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

该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削条件下的主要效果，刀具几何形状和三种主要的铝工件材料（356，380和390）在最常见的汽车加工操作中，包括车削，铣削和钻孔。影响参数的影响，例如流体（和雾）流速、空气压力、喷雾方向（和喷嘴位置）、流体的类型和成分等，的加工性能的措施，如刀具磨损/刀具寿命，切削力，芯片的形式/芯片的可折断性，表面粗糙度等进行了研究和比较，将进行敏感性分析，以确定主要的影响参数和相关的经验关系将推导出实际应用。最后，提出了一个全方位的验证。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特定应用中采用喷雾冷却替代传统泛冷的可行性，从而避免了对环境造成极大危害、对人员健康产生负面影响、增加生产成本和能源效率差等缺点，普遍存在于洪水冷却中。在喷雾冷却应用中，加工性能不会受到影响。喷雾冷却过程中主要影响参数的识别对机械加工工艺设计具有重要意义。 该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用于优化加工过程的分析模型的基础。

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.