Development of Green Cutting by Oil-Water Combined Mist Lubrication

本文研究开发了一种适用于高速车削加工和铣削加工的油水联合雾化润滑系统。该方法可以用无油污染的绿色加工代替高压、大流量的加工。油水联合雾化润滑主要由两部分组成，一是极少量的油雾作为切削点的润滑剂，二是相对大量的细水雾对刀具和工作材料起到有效的冷却作用。从喷嘴喷出的油雾被同轴喷嘴喷出的细水雾覆盖，因此油不会扩散到室内。此外，通过调整油和水的各个流量，得出了适合不同切割速度、切割深度、加工材料和进给速度的润滑条件。对难加工材料SUS304不锈钢在完全干燥、油水联合雾化润滑条件下进行了近百年的球磨试验。与这些条件相比，油水复合喷雾后，工件温度降低了50℃，表面磨损宽度减少了一半，表面粗糙度也得到了很大的改善。在01年的时间里，为了改善立铣刀在铣削过程中的润滑性，开发了环状喷雾系统。该系统由圆形腔体和狭缝组成，为工具周围提供蘑菇状的雾流。环状喷雾系统的应用，大大改善了刀具倾倒、表面不平整等失效现象。

In this research work, the oil-water combined mist lubrication system that may apply to high-speed turning operations and milling process was developed. This method may replaces using high-pressure and huge flow rate cooing with green machining without oil pollutions. The oil-water combined mist lubrication is consist of two main part, one is very small amount of oil mist that acts as lubricants of cutting point and, second is relatively large amount of water mist that present effective cooling to tool and work materials. The oil mist ejected from nozzle is covered with water mist ejected through co-axial nozzle thus, the oil never spread into circomstaces. Further, the suitable lubricating condition for various cutting speed, cutting depth, work materials and feed rate, by adjusting each flow rates of oil and water. In a 00 year period, milling process of SUS304 stainless steel that is hard to cut material was tested under the complete dry condition and oil-water combined mist lubrication. Compare with these conditions, temperature of work piece decreases by 50 ℃, frank wear width was decreased into a half and a surface roughness was greatly improved by using oil-water combined mist. In a 01 year period, the circular mist supplying system was developed to improve lubrication of end-mill during milling process. This system is consist of both circular chamber and slits that supply mushroom-like shape mist flow which surrounds the tool. Tool failure such as tipping and uneven surface finish was greatly improved by applying the circular mist supplying system.