涡流冷却静电润滑复合干式钻削技术研究

Research on Dry Drilling Technology Based on Eddy Current Cooling and Electrostatic Lubrication

为降低机械加工过程中切削液对环境造成的污染以及处理切削液时高昂的成本,提出一种兼有涡流冷却效应和静电润滑效应的干式钻削技术与装置。将气体离子化、臭氧化后吹到切削加工区域,代替切削液实现润滑、冷却的作用,获得良好的断屑效果,同时延长刀具的寿命。基于结构参数对系统放电性能、臭氧浓度以及冷却效果的影响规律,优化装置结构,形成干式辅助钻削装置。实验结果表明:当电极锥度为15°、电极直径为1 mm、铜帽内径为3 mm、气体流量为20 L/min、驱动电压为6 kV时,臭氧浓度达到峰值34.2×10^(-6)。通过与纯干式切削对比发现:所提技术的切削温度降低40.9%,刀具刃口基本没有损伤,切屑微观表面切痕分布清晰、条理均匀。所设计的涡流冷却静电润滑干式钻削技术在切削效应、冷却效果、刀具磨损以及切屑形态等方面均优于传统的干式钻削技术,可以用于六系铝材的钻削加工。

To reduce the environmental pollution caused by cutting fluid in machining process and the high cost in processing cutting fluid,a dry drilling technology and device with eddy current cooling effect and electrostatic lubrication effect was proposed.The gas was blown into the cutting area after ionization and ozonation to replace the cutting fluid to achieve lubrication and cooling,which could obtain a good chip breaking effect and prolong the tool life.Based on the influence law of the structure parameters on the system discharge performance,ozone concentration and cooling effect,the device structure was optimized to form the dry auxiliary drilling device.The experimental results show that when the electrode taper is 15°,the electrode diameter is 1 mm,the nozzle diameter is 3 mm,the gas flow rate is 20 L/min and the driving voltage is 6 kV,the ozone concentration reaches the peak of 34.2×10^(-6).By comparing with pure dry cutting,it is found that the cutting temperature of the proposed technology is reduced by 40.9%,the cutting edge of the tool is basically not damaged,and the surface of the chip microstructure is clear and uniform.The experimental results show that the designed eddy current cooling electrostatic lubrication dry drilling technology is superior to the traditional dry drilling technology in terms of cutting effect,cooling effect,tool wear and chip shape,and it can be used in the drilling of six series aluminum.