Study on Minimum Coolant Cutting Technology

为了减少加工过程中排放的环保性材料，开发最小润滑量的加工技术迫在眉睫。然而，还没有建立一种方法来评估在切削区充分冷却刀具和工件的压缩空气所携带的最小切削油量。因此，本课题的研究目标是评价刀具在最小润滑量下的冷却效率和供给条件，开发具有薄膜热敏传感器的刀具来监测切削油的雾化性能。首先，分析了干切削、风冷切割、水冷切割、高压冷却液切割和MQL切割等不同冷却条件下立铣刀的冷却效率。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，比较了MQL与其他冷却条件下的冷却效率。其次，分析了在不同的切削速度和气雾速度条件下，切削油在刀具间隙面下的雾化流动情况，并对刀具刃口周围区域的切削油雾化程度进行了估算。第三，利用表面涂层技术，研制了具有薄膜热敏传感器的状态监测工具。最后，建立了分析超高速切削的有限元模型，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.