1、附录1英文原文英文原文CHAPTERIIICOSTSTUDYOFHIGH-SPEEDCUTTINGUNDERDRYANDWETCONDITIONSFORMACHININGPROCESSESOPTIMIZATION3/1IntroductionTheaimofthisstudyistooptimizethemachiningprocessesbyinvestigatingtherelationshipbetweenthehighspeedmachining(HSM)andthetoollifeforthecuttingconditionsundertesting/Furthermore/stud
2、yingtheeffectofcuttingfluidontheselectedwearcriterion/andrelationshipbetweendifferentwearcriteriaandmachiningcostforthecuttinginsertsunderHSM/Thisinvestigationshowedthatwearrateisproportionaltocuttingspeedsupportedwithsimilarobservations12/18/19/Studyingthecorrelationbetweenhighwearratesathighcuttin
3、gspeedandmachiningcosts/providesbetterunderstandingontheperformanceofthispolicyandthebenefitofitsadoption/Currently/littleornodatahavebeenpublishedrelatingthelife-cyclecosts/toolperformance/workpiecesurfaceroughnessandworkpiecedimensionalaccuracywhenusingsolidandindexablecutters10/However/studieshav
4、efoundthattoolcostsinmetalcuttingmachinesareathirdofthecostofproducingparts/Thereforereducingproductcostisthefirstobjectiveofatoolmanagementsystem16/Thebenefitsofadoptingthisresearchguidelinewillhelpdeterminetheoptimalmachiningcostandtoolreplacementpolicybasedondifferentwearcriterionvalues/Additiona
5、llythisstudyprovidesinsightinprocesscontrolandhelpsthemanagersintheearlyprocessplanningstepstoassociatefactorssuchaspreventivemaintenance/levelsofinventory/andmachiningcost/3/2ExperimentalStudyThestudydevelopedaguidelineofchoosingtherightcuttingtool/cuttingspeed/andselectingtheappropriatewearcriteri
6、aofthecuttingtoolinsertsfortheworkmaterialunderstudy/Inthisstudyvariablewearcriteriarangingfrom0/lmmto0/6mm(toollifelimit)weretakenintoconsideration/ThisexperimentwasconductedinaccordancewiththeInternationalStandardOrganizationISO3685199346/Thetestwasdoneona(Clausing1300)variablespindlespeedmachinew
7、ithamaximumpowerof7/5Hp(seeFigure3-1)/Thetoolwearmeasurementswereperformedusinganopticalmicroscopewithamagnificationofupto300times/andaScanningElectronMicroscope(SEM)/Therotationalspeedoftheworkpiecewasmeasuredbeforeeverycutbya(HT-5100)handhelddigitalTachometertoinsurethattheworkpiecewasaccuratelyru
8、nningattheexactcuttingspeed/Ontheotherhand/theworkpiecematerialwasreplacedwhenthelength/diameterratioreaches10/basedonISO3685199346/toensureworkpiecestabilityandsafety/Twoprecutwerecarriedoutwith1/2mmdepth/tocleanupthethinlayerofrust/andtoensureworkpiecestraightness/Figure3-1Thetuningmachineusedduri
9、ngthetest/3/2/1WorkpieceandCuttingInsertsInthisstudy/hotrolledASTM4140steelwasselectedastheworkpiecematerial/Theworkpiecepropertiesarelistedasfollows/Description/Hotrolledalloysteelbars/SAE4140H(UNSH4140)Dimensions/15cmDiameterx62/25cmlengthHeatTreatment/Vacuumdegassed/processed/Cal-Altreated/anneal
10、edandspecialstraightened/conformingtoASTMA322andA304Chemicalcompositions/ThecompositionoftheworkpiecematerialislistedinTable3/1accordingtotheASTMstandards/TheexperimentwascarriedoutinaccordancewiththeinternationalstandardorganizationISO3685-9346/theexperimentwasstoppedandtheworkpiecewaschangedwhenth
11、elength/diameterratioreached10tomeettherequirementsofISO368546/Thehardnessofeachbarwascheckedacrossthediameter/andtheaveragehardnessmeasurementwas29HRC/ThetypesoftestedcuttingtoolinsertsarelistedonTable3/1accordingtotheISOdesignation/ThreetypesofcuttinginsertswereusedintheexperimentasillustratedinTa
12、ble3-2；andthecoatingpropertiesarealsolistedinTable3-3/TheconfigurationoftheinvestigatedthreecuttinginsertswasthesameaslistedinTable3/4/ThegeneralcuttinginsertassembledgeometryisshowninFigure3-2/TheinsertsweremountedrigidlyonatoolholderaredepictedinFigure3-3withanISOdesignationofSVJBR2525M16/Table3-1
13、ChemicalcompositionofASTM4140steelusedinthetestCuttinginsertsISODesignationSubstrateGradeCompanyUncoatedcementedCarbideVBMT160408/KC313KennametalTiAlNVBMT160408KC313KC5010KennametalTiN-TiCN-TiNVBMT160408KC313KC732KennametalTable3-2TypesofthetestedcuttinginsertsCarbonManganesePhosphorusSulfurSiliconN
14、ickelChromium0/40/910/0170/020/240/101/01Tin0/008Aluminum0/030Vanadium0/002Calcium0/0064Molly0/2Copper0/12Table3-3CoatingspropertiesCoatingThicknessNumberoflayersTiALN3/51TiN-TiCN-TiN3-3t-1t3(TiCNintermediate)3/2/2CoolantPropertiesItisacommonbeliefthatcoolantemulsionhelpsinreducingwearrateandcutting
15、temperature/ThecoolantusedinthetestwaswaterbasedemulsionhascommercialnameNovick/Itismixedwithwaterataconcentrationof10%/ThecoolantcompositionincludesthelistedchemicalsinTable3/5/Previousresearchersonthebettercoolantstreamdirectionsmadedifferentsuggestions/Taylor17indicatedthattoreducetoolwearthecutt
16、ingfluidistobedirectedatthebackofthechip(directionA)/PigottandColwell47foundthatbyusinghighstreamjetofcoolantaimedindirectionBitwasabletoreducetoolwear/SmartandTrent48investigatedthedirectionofcoolantinreducingthetoolwearandfoundthatthemosteffectivedirectionbetweenallothersuggestedoptionswasdirectio
17、nB/Therefore/coolantwasappliedindirectionBaslistedinFigure3/4fromanozzlewithdiameterof1/3cmandaflowrateof7/1liters/minute/However/thecurrentstudyshowedthatthisisnotnecessarilytrueinallcasesascoolantextendsthetoollife/Itwasfoundthatcoolantemulsionhelpedreducetoollifebyactivatingcertainwearmechanismat
18、highspeedmachining(HSM)/DetailedexplanationsofthistypeofcoolanteffectwillbediscussedinChapter5/Furthermore/abriefsummaryandexplanationoftypesandusageofcoolantwillbecoveredinChapter5/Table3-4AssembledcuttingtoolgeometryToolgeometryDimensionNoseradius0/8(mm)Bakerakeangle0Endreliefangle5Endcutting-edgeangle52Sidecutting-edgeangle30Siderakeangle0Sidereliefangle5
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