Collaborative Research: An Atomization-Based Cutting Fluid and CO2 Spray System for Machining Titanium Alloys

根据该奖项进行的合作研究旨在更基本地了解用于钛合金加工的雾化切削液和二氧化碳喷雾冷却和润滑应用系统。具体目标是：(i)建立对钛加工过程中雾化切削液在固定表面上形成膜的行为及其在切削界面上的渗透特性的理解；（ii）更好地了解整个切削界面的温度分布和散热特性；（iii）研究喷雾参数、喷雾单元取向角、流体性质（如表面张力和粘度）以及二氧化碳作为液滴载气的应用对刀具磨损、切削温度和切屑形成等加工性能的影响。这些目标将通过执行三个主要任务来实现：(1)模拟雾化切削液液滴的成膜行为及其对刀具-切屑界面的渗透；(2)预测了雾化切削液喷射条件下切削界面的温度分布；(3)制定了在钛合金加工过程中有效润滑和冷却的工艺方案。利用探针压力传感器和高分辨率相机，验证了模型预测的流体膜特性，包括膜厚度和膜压力。一个硬件测试平台将在合作伙伴TechSolve公司开发，用于技术能力测试和评估。对雾化液滴在刀具/切屑/工件界面处摩擦学行为的深入了解，将推动刀具设计和制造的进步，以及其他工艺的改进，如磨削、加工和轧制中的“最少量润滑剂”。由于基于雾化的切削液喷射系统使用的电能非常少，因此该冷却系统将有助于为现有的大型流体泵冷却技术节省电能。此外，在这种切削液喷射系统中使用二氧化碳可以导致开发许多环保制造工艺。通过积极参与一些校内/校外项目，包括女性参与工程项目和少数民族工程项目，将努力促进代表性不足的群体成员参与这项研究。

The collaborative research to be conducted under this award is directed toward a more fundamental understanding of an atomized-based cutting fluid and carbon dioxide spray cooling and lubrication application system for machining of titanium alloys. The specific objectives are to: (i) establish an understanding of the film formation behavior on a stationary surface from the atomized cutting fluids, and its penetration characteristics at the cutting interface during titanium machining; (ii) better understand the temperature distribution and the heat removal characteristics throughout the cutting interface; (iii) study the effects of spray parameters, spray unit orientation angle, and fluid properties (for example, surface tension and viscosity) and the application of carbon dioxide as a droplet carrier gas on the machining performances including tool wear, cutting temperature, and chip formation. These objectives will be realized through the execution of three principal tasks: (1) model the film formation behavior of the atomized cutting fluid droplets and their penetration to the tool-chip interface; (2) predict the temperature distribution at the cutting interface under the atomized cutting fluid spray conditions; and (3) develop a process plan for an effective lubrication and cooling application during machining of titanium alloys. The validation of model predictions of the fluid film characteristics including film thickness and film pressure will be accomplished by employing the probe pressure sensors, and a high resolution camera. A hardware testbed will be developed at the site of collaborative partner, TechSolve, Inc., for the technology capability testing and evaluation. The enhanced understanding of the tribological behavior of the atomized droplets at the tool/chip/work-piece interfaces will drive advances in tool design and manufacturing and improvement in other processes such as "minimum quantity lubricant" in grinding, machining and rolling. As the atomized-based cutting fluid spray system uses significantly small amount of electrical energy, this cooling system will help in saving electrical energy for those existing cooling techniques that operate a large fluid pump. Further, the use of carbon dioxide in this cutting fluid spray system can lead to developing many environmentally-friendly manufacturing processes. Efforts will be made to boost the participation of members from under-represented groups in this research by proactively participating in several on-campus/off-campus programs, including Women in Engineering Program and Minority Engineering Program.