PREMISE: Machining Performance Evaluation in Near-Dry Machining of Aluminum Alloys

这个生产实现和环境制造创新系统(Premise)项目旨在确定喷雾冷却在广泛的切割条件、刀具几何形状和三种主要铝加工材料(356、380和390)下在最常见的汽车加工操作(包括车削、铣削和钻孔)中的主要影响。对流体(和雾化)流量、空气压力、喷雾方向(以及喷嘴位置)、流体类型和组成等影响参数对刀具磨损/刀具寿命、切削力、切屑形态/切屑破碎性、表面粗糙度等加工性能指标的影响进行了研究和比较，并进行了敏感性分析，以确定主要影响参数，并得出相关的经验关系供实际应用。最后，提出了全方位的验证方法。该项目将在12个月内分四个重叠阶段进行。本项目的研究结果将验证和确立在具体应用中用喷雾冷却取代传统的洪水冷却的可行性，从而避免洪水冷却普遍存在的环境污染极大、对人员健康造成负面影响、生产成本增加和能源效率低下等缺点。在喷雾冷却应用中，加工性能不会受到影响。喷雾冷却主要影响参数的识别对机械加工工艺规划具有重要意义。本项目产生的实验数据和建立的相关经验关系也将作为开发分析模型的基础，用于机械加工过程的优化。

This Production Realization and Environment Manufacturing Innovative Systems (PREMISE) project is aimed at establishing the major effects of spray cooling under a wide range of cutting conditions, tool geometry and three major aluminum work materials (356, 380 and 390) in most commonly known automotive machining operations covering turning, milling, and drilling. The effects of influencing parameters such as the fluid (and mist) flow rate, air pressure, direction of spray (and the nozzle position), type and composition of fluid, etc., are to be studied and compared for machining performance measures such as tool-wear/tool-life, cutting forces, chip-forms/chip breakability, surface roughness, etc. A sensitivity analysis will be made in order to identify the major influencing parameters and relevant empirical relationships will be derived for practical applications. At the end, a full range of validation is proposed. The project will be conducted in four overlapping phases in twelve months. The findings of this project will validate and establish the feasibility of using spray cooling to replace conventional flood cooling in specific applications, thus avoiding the disadvantages such as extremely harmful environmental pollution, negative influence on personnel health, increased production costs and poor energy efficiency, etc., prevalent in flood cooling. The machining performance will not be compromised in spray cooling applications. The identification of the primary influencing parameters in spray cooling is important for machining process planning. The experimental data generated and the relevant empirical relationships established from this project will also serve as the basis for developing analytical models for use in the optimization of machining processes.