Cryogenic cooling for machining cast iron materials using PCD tools

目前，高强度材料（如蠕墨铸铁（CGI））的应用趋势仍在上升，这导致对未来有效的切削刀具系统和加工策略的设计要求越来越高。参考现有技术，可以计算出低温冷却介质CO2与多晶金刚石工具（PCD）组合使用的高潜力，以在连续切削条件下高效地加工CGI。（例如，CO2质量流率、喷嘴距离、攻角、喷嘴数量、CO2和MQL的组合）对PCD工具的操作行为和工件的材料性质的影响尚未被详细研究。可以假设，特别是CO2的流量可以显着降低，以机加工更经济friendly.This项目的目的是分析CO2冷却参数上的热机械载荷谱的PCD刀具连续切削过程中的CGI材料的影响。在此领域的先前发现可以完成。为了澄清CO2冷却参数对负载集合的影响，打算采用以下方法。特别是切削力和温度以及切屑形成和特定的磨损机制将被分析，以量化的CO2冷却参数对热机械载荷谱的影响。分析的重点是确定定制的低温冷却策略，设置最小量的CO2。除了基本的加工实验外，还将进行基本的材料科学测试。可以详细识别CO2冷却参数对负载谱的影响以及最终的操作行为。现在可以详细了解相关机制。调查结果将被转移到一个系统的数学评价的加工过程中，以获得实际应用的建议。在该项目的第一部分结束时，定制的CO2冷却系统的PCD工具的特定的负载集体将被开发，以抑制在CGI加工过程中的温度引起的磨损机制。在该项目的第二部分，将重点转移调查结果。因此，将使用不同的PCD工具加工更多的含铁材料。最后将完成环境和经济研究，以全面了解低温冷却系统。该项目的跨学科目标允许弥合关于CO2冷却策略对使用PCD刀具的加工应用的影响的重要差距。

The current and still rising trend for the application of high-strength materials like compacted graphite iron (CGI) leads to increased requirements concerning the design of effective future cutting tool systems and machining strategies. Referring to state of the art a high potential for the use of the cryogenic cooling media CO2 in combination with a polycrystalline diamond tool (PCD) could be figured out as high effective to machine CGI under continuous cutting conditions.However, basic effects and holistic interdependencies of the CO2 cooling parameters (e.g. CO2 mass flow rate, nozzle distance, angle of attack, number of nozzles, combination of CO2 and MQL) onto the operational behavior of the PCD tool and the material properties of the work piece have not yet been studied in detail. It could be assumed that especially the CO2 flow rate can be reduced significantly to machine more economically friendly.The aim of this project is to analyze the impact of the CO2 cooling parameters onto the thermo-mechanical load spectrum of PCD tools for continuous cutting processes of CGI materials. Previous findings in this area can be completed.To clarify the influence of the CO2 cooling parameters onto the collective of load the following approach is intended. In particular the cutting forces and temperature as well as the chip formation and the specific wear mechanisms will be analyzed to quantify the influence of the CO2 cooling parameters onto the thermo-mechanical load spectrum. The focus of the analysis is to determine a customized cryogenic cooling strategy setting a minimal amount of CO2. Besides basic machining experiments fundamental material science tests will be performed. The effect of the CO2 cooling parameters onto the load spectrum and finally the operational behavior can be identified in detail. The relevant mechanisms can now be understood in detail. The findings will be transferred to a systematic mathematical evaluation of the machining process in order to derive recommendations for practical applications.At the end of the first part of the project a customized CO2 cooling system concerning the specific load collective of the PCD tool will be developed to suppress the temperature induced wear mechanisms during machining of CGI. Within the second part of the project the transfer of the findings will be focused. Therefore, further ferrous materials will be machined using different PCD tools. Finally environmental and economic studies will be accomplished to get a holistic view onto the cryogenic cooling system. The interdisciplinary goals of this project allow to bridge an important gap regarding the impact of the CO2 cooling strategies onto machining applications using PCD tools.