Study on Minimum Coolant Cutting Technology

为了减少机械加工过程中产生的有害物质，迫切需要发展微量润滑的机械加工技术。然而，还没有建立方法来评估压缩空气携带的切削油的最小量，该最小量在切削区域中足够好地冷却切削刀具和工件。因此，本研究的目的是分析评价最小润滑量的冷却效率和供给条件，以及开发具有薄膜温度传感器的刀具，以监测切削油雾的性能。首先，分析了立铣刀在各种冷却条件下的冷却效率，如干切削、风冷切削、水冷切削、用高压冷却剂切割和MQL切割。通过分析，在较宽的切削速度、进给量和冷却液流速范围内，比较了MQL与其他冷却条件下的冷却效率。其次，分析了在不同切削速度和空气雾化速度条件下，刀具后刀面下切削油雾的流动情况，并对切削油雾向切削刃周围区域的供给率进行了评价。第三，采用表面镀膜技术，研制了用于状态监测的薄膜热传感器工具。最后，建立了超高速切削的有限元分析模型，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.