静电雾化机理及微量润滑铣削7075铝合金表面质量评价_吴喜峰.pdf

第 52 卷 第 6 期 表面技术 2023 年 6 月 SURFACE TECHNOLOGY 337 收稿日期：20221115；修订日期：20221225 Received：2022-11-15；Revised：2022-12-25 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）Fund：National Key Research and Development Plan(2020YFB2010500);National Natural Science Foundation of China(51975305,52105457);Natural Science Foundation of Shandong Province(ZR2020KE027,ZR2021QE116)作者简介：吴喜峰（1995），男，硕士生，主要研究方向为洁净精密制造。Biography：WU Xi-feng(1995-),Male,Postgraduate,Research focus:sustainable precision manufacturing.通讯作者：李长河（1966），男，博士，教授，主要研究方向为智能与洁净精密制造。Corresponding author：LI Chang-he(1966-),Male,Doctor,Professor,Research focus:intelligent and sustainable precision manufacturing.引文格式：吴喜峰,许文昊,马浩,等.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,et al.Mechanism of Electrostatic Atomization and Surface Quality Evaluation of 7075 Aluminum Alloy under Electrostatic Minimum Quantity Lubrication MillingJ.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 吴喜峰1，许文昊1，马浩1，周宗明2，刘波3，崔歆1，李长河1（1.青岛理工大学 机械与汽车工程学院，山东 青岛 266520；2.汉能（青岛）润滑科技有限公司，山东 青岛 266100；3.四川明日宇航工业有限责任公司，四川 什邡 618400）摘要：目的目的 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 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 m、Rsm=0.037 m）。结论结论 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。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 中图分类号：TG506 文献标识码：A 文章编号：1001-3660(2023)06-0337-14 DOI：10.16490/ki.issn.1001-3660.2023.06.030 精密与超精密加工 338 表 面 技 术 2023 年 6 月 Mechanism of Electrostatic Atomization and Surface Quality Evaluation of 7075 Aluminum Alloy under Electrostatic Minimum Quantity Lubrication Milling WU Xi-feng1,XU Wen-hao1,MA Hao1,ZHOU Zong-ming2,LIU Bo3,CUI Xin1,LI Chang-he1(1.School of Mechanical and Automotive Engineering,Qingdao University of Technology,Shandong Qingdao 266520,China;2.Hanergy(Qingdao)Lubrication Technology Co.,Ltd.,Shandong Qingdao 266100,China;3.Sichuan Future Aerospace Industry Co.,Ltd.,Sichuan Shifang 618400,China)ABSTRACT: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 r 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 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 Rsm obtained 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 m,Rsm=0.037 m)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 vo