MQL Cutting of Difficult-to-Machine Materials with the aids of CAE and Ultrasonic Vibration

借助 CAE 和超声波振动对难加工材料进行 MQL 切割

基本信息

批准号：
14350068
负责人：
OBIKAWA Toshiyuki
金额：
$ 6.78万
依托单位：
TOKYO INSTITUTE OF TECHNOLOGY
依托单位国家：
日本
项目类别：
Grant-in-Aid for Scientific Research (B)
财政年份：
2002
资助国家：
日本
起止时间：
2002 至 2004
项目状态：
已结题

来源：
https://kaken.nii.ac.jp/en/grant/KAKENHI-PROJECT-14350068/
关键词：
Machining MQL Difficult-to-Machine Materials CAE Ultrasonic Vibration Cutting ミスト流れ解析

项目摘要

To decrease the impact to the global environment and realize the sustainable development of manufacturing, MQL technology, in which a small amount of bio-degradable oil is supplied with plenty of compressed air, has been widely applied to machining processes. However, it is still difficult to apply MQL technology to machining of difficult-to-machine materials effectively. In this study, MQL cutting technology effective for machining difficult-to-machine materials was investigated from theoretical and experimental viewpoints. For this purpose, MQL cutting experiment of Inconel 718 and carbon steel S45C were conducted with and without ultrasonic vibration cutting ; cutting tools for monitoring cutting temperature precisely were developed ; oil mist flow around tool tip were analyzed using a general purpose code of computational fluid dynamics. In finishing Inconel 718,optimization of the pressure of compressed air, oil consumption, and coating materials of tool increased tool life at relatively high cutting speeds of 60 m/s or more. Tools for controlling the blowing direction of oil mist COD tools were developed. It was found that these tools were able to decrease oil consumption by 50-70 percent. Application of ultrasonic vibration to MQL cutting was found to be effective particularly in decreasing crater wear at slower cutting speeds, which were inevitable in machining a slender bar of smaller diameters. With tools for monitoring cutting temperature precisely, thin film thermocouples were fabricated on the tools using photolithography technology, then were coated with hard and thin TiN film. Cutting temperature in turning was measured with these tools. The flow of oil mist was analyzed for tuning and grooving. In grooving, reduction of oil consumption was related to the localization of the flow of oil mist quantitatively.

为了减少对全球环境的影响并实现制造业的可持续发展，MQL技术，其中少量的生物降解油提供了大量压缩空气，已广泛应用于加工过程。但是，将MQL技术应用于有效机器材料的加工仍然很难。在这项研究中，从理论和实验观点研究了有效加工难以机理材料的MQL切割技术。为此，进行了有或没有超声振动切割的Inconel 718和碳钢S45C的MQL切割实验。精确开发了用于监测切口温度的切割工具；使用计算流体动力学的通用代码分析了围绕工具尖端的石油雾流。在完成Inconel 718时，以相对较高的切割速度（60 m/s或更高）优化了压缩空气的压力，油消耗和工具的涂料材料。开发了控制石油雾鳕鱼工具的吹吹动方向的工具。发现这些工具能够将石油消耗量减少50-70％。发现超声振动在MQL切割中的应用是有效的，特别是在较慢的切割速度下降低火山口磨损方面，这在加工较小的直径较小的条上是不可避免的。使用用于监测温度的工具，可以使用光刻技术在工具上制造薄膜热电偶，然后用硬质和薄锡膜涂层。使用这些工具测量转弯中的切口温度。分析了油雾的流动，用于调整和槽。在凹槽中，油消耗的减少与定量石油流量的定位有关。