低温冷风切削加工实验研究
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摘要
切削力和刀具磨损是切削过程中刀具和工件之间相互作用的结果。切削力和刀具磨损都是切削过程中发生的重要物理现象,对切削过程有着重要影响。切削力将直接影响切削功率和切削热；刀具磨损量直接影响到工件加工质量和生产成本,并引起工艺系统的变形和机床的振动。所以,切削力和刀具磨损量是设计机床、刀具、夹具的重要依据,掌握它们的变化规律对分析和解决生产中实际问题具有重要的指导意义。
在金属加工中,切削液会产生环境污染,同时对人体也有害,它的使用受到了越来越多的限制。绿色制造迎合ISO14000环境标准,符合可持续发展的要求,是未来机械加工的发展趋势。低温冷风切削加工作为一种新兴的绿色制造方式,与传统的切削加工在冷却方式上有很大的不同。冷却方式的不同,会引起刀具和切屑及刀具和工件间的摩擦发生变化。具体表现为切削温度、切削力、刀具寿命、加工表面质量都与传统加工方式有所不同。
课题针对三种经典的金属材料：Q235B钢、45钢和TC4钛合金在三种不同的冷却条件下进行切削实验,试图从中找出切削力和刀具磨损量在冷风条件下的变化规律。总的来说,主要进行了下面三个方面的研究工作：
1、针对三种不同的冷却方式,对比分析切削力的变化规律。得出了在冷风条件下切削力最小的结论,同时也发现了在切削Q235B钢时冷却液不但没有起到应有的冷却润滑作用,反而增大了切削力和刀具磨损量。
2、对每种实验材料都建立起了适用于冷风条件下的切削力经验公式,通过统计学检验得出切削力与冷风温度呈指数关系变化的结论。
3、对比不同材料在不同的冷却条件下刀具的磨损量发现：在冷风条件下,刀具的磨损量是最小的。同时从刀具磨损量的角度再次说明了在切削Q235B钢时冷却液不但没有起到应有的冷却润滑作用反而增大了切削力和刀具磨损量的问题。
Cutting force and tool wear are the results of interaction between the tool and the work piece. Cutting force and tool wear, which are important physical phenomena occur during the cutting process, have important influence on the cutting process. Cutting force will directly affect the cutting power and cutting heat; tool wear can affect the work piece quality and production costs, and cause process system deformation and machine tools vibration. Cutting force and tool wear, therefore, are the important design criterion of machine tool, cutting tools and jigs. To grasp the change regularities will be of great guiding significance for the analysis and resolution of practical problems in the production.
In metal machining, cutting liquid will cause environment pollution, and it is harmful to the human body. It has been more and more restrictions for the use of cutting liquid. Green Manufacturing, which caters to the ISO14000 environment standard, and is in line with requirements of sustainable development, is the future trend of machining development. The cold-blast air cutting as a new kind of green manufacturing technology differs from the traditional cutting cooling methods. The friction result between the tool and the cutting chip, the tool and work piece are different by different cooling methods. The specific external reflection is that cutting temperature, cutting force, tool life and surface quality of work piece are somewhat different from the traditional processing methods.
The experiments using three kinds of metal material, steel Q235B and 45 as well as titanium alloy TC4 under three different cooling conditions, are carried out in this subject, in order to find the variation of cutting force and tool wear under cold-blast air cooling condition. The following three aspects are obtained in the research works:
1. Aimed at three cooling methods, cutting force are tested and analyzed. The conclusion that the cutting force is the smallest under the cold-blast air condition is obtained. And an important phenomenon that the cutting liquid cannot play its proper cooling and lubrication roles, but increased the amount of cutting force and tool wear while cutting steel Q235B is found.
2. The empirical formulas of cutting force suitable for cold-blast air machining are established for the test materials, and a conclusion obtained after statistical test is that the cold air's temperature is an index of cutting force.
3. Comparing different materials at different cooling conditions, tool wear is minimal in the cold air condition. At the same time, it showed again that when cutting Q235B the cutting fluid was not only failed to play its proper cooling and lubrication roles, but also increased the amount of cutting force and tool wear from the perspective of tool wear.
在金属加工中,切削液会产生环境污染,同时对人体也有害,它的使用受到了越来越多的限制。绿色制造迎合ISO14000环境标准,符合可持续发展的要求,是未来机械加工的发展趋势。低温冷风切削加工作为一种新兴的绿色制造方式,与传统的切削加工在冷却方式上有很大的不同。冷却方式的不同,会引起刀具和切屑及刀具和工件间的摩擦发生变化。具体表现为切削温度、切削力、刀具寿命、加工表面质量都与传统加工方式有所不同。
课题针对三种经典的金属材料：Q235B钢、45钢和TC4钛合金在三种不同的冷却条件下进行切削实验,试图从中找出切削力和刀具磨损量在冷风条件下的变化规律。总的来说,主要进行了下面三个方面的研究工作：
1、针对三种不同的冷却方式,对比分析切削力的变化规律。得出了在冷风条件下切削力最小的结论,同时也发现了在切削Q235B钢时冷却液不但没有起到应有的冷却润滑作用,反而增大了切削力和刀具磨损量。
2、对每种实验材料都建立起了适用于冷风条件下的切削力经验公式,通过统计学检验得出切削力与冷风温度呈指数关系变化的结论。
3、对比不同材料在不同的冷却条件下刀具的磨损量发现：在冷风条件下,刀具的磨损量是最小的。同时从刀具磨损量的角度再次说明了在切削Q235B钢时冷却液不但没有起到应有的冷却润滑作用反而增大了切削力和刀具磨损量的问题。
Cutting force and tool wear are the results of interaction between the tool and the work piece. Cutting force and tool wear, which are important physical phenomena occur during the cutting process, have important influence on the cutting process. Cutting force will directly affect the cutting power and cutting heat; tool wear can affect the work piece quality and production costs, and cause process system deformation and machine tools vibration. Cutting force and tool wear, therefore, are the important design criterion of machine tool, cutting tools and jigs. To grasp the change regularities will be of great guiding significance for the analysis and resolution of practical problems in the production.
In metal machining, cutting liquid will cause environment pollution, and it is harmful to the human body. It has been more and more restrictions for the use of cutting liquid. Green Manufacturing, which caters to the ISO14000 environment standard, and is in line with requirements of sustainable development, is the future trend of machining development. The cold-blast air cutting as a new kind of green manufacturing technology differs from the traditional cutting cooling methods. The friction result between the tool and the cutting chip, the tool and work piece are different by different cooling methods. The specific external reflection is that cutting temperature, cutting force, tool life and surface quality of work piece are somewhat different from the traditional processing methods.
The experiments using three kinds of metal material, steel Q235B and 45 as well as titanium alloy TC4 under three different cooling conditions, are carried out in this subject, in order to find the variation of cutting force and tool wear under cold-blast air cooling condition. The following three aspects are obtained in the research works:
1. Aimed at three cooling methods, cutting force are tested and analyzed. The conclusion that the cutting force is the smallest under the cold-blast air condition is obtained. And an important phenomenon that the cutting liquid cannot play its proper cooling and lubrication roles, but increased the amount of cutting force and tool wear while cutting steel Q235B is found.
2. The empirical formulas of cutting force suitable for cold-blast air machining are established for the test materials, and a conclusion obtained after statistical test is that the cold air's temperature is an index of cutting force.
3. Comparing different materials at different cooling conditions, tool wear is minimal in the cold air condition. At the same time, it showed again that when cutting Q235B the cutting fluid was not only failed to play its proper cooling and lubrication roles, but also increased the amount of cutting force and tool wear from the perspective of tool wear.
引文
[1]F.Klock, G.Eisenbatter. Dry Cutting. Annals of CIRP.1997, Vol.46(No.2):519～526
[3]杨颖.低温冷风在绿色加工中应用的若干问题研究.重庆大学博士研究生学位论文.2004：22～28
[4]张昌义,顾祖慰.冷风切削技术的发展应用及课题.工具技术.2002
[5]杨坤怡.制造技术.国防工业出版社,2005：
[6]横田秀雄,吴敏镜.MQL切削的现状和发展.航空精密制造技术,2004,40(1)：24～26
[7]李新龙,何宁,李亮.绿色切削中的MQL技术.航空精密制造技术,2005,41(2)：24～27
[8]Alger S R. Mists Cool the cutting edge. American Machinist,1975, Vol. 15(No.3):25-28
[9]W Donald Hewson. Development of new metal cutting oils with quantifiable performance characteristics. Lubrication Engineering,1997, No.8:23-28
[10]裴宏杰,王贵成.绿色机械加工的研究现状及其发展.机械设计与制造工程,2001,30(5)：52～54
[11]T.Cselle. Rotating tooling for dry and high speed cutting. Proceeding of Germany-France Conference on High Speed Machining,1998:85～89
[12]柯舍列夫.金属材料低温机械性能手册.吴孝隆.《低温工程》编辑部出版社,1977
[13]李晋年.黑色金属的超低温金刚石超精密切削.机械工程学报,1989,3：70～72
[14]Shang Y.Hong. Advance of Economical Cryogenic Machining Technology. Proceedings of 3rd International Conference on Manufacturing,1995:12
[15]Shang Y.Hong. Advance of Economical Cryogenic Machining Technology. Proceedings of 3rd International Conference on Manufacturing,1995:235-238
[16]Woo-Cheol Jeong. Investigation of liquid nitrogen lubrication effect in cryogenic machining [Dissertation], USA, Columbia University,2002
[17]S.Paul and A.B.Chattopadhyay. Determination and control of grinding zone temperature under cryogenic cooling. Int.J.Mach.Tools Manufact,1996, Vol.36(No.4):153-158
[18]Z.Y.Wang, K.P.Rajurkar. Wear of CBN tool in turning of silicon nitride with cryogenic cooling. International Journal of Machine Tools&Manufacture,1997,37(3):319～326
[19]孙建国.液氮冷却在切磨加工中的应用.机械工艺师,2001,No.2：35-36
[20]张震,何曙华.低温冷风切削技术浅谈.工具技术,2002,No.2
[21]贾晓鸣等.未来切削液的展望.工具技术,1998,No.1
[22]Industry round-up:metal working fluids-occupational exposure limits for oil mists. Industrial Lubrication and Tribology,1999, Vol.51 (No.1)
[23]石淼森.切削液的选用.矿山机械,1998,No.4：72-74
[29]任家隆.亚干式切削机理的探讨.制造技术与机床,2001,No.10：30-33
[30]任家隆.气体射流冷却切削.现代制造工程,2001,No.12：58-60
[31]任家隆.车削Cr12材料的绿色冷却工艺探讨.华东船舶工业学院学报,2001，Vol.15(No．3)：66-69
[32]刘存祥等.空气涡流制冷及在切削冷却中的应用.制造技术与机床.1997,No.1：29-31
[33]魏成双等.干式冷风切削技术在磨削中的应用.金属加工,2008,No.4
[34]杨颖.低温冷风在绿色加工中应用的若干问题研究.重庆大学博士研究生学位论文.2004
[35]安庆龙.低温喷雾射流冷却技术及其在钛合金机械加工中的应用.南京航空航天大学博士研究生学位论文.2006
[36]任家隆.切削中绿色射流冷却工艺的研究.中国机械工程,2000(7)：738～741
[37]陈日曜.金属切削原理(第2版).机械工业出版社,2002：135～142
[38]杨世铭,陶文铨.传热学(第三版).高等教育出版社,1998：1～11
[39]姜兆华.应用表面化学.哈尔滨工业大学出版社,2002：148～163
[40]E M Trent. Metal cutting (3rd Ed.). Oxford:Butterworth Heinemann,1991:254～264
[41]J A Williams and D Tabor. Role of lubricants in machining. Wear,1977(3):275～292
[42]孙永丰.水蒸汽作冷却润滑介质绿色切削试验研究.哈尔滨工业大学硕士学位论文.2004
[43]陈锡渠,彭晓南.金属切削原理与刀具.中国林业出版社,北京大学出版社，2006
[44]杨洪礼,鲍承友，张序萍.概率论与数理统计.北京邮电大学出版社,2007
[45]茆诗松,周纪芗.试验设计=Design of Experiment.中国统计出版社,2004
[46]唐晓芬.六西格玛核心教程：黑带读本.中国标准出版社,2002
[47]郑明新.工程材料.第二版.清华大学出版社,1991
[48]中国科学技术大学高等数学教研室.高等数学导论(中册).第二版.中国科学技术大学出版社.1995
[49]刘占强,黄传真,郭培全.先进切削加工技术及应用.机械工业出版社,2005
[50]刘志峰,张崇高,任家隆.干切削加工技术及应用=Dry machining technology and application.机械工业出版社,2005
[51]周泽华.金属切削理论.机械工业出版社,1992
[52]杨德保等.工科概率统计.北京理工大学出版社,2007
[53]《机械加工技术手册》编写组.机械加工技术手册.北京出版社,1989
[54]陈家芳.实用金属切削加工工艺手册.上海科学技术出版社,2005
[55]周泽华.金属切削原理.上海科学技术出版社,1993
[56]刘文卿.实验设计=Design of experiments.清华大学出版社,2005
[57]张晓洪.滚齿加工低温冷风微量润滑切削技术及其实验研究.四川大学博士研究生学位论文.2008
[58]张耀寰.机械加工工艺设计手册.航空工业出版社,1987
[59]梁炳文.机械加工工艺与窍门精选.机械工业出版社,2005
[60]孙德茂.数控机床车削加工直接编程技术.机械工业出版社,2005
[61]方新主.数控机床与编程.高等教育出版社,2007
[3]杨颖.低温冷风在绿色加工中应用的若干问题研究.重庆大学博士研究生学位论文.2004：22～28
[4]张昌义,顾祖慰.冷风切削技术的发展应用及课题.工具技术.2002
[5]杨坤怡.制造技术.国防工业出版社,2005：
[6]横田秀雄,吴敏镜.MQL切削的现状和发展.航空精密制造技术,2004,40(1)：24～26
[7]李新龙,何宁,李亮.绿色切削中的MQL技术.航空精密制造技术,2005,41(2)：24～27
[8]Alger S R. Mists Cool the cutting edge. American Machinist,1975, Vol. 15(No.3):25-28
[9]W Donald Hewson. Development of new metal cutting oils with quantifiable performance characteristics. Lubrication Engineering,1997, No.8:23-28
[10]裴宏杰,王贵成.绿色机械加工的研究现状及其发展.机械设计与制造工程,2001,30(5)：52～54
[11]T.Cselle. Rotating tooling for dry and high speed cutting. Proceeding of Germany-France Conference on High Speed Machining,1998:85～89
[12]柯舍列夫.金属材料低温机械性能手册.吴孝隆.《低温工程》编辑部出版社,1977
[13]李晋年.黑色金属的超低温金刚石超精密切削.机械工程学报,1989,3：70～72
[14]Shang Y.Hong. Advance of Economical Cryogenic Machining Technology. Proceedings of 3rd International Conference on Manufacturing,1995:12
[15]Shang Y.Hong. Advance of Economical Cryogenic Machining Technology. Proceedings of 3rd International Conference on Manufacturing,1995:235-238
[16]Woo-Cheol Jeong. Investigation of liquid nitrogen lubrication effect in cryogenic machining [Dissertation], USA, Columbia University,2002
[17]S.Paul and A.B.Chattopadhyay. Determination and control of grinding zone temperature under cryogenic cooling. Int.J.Mach.Tools Manufact,1996, Vol.36(No.4):153-158
[18]Z.Y.Wang, K.P.Rajurkar. Wear of CBN tool in turning of silicon nitride with cryogenic cooling. International Journal of Machine Tools&Manufacture,1997,37(3):319～326
[19]孙建国.液氮冷却在切磨加工中的应用.机械工艺师,2001,No.2：35-36
[20]张震,何曙华.低温冷风切削技术浅谈.工具技术,2002,No.2
[21]贾晓鸣等.未来切削液的展望.工具技术,1998,No.1
[22]Industry round-up:metal working fluids-occupational exposure limits for oil mists. Industrial Lubrication and Tribology,1999, Vol.51 (No.1)
[23]石淼森.切削液的选用.矿山机械,1998,No.4：72-74
[29]任家隆.亚干式切削机理的探讨.制造技术与机床,2001,No.10：30-33
[30]任家隆.气体射流冷却切削.现代制造工程,2001,No.12：58-60
[31]任家隆.车削Cr12材料的绿色冷却工艺探讨.华东船舶工业学院学报,2001，Vol.15(No．3)：66-69
[32]刘存祥等.空气涡流制冷及在切削冷却中的应用.制造技术与机床.1997,No.1：29-31
[33]魏成双等.干式冷风切削技术在磨削中的应用.金属加工,2008,No.4
[34]杨颖.低温冷风在绿色加工中应用的若干问题研究.重庆大学博士研究生学位论文.2004
[35]安庆龙.低温喷雾射流冷却技术及其在钛合金机械加工中的应用.南京航空航天大学博士研究生学位论文.2006
[36]任家隆.切削中绿色射流冷却工艺的研究.中国机械工程,2000(7)：738～741
[37]陈日曜.金属切削原理(第2版).机械工业出版社,2002：135～142
[38]杨世铭,陶文铨.传热学(第三版).高等教育出版社,1998：1～11
[39]姜兆华.应用表面化学.哈尔滨工业大学出版社,2002：148～163
[40]E M Trent. Metal cutting (3rd Ed.). Oxford:Butterworth Heinemann,1991:254～264
[41]J A Williams and D Tabor. Role of lubricants in machining. Wear,1977(3):275～292
[42]孙永丰.水蒸汽作冷却润滑介质绿色切削试验研究.哈尔滨工业大学硕士学位论文.2004
[43]陈锡渠,彭晓南.金属切削原理与刀具.中国林业出版社,北京大学出版社，2006
[44]杨洪礼,鲍承友，张序萍.概率论与数理统计.北京邮电大学出版社,2007
[45]茆诗松,周纪芗.试验设计=Design of Experiment.中国统计出版社,2004
[46]唐晓芬.六西格玛核心教程：黑带读本.中国标准出版社,2002
[47]郑明新.工程材料.第二版.清华大学出版社,1991
[48]中国科学技术大学高等数学教研室.高等数学导论(中册).第二版.中国科学技术大学出版社.1995
[49]刘占强,黄传真,郭培全.先进切削加工技术及应用.机械工业出版社,2005
[50]刘志峰,张崇高,任家隆.干切削加工技术及应用=Dry machining technology and application.机械工业出版社,2005
[51]周泽华.金属切削理论.机械工业出版社,1992
[52]杨德保等.工科概率统计.北京理工大学出版社,2007
[53]《机械加工技术手册》编写组.机械加工技术手册.北京出版社,1989
[54]陈家芳.实用金属切削加工工艺手册.上海科学技术出版社,2005
[55]周泽华.金属切削原理.上海科学技术出版社,1993
[56]刘文卿.实验设计=Design of experiments.清华大学出版社,2005
[57]张晓洪.滚齿加工低温冷风微量润滑切削技术及其实验研究.四川大学博士研究生学位论文.2008
[58]张耀寰.机械加工工艺设计手册.航空工业出版社,1987
[59]梁炳文.机械加工工艺与窍门精选.机械工业出版社,2005
[60]孙德茂.数控机床车削加工直接编程技术.机械工业出版社,2005
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