Finish boring process of hard alloy cutter based on electrostatic cooling-aided machining
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ORIGINAL ARTICLE
Finish boring process of hard alloy cutter based on electrostatic cooling-aided machining Hongchuan Cheng 1
&
Juan Zhao 2 & Ruowang Sun 2 & Songnian Liu 2 & Zhou Yang 1
Received: 25 June 2020 / Accepted: 19 October 2020 / Published online: 6 November 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract A boring process based on electrostatic cooling is proposed, and the effectiveness of the cooling process is verified by simulation and experiment. First, the action mode of active gas in the cutting area is analyzed on the basis of the electrostatic cooling mechanism and metal cutting law. Second, a corona discharge device with an external gas path is designed, and the attenuation law of the length and bending degree of the external gas path on the concentration of active gas in the transmission process is analyzed as well. Third, the precision boring cutter is modified into an internal cooling precision boring cutter with an external gas path. The gas concentration attenuation value at the outlet of the boring head is also obtained. Finally, finite element simulation and experimental analyses are conducted. Results show that the error of main cutting force between simulated and theoretical calculation is less than 2.65%, which verifies the correctness of the simulation. Electrostatic cooling can obviously reduce the feed force and cutting temperature, improve the wear life of tools, and achieve the effect of wet boring compared with dry cutting. The results of this study can be applied to the cooling process modification of cylindrical holes, V-shaped grooves, end faces, and threads during boring. In addition, it can also provide theoretical support for the cooling effect of gear hobbing experiments, welding, and other processes. Keywords Electrostatic cooling . Boring process . Active gas . Cutting force . Cutting temperature . Tool life
1 Introduction The cutter during boring needs to extend into the hole of the workpiece to be machined for cutting; the cutting heat is not easy to dissipate, and the chip is difficult to discharge [1]. At this time, the workpiece will be deformed due to thermal expansion and contraction if no cooling measures are adopted. Moreover, the surface quality will be reduced or the workpiece will be scrapped [2]. Therefore, cutting fluid is generally used to complete the cooling and lubrication functions for
* Juan Zhao [email protected] Hongchuan Cheng [email protected] 1
School of Mechanical Engineering and Automation, Northeastern University, Shenyang, China
2
School of Mechanical and Automotive Engineering, Qingdao University of Technology, Qingdao, China
ensuring the dimensional accuracy and surface roughness of precision parts and other parameters [3–5]. Emulsifier added with anti-rust agent, preservatives, and other substances is used to extend the shelf life of cutting fluid and prevent rusting of the workpiece surface and the bench of the machine tool. The abuse of cutting fluid has two common problems, namely, environmenta
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