CNC machining process complex surfaces handwheel

        Unit has a complex surface handwheel parts of the complex surface shape of the hand wheel parts more complicated and the hand wheel parts for the core part of the product. Pattern higher technical requirements: the material is aluminum or aluminum; parts surface roughness Ra = 3. 2 μm; do not allow selection of welding processing; casting not have trachoma, porosity and other defects. Before use mechanical processing methods to process the hand wheel parts, in consideration of processing costs, many using traditional methods casting blank and fitter filing and other repair parts shape approaching. Casting shape due to non-standard, and when there is trachoma, porosity and other defects, can not meet the technical requirements. Now through research to improve processes, we decided to adopt the way to complete machining of parts of the hand wheel shape processing.
        1. Process Analysis
        The choice of programming software MasterCAM. Original graphic file to be converted for the software recognized file types.
        To ensure the process efficiency and take into account the shape of the hand wheel parts particularity, roughing tool selection 16 mm carbide end mills, finishing tool then choose 10 mm carbide ball-end cutters. After the bar is to the whole of the rough, the rough turning, wire cutting two processes, the choice of vertical machining centers to complete the handwheel complex external shape of the machined parts. Handwheel remain appropriate blanks semi-finishing Finishing allowance (minimum at the balance 0.5mm); 15mm high cylindrical stepped stay (self-centering chuck clamping position) to facilitate clamping; because taking into account the shape of the hand wheel parts particularity in the process will lead to poor stability and vibration knife phenomenon occurs, in order to ensure process quality and eliminate process instability appear, so stay 20mm wide ribs to improve the rigidity of the workpiece in the process of .
        Verified by the actual processing, without leaving Strengthening ribs 20mm wide case, the process particularly unstable, vibrating knife is very serious, far less than the technical requirements; in left 20mm wide ribs case, the process is stable, eliminating the Zhen knife phenomenon, the surface roughness value Ra <3.2cm, the dimensions are reached design requirements.
        2. Process
        By analyzing the shape of the hand wheel parts, machining parts of the hand wheel clamping must be done twice. Clamping the first time in the left rough to 81 mm OD clamping reference to self-centering chuck clamping of here. At the same time as a reference center for the program to process the parts of the right hand wheel all visible shape. In order to try to remove the excess air tool path, here the whole shape into multiple independent units one by one to complete. A copy of the hand wheel parts split into 30 mm annular region and sector 50 cone region of the two parts can be programmed to note that different forms of tool path processing region should be considered depending on the shape of the region, such as this second fixture, were selected contour (Contour) machining tool paths.