| 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],51(6):317-326 |
| 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 |
| KeyWord:EMQL AlSi7Mg aluminum alloy energy consumption material removal energy specific milling energy |
| Author | Institution |
| LIN Tie-yu |
School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai , China |
| XU Jin-yang |
School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai , China |
| LI Chao |
Shanghai Smart State Technology Co., Ltd., Shanghai , China |
| AN Qing-long |
School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai , China |
| MING Wei-wei |
School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai , China |
| CHEN Ming |
School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai , China |
| SHI Lun |
School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai , China;Shanghai Smart State Technology Co., Ltd., Shanghai , China |
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| Abstract: |
| 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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