不同冷却喷雾场下硬质涂层刀具切削蠕墨铸铁性能研究
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摘要
研究在复合喷雾油膜附水滴冷却时,3种不同结构喷嘴的喷雾场及在硬质涂层刀具切削蠕墨铸铁过程中的切屑流向,并分析刀具和喷射位置对切削力的影响。研究表明:与普通圆柱型和扁平型喷嘴相比,尖嘴型喷嘴的雾化效果更佳,无大液滴现象,喷雾集中,连续雾化稳定。在硬质涂层刀具切削加工蠕墨铸铁过程中,当喷雾场只作用于刀具前刀面时,普通圆柱型喷嘴和尖嘴型喷嘴有良好的断屑作用;而尖嘴型喷嘴和扁平型喷嘴对切屑流具有更好的导向性。相对干切削和冷风辅助切削,尖嘴型喷嘴与外冷复合喷雾条件下切削蠕墨铸铁时,切削力可减小30～60 N,其中喷雾场喷射在刀具前刀面时的切削力最低。不同硬质涂层刀具需要与外冷复合喷雾的喷射位置相互匹配以达到最小的切削力。
The spraying field and cutting performance of oils on water(OoW) in the machining of compacted graphite iron(CGI) using cutting tools with hard coatings has been investigated in this paper. Three types of spray nozzles with different structures were used to explore their spray filed, as well as their chip flow during the machining of CGI. Cutting force by using specified spray nozzle and different coated tools were further analyzed under different spray locations. The results showed that, compared to the ordinary cylindrical-and flat-typed spray nozzles, the sharp mouth-typed one had concentrated jet flow, stable and continuous spray low, and no droplets of large size, hence better atomization effect. The ordinary cylindrical-and sharp mouth-typed spray nozzles had the ability to break chips when the spray position of only spraying to the rake face was applied during the machining of CGI. When spraying to the rake and flank faces simultaneous, the chip flow can obtain good flowing orientation, only with the sharp mouth-and flat-typed spray nozzles. Using the sharp mouth-typed spray nozzles, the cutting forces of OoW were 30 to 60 N lower than the cryogenic air cooling and dry cutting. The OoW with only spraying to the rake face has the lowest cutting force. Moreover, the cutting tools with hard coatings should be matched with the spray position of OoW in order to obtain the lowest cutting force.
The spraying field and cutting performance of oils on water(OoW) in the machining of compacted graphite iron(CGI) using cutting tools with hard coatings has been investigated in this paper. Three types of spray nozzles with different structures were used to explore their spray filed, as well as their chip flow during the machining of CGI. Cutting force by using specified spray nozzle and different coated tools were further analyzed under different spray locations. The results showed that, compared to the ordinary cylindrical-and flat-typed spray nozzles, the sharp mouth-typed one had concentrated jet flow, stable and continuous spray low, and no droplets of large size, hence better atomization effect. The ordinary cylindrical-and sharp mouth-typed spray nozzles had the ability to break chips when the spray position of only spraying to the rake face was applied during the machining of CGI. When spraying to the rake and flank faces simultaneous, the chip flow can obtain good flowing orientation, only with the sharp mouth-and flat-typed spray nozzles. Using the sharp mouth-typed spray nozzles, the cutting forces of OoW were 30 to 60 N lower than the cryogenic air cooling and dry cutting. The OoW with only spraying to the rake face has the lowest cutting force. Moreover, the cutting tools with hard coatings should be matched with the spray position of OoW in order to obtain the lowest cutting force.
引文
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[20] 刘永姜.油膜附水滴切削液雾化机理理论分析及其实验研究 [D].太原:中北大学,2010.LIU Yongjiang.Theoretical analysis of atomization mechanism and experimental study of oils on water (OoW) cutting fluid [D].Taiyuan:North University of China,2010.
[2] 卢健林.加工蠕墨铸铁材质刀具折断的影响因素 [J].装备制造技术,2008(7):18–19.LU Jianlin.The influence factors of tool-breaking when CGI workpieces were machined [J].Equipment Manufacturing Technology,2008(7):18-19.
[3] 张宪.切削加工蠕墨铸铁(CGI)的挑战 [J].工具展望,2008(4):24–25.ZHANG Xian.Challenges when cutting CGI [J].Tool Prospect,2008(4):24-25.
[4] 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.
[5] GEORGIOU George.蠕墨铸铁的高速加工 [J].世界制造技术与装备市场,2005(6):89–93.GEORGIOU George.CGI high-speed machining [J].World Manufacturing Engineering & Market,2005(6):89-93.
[6] 郭院.蠕墨铸铁铣削加工切屑形态的研究 [D].广州:广东工业大学,2014.GUO Yuan.Research on chip formations of milling GCI [D].Guangzhou:Guangdong University of Technology,2014.
[7] 邱汉泉,陈正德.中国蠕墨铸铁40年 [J].中国铸造装备与技术,2006(1):1–9.QIU Hanquan,CHEN Zhengde.The 40 years of vermicular graphite cast iron in China [J].China Foundry Machine & Technology,2006(1):1-9.
[8] KLOCKE F,EISENBLATTER G.Dry cutting [J].Annals of the CIRP,1997,2(2):519-526.
[9] SREEJITH P S,NGOI B K A.Dry machining:machining of the future [J].Journal of Materials Processing Tech,2000,101(1):287-291.
[10] ITOIGAWA F,CHILDS T H C,NAKAMURA T,et al.Effects and mechanisms in minimal quantity lubrication machining of an aluminum alloy [J].Wear,2006,260(3):339-344.
[11] 罗杰,王成勇,袁尧辉,等.微量润滑技术在切削加工中的应用 [J].机电工程技术,2017(5):1–9.LUO Jie,WANG Chengyong,YUAN Yaohui,et al.Research on the application of minimum quantity lubrication technology in machining [J].Mechanical & Electrical Engineering Technology,2017(5):1-9.
[12] SUN S,BRANDT M,PALANISAMY S,et al.Effect of cryogenic compressed air on the evolution of cutting force and tool wear during machining of Ti-6Al-4V alloy [J].Journal of Materials Processing Technology,2015,221:243-254.
[13] RACHID M,DRAGOS A,SEIN LEUNG S,et al.High performance cutting of advanced aerospace alloys and composite materials [J].CIRP Annals-Manufacturing Technology,2015,64(2):557-580.
[14] ISLAM A K,MIA M,DHAR N R.Effects of internal cooling by cryogenic on the machinability of hardened steel [J].International Journal of Advanced Manufacturing Technology,2017,90(1-4):10-20.
[15] NICO H,SVEN A,DANIEL G.Hybrid supply system for conventional and CO2/MQL-based cryogenic cooling [J].Procedia CIRP,2018,77:219-222.
[16] JAWAHIR I S,ATTIA H,BIERMANN D,et al.Cryogenic manufacturing processes [J].CIRP Annals-Manufacturing Technology,2016,65(2):S0007850616302402.
[17] WANG C,LIN H,WANG X,et al.Effect of different oil-on-water cooling conditions on tool wear in turning of compacted graphite cast iron [J].Journal of Cleaner Production,2017(148):477-489.
[18] LIN H,WANG C,YUAN Y,et al.Tool wear in Ti-6Al-4V alloy turning under oils on water cooling comparing with cryogenic air mixed with minimal quantity lubrication [J].The International Journal of Advanced Manufacturing Technology,2015,81(1-4):87-101.
[19] 郭以伟,王爱玲,郑智贞,等.微量油膜附水滴不同喷射方向切削效果试验研究 [J].机械工程与自动化,2008(3):109–111.GUO Yiwei,WANG Ailing,ZHENG Zhizhen,et al.Experimental study on the effect of oils on water with different spray direction [J].Mechanical Engineering & Automation,2008(3):109-111.
[20] 刘永姜.油膜附水滴切削液雾化机理理论分析及其实验研究 [D].太原:中北大学,2010.LIU Yongjiang.Theoretical analysis of atomization mechanism and experimental study of oils on water (OoW) cutting fluid [D].Taiyuan:North University of China,2010.