Study on Minimum Coolant Cutting Technology

为了减少加工过程中产生的反环境材料，开发最少润滑量的加工技术迫在眉睫。然而，目前还没有一种方法来评估切削油的最小量，该量是由压缩空气携带的，可以在切削区域充分冷却刀具和工件。因此，本项目的目的是分析评估最少量润滑的冷却效率和供应条件，以及开发用于监测切削油雾性能的薄膜热传感器工具。首先，分析了立铣刀在干式切削、风冷切削、水冷切削、高压冷却液切削、MQL切削等各种冷却条件下的冷却效率。通过分析，在较宽的切削速度、进给速度和冷却液速度范围内，对MQL的冷却效率与其他冷却条件下的冷却效率进行了比较。其次，在不同的切削速度和空气雾速条件下，分析了切削油雾在刀具间隙面下的流动情况，评估了切削油雾向切削刃周围区域供应的速率。第三，采用表面涂层技术，研制了用于状态监测的薄膜热传感器工具。最后，建立了超高速切削分析的有限元模型，发现在超高速切削范围内，最高温度随切削速度的增加而降低。

In order to reduce anti-environmental materials emitted during machining, the development of machining technology with the minimum quantity lubrication is urgent. However, no method has been established for evaluating the minimum quantity of cutting oil carried with compressed air that cools down the cutting tool and workpiece well enough in cutting area. Therefore, the objectives of this project are analyzes for evaluating the cooling efficiency and supply conditions of the minimum quantity lubrication, and the development of tools with thin film thermal sensor for monitoring the performance of the mist of cutting oil.First, the cooling efficiency of end mill under various cooling conditions has analyzed, such as in dry cutting, air cooling cutting, water cooling cutting, cutting with high pressure coolant, and MQL cutting. Through the analysis, the cooling efficiency of MQL was compared with that under other cooling conditions in the wide range of cutting speed, feed rate and coolant velocity. Secondly, the flow of the mist of cutting oil under the tool clearance face was analyzed under the various conditions of cutting speed and air mist velocity, and the rate of the mist of cutting oil supplied to the area around the cutting edge was evaluated. Thirdly, tools with thin film thermal sensor for condition monitoring was developed using the surface coating technologies. Finally, finite element modeling for analyzing ultra-high speed cutting was developed and it was found that the maximum temperature reduced with cutting speed in the range of ultra-high speed cutting.