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JX03-206@直接加热转筒式干燥机,机械毕业设计全套
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鞍山科技大学本科生毕业设计（论文） 第 1 页 附录 A TRANSACTIONS OF MATERIAL SAND HEATTRE ATMENT Vol.25 No.5 PROCEEDINGS OF THE IFHTSE CONGRESS October 2004 Dry Machining Tool Design via Chlorine Ion Implantation Tatsuhiko Aizawa1, Atsushi Mitsuo2, Shigeo Yamamoto2, Shinji Muraishi3, Taro Sumitomo1 1. Center for Collaborate Research, University of Tokyo, Tokyo, Japan 2. Tokyo Metropolitan Industrial Research Institute, Tokyo, Japan 3. Department of Materials Science Technology, Tokyo Institute of Technology, Tokyo, Japan Abstract: Dry machining has become a key issue to significantly reduce the wastes of used lubricants and cleaning agents and to improve the environmental consciousness for medical and food applications of special tooling. Since the tools and metallic works are in direct contact in dry, severe adhesive wear and oxidation are thought to occur even at the presence of hard protective coatings. Self-lubrication mechanism with use of lubricous oxide films is found to be effective for dry machining. Through the chlorine ion implantation to tools, titanium base oxides are in-situ formed on the tool surface. This oxide deforms elas to-plastically so that both friction coefficient and wear volume are reduced even in the high-speed cutting. Keywords: Dry machining, Chlorine ion implantation, Self lubrication, WC tool, TIN coating, TiCN coating DRY MACHINING is a keyword for manufacturing and production science in the twenty-first century, which requires significant reduction of environmental burden and COi emission11. In the modern high-speed wet and semi-dry machining processes, huge amounts nts鞍山科技大学本科生毕业设计（论文） 第 2 页 of lubricants and cleansing agents are wasted in daily production . Among various proposals aiming at the dry machining , in-situ formation of tribo-filrns must be an important concept to make dry machining tools .Authors have pointed out the importance on the role of in-situ formed lubricious oxide films to attain low friction and wearing state in dry. Self-lubrication is accommodated to titanium and titanium ceramic coatings via chlorine ion implantation into them. In the present paper, self-lubrication via chlorine ion implantation is applied to dry machining. Various tool and work materials are utilized to understand the dry machining tool design for high speed machining. In the case of dry-machining the steel work by bare cemented carbide tools, lower friction and wear state can be realized by self-lubrication process. Wear in the Cl-implanted, ceramic-coated tools is also significantly reduced even in the higher cutting speed range. 1. Dry Machining Tool Design As had been discussed in 10-11), two key items must be considered to make dry machining tool design. At first, the surface zone of tool materials or protective coating films is to be changed to a lubricous mono-oxide film. When titanium mono-oxide film is formed on the surface, low friction and wear state is attained by its plastic deformation at high normal pressure during cutting. Furthermore, this titanium mono-oxide is transformed to intermediate oxides or Magneli-phase oxides by oxidation during dry cutting. These oxide films have also a potential of plastic deformation so that low friction and wear state should be sustained even with increasing the cutting speed. In order that the above self-lubrication process should work in dry machining, both work and tool materials must be adequately selected together with optimization of chlorine ion implantation conditions. In the second, cutting tool shape is also optimized not only to reduce the friction and wear but also to prolong the life time of tools. Direct work-tool interaction in dry machining is difficult to describe. The tool surface shape optimization is still dependent on the skills. This difficulty in shape optimization can be relaxed by using the in-situ tribo-film coating. Since the tribo-film is formed at the vicinity of cutting edge, the cutting tool shape is slightly nts鞍山科技大学本科生毕业设计（论文） 第 3 页 modified to fulfill the steadily high speed cutting in dry. In-situ formation of titanium base oxide tribofilms requires a titanium source to yield oxides via tribo-chemical surface reaction in dry machining. One is titanium included in steel work. To be explained later, since titanium is used for de-oxidation process in steel making, its nitrides or carbides distribute as an inclusion in work material. The other is titanium-base ceramics included in the tool material. TiC is usually included in cemented carbide tools. TiN, TiC or TiCN are typical constituents of protective ceramic coating films for cutting tools. As had been discussed in 11-13), the former titanium source is often very important for control of insitu-formed tribofilm on the surface of tools. 2. Experimental Procedure How to prepare tool and work materials is explained as well as the chlorine implantation and the turning test. 2.1 Preparation of Tools The throw-away cemented carbide tools were selected as a specimen. They were shaped triangular without chip-breakers on their rake face. Two types of cemented carbide tools with P10 and P30 were used as a bare tool material. In order to investigate the effect of ceramic protective coating on the improvement of machinability, TiCN coating with alternative layers of TiN and TiC was deposited as a multi-thin later on the cemented carbide tool of the type of P10. To be noted, TiC was invoked in both cemented carbides. 2.2 Chlorine Implantation Ion implanter for Cl-implantation to cutting tools is depicted in Fig. 1. The tool specimens were mounted on a target manipulator and irradiated by scanning the beam of Cl ions. Ion beam was generated from A1C13 in a Freeman type ion source with a vaporizer and mass-selected to yield single, positive-charged chlorine beam of Cl . The dose of chlorine ions was constant 1.0 x 1017 ions/cm2 with the implantation energy of 100 keV. The chlorine ions were implanted into both the rake and the flank faces of specimen. The incident angle was fixed to normal to the tool surface and the vacuum was controlled to be less than 2 x 105 Pa nts鞍山科技大学本科生毕业设计（论文） 第 4 页 during implantation. To suppress the heating by the ion beam itself, the beam current density was limited to 0.03 - 0.05 A/m2 throughout the process. Fig. 1: Ion implanter for chlorine ion implantation to cutting tools. 2.3 Turning Test Turning tests were conducted for the evaluation of dry machinability. Both the cutting depth (Dc) and the feed (f) were fixed to be constant: Dc = 1.0 mm and f = 0.1 mm/rev. The cutting speed was varied from 10 m/min to 500 m/min. Figure 2 illustrates the mechanical interaction between workpiece and tool. Using a lathe equipped with axial load sensors, both the reactive and feed forces were measured respectively. Two types of worn surfaces were observed in the turning tests: flank wear width (VB) and the crater wear width (kT). Steel with the type of S45C after de-oxidation by addition of titanium was employed as work material. Its main chemical composition was 0.44 mass% C, 0.34 mass% Si, 0.80 mass% Mn together with 0.01 mass% Ti. Oxygen content was controlled to be 0.0011 mass %. Other contents of phosphorous, sulphur, copper, nickel and chromium were suppressed to be less than 0.001 mass %. 2.4 Characterization A laser microscope was first used to observe the in-situ formation of tribo-films on the tool surface. Various oxide formation on the tool surface was detected by using EDS (Energy Dispersive Spectroscopy) nts鞍山科技大学本科生毕业设计（论文） 第 5 页 Fig. 2: Mechanical interaction between workpiece and tool in this turning test. 3. Experimental Results and Discussion Bare WC-tools and TiCN-coated WC-tools were selected to investigate the effect of chlorine ion implantation into tool materials on the dry machinability. 3.1 Cl-Implantation to Bare WC-Tool In the turning tests, both Fc and Fs were measured to estimate the friction coefficient. Figure 3 depicts the measured friction coefficient with increasing cutting speed (Vc) for bare WC and Cl-implanted WC tools. The friction coefficient (u) of bare WC had maximum for 40 m/min 100 m/min, jo. decreased steadily with Vc. In case of Cl-implanted WC tools, (J. in the higher cutting speed range decreased with Vc from 0.7 to 0.75 for Vc = 40 to 100 m/min. It became the lowest at Vc = 300 m/min, e.g. i = 0.58 while = 0.65 for bare WC tools. This low friction coefficient in the higher cutting speed range is attained by the present Cl-implantation. 3.2 Cl-Implantation to TiCN Coatings In the turning test of titanium bearing workpiece, the self-lubrication process only worked in the higher cutting speed region. The tribofilm of titanium base oxides was difficult to form on the tool materials due to less amount of titanium source. On the other hand, the tribofilm is easy to be formed via the chlorine ion implantation to titanium base ceramic coating films, like TiCN. In the case of Cl-implantation to TiCN-coated tools, the self-lubrication process could work well in all cutting speed. nts鞍山科技大学本科生毕业设计（论文） 第 6 页 Fig. 3: Comparison of friction coefficient between bare WC and Cl-implanted WC tools. Figure 4 compared the flank wear width after a cutting length of 500 m between TiCN coated and Cl-implanted TiCN-coated WC tools for various cutting speeds. The flank wear width significantly reduced by the chlorine ion implantation to TiCN coating films. For Vc 300 m/min, the flank wear increased exponentially with Vc for TiCN-coated WC tools. Severe oxidation wear of TiCN takes place in dry condition at higher cutting speeds. In the case of Cl-implanted TiCN-coated tools, the flank wear only increases linearly with the cutting speed. In particular, VB = 55 Jim after a cutting length of 500 m at a cutting speed of Vc = 500 m/min. Fig. 4: Comparison of the flank wear width (VB) between TiCN coated and Cl-implanted TiCN-coatedWC tools. 3.3 Formation of Tribofilms Significant reduction of flank wear even at higher cutting speeds is a good proof to demonstrate that the self-lubrication process works effectively on the titanium base oxide nts鞍山科技大学本科生毕业设计（论文） 第 7 页 tribo-films. Figure 5 shows the microstructure on the flank surface of Cl-implanted TiCN after the cutting length of 500 m at Vc = 400 m/min. At the vicinity of the cutting edge the film is formed on the flank surface. In literature, the belag is expected to be working as a protective layer of tools 14) . In general, this type of films is composed of various oxides; the constituent metallic elements of workpiece or tools are oxidized during cutting at relatively high temperatures. In the case of adhesive wear, main constituents of workpiece material for example iron are easily and fast oxidized to form the hematite base oxide films. Fig. 5: Precise measurement of tool surface by the laser microscope. Fig. 6: Distribution oi Si, Mil, Ti, Fe anil O contents together with SEM micrograph. In the present dry machining, the formed film is never a simple mixture or compounds of oxides. Figure 6 depicts the distribution of silicon, manganese, titanium, iron and oxygen contents together with SEM micrograph. The in-situ formed film in Fig. 5 is divided into two regions: I- and Il-regions. The film in the I-region is mainly composed of TiOx. On the other hand, the II-region is a mixture of SiO2 and MnO. To be noted, both I- and Il-regions include much few iron nts鞍山科技大学本科生毕业设计（论文） 第 8 页 contents; iron oxides did not deposit on the flank surface during dry machining. Since the measured flank wear width by the laser microscope corresponds to the I-region, the II-region is thought to have nothing to do with the reduction of friction and wear via Cl-implantation to TiCN coating films. In-situ formation of titanium base oxides has close relationship with self-lubrication process in this dry machining via the Cl-implantation. 4. Conclusion Dry machining performances of Cl-implanted cutting tools were investigated by turning test in dry condition for wide range of cutting speed up to 500 m/min. In the case of Cl-implantation to bare WC tools, both the friction coefficient and wear were significantly reduced. In the case of Cl-implanted TiCN-coated WC tools, the flank wear was much reduced even in the high cutting speed range. The flank wear width far exceeds over 100 |im at Vc = 500 m/min while VB = 55 Jim by Cl-implantation. This improvement of tribological performance in dry machining is attributed to the self-lubrication process on the in-situ formed titanium base oxide films. Acknowledgment Authors would like to express their gratitude to Dr. T. Akhadejdamrong, Mtech, Thai for her help in experiment. This study is financially supported in part by the national project on the barrier-free processing and environmentally benign manufacturing from MEXT. References 1.T. Aizawa: Barrier-Free Processing. Ch. 9, Fundamentals and Applications in Ecomaterials. Nikka-Giren, 2002. 2 .K. Namba: Report on marketing research on super-hard alloy tools. CASTI, 2003. 3.Renevier M.M., Lobiondo N, Fox V.C., Teer D.G, Hampshire J.: Performance of MoS2/Metal Composite Coatings Used for Dry Machining and Other Industri Application. Surf. Coat. Technol., 2000, 123: 84-91. 4 .Derflinger, Brandle H., Zimmermann H.： Ne Hard/Lubricant Coating for Dry Machining. Surf. Coa Technol., 1999,113: 286-292. nts鞍山科技大学本科生毕业设计（论文） 第 9 页 5.Huu T.L., Paulmier D., Grabchenko A., Horvath M Meszaros I., Mamalis A.G, Autolubrication of Diamon Coatings at High Sliding Speed. Surf. Coat. Technol., 199108-109:431-436. 6 .Mitsuo A., Aizawa T: Improvement of Friction and We Performance of Titanium Nitride Films by Chlorine Io Implantation. Mater. Trans., 1999, 40(12): 1361-1366. 7.Aizawa T， Akhadejdarnrong T， Iwamoto C， Ikuhara Mitsuo A： Self-Lubrication of Chlorine-Implante Titanium Nitride Coating. J. Am. Ceram. Soc., 2002, 85(121-24). 8.Akhadejdamrong T, Aizawa T, Yoshitake M., Mitsuo A Feasibility， Study， of Self-lubrication ， by Chlorin Implantation.Nucl. Instrum. Meth. Phys.Res, 2003, 297:45-54. 9.Akhadejdarnrong T， Aizawa T， Yoshitake M.,， Mitsuo A Yamamoto T， Ikuhara Y：Self-Lubrication Mechanism o Chlorine Implanted TiN Coatings. Wear, 2003, 25 668-679. 10.Aizawa T， Akhadejdarnrong T， Mitsuo A.： Self-Lubricatio of Nitride Ceramic Coating by the Chlorine Io Implantation. Surf. Coat. Technol., 2004, 177-178： 573-58 11 .Mitsuo A., Uchida S., Yamamoto S. and Aizawa T Improvement of Cutting Performance for Carbide Tools vi Chlorine Ion Implantation. Surf. Coat. Technol., 2004 (ipress). 12.Aizawa T， Mitsuo A., Yamamoto S， Sumitomo Muraishi S： Self-Lubrication Mechanism via the In-sit Formed Lubricious Oxide Tribofilms. Wear (to be published). 13.Aizawa T, Mitsuo A: Dry Forming by Cl-implanted Tool Jpn. J. Technology of Plasticity (to be published). 14.S. Yamamoto, Takamori S， Osawa Y， Sato A： Tool We of High Strength Free Cutting Steel without Lead. J. Jp Inst. Metal., 2001,65 (7)： 614-620.Correspondingauthor: Dr.TatsuhikoAizawa. Email: aizawaodin.hpm.rcast.u-tokyo.ac.jp. Mail address: 4-6-1 Komaba, Tokyo 153-8904, Japan. Tel & Fax: +81-3-5452-5116 nts鞍山科技大学本科生毕业设计（论文） 第 10 页 材 料 沙 的 加 热 处 理 2004 年 10 月 经氯离子注入进行机械干燥机工具设计 Tatsuhiko Aizawa1, Atsushi Mitsuo2, Shigeo Yamamoto2, Shinji Muraishi3, Taro Sumitomo1 1. 合作研究中心、位于日本东京的东京大学 2. 位于日本东京的东京工业研究所 3. 位于日本东京的东京技术学院，材料科学技术系 摘要 :干燥机已成为一个关键问题 ,它可大大减少润滑油及清洁剂使用过程中所 产生的废物，并提高医疗及食品应用方面特殊工具的环保意识。 由于工具和金属产品在干燥条件下直接接触，机器严重受损，即使具有良好的保护涂层也会被氧化。自动注油机械原理使用 lubricous 氧化机制是对干燥机行之有效的处理。 通过将氯离子注入工具，在工具表面形成钛氧化合物的保护层。这一氧化物毁坏 ELAS，形成塑胶，即使在高速切割的条件下，配戴量及摩擦系数都会大大减少。 关键词 ：干燥机，氯离子注入，自动注油，铸工具，锡涂层， TICN 涂层 机械干燥是一个关键词 ,在 21 世纪 , 对于制造业生产科学是一个关键词。必须大 幅度减少环境负担 ,Cqi 放射物 11 在现代高速潮湿和半干燥机械运转过程中，清洗剂、润滑油在日常生产中巨额浪费。各提案旨在机械干燥 , Tribo-Filrns 的原址形成重要概念在于必须使用干燥机工具。 作者指出 ,in-situ 的重要作用在于形成 lubricious 氧化物以减少摩擦及配戴量。自动注油原理在于将氯离子注入到钛材料、钛陶瓷中。 本文自动注油将氯离子注入应用于机械干燥。 利用各种工具和材料 ,了解干燥机械以设计出高速切削工具。 对于水泥碳化物为基础的干燥机 ,只有减少摩擦 ,才能实现自动注油过程。 具有 CL-植入陶瓷保护层的工具，即使在高切削速度范围也可大大减少摩擦。 1. 干燥工具的机械设计 （曾在 1910 年至 1911 年讨论） ,两次关键项目必须考虑干切削工具设计。 首先 ,工具的表面涂层或保护区将改成 lubricous 薄膜 单一氧化物nts鞍山科技大学本科生毕业设计（论文） 第 11 页 薄膜。当在表面形成钛的单一氧化物薄膜，在高压正常切割条件下，通过塑料变形，实现低摩擦低损耗。此外 ,单 一钛氧化物在干燥切割过程中被转化成中级氧化物或氧化物Magneli。这些薄膜也有氧化塑料变形的潜能 ,使低摩擦 , 即使提高切割速度，也可保持低摩擦低损耗。 为了实现上述的自动注油过程，必须有足够的可供选择的工具和材料，同时优化氯离子注入条件。 其次 ,优化刀具形状不仅减少摩擦及损耗 ,而且延长工具的使用寿命。 很难描述干燥机中各工件的相互联系。工具表面形状优化还是依靠技术 .可以利用 Tribo 片涂层减少形状优化上的困难。因为 Tribo 形成于切割边缘附近，所以刀具形状略有修改就可以实现干燥状态下高速切割。 原址基础组 建钛氧化物 tribofilms 需要钛原料在干燥机中通过 tribo 化学物的表面反应产生氧化物。一是炼钢中的钛。后面会加以解释。由于钛用于非氧化过程 ,它的 carbides作为工作材料被分配。 另一种是列入工具材料中的钛基陶瓷材料。通常包括静态碳化物工具。锡是典型的作为切割工具陶瓷保护涂层薄膜的成分。（曾在 1911 年至 1913 年被讨论） ,前者钛源往往对于控制在工具表面上形成的低摩擦薄膜起着非常重要的作用。 2. 实验程序 如何准备工具及工作材料 ,如何解释 ,以及氯植入试验 . 2.1 准备工具 掷掉胶结碳化物工具被选为 样本。 在磨损表面，他们没有芯片破裂而形成的三角形。这两种形式与 P10 和 P30 胶结碳化物被当作单纯的工具材料。 为了调查陶瓷保护涂层在机器加工改进方面的效果， TICN 涂层替代锡层和 Tic 层作为多面超薄型被储存。此点在后面的胶结碳化物 P10 型号中将被提到。 请注意 TiC 应固定于水泥涂抹层carbides 中。 2.2 氯植入 图表 1 对氯离子注入切割工具过程进行了描述。 工具标本被装在一个目标操作中，并通过氯离子束的扫描。 离子束在自由离子源中由 a1c13Freeman 产生，通过蒸发器进行 大 量 的 收 集 产 生 单 一 的 容 易 控 制 的 氯 离 子 束 。 氯 离 子 剂 量 经 常 是ions/cm21.0X1017100，具有 100keV 的移入能源。氯离子植入到样本侧面和边缘。 这一角度被正常的固定在工具表面，移入过程中，控制真空低于 210X5PA。 加热离子束 ,束密度目前只限于 0.03-0.05A/m2 全过程 . nts鞍山科技大学本科生毕业设计（论文） 第 12 页 图表 1:氯离子注入切割工具。 2.3 转数测试 测验用于对干燥机加工能力的评定。切割的深度及强度都是固定不变的：深度为 1.0毫米，强度为 0.1 毫米 / 转，切割速度范围为 10 米 / 分至 500 米 / 分。图 2 说明工件和工具间的机械内部 运作。车床装有传感器，可准确测量出化学反应及强度。两种磨损表面在试验中被观察：侧翼宽 (VB)和坑口宽（ KT）。 s45c 型号的钢铁，通过加入钛进行非氧化处理后用于做工
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