吴喜峰,许文昊,马浩,周宗明,刘波,崔歆,李长河.静电雾化机理及微量润滑铣削7075铝合金表面质量评价[J].表面技术,2023,52(6):337-350.
WU Xi-feng,XU Wen-hao,MA Hao,ZHOU Zong-ming,LIU Bo,CUI Xin,LI Chang-he.#$NPMechanism of Electrostatic Atomization and Surface Quality Evaluation of 7075 Aluminum Alloy under Electrostatic Minimum Quantity Lubrication Milling[J].Surface Technology,2023,52(6):337-350 |
| 静电雾化机理及微量润滑铣削7075铝合金表面质量评价 |
| #$NPMechanism of Electrostatic Atomization and Surface Quality Evaluation of 7075 Aluminum Alloy under Electrostatic Minimum Quantity Lubrication Milling |
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| DOI：10.16490/j.cnki.issn.1001-3660.2023.06.030 |
| 中文关键词: 铣削 静电雾化微量润滑 7075铝合金 气流场 喷嘴位姿 表面质量 |
| 英文关键词:milling electrostatic atomization minimum quantity lubrication 7075 aluminum alloy airflow field nozzle position surface quality |
| 基金项目:国家重点研发计划(2020YFB2010500);国家自然科学基金(51975305，52105457);山东省自然科学基金(ZR2020KE027，ZR2021QE116) |
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| Author | Institution |
| WU Xi-feng | School of Mechanical and Automotive Engineering, Qingdao University of Technology, Shandong Qingdao 266520, China |
| XU Wen-hao | School of Mechanical and Automotive Engineering, Qingdao University of Technology, Shandong Qingdao 266520, China |
| MA Hao | School of Mechanical and Automotive Engineering, Qingdao University of Technology, Shandong Qingdao 266520, China |
| ZHOU Zong-ming | Hanergy Qingdao Lubrication Technology Co., Ltd., Shandong Qingdao 266100, China |
| LIU Bo | Sichuan Future Aerospace Industry Co., Ltd., Sichuan Shifang 618400, China |
| CUI Xin | School of Mechanical and Automotive Engineering, Qingdao University of Technology, Shandong Qingdao 266520, China |
| LI Chang-he | School of Mechanical and Automotive Engineering, Qingdao University of Technology, Shandong Qingdao 266520, China |
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| 中文摘要: |
| 目的 针对传统气动雾化微量润滑雾化性能差、环境气雾浓度高以及参数化可控性差的技术难题，设计了静电雾化微量润滑铣削供给系统。研究了铣刀工件约束界面的气流场并进行了静电雾化微量润滑(Electrostatic Minimum Quantity Lubrication，EMQL)机理分析与7075铝合金铣削表面质量评价。方法 通过分析铣刀工件约束界面气流场的分布情况，对气流场中的涡流场速度分布情况进行了理论建模，基于圆周涡流与进入涡流的动力学特征建立了喷嘴最佳射流位姿模型。研究了EMQL的荷电与雾化机理，在此基础上，进行了不同润滑条件下的铣削7075铝合金实验，包括干切削、浇注式、EMQL。测量了不同润滑条件下的铣削力、铣削表面粗糙度(Ra、Rsm)，此外，对2种参数条件下EMQL获得的加工表面轮廓进行了自相关分析。最后，分析了荷电润滑剂在切削区的微观作用机制。结果 在实验铣削参数条件下，进入涡流的诱导半径为0.007 m，最佳位姿参数设定如下:射流点到工件表面的距离lz=9.7 mm，射流点到铣刀边缘的距离ly=11.5 mm，喷嘴与工件水平方向的夹角γ≈40°。与干切加工相比，EMQL获得的铣削力降低了15%、18.6%;此外，与干切削相比，30 kV条件下的EMQL获得的Ra、Rsm分别降低了15.5%、25%，并且相比于20 kV的电压，30 kV的EMQL铣削表面轮廓自相关分析曲线显示出更优异的表面质量;浇注式润滑获得了最佳的表面质量(Ra=0.221 μm、Rsm=0.037 μm)。结论 荷电液滴能够提升摩擦界面毛细管的渗透性能，并且毛细渗透长度可以在提升电压的条件下增加，在高电压条件下的EMQL相比于低电压条件下的EMQL展现出更好的铣削性能。 |
| 英文摘要: |
| In order to solve the technical problems of poor atomization performance, high environmental aerosol concentration and poor parameterization controllability of traditional pneumatic atomization minimum quantity lubrication milling, an electrostatic atomization minimum quantity lubrication milling supply system has been designed. The work aims to study the airflow field at the constrained interface of tool-workpiece, analyze the mechanism of electrostatic minimum quantity lubrication (EMQL) and evaluate the milling surface quality of 7075 aluminum alloy. The airflow field distribution at the constrained interface of the tool-workpiece was analyzed to theoretically model the velocity distribution of the vortex in the airflow field. The optimal jet position of the nozzle was established based on the kinetic characteristics of the circumferential vortex and the incoming vortex. Then, the charging and atomization mechanism of EMQL were studied. On this basis, milling experiments were carried out to 7075 aluminum alloy under different lubrication conditions, including dry, flood and EMQL. Milling force and milling surface roughness (Ra, Rsm) under the different lubrication conditions were measured. In addition, autocorrelation analysis of the machined surface profiles obtained by EMQL under both parameter conditions was performed. Finally, the mechanism of the charged lubricant in the cutting zone was analyzed. Under the experimental milling parameters, when the induced radius rγ was 0.007 m, the optimal position parameters were set to lz=9.7 mm (distance from the jet point to the workpiece surface), ly=11.5 mm (distance from the jet point to the edge of the milling too) and γ≈40° (included angle between the nozzle and the workpiece in the horizontal direction). Compared with dry milling, EMQL could reduce milling force by 15% and 18.6%. In addition, compared with dry milling, the Ra and Rsmobtained by EMQL under the condition of 30 kV decreased by 15.5% and 25% respectively. Compared with that at 20 kV, the autocorrelation analysis curve of the surface profile of EMQL milling at 30 kV showed better surface quality. The best surface quality (Ra=0.221 μm, Rsm=0.037 μm) was obtained under flood lubrication. The charged droplets can enhance the capillary penetration performance at friction interface and the capillary penetration length can be increased under the condition of increasing voltage. EMQL under high voltage shows better milling performance than that under low voltage. |
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