内冷式智能车刀设计与分析及其实验研究
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摘要
针对难加工材料的无污染、高效加工需求，并根据内冷却所具备的无污染和冷却效果好等优势，本文提出了一种内冷式智能刀具概念，即在刀具内布置具有进出口的微小冷却液通道，切削时冷却液从入口进入刀具体内冷却刀具，然后通过出口回到冷却系统中，冷却液不直接排出，从而组成无污染的循环式冷却系统。通过测量冷却液在进、出口处的温度来预测刀-屑接触面的平均温度，实现切削温度的在线监测，从而根据测量的切削温度可以反映刀具的切削状态，控制系统根据切削温度的高低采取措施对切削过程进行控制。本文主要对内冷式智能刀具的结构设计理论与方法、热学特性、刀具磨损预测和控制等关键基础技术进行了系统的理论分析，并通过切削实验以验证所研制的内冷式智能刀具的切削性能。
优良的内冷却结构是实现高效冷却的基础。基于对内冷式刀具的冷却以及冷却液温升与切削温度关系的研究，并根据内冷式刀具的切削工艺要求，提出了内冷式刀具设计的一般原则。本文以内冷式车刀为例，运用FEA-CFD联合仿真方法对刀具的内冷却结构进行了优化分析，并制备了优化后的内冷式车刀。通过仿真分析，对比了普通车刀和内冷式车刀的力学和热学性能，结果表明内冷式车刀和普通车刀在强度和刚度性能方面基本一致；通入冷却液后内冷式车刀能有效地降低切削温度，在小于转折流速范围内，切削温度随着流速的增加而快速下降，而当超过转折流速后，切削温度随流速的增加而缓慢下降。通过仿真分析研究了刀-屑接触面面积和热流率、冷却液入口流速和温度对内冷式智能车刀冷却效果的影响规律。
精确的切削温度和进出口温度之间关系的解析模型是实现在线测量切削温度的理论依据。基于数值仿真结果，采用指数函数对刀具表面的温度分布进行了拟合，对刀具与水接触的表面传热系数进行了等效处理，运用集总参数法建立了内冷式刀具的热特性理论分析模型，得到了切削温度、冷却液出口温度的时间响应解析表达式。仿真结果表明所建立的内冷式刀具热特性理论模型和数值模型的结果相吻合。研究了冷却液流速、刀-屑接触面面积对切削温度与进出口温度之间关系的影响规律，运用最小二乘法拟合得到了切削平均温度和进出口温度之间的解析表达式。对冷却液流速的选择做了分析，对测量过程中存在的误差源进行了分析，并提出了相应的预防措施。通过加热实验验证了所建模型的正确性。
刀具磨损的监测和控制是提高加工质量和效率的前提。本文在系统地分析刀具磨损和临界切削温度之间关系的基础上，建立了它们之间的关联模型。切削过程中可通过实时调节冷却液流量、切削参数来调节切削温度来间接控制刀具磨损速率，即通过切削温度的控制来控制刀具的磨损。对刀具磨损时的热特性进行了理论分析，通过数值仿真研究了后刀面磨损对切削温度、出口温度的影响规律，得到了刀具磨损下切削温度的预测模型，并和不考虑刀具磨损下的预测模型进行了对比分析，结果表明在刀具的正常磨损范围内，两种模型预测的切削温度基本一致。建立了利用出口温度变化率预测刀具磨损的数学模型。提出了基于临界切削温度约束的刀具磨损控制方法，并设计了PID控制器对切削温度进行控制，通过仿真分析和切削实验证明了控制器的有效性。
为了考察内冷式智能车刀的测温以及切削性能，本文首先使用内冷式智能车刀和普通车刀对AL6061铝合金进行了对比切削实验，验证了该内冷式车刀能够有效地降低切削温度和通过冷却液进出口温度预测切削温度模型的有效性，且加工质量与普通车刀外冷切削时的结果基本一致。通过对难加工材料Ti6Al4V钛合金的对比切削实验，结果表明该内冷式车刀能够大大降低切削温度，减轻刀具前刀面的磨损，对减少刀具后刀面的磨损也有较好的效果，提高了刀具寿命和工件表面加工质量。
Due to no coolant contamination and special cooling effect for the internallycooled tool, an internally cooled smart turning tool is proposed so as to meet therequirement of the efficient cutting of difficult-to-machine materials with no coolantcontamination to the working environment and workpieces. The main idea is tobuild micro cooling channels within the tool and located close to the cutting tip,forming a closed-loop of the internal cooling circuitry. The cooling lubricantcontamination will be avoided and the cutting temperature be reduced when coolingfluid circulates flowing through the closed channel. The cutting temperature at thetool tip can be estimated by measuring the cooling fluid’s temperatures at the inletand outlet of the cooling structure. In this thesis, the key enabling technology fordesign of an internally cooled smart cutting tool were theoretical analysed includingits design theory and methods, thermal characteristics, tool wear prediction andcontrol. Experimental cutting trials are carried out to further evaluate and validatethe method and concept of applying the smart cutting tool system.
Internal cooling structure with optimal design is the foundation of efficientcooling, which is the premise of the energy-resource efficient machining. Based onthe analysis of cooling effect, and the relationship between coolant temperatures riseand the cutting temperature was proposed, in light of the mechanical and thermalrequirements of the cutting tool, and the general design principles of the internallycooled cutting tool. Taking a specific internal cooling structure, for example, itsgeometric parameters of the micro cooling structure are obtained by using combinedFEA and CFD simulations. The optimal internally cooled cutting tools are machinedby CNC Machining. The comparison of the mechanical and thermal propertiesbetween the ordinary turning tool and internally cooled turning tool was carried outthrough the indepth analysis. The results show that their mechanical properties aremore or less the same. The cooling fluid can effectively reduce the cuttingtemperature, which is depended on the flow rate and decreases rapidly as theincreasing the flow rate within a certain range. Furthermore, the cooling fluid doesnot have significant effect after exceeding the critical flow rate. The effects of thetool-chip contact surface area and heat flow rate, cooling fluid inlet velocity andtemperature are analysed.
The analytical model of the relationship between cutting temperature and inletand outlet temperatures is the basis of online measurement of cutting temperature.The temperature distribution on the tool surfaces was fitted using exponentialfunction and the equivalent surface heat transfer coefficients were obtained based on the numerical modeling. Analytical thermal model of the tool is established usingthe lumped parameter method based on the principle of heat transfer. Theoreticalanalysis and numerical simulation results are in good agreement, the influence ofinlet velocity, tool-chip interface area on cutting temperature, outlet temperature andtheir relationships are discussed, and the cutting temperature computationalalgorithm is fitted using the least-squares method. The selection of the optimal inletvelocity, the error source and countermeasures during cutting process are discussed.
Tool wear monitoring and control is a prerequisite to ensure machining qualityand safety in automated precision machining processes. The intrinsic modellingrelationship between the tool wear and cutting temperature is established using theexperimental results published at Annals of the CIRP by other researchers.Therefore, the tool wear can be controled to some extent by adaptive control of thecutting temperature by adjusting the cooling liquid flow and cutting parameters inreal time. The influence of tool wear on the thermal characteristics of the internallycooled tool is theoretical analysed. Simulations were undertaken to investigate theinfluence of flank wear on the tool cutting temperature, outlet temperature, and thecutting temperature prediction model was thus obtained with taking account of thetool wear effect. The tool wear prediction model was establised by using the outlettemperature rise. The tool wear control method based on the critical cuttingtemperature constraints is proposed. The tool wear control method based on thecritical cutting temperature constraints is proposed. A PID controller is designed tocontrol the cutting temperature, and its validity is demenstrated by the simulatedanalysis and cutting experiment.
In order to validate the cutting temperature prediction model and study thecutting performance, cutting trials on aluminum alloy6061-T6and titanium alloyTi6Al4V under different cutting conditions are carried out by using the internallycooled turning tool and ordinary tool. The cutting trails demonstrate that theinnovative tooling design concept can effectively reduce the tool temperature whilesensing the cutting temperature at tool tip, which can reduce cutting temperature,prolong the tool life and enhance the workpiece surface quality.
优良的内冷却结构是实现高效冷却的基础。基于对内冷式刀具的冷却以及冷却液温升与切削温度关系的研究，并根据内冷式刀具的切削工艺要求，提出了内冷式刀具设计的一般原则。本文以内冷式车刀为例，运用FEA-CFD联合仿真方法对刀具的内冷却结构进行了优化分析，并制备了优化后的内冷式车刀。通过仿真分析，对比了普通车刀和内冷式车刀的力学和热学性能，结果表明内冷式车刀和普通车刀在强度和刚度性能方面基本一致；通入冷却液后内冷式车刀能有效地降低切削温度，在小于转折流速范围内，切削温度随着流速的增加而快速下降，而当超过转折流速后，切削温度随流速的增加而缓慢下降。通过仿真分析研究了刀-屑接触面面积和热流率、冷却液入口流速和温度对内冷式智能车刀冷却效果的影响规律。
精确的切削温度和进出口温度之间关系的解析模型是实现在线测量切削温度的理论依据。基于数值仿真结果，采用指数函数对刀具表面的温度分布进行了拟合，对刀具与水接触的表面传热系数进行了等效处理，运用集总参数法建立了内冷式刀具的热特性理论分析模型，得到了切削温度、冷却液出口温度的时间响应解析表达式。仿真结果表明所建立的内冷式刀具热特性理论模型和数值模型的结果相吻合。研究了冷却液流速、刀-屑接触面面积对切削温度与进出口温度之间关系的影响规律，运用最小二乘法拟合得到了切削平均温度和进出口温度之间的解析表达式。对冷却液流速的选择做了分析，对测量过程中存在的误差源进行了分析，并提出了相应的预防措施。通过加热实验验证了所建模型的正确性。
刀具磨损的监测和控制是提高加工质量和效率的前提。本文在系统地分析刀具磨损和临界切削温度之间关系的基础上，建立了它们之间的关联模型。切削过程中可通过实时调节冷却液流量、切削参数来调节切削温度来间接控制刀具磨损速率，即通过切削温度的控制来控制刀具的磨损。对刀具磨损时的热特性进行了理论分析，通过数值仿真研究了后刀面磨损对切削温度、出口温度的影响规律，得到了刀具磨损下切削温度的预测模型，并和不考虑刀具磨损下的预测模型进行了对比分析，结果表明在刀具的正常磨损范围内，两种模型预测的切削温度基本一致。建立了利用出口温度变化率预测刀具磨损的数学模型。提出了基于临界切削温度约束的刀具磨损控制方法，并设计了PID控制器对切削温度进行控制，通过仿真分析和切削实验证明了控制器的有效性。
为了考察内冷式智能车刀的测温以及切削性能，本文首先使用内冷式智能车刀和普通车刀对AL6061铝合金进行了对比切削实验，验证了该内冷式车刀能够有效地降低切削温度和通过冷却液进出口温度预测切削温度模型的有效性，且加工质量与普通车刀外冷切削时的结果基本一致。通过对难加工材料Ti6Al4V钛合金的对比切削实验，结果表明该内冷式车刀能够大大降低切削温度，减轻刀具前刀面的磨损，对减少刀具后刀面的磨损也有较好的效果，提高了刀具寿命和工件表面加工质量。
Due to no coolant contamination and special cooling effect for the internallycooled tool, an internally cooled smart turning tool is proposed so as to meet therequirement of the efficient cutting of difficult-to-machine materials with no coolantcontamination to the working environment and workpieces. The main idea is tobuild micro cooling channels within the tool and located close to the cutting tip,forming a closed-loop of the internal cooling circuitry. The cooling lubricantcontamination will be avoided and the cutting temperature be reduced when coolingfluid circulates flowing through the closed channel. The cutting temperature at thetool tip can be estimated by measuring the cooling fluid’s temperatures at the inletand outlet of the cooling structure. In this thesis, the key enabling technology fordesign of an internally cooled smart cutting tool were theoretical analysed includingits design theory and methods, thermal characteristics, tool wear prediction andcontrol. Experimental cutting trials are carried out to further evaluate and validatethe method and concept of applying the smart cutting tool system.
Internal cooling structure with optimal design is the foundation of efficientcooling, which is the premise of the energy-resource efficient machining. Based onthe analysis of cooling effect, and the relationship between coolant temperatures riseand the cutting temperature was proposed, in light of the mechanical and thermalrequirements of the cutting tool, and the general design principles of the internallycooled cutting tool. Taking a specific internal cooling structure, for example, itsgeometric parameters of the micro cooling structure are obtained by using combinedFEA and CFD simulations. The optimal internally cooled cutting tools are machinedby CNC Machining. The comparison of the mechanical and thermal propertiesbetween the ordinary turning tool and internally cooled turning tool was carried outthrough the indepth analysis. The results show that their mechanical properties aremore or less the same. The cooling fluid can effectively reduce the cuttingtemperature, which is depended on the flow rate and decreases rapidly as theincreasing the flow rate within a certain range. Furthermore, the cooling fluid doesnot have significant effect after exceeding the critical flow rate. The effects of thetool-chip contact surface area and heat flow rate, cooling fluid inlet velocity andtemperature are analysed.
The analytical model of the relationship between cutting temperature and inletand outlet temperatures is the basis of online measurement of cutting temperature.The temperature distribution on the tool surfaces was fitted using exponentialfunction and the equivalent surface heat transfer coefficients were obtained based on the numerical modeling. Analytical thermal model of the tool is established usingthe lumped parameter method based on the principle of heat transfer. Theoreticalanalysis and numerical simulation results are in good agreement, the influence ofinlet velocity, tool-chip interface area on cutting temperature, outlet temperature andtheir relationships are discussed, and the cutting temperature computationalalgorithm is fitted using the least-squares method. The selection of the optimal inletvelocity, the error source and countermeasures during cutting process are discussed.
Tool wear monitoring and control is a prerequisite to ensure machining qualityand safety in automated precision machining processes. The intrinsic modellingrelationship between the tool wear and cutting temperature is established using theexperimental results published at Annals of the CIRP by other researchers.Therefore, the tool wear can be controled to some extent by adaptive control of thecutting temperature by adjusting the cooling liquid flow and cutting parameters inreal time. The influence of tool wear on the thermal characteristics of the internallycooled tool is theoretical analysed. Simulations were undertaken to investigate theinfluence of flank wear on the tool cutting temperature, outlet temperature, and thecutting temperature prediction model was thus obtained with taking account of thetool wear effect. The tool wear prediction model was establised by using the outlettemperature rise. The tool wear control method based on the critical cuttingtemperature constraints is proposed. The tool wear control method based on thecritical cutting temperature constraints is proposed. A PID controller is designed tocontrol the cutting temperature, and its validity is demenstrated by the simulatedanalysis and cutting experiment.
In order to validate the cutting temperature prediction model and study thecutting performance, cutting trials on aluminum alloy6061-T6and titanium alloyTi6Al4V under different cutting conditions are carried out by using the internallycooled turning tool and ordinary tool. The cutting trails demonstrate that theinnovative tooling design concept can effectively reduce the tool temperature whilesensing the cutting temperature at tool tip, which can reduce cutting temperature,prolong the tool life and enhance the workpiece surface quality.
引文
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