In the processing of aluminum alloy, it is very important to select the matching Cutting fluid! It is necessary to ensure good lubrication, cooling, filtration, and rust resistance. The influence of three process indicators on aluminum alloy processing In the process of aluminum alloy cutting, the concentration, pressure, and flow rate of emulsion have a significant impact on the machining quality of components.
1. Concentration of emulsion The Cutting fluid used at the factory site is a working fluid diluted by Cutting fluid concentrate and water. There are usually two methods to express the effective content of Cutting fluid: concentration and dilution ratio. The concentration of the original solution is quickly detected on-site using a refractometer, while laboratory testing generally uses titration methods for detection. The concentration of the working fluid can only be maintained within the specified range to ensure that the cutting fluid performs its intended function. The use concentration of Cutting fluid is too low, which is prone to corrosion, increased tool wear, reduced processing quality, decreased antibacterial performance, corruption and odor. On the contrary, if the concentration of Cutting fluid is too high, it will not only increase the processing cost, but also may lead to a series of problems, such as the decrease of Cutting fluid's cleaning and cooling ability, the decrease of defoaming ability, the irritation of the operator's eyes and respiratory tract, and skin allergy. Therefore, maintaining the proper concentration of Cutting fluid is an important link in the management of water-based Cutting fluid, and the concentration check is usually taken as an important indicator of Cutting fluid management. Open cutting methods, such as turning and milling, can discharge chips smoothly. The chip fluid mainly plays the role of cooling and punching chips. It does not require high concentration. Generally, Cutting fluid with a concentration of about 3%~5% is selected. When cutting in closed places, such as drilling and tapping, the processing environment is bad, chip removal is not smooth, and the tool and workpiece are squeezed each other. At this time, the cutting fluid needs to cool and lubricate the tool, as well as chip punching. This processing method requires high lubrication performance of Cutting fluid. Generally, Cutting fluid with a concentration of 5%~8% is used for drilling. During tapping, the workpiece is severely squeezed by the tool, so it is appropriate to select Cutting fluid with extreme pressure additive concentration of 8%~10%.
2. Pressure of Cutting fluid The large pressure washing of Cutting fluid plays the role of chip breaking and chip punching in part machining. In some hole machining occasions, especially deep hole machining, the pressure of Cutting fluid plays a vital role in the quality of the machined surface and tool life. When selecting Cutting fluid, it is necessary to comprehensively consider the cost of the machine tool. The higher the pressure of Cutting fluid, the higher the configuration requirements of the machine tool, and the higher the overall cost. The cooling system of the machine tool is composed of cooling water tank, filter, pump (high pressure, low pressure), water pipe, nozzle, seals, etc., to increase the pressure of Cutting fluid, and relevant connecting components need to be matched with high-pressure components. Generally, CNC machine tools are equipped with ordinary chip punching cooling systems, and when processing requirements are high, a central cooling system is selected. The Cutting fluid required by common chip punching can select the parameters of small pressure and large flow to timely move the cutting belt and the chips attached to the workpiece, guard board and fixture.
The general pressure parameter for ordinary chip cooling is 0.04-0.06MPa. The central cooling system uses a high-pressure pump. The high-pressure Cutting fluid passes through the center of the spindle, then passes through the tool body, and is sprayed directly to the cutting position of the tool. The high-pressure water is used to break chips, and the chips in the narrow space are forcefully flushed out, thus playing the role of chip breaking, cooling, lubrication, and chip punching. The central cooling system can be divided into four levels according to the selection of pressure: low pressure, medium pressure, high pressure, and ultra-high pressure.
3. Flow of Cutting fluid
The washing action of Cutting fluid washes the chips left on the workpiece, cleans and cleans the fixture, and takes away the cutting heat. Generally speaking, the larger the flow of Cutting fluid, the more obvious the chip washing effect and the better the cooling effect. However, the larger the flow, the larger the water tank capacity required to store Cutting fluid, and the corresponding increase in manufacturing costs and equipment floor area. Therefore, the larger the flow of Cutting fluid is, the better it is. The smaller the flow, the better it should be under the condition of satisfying the working conditions, so as to reduce the total cost. In order to facilitate heat dissipation and supply sufficient Cutting fluid, the capacity of the water tank shall be 3-5 times of the flow of the system cooling pump.
