林铁宇,徐锦泱,李超,安庆龙,明伟伟,陈明,时轮.基于静电微量润滑的AlSi7Mg铝合金高速铣削能量消耗研究[J].表面技术,2022,51(6):317-326.
LIN Tie-yu,XU Jin-yang,LI Chao,AN Qing-long,MING Wei-wei,CHEN Ming,SHI Lun.Energy Consumption of High-Speed Milling of AlSi7Mg Aluminum Alloys under the Electrostatic Minimum Quantity Lubrication[J].Surface Technology,2022,51(6):317-326 |
| 基于静电微量润滑的AlSi7Mg铝合金高速铣削能量消耗研究 |
| Energy Consumption of High-Speed Milling of AlSi7Mg Aluminum Alloys under the Electrostatic Minimum Quantity Lubrication |
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| DOI：10.16490/j.cnki.issn.1001-3660.2022.06.030 |
| 中文关键词: 静电微量润滑 AlSi7Mg铝合金 能量消耗 材料去除能量 铣削比能 |
| 英文关键词:EMQL AlSi7Mg aluminum alloy energy consumption material removal energy specific milling energy |
| 基金项目:国家重点研发计划(2020YFB2010600) |
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| Author | Institution |
| LIN Tie-yu | School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, China |
| XU Jin-yang | School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, China |
| LI Chao | Shanghai Smart State Technology Co., Ltd., Shanghai 200120, China |
| AN Qing-long | School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, China |
| MING Wei-wei | School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, China |
| CHEN Ming | School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, China |
| SHI Lun | School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, China;Shanghai Smart State Technology Co., Ltd., Shanghai 200120, China |
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| 中文摘要: |
| 目的 通过开展AlSi7Mg铝合金高速铣削实验，研究静电微量润滑(Electrostatic Minimal Quantity Lubrication，EMQL)条件下不同的铣削参数对铣削过程中能量消耗的影响规律。方法 采用AlSi7Mg铝合金板材，在PT50A加工中心开展EMQL条件下不同铣削参数(切削速度、进给量和铣削深度)的正交实验，以及4种润滑条件(干式、传统浇注润滑、微量润滑和EMQL)下的对比实验，监测不同铣削条件下机床功率P情况，并对功率进行曲线拟合，再依据拟合函数积分求解不同条件下铣削过程的材料去除能量Ek，进而换算出相同材料去除体积下(即单位深度下)消耗的能量E ′，然后根据功率求解铣削比能Ek。根据实验结果分析不同铣削参数和润滑条件对4种能量消耗指标(P、E、E ′和Ek)的影响规律，并将依据4种指标选出的正交实验优化参数应用于缸盖加工中。结果 尽管切削速度v和进给量f各有不同，当铣削深度ap取最小值(0.4 mm)时，功率曲线水平以及材料去除能量E均位于各数据组的最低水平。在实验11加工过程中，每毫米切削深度的材料去除能量E ′为最小值。不论ap值如何变化，铣削比能均随着f的增大而逐渐减小。EMQL与传统润滑在功率、材料去除能量及铣削比能的结果上均较为接近。根据4种指标结果选出了优化铣削参数，v=1 800 m/min，f =0.16 mm/r，ap=0.4 mm。结论 铣削深度对功率及材料去除能量的影响较显著，进给量对铣削比能的影响更为突出，而切削速度对E ′值的影响较明显。此外，EMQL对传统润滑具有较好的替代性。 |
| 英文摘要: |
| In this paper, the effects of different milling parameters on the energy consumption of AlSi7Mg alloys under the EMQL conditions were studied by carrying out the high-speed milling experiments. The orthogonal experiments under the EMQL conditions and the comparative tests between different lubrication conditions were conducted on the PT50A machining center. Three milling parameters, including the cutting speed v, the feed rate f and the milling depth ap, and four lubrication conditions, including dry milling, traditional lubrication, MQL and EMQL, were considered in the milling experiments. The v was set to 600, 1 200, 1 800 and 2 400 m/min; the f was set to 0.08, 0.12, 0.16 and 0.2 mm/r; the ap was set to 0.4, 0.7, 1.0 and 1.3 mm. The power P situation in the machining process was measured, and the curve fitting was carried out according to the power data. Then, the material removal energy E of the milling process under different conditions is calculated according to the integral of the fitting function, and the energy consumed under the same material removal volume is converted to the material removal energy per unit depth E′. Besides, the specific milling energy Ek is calculated based on the power data. According to the experimental results, the influence laws of different milling parameters and lubrication conditions on the four energy consumption indexes (P, E, E′ and Ek) were analyzed, and the optimal parameters of the orthogonal experiments were selected according to the four indexes and applied to the cylinder head machining. The results show that, although the cutting speed v and the feed rate f are different, the P and the E are at the lowest level of each data set when the milling depth ap remains the minimum value of 0.4 mm. According to the results in experiment 11, the E′ values in the machining process are at the lowest level. The traditional lubrication and EMQL methods yield the better E and E′ values. It can be found that no matter how the ap varies, the Ek gradually decreases with the elevation of the f. Both the EMQL and traditional lubrication are similar in the results of P, E, E′ and Ek. According to the P, E, E′ and Ek results, the optimal milling parameters are v = 1 800 m/min, f = 0.16 mm/r, ap = 0.4 mm. The milling depth has a significant impact on the power and material removal energy, the feed rate has a more prominent impact on milling specific energy, while the cutting speed has a significant impact on the E′ value. Additionally, the EMQL can be a better alternative to the traditional lubrication methods. |
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