Milling performance evaluation and cooling/lubrication mechanism of Al-50wt% Si alloy based on various environmentally sustainable manufacturing strategies

润滑 材料科学 表面粗糙度 机械加工 合金 冷却液 可加工性 超临界流体 冶金 润滑油 超临界二氧化碳 刀具磨损 表面光洁度 复合材料 机械工程 化学 工程类 有机化学
作者
Lu Jing,Qiulin Niu,Jiaqiang Dang,Qinglong An,Chunhao Wang,Fan Zou,Changping Li,Pengnan Li,Wenhui Yue,Tae Jo Ko
出处
期刊:The International Journal of Advanced Manufacturing Technology [Springer Science+Business Media]
卷期号:122 (2): 1023-1040 被引量:1
标识
DOI:10.1007/s00170-022-09955-x
摘要

Silicon aluminum alloy with Si weight percentage in 50% (Al-50wt% Si) is a typical difficult-to-machine composite. In order to improve its machinability, it is necessary to optimize the friction state at the tool-Si-Al alloy interface by cooling/lubrication. Using appropriate cooling and lubricating media can drive machining operations towards cleaner and more sustainable targets. However, the synergy between Si-Al alloy special material structure, material properties, and multiphase coolants/lubricants is still unknown. In this study, the machining performance of Al-50wt% Si alloy under three milling environments (MEs), namely, dry, supercritical carbon dioxide (scCO2), supercritical carbon dioxide–based minimum quantity lubrication (scCO2-MQL), was discussed. The theoretical analysis was made to understand the scCO2-MQL permeation mechanism. The effects of various cutting parameters and MEs on cutting force, cutting temperature, surface roughness, and surface morphology were investigated. The results show that the lowest cutting force and temperature can be found in scCO2-MQL ME owing to its excellent cooling/lubrication and heat transfer performance. The scCO2-MQL coolant/lubricant can inhibit the spalling and crushing of Si particles. Therefore, the lowest surface roughness which is reduced by 32.34% compared with dry milling and the best surface morphology can be obtained in scCO2-MQL milling. An interaction model between tool cutting edge-Si particles in scCO2/scCO2-MQL MEs has also been presented. The results indicate that the performance of scCO2-MQL as a clean and sustainable cooling/lubrication technique can result in an appreciable improvement in milling Al-50wt% Si alloy.
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