UG在线切割编程中的应用与技巧

UG在线切割编程中的应用与技巧
讨论了UG线切割编程模块优缺点，并通过UG的平面铣模块增强线切割编程刀具轨迹的多样性和易控制性。

在掌握电火花机床数控编程规范的基础上，研究了应用UG进行线切割编程及其程序后置处理的方法，编制了适合线切割机床的后置处理文件。

通过该方法生成的NC代码在机床上面运行情况良好。

关键词:线切割机床数控编程后置处理
前言
线切割加工通过电极丝与导电工件之间放电腐蚀成型来完成工件加工，由于是非接触加工，加工过程中不存在加工应力，因而可以进行普通机械加工难以完成的工件如淬火钢、薄壁件等脆硬材料的加工。

因此线切割加工广泛地应用在机械以及模具行业中。

美国UGS公司出品的UG软件是一款集CAD/CAM/CAE于一身的高端三维CAD软件。

其中包含零件设计、二维工程图、零件加工和仿真以及有限元分析等模块。

通过模块之间的无缝集成，实现了零件的三维信息在设计、数控加工以及有限元分析模块之间的共享，具有设计修改方便，更新迅速等特点。

1(UG线切割编程功能
1.1 UG线切割模块
UG的线切割模块包含无废料内部切割、工件内形切割、外形切割以及开口轮廓切割等几个加工子模块，如图1所示。

用户可以根据加工需要，灵活选择其中一个或者几个子模块，就可以完成零件的线切割加工任务。

这些模块基本上满足零件了从2轴到4轴的线切割加工需求。

图1 UG线切割加工模块UG免费下载 Mastercam9.1免费下载在线切割加工中，有的工件型腔(大深径比)需要采用无废料切割方式把型腔内的材料全部腐蚀掉以完成加工。

通过UG线切割模块里面的无废料内部切割方式生成的刀具轨迹，有时
存在不合理的刀路，如尖角等，这就要求我们对走刀方式进行控制。

然而采用无废料内部切割模块生成的程序其走刀方式是软件默认的方式，无法控制、修改。

1.2 巧用UG平面铣模块编制线切割程序
由于线切割编程模块存在不便之处，在分析了UG平面铣模块的特点后，决定采用这个模块来编制线切割无废料内部切割程序，达到控制线切割走刀方式的目的。

图2为平面铣模块的子模块面板。

图2 平面铣模块
UG平面铣模块是针对零件的平面部分进行三轴加工的模块，其特点是铣削加工发生在XY平面上，Z轴的作用主要是下刀、提刀以及在加工中避让夹具等功能。

走刀方式具有灵活、易于控制等优点，可采取的走刀方式有单方向、往返方式、跟随工件外形、铣外形以及混合加工等等，如图3所示。

线切割机床的工作平面为XY平面，通过线切割丝在二维平面上的运动完成零件的加工。

如果能够在UG平面铣模块编程时，抑制Z轴下刀和抬刀，就可以生成只含XY两个坐标的刀具轨迹文件。

通过后处理便可以生成适用于线切割机床的数控程序，这样就极大地增强了线切割编程走刀方式的可控性。

图3 平面铣走刀方式
图4是一个典型零件的外形，现在需要用无废料内部切割方式进行椭圆内型腔的加工，如果直接采用UG线切割模块里面的无废料内部切割方式进行加工，则生成的刀具轨迹如图5中轨迹1所示，轨迹里面存在尖角，机床在尖角处突然变向容易而引起冲击。

图5中轨迹2和轨迹3是通过平面铣方式生成的两种不同走刀方式的刀具轨迹。

从这三种走刀轨迹可以看
出，采用平面铣的刀具轨迹有更好的可控性，而且生成的程序更加平滑，没有尖角，因而不会引起机床的冲击，更好地保证了零件的加工精度以及延长了机床的使用寿命。

图4 典型线切割工件
图5 线切割模块生成刀具轨迹
2(进口线切割机床数控编程
我单位某进口线切割机床具有很高的定位精度和重复定位精度，适合加工表面粗糙度要求高，尺寸精度控制严格的零件。

现以该机床的程序编制为例，介绍线切割程序编制一般步骤。

前述生成的刀具轨迹是刀具在加工过程中所经过的一系列位置点的集合，称之为刀位，以一定格式和表述方法来记录这些刀位位置信息的文件称为刀位文件。

在UG中，这些文件一般都以cls(cutter location source)文件格式保存，里面不仅
记录了刀位的点位信息，同时还包含刀具信息以及进给、主轴转速等其他加工信息。

刀位文件不能直接用于数控机床，要使数控机床识别这些刀位，就应该将其转变成机床能够识别的NC代码。

图6为刀位文件转换成NC代码的流程图。

其中后置处理文件包含两个，一个是以tcl结尾的文件，另外一个是以def结尾的文件。

UG 后处理中，通过这两个文件来定义机床类型以及在后置处理中生成NC代码的格式。

通过后置处理编辑器POSTBUILDER创建和编辑上述两个文件，使其符合特定的机床规范。

图6 刀位文件后置处理流程图
2.1编程规范与后置处理
在编制该机床的后置处理器之前，首先要了解该机床的程序规范。

该线切割机床的编程规范有如下一些特点，(1)程序开头以N作为序号，后面的数字从1往后以1逐步递增;(2)程序第一段以G00作为机床的定位点，此点必不可少，而且只能在一个程序中出现一次。

然后再进行直线(G01)、圆弧(G02或者G03)等的插补;(3)程序中每一段都以分号“;”结束;(4)圆弧中心I、J值为从圆弧起点指向圆心的向量;(5)当整段程序运行完成以后，以M02完成该程序段。

2.2 UG后处理编制
在了解了该机床的编程规范后，下面的工作就是按照该规范创建、编辑与之相应的后置处理文件。

最后进入后置处理时，输入创建的后置处理文件，把刀位文件
转换为该机床的NC代码。

UG的后置处理文件编辑器POSTBUILDER主界面如图6所示，选择相应机床类型，然后根据规范编辑机床行程、程序序号以及程序结尾等相关内容，保存创建内容，POSTBUILDER自动生成上述两个文件(.tcl，.def)，就可以应用于后置处理器中了。

上述采用平面铣模块生成的线切割刀位文件在进行后置处理时，需另外编制后置处理文件。

其中机床类型选择为三轴铣，否则在进行后置处理的时候系统会出错。

其余内容按照编程规范进行编辑、修改即可。

图7 后置处理文件编辑器
2.3编程实例
以上述图4中的零件为例，采用平面铣模块创建如图5中轨迹2，生成刀位文件。

创建、编辑后处理文件并保存。

通过后置处理生成的NC代码如下，该NC代码在机床上面运行良好。

N1 G00 X0.0 Y1.;
N2 G01 X0.02;
N3 G01 X0.03;
...
N259 G02 X18.545 Y-47.884 I-54.147 J152.257; N260 G02 X0.0 Y-49. I-18.662 J155.49; N261 M02;
3.结束语
利用UG软件进行线切割数控编程，缩短了程序编制时间，提高了加工效率。

通过对线切割数控规范的分析，创建了后置处理文件并应用于后置处理器，把刀位文件转化成了机床能够识别的NC程序。

同时，通过平面铣模块进行线切割无废料
切割程序的编制，丰富了线切割程序走刀方式的多样性和可操作性，成为了线切割编程模块有益的补充。

实践证明，采用这种方法进行线切割程序编制取得了很好的经济效益。

,英文版 ,
Two regulations promulgated for implementation is in the party in power for a long time and the rule of law conditions, the implementation of comprehensive strictly strategic plan, implementation in accordance with the rules and discipline to manage the party, strengthen inner-
party supervision of major initiatives. The two regulations supporting each other, the < code > adhere to a positive advocate, focusing on morality is of Party members and Party leading cadres can see, enough to get a high standard; < rule > around the party discipline, disciplinary ruler requirements, listed as "negative list, focusing on vertical gauge, draw the party organizations and Party members do not touch the" bottom line ". Here, the main from four square face two party rules of interpretation: the first part introduces two party Revised regulations the necessity and the revision process; the second part is the interpretation of the two fundamental principles of the revision of laws
and regulations in the party; the third part introduces two party regulations modified the main changes and needs to grasp several key problems; the fourth part on how to grasp the implementation of the two regulations of the party. < code > and < Regulations > revised the necessity and revised history of the CPC Central Committee the amendment to the Chinese Communist
Party members and leading cadres honest politics several guidelines > and < Chinese Communist Party discipline and Punishment Regulations > column 1 by 2015 to strengthen party laws and regulations focus. Two party regulations revision work lasted a Years, pooling the wisdom of the whole party, ideological consensus, draw historical experience, respect for the wisdom of our predecessors, which reflects the unity of inheritance and innovation; follow the correct direction, grasp the limited goals, adhere to the party's leadership, to solve the masses of the people reflect a focus on the problem. The new revision of the < code > and < rule >, reflects the party's 18 and the eighth session of the third, the spirit of the fourth plenary session, reflecting the experience of studying and implementing the General Secretary Xi Jinping series of important speech, reflects the party's eighteen years comprehensive strictly practice. (a) revised two regulations of the party need of < the ICAC guidelines > in < in 1997 Leaders as members of the Communist Party of China clean politics certain criteria (Trial) > based on revised, the promulgation and implementation of January 2010, to strengthen the construction of the contingent of leading cadres play
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administration > and < rule > the two is likely to be more relevant regulations first amendment. By revising, really put the authority of Party discipline, the seriousness in the party tree and call up the majority of Party members and cadres of the party constitution of party compasses party consciousness. (II) two party regulations revision process the Central Committee of the Communist Party of China attaches great importance to two regulations revision . Xi Jinping, general books recorded in the Fifth Plenary Session of the eighth session of the Central Commission for Discipline Inspection, on the revised regulations < > made clear instructions. According to the central deployment, the Central Commission for Discipline Inspection from 2014 under six months begin study two regulations revision. The Standing Committee of the Central Commission for Discipline Inspection 4 review revised. Comrade Wang Qishan 14 times held a special meeting to study two regulations revision, amendment clarifies the direction, major issues of principle, path and target, respectively held a forum will listen to part of the province (area) secretary of the Party committee, Secretary of the Discipline Inspection Commission, part of the central ministries and state organs Department
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(autonomous regions, municipalities) Party, the central ministries and commissions, state ministries and commissions of the Party (party), the General Political Department of the military, every 3 people organization of Party of two regulations revision opinion. Central Commission for Discipline Inspection of extensive solicitation of opinions, careful study, attracting, formed a revised sent reviewers. In October 8 and October 12, Central Committee Political Bureau Standing Committee and the Political Bureau of the Central Committee After consideration of the two regulations revised draft. On October 18, the Central Committee of the Communist Party of China formally issued two regulations. Can say, two laws amendment
concentrated the wisdom of the whole party, embodies the party. Second, < code > and < Regulations > revision of the basic principles of two party regulations revision work and implement the party's eighteen, ten eight plenary, the spirit of the Fourth Plenary Session of the Eleventh Central Committee and General Secretary Xi Jinping important instructions on the revised < low political criterion > and < Regulations >, highlighting the ruling party
characteristics, serious discipline, the discipline quite in front
of the law, based on the current, a long-term, advance as a whole, with Bu Xiuding independent < rule > and < rule >. Main principle is: first, adhere to the party constitution to follow. The constitution about discipline and self-discipline required specific, awaken the party constitution of party compasses party consciousness, maintaining the
authority of the constitution. General Secretary Xi Jinping pointed out that "no rules, no side round. Party constitution is the fundamental law, the party must follow the general rules. In early 2015 held the eighth session of the Central Commission for Discipline Inspection Fifth
Plenary Session of the 16th Central Committee, Xi Jinping again pointed out that constitution is the party must follow the general rules, but also the general rules." the revision of the < code > and < rule > is Method in adhere to the regulations established for the purpose of combining rule of virtue is to adhere to the party constitution as a fundamental to follow, the constitution authority set up, wake up the party constitution and party rules the sense of discipline, the party constitution about discipline and self-discipline specific requirements.
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of Party members and the ideological and moral standards. The revised < > Ji method separately, Ji, Ji Yan to Method, as a "negative list", emphasizing the heteronomy, focusing on vertical gauge. Is this one high and one low, a positive reaction, the strict party discipline and
practice results transformation for the integration of the whole party
to observe moral and discipline requirements, for the majority of Party members and cadres provides benchmarking and ruler. Third, insist on to. In view of the problems existing in the party at the present stage, the main problems of Party members and cadres in the aspect of self-discipline and abide by the discipline to make clearly defined, especially the party's eighteen years strict political discipline and political rules, organization and discipline and to implement the
central eight provisions of the spirit against the four winds and other requirements into Disciplinary provisions. Not one pace reachs the designated position, focusing on in line with reality, pragmatic and effective. After the revision of major changes, major changes in the < code > and < rule > modified and needs to grasp several key problems (a) < code > < code > adhere to according to regulations
governing the party and party with morals in combination, for at the present stage, the leadership of the party members and cadres and Party members in existing main problems of self-discipline, put forward principles, requirements and specifications, showing Communists noble moral pursuit, reflected at all times and in all over the world ethics from high from low 5 common requirements. One is closely linked to the "self-discipline", removal and no direct relation to the provisions of . the second is adhere to a positive advocate, "eight prohibition" 52 are not allowed to "about the content of the" negative list moved into synchronization amendment < cases >. Three is for all the party members, will apply object from the leadership of the party members and cadres to
expand to all Party members, fully embodies the comprehensive strictly required. The fourth is prominent key minority, seize the leadership of the party members and cadres is the key, and put forward higher requirements than the ordinary Party members. Five is to simplify, and strive to achieve concise, easy to understand, easy to remember. The revised < code > is the ruling Party since the first insists on a positive advocate forAll Party members and the self-discipline norms, moral declaration issued to all members of the party and the National People's solemn commitment. > < criterion of a clean and honest administration consists of 4 parts, 18,
more than 3600 words. After the revision of the < code >, a total of eight, 281 words, including lead, specification and Party member cadre clean fingered self-discipline norms, etc. Part 3 members low-cost clean and self-discipline, the main contents can be summarized as "four must" "eight code". Lead part, reiterated on ideal and faith, fundamental purpose, the fine traditions and work style, noble sentiments, such as "four must" the principle of requirements, strong tone of self-discipline, The higher request for 6 and supervised tenet, the foothold in permanent Bao the party's advanced nature and purity, to reflect the revised standards requirements. Members of self-discipline norms around the party members how to correctly treat and deal with the "public and private", "cheap and rot" thrifty and extravagance "bitter music", put forward the "four norms". Party leader cadre clean fingered self-discipline norms for the leadership of the party members and cadres of
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of leaders, especially Xi Jinping, general secretary of the important discussion, refer to the "three discipline and eight points for attention" statements, and reference some embody the Chinese nation excellent traditional culture essence of epigrams. (2) the revised regulations, the main changes in the revised Regulations > to fully adapt to the strictly requirements, reflects the according to the regulations governing the law of recognition of deepening, the realization of the discipline construction and Jin Ju. < rule > is party a ruler, members of the basic line and follow. And the majority of Party members and cadres of Party organizations at all levels should adhere to the bottom line of thinking, fear discipline, hold the bottom line, as a preventive measure, to keep the party's advanced nature and purity. 1, respect for the constitution, refinement and discipline. Revised < rule > from comprehensive comb physical constitution began, the party constitution and other regulations of the Party of Party organizations and Party discipline requirements refinement, clearly defined in
violation of the party constitution will be in accordance with
regulations to give the corresponding disciplinary action. The original 10 categories of misconduct, integration specification for political discipline, discipline, honesty and discipline masses Ji Law and discipline and discipline and
other six categories, the content of < rule > real return to Party discipline, for the majority of Party members and listed a "negative
list. 7 2, highlighting the political discipline and political rules. > < Regulations according to the stage of the discipline of outstanding performance, emphasizing political discipline and political rules, organization and discipline, in opposition to the party's leadership and the party's basic theory, basic line, basic program and basic experience, the basic requirement of behavior made prescribed punishment, increase the cliques, against the organization such as violation of the provisions, to ensure that the central government decrees and the Party of centralized and unified. 3, adhere to strict discipline in the law
and discipline In front, Ji separated. Revised < Regulations > adhere to the problem oriented, do Ji separated. Any national law existing content, will not repeat the provisions, the total removal of 79 and criminal law, repeat the content of the public security management punishment law, and other laws and
regulations. In the general reiterated that party organizations and Party members must conscientiously accept the party's discipline, die
van comply with national laws and regulations; at the same time, to
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made provisions, so as to realize the connection of Party discipline and state law. 4, reflect Wind building and anti-corruption struggle of the latest achievements. < rule > the party's eighteen years implement the spirit of the central provisions of the eight, against the requirements of the "four winds" and transformation for disciplinary provisions, reflecting the style construction is always on the road, not a gust of wind. In the fight against corruption out of new problems, increase the trading rights, the use of authority relatives profit and other disciplinary terms. Prominent discipline of the masses, the new against the interests of the masses and ignore the demands of the masses and other disciplinary terms and make provisions of the disposition and the destruction of the party's close ties with the masses.
Discipline to protect the party's purpose. 8 of these regulations, a total of three series, Chapter 15, 178, more than 24000 words, after the revision of the regulations a total of 3 series, Chapter 11, 133, 17000 words, divided into "general" and "special provisions" and "Supplementary Provisions" Part 3. Among them, add, delete, modify the provisions of the proportion of up to nearly 90%. 1, the general general is divided into five chapters. The first chapter to the regulations of the guiding ideology, principles and scope of application of the provisions, highlight the strengthening of the party
constitution consciousness, maintenance the authority of Party Constitution, increase the party organizations and Party members must abide by the party constitution, Yan Centralized centralized, would examine at all levels of the amended provisions
implementing and maintaining Party discipline, and consciously
accept the party discipline, exemplary compliance with national laws and regulations. The second chapter of discipline concept, disciplinary action types and effects of the regulations, will be a serious warning from the original a year for a year and a half; increase the Party Congress representative, by leaving the party above (including leave probation) punishment, the party organization should be terminated its representative qualification provisions. The third chapter of the disciplinary rules of use prescribed in the discipline rectifying process, non convergence, not close hand classified as severely or heavier punishment. "Discipline straighten "At least eighteen years of five years, these five years is to pay close attention to the provisions of the central eight implementation and anti -" four winds ". The fourth chapter on suspicion of illegal party disciplinary distinguish five different conditions, with special provisions were made provisions, to achieve effective convergence of Party and country 9 method. < rule > the provisions of Article 27, Party organizations in the disciplinary review found that party members have committed embezzlement, bribery, dereliction of duty dereliction of duty and other criminal law act is suspected of committing a crime shall give cancel
party posts, probation or expelled from the party. The second is < Regulations > Article 28 the provisions of Party organizations in the disciplinary review But found that party members are stipulated in the criminal law, although not involved in a crime shall be investigated for Party discipline and responsibility should be depending on the specific circumstances shall be given a warning until expelled punishment. This situation and a difference is that the former regulation behavior has been suspected of a crime, the feeling is quite strict, and the latter for the behavior not involving crime, only the objective performance of the provisions of the criminal code of behavior, but the plot is a crime to slightly. < Regulations > the 29 provisions, Party organizations in the discipline review found that party members and other illegal behavior, affect the party's image, the damage to the party, the state and the people's interests, we should depend on the situation Seriousness given disciplinary action. The loss of Party members, seriously damaging the party's image of behavior, should be given expelled from the party. At this article is party member is in violation of the criminal law outside the other illegal acts, such as violates the public security administration punishment law, customs law, financial laws and regulations behavior. The fourth is < cases > Article 32 stipulates, minor party members and the circumstances of the crime, the people's Procuratorate shall make a decision not to initiate a prosecution, or the people's court shall make a conviction and exempted from criminal punishment shall be given within the party is removed from
his post, probation or expelled from the party. Party members and crime, sheets were fined in accordance with For acts; the principal Ordinance amended the provisions of the preceding paragraph. This is the new content, in order to achieve Ji method effective convergence. Five is < > the thirty third article 10 of the provisions, the Party member due to an intentional crime is sentenced to criminal law (including probation) sheets or additional deprivation of political rights; due to negligence crime and was sentenced to three years or more (excluding three years) a penalty, shall give expelled punishment. Due to negligence crime is convicted and sentenced to three years (including three years) in prison or be sentenced to public surveillance, detention, shall in general be expelled from the party. For the individual may not be expelled from the party, should control Approval. This is followed and retained the original > < Regulations the provisions of punishment party
authorization rules and report to a level party
organizations. For is "party members with criminal acts, and by the criminal punishment, generally should be expelled from the party". The fifth chapter of probationary Party member of the discipline and discipline after missing members of the treatment and punishment decisions, such as the implementation of the provisions, clear the related party discipline and punishment decision made after, for duties, wages and other relevant alteration formalities for the longest time. 2, sub sub section will the original regulations of
10 categories of acts of violation of discipline integration revised into 6 categories, respectively, in violation of the punishments for
acts of political discipline "in violation of discipline behavior of punishment" in violation of integrity of disciplinary action points "of violation punishments for acts of mass discipline" "the violation of
work discipline, punishment" in violation of discipline of life behavior punishment "6 chapters. 3, annex" Supplementary Provisions "clear authority making supplementary provisions of, cases of interpretative organ, as well as regulations implementation time and retroactivity etc..
11 (3) learning understanding > < regulations needs to grasp several key problems The first problem -- about the violation of political
discipline behavior > < new ordinance chapter 6 the political discipline column for the six disciplines, that is the main opposition to Party leadership and the opposition of the basic
theory, basic line, basic program and basic experience, basic requirements of misconduct made provisions of the disposition,
especially the eighteen since the CPC Central Committee put forward the Yan Mingzheng treatment of discipline and political rules requirements and practical achievements transformation for Discipline article, increase the false debate central policies, cliques, against the organization review, make no discipline of the principle of harmony terms. These are the party's eighteen years in comprehensive strictly Process combined with the practice of rich content. (1) false debate the central policies and undermine the Party of centralized and unified the
problem is made in accordance with the provisions of the party constitution. Constitution in general programme requirements adhere to democratic centralism is one of the requirements of the construction of the party must adhere to the four cardinal. Application of this
principle is not only the party the basic organization principle and is also the mass line in party life, it requires that we must fully develop inner-party democracy, respect for the dominant position of Party members, safeguarding the Party member democratic rights, give full play to the enthusiasm and creativity of the party organizations at all
levels and Party members, at the same time, also must implement the
right concentration, ensure the party's mission < the chaos in unity and concerted
action to ensure that the party's decision to get quickly and effectively implementing. The Party Central Committee formulated the major principles and policies, through different channels and ways,
fully listen to the party organizations and Party members of the opinions and suggestions, but 12 is some people face to face not to say back blather "" will not say, after the meeting said, "" Taiwan does not say, and nonsense ", in fact, not only disrupt the people thought, some causing serious consequences, the damage to the Party of the centralized and unified, hinder the central policy implementation, but also a serious violation of the democratic system of principles. There is no doubt that shall, in accordance with the Regulations > 4 Specified in Article 6 to give the appropriate punishment. For did not cause serious。