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With the rapid development of automobile manufacturing at home and abroad, CAD/CAM technology has been widely used in the engine processing industry. This paper describes some specific details of the application of PowerMILL software in the engine processing of FAW Dalian Diesel Engine Factory.
I. Overview
The CAD software applied by the product development department of FAW Dalian Diesel Engine Factory is the two softwares of AutoCAD and Pro/ENGINEER, that is, two-dimensional and three-dimensional CAD documents coexist. For two-dimensional AutoCAD documents, when converting to the processing features required for CAM processing, the processing features are first generated by Delcam PowerMILL software, and then CNC programming is performed. For 3D Pro/ENGINEER documents, machining features can be extracted directly from PowerMILL software for CNC programming. At the trial production of 6DE2 products carried out by FAW Dalian Diesel Engine Factory, the above two methods were used for programming.
Since PowerMILL directly receives CAD data, it avoids the time wasted by repeatedly searching for the relevant dimensions of the drawing during manual programming, and the programming efficiency is greatly improved, which has gained valuable time for the new product to go on the market.
Second, the development of post-processing technology
Post-processing technology is one of the important links of CAM technology. For different CNC systems (such as FANUC, SIEMENS and TOSHIBA, etc.), different post-processing procedures should be developed for the CAM system. At the same time, due to the difference between the two-dimensional processing and the essence of three-dimensional processing, the post-processing required by the PowerMILL system is also different. In two-dimensional machining, especially in the machining of engines, it is mainly the processing of points (mainly the processing of hole positions, sometimes with very small plane machining). In 3D machining, it is mainly surface machining. However, no matter how complicated the surface is, the CAM system approximates the complex surface with a small straight line segment within the accuracy requirement. The G code generated by the CAM system is mainly G01. The machining program generated for the surface machining shown in Figure 1 is as follows:
Figure 1 3D machining
%
:0001
N10G91G28X0Y0Z0
N20G40G17G80G49
N30G0G90Z33.031
N40T1M6
N50G54G90
N420X1.828Y21.705S1500M3
N430G43Z28.031H1M8
N440G1Z22.531F500
N450X1.142Y21.014
N460X.247Y21.705
..........
..........
N8180X22.679Y35.32
N8190G0Z33.031
N8200M9
N8210G91G28Z0
N8220G49H0
N8230G28X0Y0
N8240M30
The default post-processing provided by DELCAM's PowerMILL software meets the requirements of 3D machining. In two-dimensional processing, hole machining (drilling, expanding, reaming, tapping, twisting, etc.) is dominated by G81, in which parameters such as pitch and dwell time are missing during tapping. Taking FANUC as an example, when tapping and drilling, the default post-processing is applied, and the generated G code format is as follows:
G81G99Z-167.R-95.F341
The code generated by the application of the post-processor developed by the author is as follows:
G84G99Z-167.0R-95.0P300F2.0
In view of the above situation, the author developed the post processing procedures for PowerMILL software hole machining (drilling, expanding, reaming, tapping and boring) for the three machining centers of TOYODA, YEONGCHIN and TOSHIBA, so that all the hole machining functions are obtained. Fully play to ensure the process requirements of the product processing process.
The post-processing of the YEONGCHIN machining center is as follows:
Machinefanuc15m
#OriginaloptionbyFaw_DDEWLiGuangQuan
definewordNT
Addressletter="T"
Addresswidth=1
Fieldwidth=2
Notmodal
Enddefine
definewordTS
Addressletter="N"
Addresswidth=1
Fieldwidth=3
Notmodal
Enddefine
definewordTPN
Addressletter="(TOOLPATH:*******"
Addresswidth=20
Fieldwidth=30
Enddefine
Defineformat(ID)
Addressletter=":"
Enddefine
Defineformat(N)
Notpermanent
Enddefine
Defineformat(G1)
Leadingzeros=true
Notmodal
Enddefine
Defineformat(F)
Modal
Decimalpoint=true
Decimalplaces=2
Trailingzeros=false
Imperialformats=metricformats
Enddefine
Defineformat(HM1M2)
Leadingzeros=true
Enddefine
Defineformat(P)
Fieldwidth=3
Metricformats
Decimalpoint=false
Decimalplaces=0
Trailingzeros=true
Imperialformats=metricformats
Enddefine
definewordPF
Addressletter="F"
Fieldwidth=5
Notmodal
Metricformats
Decimalpoint=true
Decimalplaces=2
Trailingzeros=false
Imperialformats=metricformats
Enddefine
Defineformatall
Tapeposition=0
Enddefine
Wordorder=(+TPNNTTSPPFD)
Definekeys
Toolradius=D
Cycledwell=P
Dwellnotused
Enddefine
Definecodes
Cycleretract=G699
Linear=G11
Compoff=G240
Componleft=G241
Componright=G242
Enddefine
Messageoutput=false
Blockorder=true
Toolresetcoordinates=3
Integer51=4
Integer69=2
Incrementalcentre=false
Integer34=0
Integer35=1
Integer36=0
Integer37=1
Defineblocktapestart
"%"
IDProgID
Rapid;incrementaldata;G628;zcoord0
Incrementaldata=C;G630;ycoord0;xcoord0
Enddefine
Defineblocktoolchangefirst
toolnumberToolNumber
Changetool
If(NextTool<>0)
NTNextTool
Endif
TSToolNumber
Setswa
Enddefine
Defineblocktoolchange
If(word[30]=7orword[30]=8)
M29
Endif
Rapid;incrementaldata;G628;zcoord0
Incrementaldata;G630;ycoord0;xcoord0
Compensationoff;G149;G480=C
Changetool
If(NextTool<>0)
NTNextTool
Endif
TSToolNumber
Setswa
Enddefine
Defineblockmoverapid
If(swa)
TPNToolPathName;")"
G259;absolutedata;rapid;G6;xcoord;
Ycoord;zcoord;spindle;toollength;M1;M2
Unsetswa
Else
Rapid;G6;xcoord;ycoord;zcoord;spindle;
Toollength;M1;M2
Endif
Enddefine
Defineblockmovelinear
Linear;G2;xcoord;ycoord;zcoord;toolradius;
Feedrate;M1;M2
Enddefine
Defineblockmovecircle
N;G1;G3;xcoord;ycoord;zcoord;keyi;keyj;keyk;feedrate
Enddefine
Defineblockcyclestart
If(cycle=1)
G4;cycleretract;xcoord;ycoord;
Drillholedepth;clearplane;feedratePrat
Endif
If(cycle=2orcycle=3orcycle=>5)
G4;cycleretract;xcoord;ycoord;drillholedepth;
Clearplane;cycledwell;feedratePrat
Endif
If(cycle=4)
G4;cycleretract;xcoord;ycoord;drillholedepth;
Clearplane;cycledwell;
PF (Cycfed/ToolSpeed ​​[ToolNum])
Endif
Enddefine
Defineblockmovecycle
Xcoord;ycoord;M1;M2
Enddefine
Defineblockmovetap
Xcoord;ycoord;M1;M2
Enddefine
Defineblockcycleend
Endofdrill
Enddefine
Defineblocktapeend
If(word[30]=7orword[30]=8)
M29
Endif
Rapid;incrementaldata;G628;zcoord0
Rapid;incrementaldata=C;G628;ycoord0
G140; G249; G480=C
Changetool
Endoftape
Enddefine
End
Third, application examples
Through the application of this technology, the author completed the trial production programming of three types of engines (6DE1, 6DE2 and high horsepower engines) for FAW Dalian Diesel Engine Factory with high efficiency and high quality.
The following describes the preparation of the 6DE1 engine product cylinder head injector processing program. The equipment used is the YEONGCHIN vertical machining center. Due to the particularity of the product and the limitations of the equipment, it is theoretically required that the angle between the bottom surface of the cylinder head and the work surface is 3.840966°, and the angle between the first injector nozzle and the sixth injector nozzle of the cylinder head and the X axis of the machining center. It is 14.51082°. This requires that the above requirements must be met during the manufacture and installation of the fixture, and it is actually difficult to meet the above requirements. When the 14.51082° is over 0.006°, a qualified product cannot be processed. The solution to the above problem is to machine a cylinder head on the assembled fixture, perform inspection on the coordinate measuring device, and analyze the result of the inspection through CAD to find the angular deviation. Then adjust with PowerMILL and re-generate the NC machining program in this coordinate system. Under normal circumstances, only a cylinder head can be processed and analyzed to obtain a CNC machining program for qualified products. The following is a post-processing program written by the author to process the machining code for the injector head of the YEONGCHIN vertical machining center. The holes to be machined are six M32 holes as shown in Figure 2 and have a depth of 33 mm. The tool path generated during machining is shown in Figure 3. The generated processing code is as follows:
Figure 3 tool path
%
:0001
G00G91G28Z0
G91G30Y0X0
T1
M06
N1
(TOOLPATH:)
G59G90G00X-29.556Y-68.85S120M03
G00G43Z86.552H01M08
G00Z81.552
G84G99Z49.551R81.551P300F1.5
G80
G00Z86.552
G01X100.844Y-102.6F9999.0
G00Z72.508
G84G99Z40.508R72.508P300F1.5
G80
G00Z77.508
G01X231.244Y-136.35F9999.0
G00Z63.465
G84G99Z31.465R63.465P300F1.5
G80
G00Z68.465
G01X361.644Y-170.1F9999.0
G00Z54.422
G84G99Z22.421R54.421P300F1.5
G80
G00Z59.422
G01X492.044Y-203.85F9999.0
G00Z45.378
G84G99Z13.378R45.378P300F1.5
G80
G00Z50.378
G01X622.444Y-237.6F9999.0
G00Z36.335
G84G99Z4.335R36.335P300F1.5
G80
G00Z86.552
M09
G00G91G28Z0
G00G91G28Y0
G40G49G80
M06
M02
Through the above procedure, it can be seen that the accuracy of the NC program is greatly improved by using PowerMILL. At the same time, the tool path is optimized, which saves processing time and brings some economic benefits to the enterprise.
Fourth, the conclusion
(1) Through the use of Delcam software, programming efficiency is greatly improved. The numerical control program of the engine cylinder head is shortened from one manual time to one week. The CNC programming time savings of the engine block are more significant.
(2) Program block normalization. Due to the constraints of the post-processor, the generated NC program is output in strict accordance with the format of the post-processor constraint.
(3) Reduce the trial cutting time. Due to the normalization of the program block, it is only necessary to track the first step when the product performs multi-step trial cutting. Thereby improving the processing efficiency of the product.
(4) The flexibility of programming is large. In manual programming, all machining programs are reprogrammed when the clamping method changes. With the above technique, it is only necessary to adjust the direction of the coordinates and re-output the program. Thereby reducing the trial production time of the product.
(5) Avoid collisions. The fixture can be used as a non-machining object during programming. PowerMILL software can automatically identify the objects to be machined, thus protecting the processing equipment and fixtures.
(6) High processing accuracy. CAD data can be received directly, avoiding data trade-offs during manual calculations.
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