利用纳米颗粒增强最小量润滑(MQL)技术高速加工2219铝的研究

Surfaces Pub Date : 2023-01-22 DOI:10.3390/surfaces6010003
Sagil James, Mehrshad Mazaheri
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引用次数: 0

摘要

高速加工过程受到切削区摩擦产生的热量积累的显著影响,导致刀具寿命降低,加工产品质量差。由于切削液的冷却和润滑特性,切削液的使用有助于将热量排出该区域。然而,传统切削液的使用除了增加总体制造成本外,还会对人类健康和环境造成相当大的损害。近年来,最小量润滑(MQL)已被用作替代润滑策略,因为它显著减少了切削液消耗,消除了冷却剂处理/处置需求,从而降低了运营成本。在这项研究中,我们研究了MQL纳米流体在2219铝合金高速切削过程中的微观组织表面精加工和热量产生。2219铝合金提供了增强的强度重量比和高断裂韧性,通常用于广泛的航空航天和其他高温应用。然而,这些材料基于mql的高速加工尚无相关文献。在这项研究中,我们研究了洪水冷却剂和五种不同的MQL纳米流体,这些纳米流体是由合成0.2%至2%浓度的Al2O3纳米颗粒制成的超食品级矿物油。研究结果揭示了所选择的MQL与相应表面精加工之间的化学关系,表明纳米颗粒浓度为0.5%的MQL纳米流体获得了最优的加工效果。此外,增加纳米颗粒浓度并不会导致加工结果的进一步改善。我们还发现,在冷却液中加入0.5%浓度的纳米颗粒有助于降低工件-工具界面的温度,获得良好的表面光洁度。
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Study on High-Speed Machining of 2219 Aluminum Utilizing Nanoparticle-Enhanced Minimum Quantity Lubrication (MQL) Technique
High-speed machining processes are significantly affected by the accumulation of heat generated by friction in the cutting zone, leading to reduced tool life and poor quality of the machined product. The use of cutting fluids helps to draw the heat out of the area, owing to their cooling and lubricating properties. However, conventional cutting fluid usage leads to considerable damage to human health and the environment, in addition to increasing overall manufacturing costs. In recent years, minimum quantity lubrication (MQL) has been used as an alternative lubricating strategy, as it significantly reduces cutting fluid consumption and eliminates coolant treatment/disposal needs, thereby reducing operational costs. In this study, we investigated microstructural surface finishing and heat generation during the high-speed cutting process of 2219 aluminum alloy using an MQL nanofluid. 2219 aluminum alloy offers an enhanced strength-to-weight ratio and high fracture toughness and is commonly used in a wide range of aerospace and other high-temperature applications. However, there is no relevant literature on MQL-based high-speed machining of these materials. In this study, we examined flood coolant and five different MQL nanofluids made by synthesizing 0.2% to 2% concentrations of Al2O3 nanoparticles into ultra-food-grade mineral oil. The study results reveal the chemistry between the MQL of choice and the corresponding surface finishing, showing that the MQL nanofluid with a 0.5% concentration of nanoparticles achieved the most optimal machining result. Furthermore, increasing the nanoparticle concentration does result in any further improvement in the machining result. We also found that adding a 0.5% concentration of nanoparticles to the coolant helped to reduce the temperature at the workpiece–tool interface, obtaining a good surface finish.
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