基于流体动力学与摩擦学耦合的切削液时间与空间多尺度作用机理与模型研究

切削加工中大量的切削液消耗占总制造成本的16％以上，且使用后还需投入额外成本进行无害化处理。科学认识切削液的使用不仅对加工过程的质量控制至关重要，而且有利于减少切削液使用量降低环境污染。然而，切削液使用中流体-刀具-工件之间的动态相互作用机理却尚不明确，使得切削液优化和加工工艺的提高陷入瓶颈。本项目旨在开发并验证用于预测切削液与工件和刀具之间相互作用的多尺度/多物理场仿真模拟器，以优化切削液的关键参数来减少热量并降低摩擦，从而提高工件质量和刀具性能。研究围绕建模，计算和实验展开，从二维发展到三维，从一般光滑刀具到具备随机特征的磨削刀具。首先开发和验证一个耦合多尺度的3D模型，用于模拟切削液与具有光滑或随机微观几何形状的直切削刃的相互作用；然后将模型拓展到切削液与线性或旋转倾斜的直切削刃及随机微切削刃的相互作用中；最后根据模型结果制定切削液应用优化策略，以提高加工效率和工件表面完整性。

Accounting for more than 16% of manufacturing costs and used in great quantities of which two thirds needs to be environmentally disposed, the manner in which cutting fluids are applied to the tool-workpiece interface is critical for the quality of parts. A scientific understanding of how to apply them is not only critical to the quality of machining processes but also offers an avenue to reduce their use, leading to a cleaner environment and healthier working conditions. However, fluid-tool-workpiece dynamic interactions have yet to be studied in detail, which leads to confront the bottleneck affecting the fluid application and machining process optimization. This project aims to develop and validate a multiscale/multiphysics simulator to predict the interaction between the stream of cutting fluid and workpiece and cutting tools so that key parameters of the coolant outlet can be optimized to reduce heat generation and friction, leading to both improved workpiece quality and substantially better tool performance. The modelling, computational and experimental work will progress from 2D to 3D and generally from smooth to stochastic parameters. A 3D coupled multiscale model for simulating the interaction of cutting fluid with straight cutting edges with either smooth or stochastic micro-geometry will be developed and validated. This will be then developed for simulating the interaction of cutting fluid with linear or rotating obliquely-oriented, straight cutting edges, as well as for simulating the interaction of the cutting fluid with stochastic micro-cutting edges. At the end strategies will be developed to find the operating and setup parameters of the fluid delivery system that optimize fluid use and maximize cooling and lubrication, leading to better machining efficiency and workpiece surface integrity.