Trln Minh Diic vo Dtg

Trln Minh Diic vo Dtg Tap chf KHOA HOC & CONG NGHE 173(13): 171-176

NGHIEN C t r u CHt TAO BAU PHUN DUNG DICH LANH CHO BOI TRON LAM NGUOI TOI THifcU, U N G DUNG VAO PHAY CtfNG THEP S K D l l

TrSn Minh Diic, Pham Quang Dong, Tran Th^ Long', Tran Quy^t Chien

Trudng Dgi hgc Ky thugt Cong nghiep - DH Thdi Nguyen

TOM

T A T

B6i tron lam ngupi t6i thilu (Minimum quantity lubrication - \\k tit la MQL) da dugc nghien cuu

\i ling dung kha ph6 biSn trong cSng ngh? gia cong c3t got. Nhugc di6m co ban cua MQL la kha nSng lam nguoi trong vimg cit bi hJin che. De kliSc phuc nhugc dilm n^y, bai bao gicri thiSu m6t so ket qua ban dau vh viSc nghien ciiu, thiet ke, chg tao dau phun khi lanh theo hi£u ling R^nque-Hilsch, ling dung dau phun khi l^inh de thiet ke, ch6 tao diu phun dung djch lanh dudi dang suong mt diing cho cdng ngh^ MQL. Bai bao ciing gidi thieu kh qua nghien ciiu han dau ve viec danh gia hi£u qua ciia dau phun dung dich lanh ling dimg trong MQL khi phay ciing thep SKDl 1 qua toi co d6 cling HRC = 58 - 60. Ket qua cho thiy bang cSch su dung cong nghe nay da lam giam cac thanh phSn lyc cat Py, Pj o miic 86% - 88%, hifii bin cua dung cy dat 57 phiit, tang 152% so vdi khi gia cong sii diing MQL v6i dung dich Emulsi khong lanh. Day la hudng nghiSn ciiu mdi c6 nhilu triln vpng de md rong kha nSng cong nghe cua MQL, dSc biet la trong gia c5ng vat lieu ciing.

TIT khoa: Gia cdng vgt lieu cdng; Phay cdng, Bdi tran lam nguoi loi thieu — MQL; Ddu phun khi Ignh; Ddu phun dung dfch lanh

DAT VAN DE

B6i tron lam ngupi t6i thieu-MQL da dugc nghien ciiu va ling dung kha rpng rai trong cong nghe gia cong cat gpt. MQL la mgt giai phap thay the cho he thong gia cong kho va boi tran lam ngupi kieu tudi tran. Ban chat ciia MQL la dua mpt lugng dung djch tran ngupi han che (toi thieu) vcs'i luu lupng 0,23 - 0,25 ml/ph tryc tiep vao viing cat du6i dang suang mii hoac duai dang dong tia dung djch ap lyc cao [12, 15]. Do dung dich dugc dua true tiep vao viing cat nen hieu qua boi tran cao, g6p phiin cai thien dieu kien ma sat trong viing cit. Vi vay, MQL gop phSn nang cao hieu qua ciia qua trinh cat tir do giam chi phi gia cong. Ngoai ra, MQL cho thSy day la mpt gia phap cong ngh? tiet kiem, than thien vcri moi truang va it anh huang den siic khoe ciia ngu'cfi lao dong [3-5, 10, 15].

Nhupc diem ca ban ciia MQL la kha nang lam ngupi hi han che, nhiet cat truyen vao phoi, vao chi tiet gia cong Idn [6]. Do do, viec ling dyng cong ngh? MQL trong san xuat con mpt so han che. Dac biet trong gia cong vat li?u CO cirng, dp ben cao [16, 17]; v^t li?u kho gia cong, v.v [7, 8, 12, 15].

'Tel: 0985 288777, Email:lranthelong@tnut.edu.vn

De khac phuc ton tai nay, mgt hudng nghien cii'u moi dang dugc quan tam do la MQL phoi hgp vai lam ngupi tich eye \6i mdt so giai phap nhu diing dong khi lanh phun tryc tiep vao viing cat hoac diing ddng khi lanh trpn vdi dung djch tran nguoi de tao ra dong dung djch dudi dang suong mil nhiet dp thap,v.v.

(MQL dung dung djch lanh) [I, 13].

Trong bai bao nay, cac tac gia giai thieu mpt so ket qua ban dau ve viec nghien ciiu, thiet k4 chS tao thiet bi tao ddng khi l^nh bang hi6u ling Ranque-Hilsch (ggi tat la diu phun khi Ignh). iTng dung dau phun khi Ignh de thiSt k4 chg tao thiit bj tao ra dong dung djch lanh diing trong MQL (ggi tat la dSu phun dung dich lanh). Cac tac gia gidi thieu ket qua nghien ciiu ban dau khi MQL su dung dung dich Ignh de phay ciing thep SKDl 1. Chi tieu danh gia la cac thanh phan luc cat Py, P^; tuoi bin ciia dung cy; nhdm be mat chi tiet gia cong Ra, Rz. De giai quyet van de, cac tac gia sir dung phucrng phap nghien ciiu ly thuyet kit hgp vdi thuc nghiem.

GlAl QUYET V A N D E

Che tao thiet bi t^o dong khi lanh

Thiet hi tao ra khi Ignh va ndng phan tach tir

mpt nguon khi nen duy nhat dya tren hi?u ling

Tran Minh Diic vd Dig Tap chi KHOA HOC & C 6 N G NGHE 173(13): 171-176 Ranque-Hilsch [9] (gpi tat la hieu ling "ong

xoay"). S a do nguyen ly tao dong khi lanh cho d hinh 1.

Hinh 1. Nguyin ly tao ddng khi lanh trong dng xody Ranque-Hilsch Dong khi nen dugc dua vao cua 1 theo phuang tiep tuyen vdi thanh ong va tgo nSn dong xoay thuan 2 trong thanh 6ng di ve phia ciia ndng c6 van dieu chinh 4. Tgi day, dong xoay khi gap van 4, mpt phan khi ndng 3 thoat ra ngoai, phan con lai bi phan xg tao dong xoay ngugc ve phia ciia Ignh 5. Van 4 dilu chinh sy can bang giira lugng khi nong thoat ra va lugng khi duoc day ngugc lai. Hai dong khi ndng va lanh nay dugc md ta trong mo hinh ong Ranque-Hilsch (hinh 1). Sy thay doi nhiet dg giira cac ludng khong khi ndng va lanh phy thupc cac thong s6 nhu ap suat khi nen, nhi?t dp mdi trudng, cac dgc tinh hinh hoc ciia 6ng,v.v. Den nay, c a che vat ly ciia viec tach nhiet van chua dugc giai quyet hoan toan [2].

Tren c a sd nguyen ly nay, nhdm tac gia da nghien ciin, thiet ke, che tao thanh cong ong xoay (gpi tM la dau phun khi Ignh). Cac budc thiet ke, che tao thir nghiem va nghien ciiu xac dinh cac thong so toi uu ciia thiet bj se dugc trinh bay trong cac nghien ciiu tiep theo, CJ day, cac tac gia chi gidi thieu ket cau ciia thiet bi ma nhdm da che tgo thanh cong, mpt so hinh anh cua thiet bj va ket qua thu nghiem vdi nhiet dp dong khi lanh cho d hinh 2.

Ket qua cho thay sy chenh !ech giira nhiet dp ddng khi vao va nhiet dp ddng khi lanh ra la tir 35°C den 4 0 ' ' c . Trong d i l u kien thi nghiem, ap suat khi nen 6 bar, khi nhiet dp moi trudng 31,5"C, nhiet dp dong khi lanh dgt IjS^C nhu hinh 2a (chenh lech so voi nhiet dong khi vao 36,7*'C). Khi nhiet do mdi trudng lO^C, nhiet dp ddng khi Ignh dgt - 29°C n h u hinh 2b.

DSu phun khi Ignh cd the dung phun tryc tiep ddng khi lanh vao viing cat de lam ngupi hope diing phoi hgp vdi k6t cau khac dS che tao dau phun dung djch lanh.

Hinh 2. Thiet bi tgo ddng khi lanh Uu diem noi bat cua dau phun khi lanh theo hieu ling "ong xoay" ia ket cau dan gian, hieu suat lam viec cao, khdng can dien, khong can bao dudng, su dung an toan,v.v. [2] nen ngoSi vi?c irng dyng vao cdng nghe boi tron lam ngupi trong gia cong cat got thi thiel bi nay con dupe su dung vao nhieu ITnh vuc cong nghiep khac nhu de lam ngupi cac thiet hi cong nghiep, sir dung ddng khi nong de say kho linh kien dien tii, lam nong cac san pham,v.v.

Che tao dau phun dung djch lanh Tren c a cd dau phun khi lanh, nhdm tac gia tiep tuc nghien cuu, thiet ke, che tgo thanh cong dau phun dung dich nhiet dp thap du6i dgng s u a n g rnu diing cho M Q L (gpi tat la dau phun dung dich lanh). Qua trinh tinh toan thiet ke, nghien cuu thyc nghiem de xac dinh cac thong sd ket cau,v.v. se d u g c gioi thi?u trong nhung cong bo tiep theo.

Vai myc dich vtra phyc vy nghien cihi, vira triln khai vao thuc te san xuat d Viet Nam nen nhiet dp dau vao dung lam can cii tinh

TrSn Minh Diic va Dig Tap chi KHOA HQC & CONG NGH$ 173(13): 171 -176 toan la nhiet dp mdi trudng tii 25''C - SS^'C va

yeu cau nhiet dp d4u ra tir 4^0 - M^C. Hinh dang dau phun dung dich lanh va kit qua do nhiet dp ddng dung dich Ignh cho d hinh 3, ket qua do nhiet dp ddng dung dich tren dau phun Noga (klidng lanh) cho d hinh 4.

Hinh 4. Kel qua do nhiel do dau phun MQL Dieu ki?n thi nghiem: nhiet dp mdi trudng 31,5°C, nhiet do dung djch Emulsi 30,0''C, ap suat khi nen 6 bar thi nhiet dp ddng dung dich Ignh la 12,4'*C. Vdi dau phun Noga diing cho MQL thdng thudng nhi?t do ddng dung djch la 22,7''C nhu hinh 4 (cao han so vai ddu lanh I0,2°C).

Thi nghiem khao sat hieu qua cua dau phun dung dich lanh

Muc dich

Danh gia hieu qua ciia MQL su' dung dung djch lanh so vdi MQL sir dyng dung dich thong thudng khi phay ciing thep SKD 11 Hi thong thi nghiem

May: trung tam gia cong Mazak 530C - Nhat Ban san xuat

Dung cy c5t: phay mat dSu 050 gan manh hgp kim ciing APMT 1604 PDTR LT 30 phii PVD ciia hang LAMINA (Thuy Dien).

Mlu thi nghiem: Thep SKDll, kich thudc 90 X 48 X 50, do ciing HRC = 58 - 60.

He thong MQL:

- Dau phun dung djch Ignh; Dau phun NOGA;

he thong dong hd va dn ap, may nen khi.

- Dung dich tran ngudi: dung dich Emulsi 5%;

Thiet hi do:

- Lyc kl 9257BA cCia hSng Kistler, he th6ng thu thap va sir ly du' lieu N7 National instruments, phin mem DASYLablO va may tinh ca nhan;

- May do nham Mitutoyo SJ-210;

He thong thi nghiem vdi dau phun dung djch lanh cho d hinh 5 va vdi dau Noga nhu hinh 6.

Hinh 5. He thdng ihi nghiem vdi ddu phun dung djch Ignh

Hinh 6. He thong thi nghiem vdi ddu phun Noga Chi do cong nghe

Phay mat phang vai che dp cdng ngh?:

Che dp cat:

Vgn tdc cat V=100m/p; lugng chay dao S^ = 0,08 mm/rang, Sp=50,96mm/ph; chieu rong cdt B = 0,2mm.

Chi dp tran ngudi:

173

Tran Minh Diic v d 0 ( g Tap chi KHOA HQC & C 6 N G NGHE 173(13): 171-171 - Nhiet dp moi trudng 30 C - 3 2 X (dieu ki6n

t y nhien).

- M Q L sii dung dSu phun Noga vdi dung djch Emulsi 5%, nhiet dp trung binh ciia dung dich 22''C;

- M Q L SIX dung dau phun dung dich Ignh vdi dung dich Emulsi 5%, nhiet dp trung binh cua dung dich n ^ C ;

- Ap su4t ddng khi P = 6 bar; luu lugng Q = 0,23 - 0,25 ml/ph; phun vao mat sau cua dao.

TriSn khai thinghiim

Thi nghiem nghiSn vdi hai c h i dd tran ngudi la M Q L su dyng dau phun N o g a (ggi tat la dung dich Emulsi) va dau phun tgo dung djch Ignh (ggi tdt la dung dich Emulsi lanh) . Do luc cdt, nham b l mgt va qua trinh xii ly so lieu dugc thuc hien sau moi Ian cat.

Tudi b i n ciia dao d u g c xac dinh den khi dao mdn khoe Het, hfit kha nang cat (cdn cir theo chi lieu /{«: cdt vd mdn dting cdt [6]).

KET QUA V A T H A O LUAN

Anh hudng cua che do tron ngupi gom: M Q L vdi dung djch dung dich Emulsi va M Q L vdi dung djch Emulsi lanh den cac thanh phan lyc cdt Py, P^; d i n tri sd nham b l mgt Ra, Rz cho d cac tir hinh 7 - hinh 10.

Hinh 7. Anh hirang ciia chi do Iran ngugi din luc Py

Hinh 8. Anh hudng cua che dg Iron ngudi din luc P^

174

Hinh 10. Anh hudng ciia chi do tran ngudi den trj sd Ri

K6t qua tren cho thay:

Giai doan ban dSu (lan c i t 1 d i n ISn cdt thii 7) lyc cdt tang nhanh, nham be mgt khdng on dinh va giam dan. Nguyen nhan: O giai doan nay dao mdn nhanh, qua trinh cat chua on dinh, lyc cat tang nhanh. Liic nay do vet mon tren dao chua 6n djnh, sy hinh thanh mang ddu giiia mat sau va b l mat gia cong chua tot, su cao x u d c len be mat gia cong nhieu nen trj sd nham Idn. K i t qua nay phii hgp vdi cac nghien ciru trudc day [15]. Ci giai doan nay, M Q L diang dau phun Emulsi Ignh chua cd sy khac bi?t nhifiu so vdi Emulsi thong thudng..

Giai doan mdn dn dmh (tii Ian cat thii 8) luc cat, mdn va tudi ben ciia dung cy da c6 sy khac bi?t. M Q L sii' dung Emulsi lanh, tri so trung binh cua cac thanh phan luc cat Py, Pi giam cdn Ian lugt 86%, 8 8 % va so ISn cdt trong trang thai 6n dinh la 32 lan so vdi 22 lan so vdi khi sii dyng Emulsi khong lanh.

Nguyen nhan: luc nay dung djch Emulsi lanh phat huy vai trd lam ngupi vugt troi hon so v d i dung djch Emulsi khdng lanh [1]. Nhcr nhiet cdt giam nen da cai thien dugc dieu ki?n cdt gpt, lam giam dp mdn, tang tuoi ben ciia

Trari Minh Diic vd Dtg Tap chi KHOA HQC & CONG NGHE 173(13): 171 -176 dao. Trong giai doan nay, trj s6 nham b l mgt

khong cd su khac biet ro net. Nguyen nhan: do dp mon ciia dao on djnh, qua trinh cao xudc ciia dyng cy len b l mat gia cdng giam [6].

Giai dogn mdn nhanh, tri so cac thanh phan lyc cdt, nham b l mat d i u tang nhanh. Qua trinh thi nghiem tiSn hanh d i n khi dao mdn khde lilt, h i t kha nang cdt (danh gid trirc tiep thong qua chi tieu lire cdt). Ket qua tudi bin ciia dao khi M Q L vdi Emulsi la 37,5 phut (25 lan cat); khi M Q L vdi Emulsi lanh la 57 phiit (38 Idn cdt), tang 152% so vdi M Q L vdi Emulsi.

KET LUAN Ddng gop mdi:

- Da nghien cuu, thiit ke v a c h i tao thanh cong dau phun khi lanh theo nguyen ly "ddng xoay" trong dieu kien Viet N a m . Ket qua da tao dugc ddng khi lanh vdi miic chenh lech giiia nhiet d o dau vao va n h i l t do dau ra ctia ddng khi Ignh la SS^C - 40''C.

- T r l n c a s d dau phun khi Ignh, da nghien ciiu, thiet ke va che tgo thanh cong dau phun dung djch lanh ling dung cho M Q L . Ket qua da c h i tao thanh cdng dau phun tao ra dugc ddng dung djch lanh dudi dgng s u a n g mil cd nhi?t do chenh lech so vdi nhiet do dung djch dau vao den 20^C.

- Da nghien ciiu danh gia d u g c hieu qua ciia MQL vdi dung dich Emulsi lanh khi phay Cling thep S K D l l . K i t qua khi phay thep SKD II CO dp Cling H R C = 58 - 60, neu MQL vcri dung dich Emulsi lanh lam giam t n so cac thanh phan luc cat Py, P^ tir 8 6 % - 8 8 % va tudi b i n ciia dyng cy tang 1 5 2 % so vcri MQL diing dung d i c h Emulsi khong lanh. Ket qua nay b u d c dau m d ra hudng nghien cuu mdi nhdm m d rpng kha nang cdng nghe cua MQL giiip nang cao h i l u qua Kinh te - Ky thuSt trong gia cdng v | t li$u ciing.

Nhirng d i l m han c h i c i n tiep tuc nghien ciiu:

- Ket cau ciia cac dau phun chua that hoan thien;

- Chua cd thiet bj d o nhi?t dp cat nen chua tryc tiep danh gia true tiep d u g c anh h u d n g

ciia qua trinh bdi tran lam ngupi d i n nhiet cat.

D i y la h u d n g nghien ciiu mdi cdn nhieu tilm nang va kha nang ling dung thyc tien rat kha thi. N h o m tac gia tiep tuc cd cac nghien ciiu tiep theo va dac bi^t la triln khai ling dung vao thuc tien san xuat.

T A I L I E U T H A M K H A O 1. Arjomandi M., Xue Y. (2007), "An invenstigation of effect ofthe hot end plugs on the efficiency of the ranque - hilsch vortex tube".

Journal of Engineering Science and Technology, 2(3), pp,211-217.

2. Balraer R.T. (1988), "Pressure-driven Ranque- Hilsch temperature separation in liquids", Trans.

ASME, J Fluids Engineering, 110, pp. 161—164.

3. C- aiiskan H., Kurbanoglu C , Panjan P., Cekada M., Kramar D. (2013), "Wear behavior and cutting performance of nanostructured hard coatings on cemented carbide cutting tools in hard milling", Tribology International, 62, pp. 215-222.

4. Dhar N. R, Islam S., Kamruzzaman M. (2007),

"Effect of minimum quantity lubricadon(MQL) on Tool Wear, Surface Roughness and Dimennsional Deviation in Turning AlSl - 4340 Steel", G. U.

Journal of Science, 20, pp. 23 - 32, 5. Duong Xuan Truong and Tran Minh Due (2013), "Effect of Cutting Condition on Tool Wear and Surface Roughness during Machining of Inconel 718", International Journal of Advanced Engineering Technology, 4, pp. 108-112.

6. Davim J. P. (2011), "Machining of Hard Materials", Springer-Verlag London Limited.

1. Elmunifi M. H. S, Kumiawan D., Noordin M.Y.

(2015), "Use of castor oil as cutting fluid in machining of hardened stainless steel with minimum quantity of lubricant", Procedia CIRP, 2 0 , p p . 4 0 8 ^ l l .

8. Hassanpour H., Sadeghi M. H., Shajari A. R. S.

(2016), "Investigation of Surface Roughness, Microhardness and White Layer Thickness in Hard Milling of AlSl 4340 Using Minimum Quantity Lubrication", Journal of Cleaner Production, doi: 10.1016/jjclepro.2015.12.091.

9. Hilsch, Rudolf (1947), "The use of the expansion of gases in a centrifugal field as cooling process",7%e Review of Scientific Instruments, 18 (2),pp.l08-113.

10. Kang M. C , Kim K. H., and Shin S H.

(2008), "Effect of the Minimum .Quantity Lubrication in High-Speed End-Milling of AISI D2 Cold-Worked Die Steel (62 HRC) by Coated 175

Tran Minh Diic vo Dig Tap chf KHOA HQC & CONG NGHfi 173(13): 171-176 Carbide Tools", Surf. Coal. Technol, 202, pp.

5621-5631.

11. Le Thai Son, Tran Minh Due, Nguyen Dang Binh, Nguyen Van Cuong (2013), "An Investigation on Effect of Characteristics of the Made in Vietnam Peanut oil MQL on Tool life in Hard homing 9CrSi steel". Machining qnd Machinability of Materials, 13, pp. 428-438.

12. Lee P. H., Nam J. S., Li C. and U e S. W.

(2012) , "An Experimental Study on Micro- Grinding Process with Nanofluid Minimum Quantity Lubrication (MQL)", International Journal of Precision Engineering and Manufacturing, 13, pp. 331-338,

13. Park K. H., Yang G. D, Suhaimi M. A., Lee D.

v., Kim T. G., Kim D. W. and Lee S. W, (2015),

"The effect of cryogenic cooling and minimum quantity lubrication on end milling of titanium alloy Ti-6A1-4V", Journal of Mechanical Science and Technology, 29 (12), pp. 5121-5126.

14. Sidik N. A. C . Samion S., Ghaderian J., Yazid M. N A. W. M. (2017), "Recent progress on the application of nanoiluids in minimum quantity lubrication machining: A review", International Journal of Heat and Mass Transfer, 108, pp. 79-89.

15. Tran Minh Due, Tran The Long and Tran Bao Ngoc (2017), "Performance of AljOj Nanofuid in minimum quantity lubrication in hard milling of 60Si2Mn steel using cemented carbide tools". Advances in Mechanical Engineering, 9(7), pp. 1 - 9.

16. Tran Minh Due and Tran The Long (2016),

"Investigation of MQL-Employed Hard-Milling Process of S60C Steel Using Coated-Cemented Carbide Tools", Journal of Mechamcs Engineering and Automation, 6, pp. 128-132.

17. Tasdelen B., Wikblom T., Ekered S. (2008),

"Studies on minimum quantity lubrication (MQL) and air cooling at drilling", yow/'na/ of materials processing technology, 200, pp.339-346.

S U M M A R Y

M A N U F A C T U R I N G R E S E A R C H O F V O R T E X T U B E A P P L I E D TO MINIMUM Q U A N T I T Y L U B R I C A T I O N FOR H A R D MILLING

O F S K D l l T O O L S T E E L

Tran Minh Due, Pham Quang Dong, Tran The Long', Tran Quyet Chien University of Technology - TNU Minimum quantity lubrication (MQL) has been studied and widely applied to machining operations due to some superior advantages comp^ed to diy and wet machining. MQL machining uses mixtures of high pressure air and a tiny amount of cutting fluids, which is effectively supplied to the machining interface to reduce the friction. However, there were limitations to this technique because of its weak cooling effect. To overcome the abovementioned problems, this paper aims to introduce some results of manufacturing research of vortex tool cooling mist system used in MQL for hard milling of SKDll tool steel ( 5 8 - 6 0 H R C ) . The obtained results reveal that by using this proposed technique, the reduction of cutting forces Fy, F^ is about 86% - 88%, and the tool life reaches 57 minutes (152% higher than that of machining without vortex tool cooling mist system.

Keywords: Hard machining; Hard milling; Minimum quantity lubrication - MQL; Vortex tube;

Vortex tool cooling misl system

Ngdy nlt$n bdi: 01/11/2017; Ngdy phan biin; 28/11/2017; Ngdy duy?! d&ng: 29/11/2017 Tel: 0985 288777, Emailtrantkelong@tnut.edu.vt

176