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Database Development for Comparative Analysis of the Performance of Metalworking Fluids Based on Drilling Operations

机译:基于钻井作业的金属加工液性能对比分析数据库开发

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摘要

Metalworking fluids (MWFs) play a significant role in machining operations. Despite their importance, the manufacturing industry lacks tools to make functionally sound and economical decisions about them.In this research project, a second generation drilling testbed was developed to evaluate the performance of MWFs with respect to lubricity and cooling capacity. A desktop drilling machine was used to make the testbed with a load cell sensor and a thermocouple located in the oil-hole of the drill. The testbed characterized MWFs based on torque, thrust, and temperature measurements. A standardized test procedure was developed to ensure that comparisons of fluids were accurate, repeatable, and representative of the actual differences in the fluids. System repeatability was found to be very good with a coefficient of variation well under 0.1. The system was found to determine differences within 1-2.9% for torque, 1.4-2.5% for thrust, and 2.7-8.2% for temperature based on fivereplicates per experimental condition and an ?? = 0.05 statistical analysis. Ten MWFs were chosen, representing a cross-section of soluble oils, semi-synthetics, andsynthetic products from a variety of manufacturers. The performance of these fluids at a 10% concentration was analyzed based on a set of four separate comparative experiments designed to compare various drilling conditions and reveal how the MWFs performed based on changes of workpiece material, feedrate, and dilutent. The results were evaluated within each experiment by comparing how individual fluids performed within their type and how fluid types performed with respect to each other. Comparative analysis was also conducted among separate experiments to determine how changes in feedrate, workpiece material, and dilutent affect MWF performance. Conclusions based on the data analysis are presented. Additional MWF evaluation tests were used to further characterize the fluids. Tests for viscosity, surface tension, emulsion stability, and corrosion inhibition were conducted. These results were compared with the lubricity and cooling results to check for correlation. General trends indicated a correlation between fluid performance inlubrication and viscosity and surface tension results. Surface tension was found to be more a function of the emulsifiers and additives used in a fluid than the concentration of oil, while viscosity showed a definite correlation with oil content. It was also found that the synthetic fluids showed the most resistance to fluid breakdown due to hard water asmeasured by emulsion stability titration testing. There was no correlation found between type of fluid (soluble oil, semi-synthetic, and synthetic) and corrosion inhibition or surface tension.
机译:金属加工液(MWF)在机加工操作中起着重要作用。尽管它们很重要,但制造业缺乏用于对其进行功能合理和经济决策的工具。在此研究项目中,开发了第二代钻井试验台来评估MWF在润滑性和冷却能力方面的性能。使用台式钻床制造带有负载传感器和位于钻头油孔中的热电偶的测试台。该测试台基于扭矩,推力和温度测量来表征MWF。制定了标准化的测试程序,以确保流体的比较准确,可重复并代表流体中的实际差异。发现系统的可重复性非常好,变异系数小于0.1。根据每个实验条件的5次重复和Δε值,发现该系统确定的扭矩差在1-2.9%范围内,推力在1.4-2.5%范围内,温度在2.7-8.2%范围内。 = 0.05统计分析。选择了十个MWF,它们代表了来自各种制造商的可溶性油,半合成和合成产品的横截面。基于一组四个独立的对比实验分析了这些流体在10%浓度下的性能,这些实验旨在比较各种钻探条件,并揭示出MWF如何根据工件材料,进给率和稀释剂的变化进行工作。在每个实验中,通过比较各个流体在其类型内的表现方式以及流体类型相对于彼此的表现方式来评估结果。还对单独的实验进行了比较分析,以确定进给速度,工件材料和稀释剂的变化如何影响MWF的性能。提出了基于数据分析的结论。其他MWF评估测试用于进一步表征流体。进行了粘度,表面张力,乳液稳定性和缓蚀性能的测试。将这些结果与润滑性和冷却性结果进行比较,以检查相关性。总体趋势表明,流体性能润滑与粘度和表面张力结果之间存在相关性。发现表面张力是流体中使用的乳化剂和添加剂的功能,而不是油的浓度,而粘度显示出与油含量的明确关系。还发现,通过乳液稳定性滴定测试测量,由于硬水,合成流体显示出对流体分解的最大抵抗力。流体类型(可溶性油,半合成油和合成油)与腐蚀抑制或表面张力之间没有相关性。

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