Modeling and analyzing the effects of air-cooled turning on the machinability of Ti–6Al–4V titanium alloy using the cold air gun coolant system
Modeling and analyzing the effects of air-cooled turning on the machinability of Ti–6Al–4V titanium alloy using the cold air gun coolant system
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DOI：
10.1007/s00170-012-4547-8
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发表时间：
2013-07
期刊：
影响因子：
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通讯作者：
Nun-Ming Liu;K. Chiang;Chen-Ming Hung
中科院分区：
文献类型：
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作者：
Nun-Ming Liu;K. Chiang;Chen-Ming Hung
本研究为模拟和分析空冷对钛合金硬态车削加工性能的影响提供了数学模型。实验中使用了冷气枪冷却系统，并产生了一股压缩冷气来冷却切割过程。对于硬车削来说，空气冷却工艺似乎是一个很好的环保选择。在本实验研究中，选择了切削速度、进给速度和切削深度作为数值因素，以冷却方式作为分类因素。采用基于响应面方法(RSM)的四因素(三个数值+一个分类)D-最优设计的实验方案进行实验研究。建立了基于响应面模型的数学模型，对干切削和风冷条件下硬态车削过程中的切削温度和表面粗糙度进行了建模和分析。并对刀具磨损和切屑形成进行了研究。在切割过程中，气体形式的压缩冷却空气比任何传统的冷却剂都能更好地将润滑剂渗透到切削区。结果表明，空冷显著降低了加工温度，减少了刀具磨损，获得了最佳的加工表面。硬态车削Ti-6Al-4V钛合金空冷条件下的加工性能优于干切削条件下的加工性能。这种风冷切割过程很容易产生起皱和折断的切屑。因此，风冷车削工艺在硬车削加工中提供了干式车削的极具吸引力的替代方案。
This study provides the mathematical models for modeling and analyzing the effects of air-cooling on the machinability of Ti–6Al–4V titanium alloy in the hard turning process. A cold air gun coolant system was used in the experiments and produced a jet of compressed cold air for cooling the cutting process. The air-cooling process seems to be a good environment friendly option for the hard turning. In this experimental investigation, the cutting speed, feed rate and cutting depth were chosen as the numerical factor; the cooling method was regarded as the categorical factor. An experimental plan of a four-factor (three numerical plus one categorical) D-optimal design based on the response surface methodology (RSM) was employed to carry out the experimental study. The mathematical models based on the RSM were proposed for modeling and analyzing the cutting temperature and surface roughness in the hard turning process under the dry cutting process and air-cooling process. Tool wear and chip formation during the cutting process were also studied. The compressed cooling air in the gas form presents better penetration of the lubricant to the cutting zone than any conventional coolants in the cutting process do. Results show that the air-cooling significantly provides lower cutting temperature, reduces the tool wear, and produces the best machined surface. The machinability performance of hard turning Ti–6Al–4V titanium alloy on the application of air-cooling is better than the application of dry cutting process. This air-cooling cutting process easily produces the wrinkled and breaking chips. Consequently, the air-cooled cutting process offers the attractive alternative of the dry cutting in the hard turning process.