night shift will be sent to the machine as far as possible
(4) in principle, tonggong should be tested in the “to be tested area”. After the test is OK, the programmer should place it in time
In the “qualified area”, the tooling technician is only allowed to take the workpiece in the “qualified area”;
(5) if the unqualified workpiece is detected, it shall be reported to the director of the Department, who shall decide whether to add it again
Work, refuel or check according to the qualified workpiece;
(6) if the head of the department checks the unqualified parts as qualified ones, which leads to mold quality problems
Therefore, the head of the Department is mainly responsible.
- Relevant standards and regulations:
(1) the four sides of the mould material in the front and rear moulds are divided into the middle, and the bottom surface is zero;
(2) in the four sides of the original body mold, if the PL surface is a plane, the plane takes the number; if the PL surface is not a plane, the bottom takes the number. Get the datum angle of the non original mold embryo;
(3) the two sides of the row are divided into the middle, the bottom of the row touches one side, and the depth is zero on the top in principle. If the technician has done other water transportation and inclined holes before CNC machining, the bottom is zero;
(4) tonggong is represented by T, R and f respectively;
(5) the reference angle is the corner with the die number printed on the front and rear die material;
(6) the profile of the stop copper male of the R package should be reduced by 0.08mm to ensure that the product does not scratch hands;
(7) in principle, the X direction is the long dimension, and the Y direction is the short dimension;
(8) when “contour contour” and “optimum contour” are used for finish machining, the machining direction shall be “parallel milling” as far as possible; when flying knife is used for finish milling, the “parallel milling” must be adopted;
(9) in principle, there are four corners at the bottom of the copper palm, one corner corresponds to the mold datum angle, the chamfer angle C4, and the other three corners are rounded R2;
(10) when white steel cutter is used to process copper profile, the spark position parameter should be 0.015mm more than the required value;
(11) the copper male reference level shall be machined to the bottom, and 0.2mm shall be left at the bottom (to prevent the cutter from touching the code board);
(12) the tolerance of tool path compiling and calculating surface: 0.05mm, 0.025mm and 0.008mm respectively;
⒀ when alloy knife is used for finishing straight body surface of steel, Z cutting amount is 1.2mm, when handle is used, Z cutting amount is 0.50mm. The straight body surface must be milled in order;
(14) in principle, the length of the list should be controlled within 250mm and the height should be controlled within 100mm.
- When cutting copper material, the length and width of one side should be 2.5mm, and the total height should be 2-3mm, that is, 105 × 65 × 45 should be cut for 100 × 60 × 42. If the length and width are multiples of 5, the height can be any integer, and the minimum copper size is 40 × 20 × 30 (after processing).
The unified regulations of numbering are as follows:
Tn23001 A1 (tn23001 front die copper male 1)
Tn23001 r-a1 (tn23001 right front die copper male 1)
Tn23001 l-a1 (tn23001 left front die copper male 1)
Tn23001 R1 (tn23001 rear die copper male 1)
Tn23001 r-r1 (tn23001 right rear die copper male 1)
Tn23001 l-r1 (tn23001 left rear die copper male 1)
Tn23001 sla1 (tn23001 row a copper male 1)
Tn23001 ina1 (tn23001 phase a copper male 1)
Tn23001 xda1 (tn23001 square a copper male 1)
Tn23001 tb1 (tn23001 push plate copper male 1)
Tn23001 MG1 (tn23001 modified copper male 1)
- Unified regulations on storage of drawings:
D: 03 / tn23001d.mc8 (3D product drawing)
\ ASM.MC8 (internal model combination diagram)
\CAV\ CAV.MC8 (3D drawing of mould and Copper drawing of front mould)
\Cav-1.mc8 (front die copper male 1, including tool path)
\CAV- CNC.MC8 (front die tool path diagram)
\COR\ COR.MC8 (3D drawing of back die and Copper drawing of back die)
\Cor-1.mc8 (rear die copper male 1, including tool path)
\COR- CNC.MC8 (road map of rear die)
\IN\ IN.MC8 (phase part 3D drawing and phase part Copper drawing)
\SL\ SLA.MC8 (row position a3d diagram and its copper map)
\Sla-1.mc8 (row position a copper male 1, including tool path)
\XD\ XDA.MC8 (oblique a3d diagram and its coppergraph)
\Xda-1.mc8 (bevel a copper male 1, including knife path)
\EDM \ *. MC8 (all spark count charts)
\EDW \ *. MC8 (all WEDM drawings)
\Modify / modify 1
\Modify2 the second modification
- CNC Internal shared file*
- The paper should be concise, clear and easy to understand. Copper map lines should be thick, try to use integer dimensions. The standard angle of copper should be marked clearly, with die number, copper number, copper 3D drawing, spark position size, precautions (connection sequence, shift machining, rotary machining, machining after removing insert, copper wire cutting, etc.), programmer’s signature for confirmation, and department director’s review (specific according to the sample).
- Copper wire cutting drawings shall be concise, clear and easy to understand. The parts to be cut should be indicated by section line, including die number, copper number, spark position, datum position of computer drawing, cutting slope, precautions, website of computer drawing, signature and confirmation of programmer, and approval of department head (according to the sample).
