The new-style green of material of cutting difficult treatment is efficient and cooling lubricant technology

Time:2023-06-13 17:41:53
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source:COCKRIEL CNC Machining

Well-known, in cutting treatment process, to reduce cutting force (power) wear away with cutting tool, improve quality of surface of cutting tool service life, treatment and manufacturing efficiency, mostly the enterprise can use cooling lubricant. Liquid refrigeration lubricant calls cutting fluid or cooling lubricating fluid normally, general component is cutting fluid water radical and oil base two kinds big, water radical includes water and its solution, oil radical includes vegetable oil, animal oil and mineral oil and its miscella. To improve the cooling and lubricant performance of cutting fluid, special when material of cutting difficult treatment, need to join toward contact extremely press additive, wait like S, Cl and P. The antirust additive in emulsion (be like inferior sodium nitrate) it is poisonous, harmful material more, cause cancer even. Fluid of oil radical cutting can produce a large number of smoke below the action of cutting high temperature, although the S that adds in both, Cl and P can increase osmotic, make chemical and adsorptive film or physisorption film with the surface, reduce attrition, but they have intense excitant taste, healthy to human body harm is very great, want to handle waste liquid to be able to raise a lot of cost again at the same time. According to statistic, 20% of waste liquid. This shows, use cutting fluid is having very big negative effect: It is to human body health causes great harm, 2 it is right the environment causes serious pollution. As the development of science and technology, the knowledge that people pollutes to the environment is deeper and deeper, code of together with environmental protection is strict with each passing day, pressing requirement machinery makes an enterprise must take the environment in machining process seriously to pollute a problem, because this advanced the idea of green cutting, do not pollute an environment namely and the cutting that does not endanger health. The high speed, ultimate goal that exceeding high-speed to do type cutting is green cutting pursuit, but it still cannot be carried out extensively inside quite long period. Because this shows the main task of level,should consider how to make what use cutting liquid namely incorrect environment causes pollution or little pollution. Main research has 2 sides: It is to manufacture harmless additive, 2 it is research little or the cooling lubricant of free from contamination (include gas and liquid) , research green cutting technology. Green cutting technology is the main component that machinery makes an enterprise carry out green to make a technology, already made a kind of of 21 centuries advanced production technology. The research current situation of green cutting technology lubricates to realize cutting to cool of the technology little or free from contamination, each country scholar did many experiment to study the work, development goes a lot of cutting cooling and lubricant technology, be like minimum (minim) lubricant (Minimal Quantity Lubrication, MQL) technology, pulverization is cooling and lubricant efflux of technology, liquid is cooling and lubricant refrigeration of technology of refrigeration of air cooling of technology, low temperature, liquid nitrogen works type cutting technology and Gan Shijing phone cooling technology. (1) minimum (minim) lubricant technology. The interpose that a few experts that this law is Western Europe country put forward at working type and wet a kind of between cutting lubricant technology. This technology is to will be compressed after air mixes vaporization with a few lube, again eject arrives treatment place, make thereby knife - bits contact area gets cool and lubricating. This technology can reduce a knife greatly - bits and knife - the attrition between treatment surface, rise to drop cutting temperature, reduce cutting tool to wear away, the function that improves treatment efficiency and treatment surface quality. If a machining center is in traditional and wet fluid of cutting of the need in cutting 20 ～ 100L/min, MQL technology needs only (15 ～ 30) × 10-4L/min, it is about wet the 1/3000 ～ 1/40000 of cutting. But this technology still exists at present 2 sides issue is masty: It is how minimum decides, 2 it is cooling lube still has pollution. Because this MQL technology is not dry type pure green, reason calls skill of accurate green cutting. On this foundation, MQL technology develops to lubricate for microtherm pulverization again cutting technology, namely compress air to fall reach a few degrees 0 times, mix vaporization with lube again, the effect is close friends than compressing air commonly, but still have a few pollution. (2) pulverization is cooling and lubricant technology. This law is cutting fluid the eject after pulverization arrives the cooling and lubricant technology of cutting area, although this technology has better effect, but pollution is relatively serious, working area must close, inconvenience is popularized and use. (3) liquid efflux is cooling and lubricant technology. This law is cutting fluid uses high-pressured efflux spray to cutting area, with pouring law photograph is compared, this technology can improve cutting tool service life, but pollution is relatively serious also. (4) technology of refrigeration of microtherm air cooling. This law must have system of refrigeration of microtherm air cooling, include to compress dehumidify of air source, air implement, the composition such as canal of air condenser, adiabatic canal, wind mouth, aspiration and dust arrester. To make its have antirust with lubricant action, still must gush enters a few vegetable oil, this technology also has pollution and the system is complex, inconvenience is popularized and use. (5) liquid nitrogen refrigeration does type cutting technology. This law is to use liquid nitrogen to make cutting cools in microtherm undertake below condition. Often have 2 kinds of kind: It is bottled pressure gush goes to the oneself that relies on liquid nitrogen cutting area; 2 it is to rely on liquid nitrogen be heated to evaporate cutting tool of circular indirect cooling, this is method of cutting of dry type of a kind of low temperature. Liquid nitrogen is the by-product of the process that make oxygen, low-cost, can use circularly and free from contamination, but store facility cost is higher, use rise no-go. Additional, the exterior chemistry active that issues cutting in the microtherm condition of liquid nitrogen is extremely strong, expose can rust very quickly in air. (6) technology of cutting of refrigeration of Gan Shijing report. Technology of cutting of refrigeration of Gan Shijing report is before Russia the technology of dry type cutting that in 20 centuries 80 time invent, its fundamental is to will compress air ionization, smelly oxidation (use up power not to exceed 25W) , next by nozzle sends to cutting area, in cutting special aeriform atmosphere is formed all round the dot. Atmosphere of this kind of gas dropped cutting area temperature not only, more important is to be able to be in cutting tool and cut the oxidation film that has lubricant effect is formed on bits, cutting tool and workpiece interface, make be shown to control stress state by treatment surface, add the service life of the spare parts thereby. Company of technology of Russia Luo Shi ever had done a large number of tests to this, discovery falls in most circumstance, the service life of the cutting tool when using technology of refrigeration of Gan Shijing report and wet cutting comparatives or exceed, cutting force is reduced somewhat, the spare parts after be being machined especially need not be cleaned via 2 again, divide outside reducing pollution, also reduced the cost that waste liquid handles greatly. According to introducing, in the national defence that is in Russia at present and car company, about already 5000 machine tools use this technology. 1 vapor of 　 of cooling and lubricant technology makes new-style green cutting cutting refrigeration lubricant usually, people always considers to use microtherm liquid or gas makes cutting refrigeration lubricant, and before B of · of B of · of husband of Er of dagger of heart of Russia scholar wave stalking or branch is converse however thinking, lubricate at putting forward to cool with high temperature vapor 1988 cutting area this one bold idea, won patent. 1998 Gede the cutting experiment of A of · V · and B of · of B of · of Ma Erke's husband proves Liefusiji: T15K6 (YT15) 45 steel, stainless steel reachs turning of hard alloy cutting tool when casting pig, the service life of cutting tool raised 1 ～ 1.

5 times, the milling effect of interrupted cutting is better, can raise 1 ～ 3 times. Place is 500 ～ 700W with the power that increases shrinkage fitting buy, the temperature that gotten saturated steam spray head is in is 100 ℃ , reach cutting area (cooling distance 20mm) the steam temperature when is 85 ℃ . This task group begins this research from 2002, now already from phase of test facilities of primary reason of the type that put store (heat power is 3500W) , the course follows level of system of hairdo small-power air feed (heat power is 1200W, temperature pressure can accuse oneself) , to phase of device small-power, miniaturization (heat power is 800W, temperature pressure is controallable, nozzle outlet temperature is 125 ℃ ) , till industry uses systematic level (stand-alone is used, much chance is used -- the type that put store + eddy current heats 2 times) . System of small-sized air feed is shown 1 times like the graph. Nextpage 　 uses YT15 (P10) cutting 45 steel (normalizing) , with YG6 (K15) TC4 of alloy of 1Cr18Ni9Ti of cutting austenite stainless steel, titanium and GH4169 of alloy of Ni radical high temperature, make refrigeration with vapor lubricant and dry cut, the cutting experiment of emulsion undertook contrast, if express 1 ～ ,as a result 4 are shown. When cutting 1Cr18Ni9Ti, the cutting rate that vapor makes cutting refrigeration lubricant be cut than working rose 11% , compare emulsion rose 5% ; When cutting TC4, the cutting rate that cuts than working rose 15% , compare emulsion rose 10% ; When cutting GH4169, the cutting rate that cuts than working rose 8.

3% , compare emulsion rose 3.

2% . Relevant report thinks, the cooling and lubricant action of cooling lubricant developed cutting only very few one part. The knife when cutting - the attrition of bits contact area is lubricant the principle is capillary permeate theory, namely knife - bits contacts the refrigeration of the area to lubricate is to rely on the capillarity of cooling lubricant to act well. Relevant capillary model has T.

The cuboid model of Willms and Godlevski.

The cylinder model of A. About knife of cooling lubricant infiltration - the process of bits contact area, they think capillary cent is infiltration of lubricant of liquid state refrigeration 3 phase, it is infiltration of normal temperature liquid, 2 it is normal temperature liquid is in capillary in cutting temperature (hundreds of degrees) below action, produce bulk to expand, pressure is elevatory, small drop evaporates " explosion " , enter the 3rd phase thereby -- phase of gas phase fill, happened namely " explosion " vapour fill arrived capillary in, the liquid that at the same time capillary mouth is in is given by the top again, restricted follow-up liquid infiltration thereby, this explains the action of lubricant of liquid state refrigeration called very big discount. And overheat vapor is in capillary medium infiltration is relatively successful, leave out the 2nd phase -- evaporate " explosion " level, make it is finished smoothly permeate, consequently cooling and lubricant action compares liquid or microtherm gas (compress air) be close friends. The reason with the cooling and lubricant good function of Nextpage 　 steam still depends on steam be in capillary in permeated time is less than capillary existence time far, and can form lubricant layer with capillary wall, replaced the oxidation film that is wiped, avoided a knife - the direct contact attrition between bits, formed screen layer, reduced a knife thereby - the attrition between bits, make diffuse to be reduced with the trend of felt. The cooling action of vapor depends on the indirect cooling action of efficient and lubricant action not only, return those who depend on ability of convection heat exchange to increased to drop cutting temperature effectively, this is immediate cooling effect. Its will be overheat vapor as a result the result that makes cooling lubricant than liquid or microtherm gas is good much. Afore-mentioned test results show this well. Graph 2 with the graph 3 it is a knife respectively - what temperature of bits contact area and thermal current distributing is finite yuan emulate. When using vapor to make cooling lubricant, cutting area is highest temperature is apparent under dry cut, dry temperature of area of the cutting when cutting is highest it is 620 ℃ about, and temperature of area of the cutting when vapor makes cutting refrigeration lubricant is highest it is 500 ℃ about, when can be being cut than working reduce about 20% . Cutting temperature top part has certain space to cutting point, dry when cutting, be about to point 0.

5mm, and vapor is about when cooling lubricant 0.

4mm, knife - bits contact length is dry about 50% when cutting. Of vapor efflux the 10 ～ that forcing coefficient of convection heat exchange is coefficient of heat exchange of air nature convection about 15 times, reason vapor still has effect of efficient refrigeration of convection heat exchange. Because this vapor makes cutting,cooling lubricant can drop cutting temperature apparently. Technologies of 2 cutting of refrigeration of Gan Shijing report this technology is through ionization device air ionization creates ozone O3, because ozone has very strong chemical active, can be in knife - bits contact area makes oxidation film, reduce the attrition of cutting process thereby, reduce cutting force already, drop cutting temperature again. Cutting experiment makes clear: When using GH4169 of cutting of hard alloy YG8, with dry cut photograph comparing, cutting force is reduced about 10% , cutting thermal drop is small about 5% , cutting tool wears away reduce 30% , with comparative when use emulsion; When cutting TC4, with dry cut photograph comparing, cutting force is reduced 6% , cutting thermal drop is small 5% , cutting tool wears away reduce 30% ～ 50% . Of material of active of the surface after be being machined especially decompose, can eliminate completely by the pollution of treatment surface, do not need 2 times of workpiece to clean, reduced waste liquid greatly discharge, reduced environmental pollution already, saved resource and the sources of energy greatly again, reduced production cost. Emulsion of 3 ultrasonic processing makes cutting juice implementation is energy-saving cutting grinding processes the technique that decreases a platoon now a large number of medium use emulsion, to achieve the cooling and lubricant result of expect, at any cost successive and pouring, the kill that such doing was to waste resource and the sources of energy already, caused a harm to the health of environment and human body again, the processing of waste liquid also increased to make cost. If emulsion or other water base cutting fluid undertakes handling with ultrasonic first, make its particle diameter is reduced, distributing to achieve a large number of energy equably, enter cutting area more easily, permeate a knife - what bits contacts an area is capillary in, enhance cooling and lubricant performance thereby. Cutting experiment makes clear: With ultrasonic treated force of the cutting when emulsion makes cutting juice than unsettled emulsion is reduced 10% , this was equivalent to reducing emulsion dosage; Treatment surface quality got ameliorative, machine trace regulation, put in felt phenomenon scarcely; The snail that cuts bits appearance to show regulation coils shape and color becomes shallow, namely cutting thermal drop is small. Emulsion of processing of 4 magnetic field makes cutting juice implementation is energy-saving the technology that decreases a platoon is like an emulsion or other water base the magnetic field that cutting fluid traverses particular strength first undertakes handling, the emulsion that also can get be handlinged with ultrasonic makes the similar result when cutting fluid. It is difficult that the last word regards cooling lubricant as to be in overheat vapor overheat vapor the refrigeration with be had better in the cutting that processes data is lubricant the effect, and its origin is extensive, it is the cooling and lubricant technology of a kind of efficient green. Technology of electrostatic and cooling cutting is in dry type material of cutting difficult treatment when GH4169 of alloy of Ni radical high temperature and titanium alloy TC4 but relatively reduce cutting tool significantly wear away, it is a kind of green efficient cutting engineering technology. Classics ultrasonic and the emulsion that magnetic field handles make cooling lubricant, emulsion particle diameter is reduced greatly and achieved a large number of energy, make its permeate function to increase greatly, accordingly, classics ultrasonic and the emulsion that magnetic field handles make cooling lubricant also is a kind energy-saving the cooling method of lubrication that decreases a platoon. CNC Milling CNC Machining