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The physical map presented in Figure 1 is an outsourced component produced during the internship training at our hospital. It is a conveying screw shaft, a key part used in material transportation on a machine. The material used is cast aluminum alloy. Overall, the component features a tapered thread with a left-hand configuration, and the spiral groove has a complex shape. The length of the spiral section is 550 mm, which makes the rigidity during machining poor. Additionally, the cutting amount must be kept low to avoid deformation. The spiral groove is composed of three arcs and includes straight segments, making it a special-shaped thread that cannot be machined using conventional lathes. Moreover, there is no standard thread-cutting code available for CNC lathes, which adds significant complexity to both the programming and tool selection process.
**Processing Program Analysis**
In CNC machining, the core idea lies in accurately describing the contour of the part. Therefore, the main challenge in this thread programming is how to precisely model the spiral groove. Since no standard thread-cutting code can be directly used, we opted for macro programming using the G32 command. For instance, when machining an R4mm arc, as shown in Figure 2, the program needs to calculate and define the exact coordinates of each point along the arc.
As illustrated in Figure 2, the coordinates of points on the R4mm arc change throughout the machining process. To calculate these coordinates, we first define the starting point A of the thread. From there, we determine the center point B of the R4mm arc, which remains constant. Similarly, we find the centers C and D for the R5mm and R25mm arcs. Using the start angle for the R4mm arc, we apply the circle equation to compute the coordinates of any point on the arc. For example, the X-coordinate can be calculated as #3 = COS[#1] * 4, where #1 represents the start angle, and #3 is the X value. After converting the circular coordinate system into the workpiece coordinate system, the formula becomes #3 = COS[#1] * 8 + 94.688, accounting for the diameter at the center of the R4mm arc. Similarly, the Z-coordinate is calculated as #2 = SIN[#1] * 4, and after conversion, it becomes #2 = SIN[#1] * 4 - 593.575, reflecting the Z-coordinate of the R4mm arc’s center.
Once the starting and ending points are determined, the G32 command is used to connect them, completing the macro programming for the R4mm arc. The full program is then developed accordingly.
For more detailed information, please download the attachment or refer to *Metalworking (Cold Processing)*, Issue 23, 2013.