摘要
在高效切磨削加工过程中,所消耗的能量大部分转化为热并积聚在加工区中,导致加工区温度的急剧升高,同时大量冷却液的使用造成了环境以及健康等一系列的负面影响。本课题在现有的绿色冷却方式基础上,进一步探索新型高效冷却方式。
热管是一种能以较小的温度梯度来远距离地传输热量,而无需外加动力的传热组件。它利用工质蒸发的汽化潜热把热量从蒸发段传输到冷凝段,具有很高的传热率。
本文针对高效加工过程中的冷却问题,结合热管的高导热性及结构的多样性,提出了研制热管式金刚石磨头的设想。根据加工中的热源强度,在旋转热管的基础上,制定热管式金刚石磨头的设计要求,确定设计的主要参数:热管式磨头的工作温度、磨头的几何尺寸、磨头的材料、工质的选择、充液量的计算、热阻的分析以及冷凝装置的设计。按照设计要求,制作出热管式磨头。
通过对热管的等温性能、启动性能,以及自身的传热能力的评价,验证了热管式磨头设计的可行性和传热效果。为进一步验证热管式磨头在实际加工中的冷却效果,利用夹丝半人工热电偶法对钛合金铣磨温度进行了测量。初步试验结果表明:在相同加工用量条件下,热管式磨头相对于普通磨头,起到了一定的冷却作用。
In the process of high efficiency machining, most of the energy consumed is turned to heat which accumulates in the grinding area and makes the temperature rise fast. As a result of using cutting fluids commonly, pollution and health problems are considered. A new high efficiency cooling method is being studied in our research group.
Heat pipe is a device that can transport thermal energy for long distance with relatively low temperature gradient, without external power supply. It uses the latent heat of vaporization of the working fluid to bring the heat from the evaporator to the condenser, which gives a very high thermal conductivity compared with a simple solid model.
This paper mainly addresses the problem of cooling in the high efficiency machining. A new type of diamond grinding head with heat pipe cooling is developed, combined with the high thermal conductivity and its arbitrary structure. The design requirements of heat pipe, such as: working temperature, geometric size, material, working fluid and its filling quantity, thermal resistance and the cooling unit are proposed, based on the heat source in the processing. Then the heat pipe grinding head is made according to the requirements.
The feasibility and effect of the heat pipe grinding head are verified by the evaluations of the isothermal performance, startup performance and the thermal conductivity itself. For further verification, a quasi-artificial constantan-titanium alloy thermoelectric couple is used for measuring the grinding temperature. The experimental results indicate that: the heat pipe grinding head has certain influence on reducing the temperature in the cutting area, compared with the ordinary grinding head in the same grinding parameters.
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