Manufacturing the Future with Supercritical CO2 and Minimum Quantity Lubrication

用超临界二氧化碳和微量润滑制造未来

• 批准号: EP/W001950/1
• 负责人: Nikil Kapur
• 金额: $ 96.63万
• 依托单位: University of Leeds
• 依托单位国家: 英国
• 项目类别: Research Grant
• 财政年份: 2022
• 资助国家: 英国
• 起止时间: 2022 至 无数据
• 项目状态: 未结题
• 来源: https://gtr.ukri.org/projects?ref=EP%2FW001950%2F1
• 关键词: Manufacturing; Future; Supercritical; CO2; Minimum

Currently the dominant approach for cooling and lubricating machining processes, such as drilling, milling and turning, is to use emulsion-based coolants (otherwise known as metalworking fluids) at high flow rates. There are many serious environmental, financial and health and safety reasons for reducing industry's reliance on emulsion coolants - an estimated 320,000 tonnes/year in the EU alone, up to 17% of total production costs, and over 1 million people are exposed regularly to the injurious effects of its additives which can cause skin irritation and even cancers. Serious environmental problems are also caused by the up to 30% of coolant that is lost in leaks and cleaning processes and which eventually ends up polluting rivers.These issues have motivated extensive research efforts to identify more sustainable machining processes. There is growing and compelling evidence from preliminary studies that cryogenic machining with supercritical CO2 (scCO2) with small amounts of lubricant (Minimum Quantity Lubrication, MQL, referred to as scCO2+MQL machining) can provide a high-performing and more sustainable alternative. Current knowledge gaps in the relationships between key input and output variables, the reasons for variations in performance and concerns over the release of CO2, are preventing a major uptake of this technology by UK manufacturers. This project aims to test the hypothesis that optimising combinations of CO2 with small amounts of the appropriate lubricant can provide reliable, step-change improvements in the performance and sustainability of machining operations. It will carry out a systematic investigation into the effect of scCO2+MQL on cutting forces, heat and tool wear mechanisms during machining of titanium, steels and composite stacks. It will develop: (a) advanced experimental methods in combination with full-scale machining trials to explore how lubrication and heat transfer affect machining performance; (b) lifecycle assessment and scavenging methods for sustainable re-use of CO2; (c) machine learning methods to predict the relationships between process inputs and outputs and (d) develop an effective and efficient optimisation methodology for balancing competing financial, performance and sustainability objectives in scCO2+MQL machining. These will deliver the knowledge, experimental and modelling methods and software tools that UK industry needs to exploit this enormous as-yet untapped potential.The project will involves staff and postdoctoral research assistants from the Universities of Leeds and Sheffield and the Advanced Manufacturing Research Centres in Sheffield, with advice and guidance from a Project Steering Group comprised of leading international academic and industrial experts. Collectively, the team has the expertise in (a) manufacturing systems and tribology; (b) energy systems and lifecycle assessment; (c) fluid mechanics and heat transfer, and (d) machine learning and optimisation, needed to provide the 'how' and 'why' UK industry needs to reliably achieve or exceed the performance improvements seen in preliminary studies, namely doubling of tool life. We will work with our industrial and business sector collaborators to drive transformations in machining rate, process cost and accompanying safety, environmental and quality metrics for the benefit of the UK's defence, civil nuclear and medical manufacturing industries through the 2020s and beyond.

当前，冷却和润滑加工过程的主要方法，例如钻孔，铣削和转弯，是在高流速下使用基于乳液的冷却剂（也称为金属加工液）。减少行业对乳液冷却剂的依赖有许多严重的环境，财务和健康和安全原因 - 仅欧盟估计每年320,000吨，占总生产成本的17％，超过100万人经常暴露于其添加剂的伤害效果，这可能会导致皮肤刺激甚至是Cancers。严重的环境问题也是由多达30％的冷却液在泄漏和清洁过程中丢失的，最终最终污染河流的30％引起的。这些问题促使广泛的研究工作以确定更可持续的加工过程。从初步研究中有越来越多的证据，即用超临界二氧化碳（SCCO2）进行低温加工，少量润滑剂（最小数量润滑，MQL，称为SCCO2+MQL加工）可以提供高强度和更可持续的替代方案。当前的知识差距在关键输入和输出变量之间的关系，性能变化的原因以及对CO2发行的关注的原因正在阻止英国制造商对这项技术的重大吸收。该项目旨在检验以下假设：将二氧化碳与少量适当的润滑剂的优化组合可以提供可靠的，逐步改变加工操作的性能和可持续性。它将对SCCO2+MQL对钛，钢和复合堆栈加工过程中的切割力，热和工具磨损机构的影响进行系统的研究。它将开发：（a）高级实验方法与全尺寸加工试验结合使用，以探索润滑和传热如何影响加工性能； （b）可持续重复使用CO2的生命周期评估和清除方法； （c）机器学习方法可以预测过程输入与输出之间的关系，以及（d）在SCCO2+MQL加工中开发一种有效，有效的优化方法，以平衡竞争财务，绩效和可持续性目标。这些将提供英国行业所需的知识，实验和建模方法和软件工具，以利用这一巨大的尚未开发的潜力。该项目将涉及来自利兹和谢菲尔德大学以及谢菲尔德大学的员工和博士后研究助理，以及由Sheffield的高级制造研究中心，以及由领先的国际学术和工业学术专家组成的项目指导小组的建议和指导。总体而言，团队拥有（a）制造系统和摩擦学方面的专业知识； （b）能源系统和生命周期评估； （c）流体力学和传热，以及（d）机器学习和优化，需要提供“如何”和“为什么”英国行业需要可靠地实现或超过初步研究中所看到的绩效改进，即使工具寿命增加一倍。我们将与工业和商业部门的合作者合作，以在2020年代及以后的英国国防，民用核和医疗制造业的利益方面推动加工速度，流程成本以及伴随的安全，环境和质量指标的转型。