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Additive Solutions for Subtractive Problems in Cutting Tool - Next Generation Machining Processes for Advanced Alloys.

切削刀具减材问题的增材解决方案 - 先进合金的下一代加工工艺。

基本信息

批准号：
1942701
负责人：
金额：
--
依托单位：
University of Bath
依托单位国家：
英国
项目类别：
Studentship
财政年份：
2017
资助国家：
英国
起止时间：
2017 至无数据
项目状态：
已结题

来源：
https://gtr.ukri.org/projects?ref=studentship-1942701
关键词：
Additive Solutions Subtractive Problems Cutting

项目摘要

The manufacturing industry is a fundamental sector of all industrialised countries. However, the traditional techniques utilised are no longer viable in a social, economic or environmental capacity. One of the major branches of this industry is machining and has two of the largest consumables; cutting tools e.g. drill bits and cutting fluids (a mixture of oil, water and chemical additives that are sprayed at the cutting tool). When in use, cutting tools get very hot and are subjected to high pressures. This causes them to wear down very quickly and become unusable. To prolong the life of the tools, cutting fluids are sprayed directly at them during machining, reducing the temperature and lubricating the surface of the cutting tool. However, cutting fluids are not environmentally friendly, not sustainable, have associated health risks, are unusable in certain applications e.g. nuclear or medical and account for 15-20% of the total manufacturing cost of a component/ product. There have been alternative attempts to thermally stabilise cutting tools over the last 20 years. For very small, stationary tools, a radiator in the tool holder has been utilised to indirectly cool the tool and fluid has been passed through a channel that loops inside the tool and back out through the tool holder. These are not feasible methods for larger, rotating tools. In order to reduce the temperature of some rotating tools, cutting fluids have been delivered from the tool holder, to the end of the tool, through a central hole. However, this method still requires the use of harmful cutting fluids. The aim of this project is to reduce the temperature in cutting tools in pursuance of a longer tool life and removal of the cutting fluid requirement. This will subsequently reduce the amount of material waste and detrimental side effects of cutting fluids.In order to achieve this the following objectives will be investigated: 1) additive manufacturing methods. Additive manufacturing builds a three-dimensional object, layer by layer and enables the development of highly complex internal structures that would otherwise be physically impossible. This will allow for the optimum design of internal cooling channels and flow paths. 2) The optimum design will be found through the application of computational fluid dynamics and thermal analysis, 3) the investigation of flow paths in rotating cylinders, 4) application of optimisation algorithms and, 5) experimental testing of the additively manufactured prototype tools on a specially developed rig.

制造业是所有工业化国家的基本部门。然而，所使用的传统技术在社会、经济或环境能力方面不再可行。该行业的一个主要分支是机械加工，拥有两种最大的消耗品：刀具，如钻头和切削液(喷洒在刀具上的油、水和化学添加剂的混合物)。在使用时，刀具会变得非常热，并受到高压。这会导致它们很快磨损，变得无法使用。为了延长刀具的寿命，切削液在加工过程中直接喷洒到刀具上，降低了刀具的温度，并对刀具表面进行了润滑。然而，切削液对环境不友好，不可持续，有相关的健康风险，在某些应用中不可用，例如核或医疗，占部件/产品总制造成本的15%-20%。在过去的20年里，已经有了对刀具进行热稳定的替代尝试。对于非常小的固定工具，工具夹具中的散热器被用来间接冷却工具，流体通过工具内部的通道循环并通过工具夹具返回。对于较大的旋转工具，这些都不是可行的方法。为了降低一些旋转刀具的温度，切削液通过中心孔从刀架输送到刀具末端。然而，这种方法仍然需要使用有害的切削液。该项目的目的是降低刀具的温度，以追求更长的刀具寿命和去除切削液的要求。这将减少材料浪费的数量和切削液的有害副作用。为了实现这一目标，将研究以下目标：1)添加剂制造方法。加法制造一层一层地构建三维物体，并使开发高度复杂的内部结构成为可能，否则这些结构在物理上是不可能的。这将允许内部冷却通道和流动路径的优化设计。2)通过应用计算流体力学和热分析，3)旋转气缸内流动路径的研究，4)优化算法的应用，5)在专门开发的试验台上对附加制造的原型工具进行实验测试，将找到最佳设计。