用AdvantEdge分析蠕墨铸铁切削时高压切削液的冷却润滑机理
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摘要
使用AdvantEdge软件对不同切削液压力下车削蠕墨铸铁的过程进行二维仿真,研究切削过程中切屑变形、切削温度、刀–屑摩擦及切削力的变化规律,分析高压切削液的冷却润滑机理。仿真结果表明:增大切削液压力可以减小黏结摩擦区和滑动摩擦区长度,加快切削液与工件之间的热量传递速率;同时,高压切削液能够克服莱顿弗罗斯特效应形成的气体保护层,更好地对流换热和冷却;但切削液压力并非越大越好,在15～18 MPa时可以在减少能耗的同时获得较好的冷却润滑效果。
Based on the cutting fluid simulation function of AdvantEdge, 2 D turning simulation is carried out for vermicular cast iron under different cutting fluid pressures. The variation of chip deformation, cutting temperature, tool-chip friction and cutting force in the cutting process ae studied. The cooling and lubrication mechanism of high-pressure cutting fluid are also analyzed. The simulation results show that the increase of cutting fluid pressure can reduce the lengths of the sticking zone and the sliding friction zone, thereby increasing the heat exchange rate between workpiece and fluid. At the same time, the high-pressure cutting fluid can overcome the gas protective layer formed by the Leidenfrost effect, achieving better heat convection and cooling. However, the increased pressure does not lead to better cooling effect and the cutting fluid pressure should be 15 to 18 MPa for good cooling and lubrication at low energy cost.
Based on the cutting fluid simulation function of AdvantEdge, 2 D turning simulation is carried out for vermicular cast iron under different cutting fluid pressures. The variation of chip deformation, cutting temperature, tool-chip friction and cutting force in the cutting process ae studied. The cooling and lubrication mechanism of high-pressure cutting fluid are also analyzed. The simulation results show that the increase of cutting fluid pressure can reduce the lengths of the sticking zone and the sliding friction zone, thereby increasing the heat exchange rate between workpiece and fluid. At the same time, the high-pressure cutting fluid can overcome the gas protective layer formed by the Leidenfrost effect, achieving better heat convection and cooling. However, the increased pressure does not lead to better cooling effect and the cutting fluid pressure should be 15 to 18 MPa for good cooling and lubrication at low energy cost.
引文
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[2] 袁华,王成勇,郭院,等.蠕墨铸铁加工研究进展 [J].机床与液压,2014,42(13):162–167.YUAN Hua,WANG Chengyong,GUO Yuan,et al.Research development of compacted graphite iron machining [J].Machine Tool & Hydraulics,2014,42(13):162-167.
[3] GASTEL M,KONETSCHNY C,REUTER U,et al.Investigation of the wear mechanism of cubic boron nitride tools used for the machining of compacted graphite iron and grey cast iron [J].International Journal of Refractory Metals & Hard Materials,2000,18(6):287-296.
[4] SU G S,GUO Y K,SONG X L,et al.Effects of high-pressure cutting fluid with different jetting paths on tool wear in cutting compacted graphite iron [J].Tribology International,2016,103:289-297.
[5] 苏国胜,郭延阔,孔凡东,等.蠕墨铸铁切削中高压切削液对刀具磨损的影响 [J].机械设计与制造,2016(1):122–125.SU Guosheng,GUO Yankuo,KONG Fandong,et al.High pressure jetting cutting fluid influence on the tool wear of cutting compacted graphite iron [J].Machinery Design & Manufacture,2016(1):122-125.
[6] NAYYAR V,KAMINSKI J,KINNANDER A,et al.An experimental investigation of machinability of graphic cast iron grades;flake,compacted and spheroidal graphite iron in continuous machining operation [J].Procidia CIRP,2012,1(7):488-493.
[7] 杨友胜,张建平,聂松林.水射流喷嘴能量损失研究 [J].机械工程学报,2013,49(2):139–145.YANG Yousheng,ZHANG Jianping,NIE Songlin.Energy loss of nozzles in water jet system [J].Journal of Mechanical Engineering,2013,49(2):139- 145.
[8] JOHNSON G R,COOK W H.A constitutive model and data for metals subjected to large strains,high strain rates and high temperature [C]// International Ballistics Society.Proceedings of the 7th International Symposium on Ballistics.Hague:International Ballistics Society:1983:541-547.
[9] LJUSTINA G,FAGERSTROM M,LARSSON R.Hypo- and hyper-inelasticity applied to modeling of compacted graphite iron machining simulations [J].European Journal of Mechanics A/Solid,2013,37:57-68.
[10] 文怀兴,马朝阳.冷却方式对车削45钢结果影响的有限元分析 [J].组合机床与自动化加工技术,2017(7):89–91.WEN Huaixing,MA Chaoyang.Finite element analysis of the impact of the results of turning 45 steel in cooling mode [J].Modular Machine Tool & Automatic Manufacturing Technique,2017(7):89-91.
[11] 陈日曜.金属切削原理 [M].北京:机械工业出版社,1993.CHEN Riyao.Principle of metal cutting [M].Beijing:China Machine Press,1993.
[12] SOFYANI S A,MARINESCU I D.Analytical modeling of the thermal aspects of metalworking fluids in the milling process [J].International Journal of Advanced Manufacturing Technology,2017,92(9-12):3953-3966.
[13] WILLIAMS J A,TABOR D.The role of lubricants in machining [J].Wear 1977,43:275-292.