卷板機(jī)設(shè)計(jì) -四輥卷板機(jī) 【更新】【含CAD圖紙+PDF圖】

喜歡這套資料就充值下載吧。資源目錄里展示的都可在線預(yù)覽哦。下載后都有，請(qǐng)放心下載，文件全都包含在內(nèi)，【有疑問咨詢QQ:1064457796 或 1304139763】 摘 要本說明書是按照所設(shè)計(jì)的卷板機(jī)內(nèi)容撰寫的，主要包括卷板機(jī)軸輥的受力分析、電動(dòng)機(jī)的選擇、主減速器的設(shè)計(jì)、側(cè)輥傳動(dòng)系統(tǒng)的設(shè)計(jì)、下輥液壓傳動(dòng)系統(tǒng)的設(shè)計(jì)以及對(duì)下輥液壓同步控制系統(tǒng)進(jìn)行了研究。從而保證了下輥在上升的過程中始終能夠保持兩端同步。四輥卷板機(jī)主要為鍋爐廠輥制鍋爐圓筒而設(shè)計(jì)，它可以用于各種型號(hào)鍋爐圓筒的生產(chǎn)和加工，也在造船、石油化工、航空、水電、裝潢、及電機(jī)制造等工業(yè)領(lǐng)域得到了廣泛的應(yīng)用，用以把金屬板料卷制成圓筒、圓錐以及弧形板等各種零件。該四輥卷板機(jī)利用其四個(gè)輥筒的空間布置，最大范圍地減少了剩余直邊的出現(xiàn)、降低了生產(chǎn)成本、提高了生產(chǎn)效率。關(guān)鍵詞：四輥卷板機(jī) 輥制 剩余直邊 弧形板AbstractThis statement is in accordance with the design cylinder content written mainly include the pressure analysis of cylinder axle roller, electric motors choice, the reducer design, lateral roller drive train system design, the design of the roller hydraulic drive train system on the roller and hydraulic control systems simultaneously conducted research. Thereby ensuring an increase in the course of the roller always able to maintain both simultaneously. The four cylinder roller machine mainly boiler plant roller system designed boilers cones, which can be used for various types of boilers cones production and processing are also shipbuilding, petrochemical, aviation, utilities, furniture, and electrical manufacturing industries widely applied to the metal plate material volumes produced cones, circular cone arc boards and various parts. The four cylinder roller machine use its four roller cylinders space layout, the greatest scope to reduce the margin in the remaining departments, reducing production costs, improving production efficiency.Key words: four-cylinder roller machine Roller machineLeft straight-side Arc board目 錄摘 要 Abstract第1章：緒 論11.1卷板的分類及特點(diǎn)11.2卷板機(jī)的分類及特點(diǎn)11.3 W12 40X2000型四輥卷板機(jī)的用途31.4 傳動(dòng)系統(tǒng)設(shè)計(jì)4第2章：卷板機(jī)軸輥受力分析4 2.1作用在卷板機(jī)輥?zhàn)由系膹澢ぞ?2.2卷板機(jī)的空載扭矩52.3四輥卷板機(jī)的卷板力5第3章 ：電動(dòng)機(jī)的選擇與計(jì)算93.1電動(dòng)機(jī)功率的計(jì)算93.2電動(dòng)機(jī)的選擇9第4章：主減速器的設(shè)計(jì)104.1電動(dòng)機(jī)型號(hào)的確定104.2傳動(dòng)比的分配114.3傳動(dòng)系統(tǒng)的運(yùn)動(dòng)和動(dòng)力參數(shù)設(shè)計(jì)114.4高速級(jí)斜齒圓柱齒輪傳動(dòng)的設(shè)計(jì)計(jì)算134.4.1選擇精度等級(jí)，材料和齒數(shù)134.4.2 按齒面接觸強(qiáng)度設(shè)計(jì)144.4.3按齒根彎曲疲勞強(qiáng)度設(shè)計(jì)164.4.4齒輪幾何尺寸的計(jì)算174.5中間級(jí)斜齒圓柱齒輪傳動(dòng)的設(shè)計(jì)計(jì)算184.5.1選擇精度等級(jí)，材料和齒數(shù)184.5.2 按齒面接觸強(qiáng)度設(shè)計(jì)184.5.3按齒根彎曲疲勞強(qiáng)度設(shè)計(jì)204.5.4齒輪幾何尺寸計(jì)算224.6 低速級(jí)斜齒圓柱齒輪傳動(dòng)的設(shè)計(jì)計(jì)算224.6.1選擇精度等級(jí)，材料和齒數(shù)224.6.2 按齒面接觸強(qiáng)度設(shè)計(jì)234.6.3按齒根彎曲疲勞強(qiáng)度設(shè)計(jì)254.6.4幾何尺寸計(jì)算264.7高速軸的設(shè)計(jì)以及軸的校核27第5章: 側(cè)輥傳動(dòng)系統(tǒng)的設(shè)計(jì)315.1側(cè)輥電動(dòng)機(jī)的確定315.2側(cè)輥減速器的確定32 5. 3蝸輪蝸桿傳動(dòng)設(shè)計(jì) 31第6章：下輥筒液壓缸的設(shè)計(jì)356.1下輥液壓系統(tǒng)的工作原理356.2下輥筒液壓缸設(shè)計(jì)36第7章：輥筒軸的強(qiáng)度校核41第8章：專題論文438.1前言438.2四輥卷板機(jī)工作原理438.3液壓同步控制系統(tǒng)研究及設(shè)計(jì)原理458.4結(jié)論46結(jié)束語47致謝48參考文獻(xiàn)49附錄1中文譯文50附錄2英文原文77IV附 錄I(中文譯文)3.5 刀具成本的檢測(cè)加工成本是加工工具成本和切削成本的總和。機(jī)床成本由閑置費(fèi)用，加工費(fèi)用和工具改變費(fèi)用組成。當(dāng)改變切削速度的情況下閑置費(fèi)用保持不變。從機(jī)械數(shù)據(jù)手冊(cè)24上表明機(jī)械設(shè)備成本的公式如下：為了優(yōu)化切割條件,必須確定切割深度大小和切割速度的數(shù)學(xué)關(guān)系式.在 我們學(xué)習(xí)的泰勒模型將被用于確定切削速度對(duì)切削刀具壽命的影響:VT =C -3-2V=切削速度T=切割時(shí)產(chǎn)生的標(biāo)準(zhǔn)金額側(cè)翼磨損(例如.0.2毫米)N和C都是由被使用的材料或者工作條件所決定的常數(shù). ,為了確定進(jìn)給時(shí)的常數(shù)n和C我們以4140鋼在實(shí)驗(yàn)的條件下進(jìn)行研究，以LogV和LogT為坐標(biāo)進(jìn)行作圖，畫出了三種類型的進(jìn)給圖形，圖3-8A、圖3-8B是對(duì)KC313為研究對(duì)象在干和濕的條件下分別做出的圖形，圖3-9A和圖3-9B是對(duì)KC732為研究對(duì)象在干和濕兩種狀態(tài)下所做的圖形，另外,圖3-10A、圖3-10B是以KC5010為研究對(duì)象在干和濕兩種狀況下所做的圖形. 從上述的圖形可以看出不管測(cè)量的次數(shù)有多少,其結(jié)果都是呈直線分布的形式下降,從曲線我們能夠看出，在相同的切削速度的條件下，增加磨損標(biāo)準(zhǔn)和對(duì)KC313和KC732使用冷卻液都可以提高工具的使用壽命。然而，對(duì)于KC5010來說提高磨損標(biāo)準(zhǔn)和降低使用冷卻液對(duì)提高KC5010工具壽命有好處。冷卻乳液的這種抑制作用和對(duì)磨損機(jī)構(gòu)的效果我們把它列入到了第五章。以及其他類型的磨損也將插入到那里研究。金屬的切削研究主要集中在刀具的磨損、刀具的壽命和磨損機(jī)理。不過,未來的研究應(yīng)該更加關(guān)注其他因素的影響:l 通過工廠體系建立磨損標(biāo)準(zhǔn)，基本的刀具磨損開端取決于工廠的產(chǎn)品。l 使用刀具的類型，向碳素鋼刀具和高速切削刀具。這對(duì)于研究在干和濕的條件下研究影響刀具壽命的因素常數(shù)（C，n）是有用的。這將提高刀具的壽命，因?yàn)樗矊⒂绊懙角邢鞯慕?jīng)濟(jì)性24。為了確定切削液在選擇磨損標(biāo)準(zhǔn)時(shí)所起的作用,不同的磨損標(biāo)準(zhǔn)和經(jīng)常的進(jìn)給成本在HMS下必須被研究。不同切削標(biāo)準(zhǔn)的刀具壽命常數(shù)在表（3-7）所列的表格中被摘錄和劃分。從圖3-8A/B。圖3-9A/B、圖3-10A/B的常數(shù)（C，n）的價(jià)值在表3-8和表3-9中被反映出來。在以后的圖中說明這些參數(shù)和磨損標(biāo)準(zhǔn)的關(guān)系。圖3-11描述了n和磨損標(biāo)準(zhǔn)的關(guān)系。當(dāng)提高n時(shí)磨損標(biāo)準(zhǔn)的變化。(a)以Log（T）和Log(V)為坐標(biāo)在不同的磨損標(biāo)準(zhǔn)的情況下所做的圖形（干條件）(b)以Log（T）和Log(V)為坐標(biāo)在不同的磨損標(biāo)準(zhǔn)的情況下所做的圖形（濕條件）圖3-8 KC313在不同的磨損標(biāo)準(zhǔn)下由時(shí)間（T）和速度（V）為坐標(biāo)所做的圖形（a）以Log（T）和Log(V)為坐標(biāo)在不同的磨損標(biāo)準(zhǔn)的情況下所做的圖形（干條件）(b) 以Log（T）和Log(V)為坐標(biāo)在不同的磨損標(biāo)準(zhǔn)的情況下所做的圖形（濕條件）(a)以Log（T）和Log(V)為坐標(biāo)在不同的磨損標(biāo)準(zhǔn)的情況下所做的圖形（干條件）(b)以Log（T）和Log(V)為坐標(biāo)在不同的磨損標(biāo)準(zhǔn)的情況下所做的圖形（濕條件）圖3-9 KC732在不同的磨損標(biāo)準(zhǔn)下由時(shí)間（T）和速度（V）為坐標(biāo)所做的圖形（a）以Log（T）和Log(V)為坐標(biāo)在不同的磨損標(biāo)準(zhǔn)的情況下所做的圖形（干條件）(b) 以Log（T）和Log(V)為坐標(biāo)在不同的磨損標(biāo)準(zhǔn)的情況下所做的圖形（濕條件）（a） 以Log（T）和Log(V)為坐標(biāo)在不同的磨損標(biāo)準(zhǔn)的情況下所做的圖形（干條件）(b)以Log（T）和Log(V)為坐標(biāo)在不同的磨損標(biāo)準(zhǔn)的情況下所做的圖形（濕條件）圖3-10 KC5010在不同的磨損標(biāo)準(zhǔn)下由時(shí)間（T）和速度（V）為坐標(biāo)所做的圖形 （a）以Log（T）和Log(V)為坐標(biāo)在不同的磨損標(biāo)準(zhǔn)的情況下所做的圖形（干條件） (b) 以Log（T）和Log(V)為坐標(biāo)在不同的磨損標(biāo)準(zhǔn)的情況下所做的圖形（濕條件）表3-7 刀具壽命常數(shù)的范圍劃分RangeCutting InsertCondition0 LogT 2.6KC313Dry0 Log T 4.1KC313Wet0 LogT 2.6KC5010Dry0 Log T 1.75KC5010Wet0 LogT 2.1KC732Dry0 Log T 2.4KC732Wet表3-8 在三種刀具材料下由C和n所做的磨損標(biāo)準(zhǔn)圖（干條件下）WearCriteria(mm)KC 313KC 5010KC732CnCnCnconstantconstantconstantconstantconstantconstant0.151420.2605180.2486300.2880.21650.2125600.2649640.3640.251960.2405960.27810990.3710.32380.2936050.27912330.3930.352500.2756120.27913990.4210.42630.2816250.28115030.4340.452820.2926250.27815170.4340.52920.2946300.27615770.4420.553020.2966320.27415920.4430.63130.3006380.27416110.444 表3-9 在三種刀具材料下由C和n所做的磨損標(biāo)準(zhǔn)圖（濕條件下）KC 313KC 5010KC732Wear criterion(mm)CnCnCn0.151670.2014970.298881.0500.3320.21870.2106190.3101051.960.3530.252280.2406100.3121297.180.39300.32440.2506280.3091545.250.42400.352670.2606260.3001782.380.45400.42910.2806190.2901918.670.46800.453380.3106150.2822137.960.49100.53030.3106160.279 2477.420.52400.553970.3406180.2782837.920.55400.64220.3506260.2793243.390.5830在這兩種條件下價(jià)值能夠得到提高，另外，濕潤(rùn)條件n的價(jià)值要比干燥條件n的價(jià)值低，直到磨損標(biāo)準(zhǔn)達(dá)到0.38以后，干燥條件的n開始大于濕潤(rùn)條件的 n。圖3-11B可以看出C在磨損標(biāo)準(zhǔn)所做的圖形中，在干和濕的條件下磨損標(biāo)準(zhǔn)提高時(shí) C也隨之提高。然而，濕的條件下C的價(jià)值要比干的條件下高。這證明在整個(gè)切削過程中通過使用冷卻液提高刀具的壽命和提高磨損標(biāo)準(zhǔn)都可以一直的保護(hù)切削刀具材料。接下來，圖3-12A描述了KC732材料在干和濕的條件下n與磨損標(biāo)準(zhǔn)之間的關(guān)系。磨損價(jià)值隨著n的提高而提高。此外，濕曲線要比干曲線高。圖3-12B描述的一個(gè)常數(shù)C和磨損價(jià)值的比例關(guān)系。然而，濕條件的C曲線比干條件下的曲線高，這表面對(duì)于材料KC732來說使用冷卻液是有益處的。更為重要的這有利于提高磨損標(biāo)準(zhǔn)。C的價(jià)值越高，刀具的使用壽命也就變的越高。圖3-13A表明冷卻液對(duì)刀具性能的影響。因此。n越高，刀具的使用壽命就越低。圖3-13B可以看出通過使用冷卻液和提高磨損價(jià)值可以降低C，這說明刀具在濕潤(rùn)的條件下，刀具的使用壽命比較短。之前研究的都是材料KC313和材料KC732，提高n就意味著刀具的壽命將被縮短。然而。大幅度的提高濕曲線C超過干曲線C的補(bǔ)償下降，KC313和KC732的使用壽命將延長(zhǎng)。與次相反。KC5010對(duì)此正好相反。圖3-14A和圖3-14B是沒有被碳包裹的情況（KC313）。他表面了在干和濕的切削條件下不同磨損標(biāo)準(zhǔn)的切削速度的價(jià)值的關(guān)系。（a） n與磨損標(biāo)準(zhǔn)為坐標(biāo)建立的關(guān)系圖（干和濕條件下）（b） C與磨損標(biāo)準(zhǔn)為坐標(biāo)建立的關(guān)系圖（干和濕條件下）圖3-11 KC313的以泰勒常數(shù)與磨損標(biāo)準(zhǔn)為坐標(biāo)建立的關(guān)系圖（a）n與磨損標(biāo)準(zhǔn)為坐標(biāo)建立的關(guān)系圖（干和濕條件下）(b) C與磨損標(biāo)準(zhǔn)為坐標(biāo)建立的關(guān)系圖（干和濕條件下）(a) n與磨損標(biāo)準(zhǔn)為坐標(biāo)建立的關(guān)系圖（干和濕條件下）(b) C與磨損標(biāo)準(zhǔn)為坐標(biāo)建立的關(guān)系圖（干和濕條件下）圖3-12 KC732的以泰勒常數(shù)與磨損標(biāo)準(zhǔn)為坐標(biāo)建立的關(guān)系圖（a）n與磨損標(biāo)準(zhǔn)為坐標(biāo)建立的關(guān)系圖（干和濕條件下）(b) C與磨損標(biāo)準(zhǔn)為坐標(biāo)建立的關(guān)系圖（干和濕條件下） (a) n與磨損標(biāo)準(zhǔn)為坐標(biāo)建立的關(guān)系圖（干和濕條件下）(b)C與磨損標(biāo)準(zhǔn)為坐標(biāo)建立的關(guān)系圖（干和濕條件下）圖3-13 KC5010的以泰勒常數(shù)與磨損標(biāo)準(zhǔn)為坐標(biāo)建立的關(guān)系圖（a）n與磨損標(biāo)準(zhǔn)為坐標(biāo)建立的關(guān)系圖（干和濕條件下）(b) C與磨損標(biāo)準(zhǔn)為坐標(biāo)建立的關(guān)系圖（干和濕條件下）.這兩個(gè)條件表明當(dāng)磨損標(biāo)準(zhǔn)增加的同時(shí)機(jī)床的成本下降。盡管如此，當(dāng)成本增加的速度達(dá)到再增加就叨叨最佳時(shí)。圖3-15A和圖3-15B是由磨損標(biāo)準(zhǔn)在（0.4-0.6毫米）時(shí)，干和濕條件下經(jīng)濟(jì)性的比較。干切削的最佳切削速度是90米/分而濕切削的最佳切削速度是120米/分。在圖3-16A和圖3-16B中列出了在干和濕的條件下含有KC732涂層的速度與成本的函數(shù)關(guān)系。再次，當(dāng)磨損標(biāo)準(zhǔn)增加的時(shí)候，成本下降。此外，干切削的最佳切削速度是260米/分，而濕切削的最佳切削速度是360米/分。這表面冷卻液對(duì)這種材料很重要，它不僅可以降低成本，而且還可以提高生產(chǎn)率。圖3-17A和圖3-17B概括了在干和濕的條件下，對(duì)涂有TIALN的材料KC5010的切削速度和成本之間的關(guān)系。當(dāng)切削速度提高時(shí)，切削成本也隨之提高，當(dāng)磨損標(biāo)準(zhǔn)提高，切削成本下降。在這兩種切削條件下，最佳的切削成本是在速度最低達(dá)到210米/分的時(shí)候。圖3-18A和圖3-18B描述的是在不同的磨損標(biāo)準(zhǔn)和不同的切削條件下KC732和KC5010的切削成本的比較。它可以明確地反映出對(duì)于KC732來說，冷卻液可以延長(zhǎng)刀具的壽命。切削速度從260米/分到360米/分為最佳的切削速度。不過，對(duì)于KC5010來說在高速加工的情況下冷卻液可以使它的刀具壽命降低而且使切削成本提高。從上面這些數(shù)據(jù)可以看出對(duì)于KC732來說，在速度為210米/分-310米/分的速度范圍內(nèi)干切削要比濕切削的經(jīng)濟(jì)效率高。當(dāng)速度達(dá)到310米/分是效率最高。對(duì)于切削材料KC5010來說在干條件下速度為210米/分時(shí)切削成本有效。因此，不管KC732的成本，它的磨損都遠(yuǎn)遠(yuǎn)的超過沒有處理的KC313和KC5010。表3-10總結(jié)了干和濕條件下的最佳切削速度和最佳的切削成本。圖3-19A和圖3-19B列出的是沒有經(jīng)過處理的KC313在干和濕的條件下，不同的切削速度下切削成本和磨損標(biāo)準(zhǔn)之間的關(guān)系。圖3-20A和圖3-20B列出了處理后的KC732在干和濕的條件下的磨損標(biāo)準(zhǔn)函數(shù)。圖3-21A和圖3-21B列除了KC5010在干和濕的條件下的磨損標(biāo)準(zhǔn)函數(shù)。曲線表面在切削速度相同的條件下，增加磨損標(biāo)準(zhǔn)，切削成本下降。在圖3-22A表明在濕的條件下改變KC313的性能要比在干的條件下改變其性能使刀具的壽命降低。在圖3-22B可以看出KC732和KC5010經(jīng)過表面處理后的結(jié)果和側(cè)面的磨損情況。這清楚的表明在濕潤(rùn)的條件下KC372表面涂TIN-TICN-TIN要比在干的條件下效果明顯。在濕的條件下對(duì)KC5010表面涂TIALN會(huì)減少它的刀具壽命。最后，KC732在所有條件下它的切削性能都要遠(yuǎn)遠(yuǎn)的超過KC5010。(a) 在不同磨損標(biāo)準(zhǔn)下，切削速度與成本的關(guān)系圖干切削條件下）(b) 在不同磨損標(biāo)準(zhǔn)下，切削速度與成本的關(guān)系圖（濕切削條件下）圖3-14 KC313的速度與切削成本的變化 （a）在不同磨損標(biāo)準(zhǔn)下，切削速度與成本的關(guān)系圖（干切削條件下） (b) 在不同磨損標(biāo)準(zhǔn)下，切削速度與成本的關(guān)系圖（濕切削條件下）(a) 在磨損標(biāo)準(zhǔn)為0.4毫米時(shí)，成本與切削速度的關(guān)系圖(b) 在磨損標(biāo)準(zhǔn)為0.6毫米時(shí)，成本與切削速度的關(guān)系圖圖3-15 以成本和速度為坐標(biāo)軸，在干和濕兩種情況下分別在兩種磨損標(biāo)準(zhǔn)下的比較。 （a）在磨損標(biāo)準(zhǔn)為0.4毫米時(shí)，成本與切削速度的關(guān)系圖 (b) 在磨損標(biāo)準(zhǔn)為0.6毫米時(shí)，成本與切削速度的關(guān)系圖(a) 在不同的磨損標(biāo)準(zhǔn)的情況下，切削速度和成本的關(guān)系圖（干條件下）(b)在不同的磨損標(biāo)準(zhǔn)的情況下，切削速度和成本的關(guān)系圖(濕條件下）圖3-16 KC732的切削速度和成本的關(guān)系圖 （a）在不同的磨損標(biāo)準(zhǔn)的情況下，切削速度和成本的關(guān)系圖（干條件下）(b) 在不同的磨損標(biāo)準(zhǔn)的情況下，切削速度和成本的關(guān)系圖（濕條件下）(a) 在不同的磨損標(biāo)準(zhǔn)的情況下，切削速度和成本的關(guān)系圖（干條件下）(b) 在不同的磨損標(biāo)準(zhǔn)的情況下，切削速度和成本的關(guān)系圖（濕條件下）圖3-17 KC5010的切削速度和成本的關(guān)系圖 （a）在不同的磨損標(biāo)準(zhǔn)的情況下，切削速度和成本的關(guān)系圖（干條件下）(b) 在不同的磨損標(biāo)準(zhǔn)的情況下，切削速度和成本的關(guān)系圖（濕條件下）(a)在磨損標(biāo)準(zhǔn)為0.4毫米的情況下，成本和速度的關(guān)系圖(b)在磨損標(biāo)準(zhǔn)為0.6毫米的情況下，成本和速度的關(guān)系圖圖3-18 在不同的磨損標(biāo)準(zhǔn)的情況下，對(duì)KC732和KC5010的切削成本的比較。（a）在磨損標(biāo)準(zhǔn)為0.4毫米的情況下，成本和速度做出的關(guān)系圖 (b) 在磨損標(biāo)準(zhǔn)為0.6毫米的情況下，成本和速度做出的關(guān)系圖表3-10 在相同的磨損標(biāo)準(zhǔn)時(shí)，三種刀具材料的比較刀具類型磨損標(biāo)準(zhǔn)(mm)最佳成本/ 速度(m/min)干濕KC3130.647$ /9040$/90KC50100.634$ /21036$/210KC7320.629$ /26028.84$/360(a)在不同的切削速度下，磨損標(biāo)準(zhǔn)與切削成本的關(guān)系圖（干條件下）(b)在不同的切削速度下，磨損標(biāo)準(zhǔn)與切削成本的關(guān)系圖（濕條件下）圖3-19 KC313 磨損標(biāo)準(zhǔn)和成本的關(guān)系圖（a）在不同的切削速度下，磨損標(biāo)準(zhǔn)與切削成本的關(guān)系圖（干條件下）(b) 在不同的切削速度下，磨損標(biāo)準(zhǔn)與切削成本的關(guān)系圖（濕條件下）(a) 在不同的切削速度下，磨損標(biāo)準(zhǔn)與切削成本的關(guān)系圖（干條件下）(b)在不同的切削速度下，磨損標(biāo)準(zhǔn)與切削成本的關(guān)系圖（濕條件下）圖3-20 KC732 磨損標(biāo)準(zhǔn)和成本的關(guān)系圖（a）在不同的切削速度下，磨損標(biāo)準(zhǔn)與切削成本的關(guān)系圖（干條件下）(b) 在不同的切削速度下，磨損標(biāo)準(zhǔn)與切削成本的關(guān)系圖（濕條件下）(a) 在不同的切削速度下，磨損標(biāo)準(zhǔn)與切削成本的關(guān)系圖（干條件下）(b) 在不同的切削速度下，磨損標(biāo)準(zhǔn)與切削成本的關(guān)系圖（濕條件下）圖3-21 KC5010 磨損標(biāo)準(zhǔn)和成本的變化圖 （a）在不同的切削速度下，磨損標(biāo)準(zhǔn)與切削成本的關(guān)系圖（干條件下）(b) 在不同的切削速度下，磨損標(biāo)準(zhǔn)與切削成本的關(guān)系圖（濕條件下）(a) KC313在磨損標(biāo)準(zhǔn)為0.4毫米的情況下刀具的壽命圖（干和濕）（b）在磨損標(biāo)準(zhǔn)為0.4毫米的情況下，KC732和KC5010的刀具壽命圖（干和濕）圖3-22 在磨損標(biāo)準(zhǔn)為0.4 毫米，干和濕條件下，刀具壽命的比較（a）KC313在磨損標(biāo)準(zhǔn)為0.4毫米的情況下刀具的壽命圖（干和濕）(b) 在磨損標(biāo)準(zhǔn)為0.4毫米的情況下，KC732和KC5010的刀具壽命圖（干和濕）在實(shí)驗(yàn)測(cè)試的速度范圍內(nèi)，分別在干和濕的情況下，對(duì)刀具材料重新進(jìn)行測(cè)試。結(jié)果提出了不經(jīng)過熱處理的KC313，表面涂有TIALN的KC5010和KC732。從圖3-23A和圖3-23B可以看出KC313在切削速度分別為100米/分、160米/分的情況下，理論和實(shí)驗(yàn)的結(jié)果。理論和實(shí)驗(yàn)結(jié)果的一致表明了泰勒公式在刀具壽命預(yù)言中是正確的。圖3-24A和圖3-24B表明KC5010在理論和實(shí)驗(yàn)中的結(jié)果，在速度為280米/分和速度為390米/分的情況下完全的一致被證明。KC732的理論和實(shí)驗(yàn)的數(shù)據(jù)在速度分別為280米/分和390米/分的情況下在圖3-25A和圖3-25B中被證明。本節(jié)介紹樣本結(jié)果與其他數(shù)字列入附錄。(a)速度為100米/分的情況下KC313理論和實(shí)驗(yàn)的關(guān)系圖(b)速度為160米/分的情況下KC313理論和實(shí)驗(yàn)的關(guān)系圖圖3-23 在不同速度的情況下KC313分別在干和濕時(shí)理論和實(shí)驗(yàn)的結(jié)果（a）速度為100米/分的情況下KC313理論和實(shí)驗(yàn)的關(guān)系圖 (b) 速度為160米/分的情況下KC313理論和實(shí)驗(yàn)的關(guān)系圖 (a)KC5010在速度為280米/分的情況下理論和實(shí)驗(yàn)的關(guān)系圖(b)KC5010在速度為390米/分的情況下理論和實(shí)驗(yàn)的關(guān)系圖圖3-24 KC5010在不同的速度情況下，分別在干和濕時(shí)理論和實(shí)驗(yàn)的關(guān)系（a）KC5010在速度為280米/分的情況下理論和實(shí)驗(yàn)的關(guān)系圖(b) KC5010在速度為390米/分的情況下理論和實(shí)驗(yàn)的關(guān)系圖(a)KC732在速度為280米/分時(shí)理論和實(shí)驗(yàn)的關(guān)系圖(b)KC732在速度為390米/分時(shí)理論和實(shí)驗(yàn)的關(guān)系圖圖3-25KC732在不同的速度情況下，分別在干和濕時(shí)理論和實(shí)驗(yàn)的關(guān)系（a）KC732在速度為280米/分時(shí)理論和實(shí)驗(yàn)的關(guān)系圖(b) KC732在速度為390米/分時(shí)理論和實(shí)驗(yàn)的關(guān)系圖附 錄II（外文原文）3.5 Testing of Tool Life CostMachining cost is the sum of the machine tool cost and the cutter cost. The machine cost consists of idle cost, machining cost, and tool changing cost. The machining cost decreases with increased cutting speed; while the idle cost remains constant with changes in cutting speed. From the machining data handbook 24 the generalized machining cost equation is listed below: In order to optimize the cutting condition, it is essential to determine the mathematical relationship between the cuttings inserts type and cutting speed. In our study Taylors model will be used in relating the cutting tool life to the cutting speed:VT =C 3-2V= cutting speedT= Cutting time to produce a standard amount of flank wear (e.g. 0.2mm) n and C are constants for the material or conditions used.In order to determine constants n and C for the cutting inserts under study in machining 4140 steel and the conditions used in the experiments, a LogV against LogT is drawn and shown for the three types of cutting inserts under study Figure 3-8A, Figure 3-8B are for KC313 under dry and wet conditions, Figure 3-9A, and Figure 3-9B are for KC732. In addition, Figure 3-10A, and Figure 3-10B are for KC5010. It can be seen from the aforementioned figures that in-spite of considerable scatter in test measurements, the results fall reasonably well on a straight line. From the curves it can be seen that for the same cutting speed the tool life increases by increasing the wear criterion and introduction of coolant emulsion for KC313 and KC732. However, as seen in KC5010 tool life increases by increasing the wear criterion and decreases by introducing coolant. This negative behavior of KC5010 toward coolant emulsion and the effect of wear mechanisms behind it will be covered in Chapter 5. As well as the wear kinds on other inserts investigated in this research.Metal cutting studies focused on tools wear, tool life, and wear mechanisms. However, future research should pay more attention to other factors as well:l Wear criterion value set up by the factory system, which basically the tool wear threshold value that suits the factory product.l Types of tools used, such as carbide tips and high speed tools. Studying the variation of tool life wear under dry and wet cutting that effect the tool life equation constants (C,n) is useful. This will improve tool life because it also affects the economy of cutting 24.In order to determine the effect of cutting fluid on the selected wear criterion, relationship between different wear criteria and machining cost for the cutting inserts under HSM must be studied. The value of the tool life constants (C,n) for different wear criteria are extracted and plotted within the ranges listed in table (3-7). The values of the constants (C, n) extracted from Figure 3-8A/B, Figure 3-9AIB, and Figure 3-10 are shown in tables 3-8 and 3-9. Further explanation of the relationship between these parameters and wear criteria will be covered through out the next figures. Figure 3-11A represents the relationship between n and wear criterion. As wear criterion increase n.(a) Log (time) versus Log (speed) at different wear criteria (dry condition).(b) Log (time) versus Log (speed) at different wear criteria (wet condition)Figure 3-8 Time versus speed at different wear criteria KC313. (a) Log (time) versus Log (speed) at different wear criteri(drycondition). (b) Log (time) versus Log (speed) at different wear criteria (wet condition).(a) Log (time) versus Log (speed) at different wear criteria (dry condition)(b) Log (time) versus Log (speed) at different wear criteria (wet condition).Figure 3-9 Time versus speed at different wear criteria KC732 (a)Log (time) versus Log(speed) at different wear criteria (dry condition), (b) Log (time) versus Log (speed) at different wear criteria (wet condition)(a) Log (time) versus Log (speed) at different wear criteria (dry condition).(b) Log (time) versus Log (speed) at different wear criteria (wet condition)Figure 3-10 Time versus speed at different wear criteria KC5010 (a) Log (time) versus Log(speed) at different wear criteria (dry condition), (b) Log (time) versus Log (speed) at different wear criteria (wet condition).Table 3-7 Ranges of plotted tool life constants.RangeCutting InsertCondition0 LogT 2.6KC313Dry0 Log T 4.1KC313Wet0 LogT 2.6KC5010Dry0 Log T 1.75KC5010Wet0 LogT 2.1KC732Dry0 Log T 2.4KC732WetTable 3-8 Wear Criteria versus C and n for three cutting inserts (Dry Condition).WearCriteria(mm)KC 313KC 5010KC732CnCnCnconstantconstantconstantconstantconstantconstant0.151420.2605180.2486300.2880.21650.2125600.2649640.3640.251960.2405960.27810990.3710.32380.2936050.27912330.3930.352500.2756120.27913990.4210.42630.2816250.28115030.4340.452820.2926250.27815170.4340.52920.2946300.27615770.4420.553020.2966320.27415920.4430.63130.3006380.27416110.444Table 3-9 Wear Criteria versus C and n for three cutting inserts (Wet Condition).KC 313KC 5010KC732Wear criterion(mm)CnCnCn0.151670.2014970.298881.0500.3320.21870.2106190.3101051.960.3530.252280.2406100.3121297.180.39300.32440.2506280.3091545.250.42400.352670.2606260.3001782.380.45400.42910.2806190.2901918.670.46800.453380.3106150.2822137.960.49100.53030.3106160.279 2477.420.52400.553970.3406180.2782837.920.55400.64220.3506260.2793243.390.5830values increase for both cutting conditions. In addition, n values for wet condition is lower than dry conditions up until wear criterion 0.38 after which n for wet starts to get bigger. Figure 3-11B shows C values versus wear criterion, and reveals C increases as the wear criterion increases for both dry and wet cutting. However, C values under wet condition are getting higher than under dry conditions. This proves the increase in tool life by introducing coolant emulsion and by increasing the wear criterion for this cutting tool material during cutting.Next, Figure 3-12A represents values of n with respect to wear criterion for KC732 material under dry and wet conditions. As the wear criteria increase n values increase. Furthermore, wear curve is higher than dry curve. Figure 3-12B presents a proportional relationship between constant C values and wear criterion. However, wet C curve is higher than dry curves, which indicates the benefit of using coolant emulsion for material KC732. This benefit becomes more essential by increasing the wear criterion. The higher the C value; the higher the tool life becomes. Figure 3-13A shows the effect of introducing coolant emulsion on cutting tool performance. Therefore, the higher n; the lower the tool life is. Figure 3-13B shows the drop in C values by increasing the wear criterion and coolant usage; thus indicating a shorter tool life in wet cutting condition. During the previous curves of KC313 and KC732 materials, the increase in n values was an indication off shortened tool life. However, the huge increase in wet C curves over dry C over compensated the drop and elongated tool life for KC313 and KC732. In contrast, the case is for KC5010. Figure 3-14A and Figure 3-14B are for uncoated cemented carbide (KC313). It shows the relationship between cost cutting speeds for different wear criteria under dry and wet cutting.(a) n values versus wear criterion (wet and dry).(b) C values versus wear criterion (wet and dry).Figure 3-11 Taylors constants for KC313 versus wear criteria,(a) n values versus wear criteria (wet and dry), (b) C values versus wear criteria (wet and dry).(a) n values versus wear criterion (wet and dry).(b) C values versus wear criterion (wet and dry).Figure 3-12 Taylors constants for KC732 versus wear criteria, (a) n values versus wear criteria (wet and dry), (b) C values versus wear criteria (wet and dry).(a) n values versus wear criterion (wet and dry). (b) C values versus wear criterion (wet and dry)Figure 3-13 Taylors constants for KC5010 versus wear criteria, (a) n values versus wear criteria (wet and dry), (b) C values versus wear criteria (wet and dry).Both conditions indicate as the wear criteria increases the machining cost decreases. Nonetheless, as the speed increases the cost reaches optimum value and then increases. Figure 3-15A and Figure 3-15B show economical comparison between dry and wet cutting at (0.4 and 0.6 mm) wear criterion. Optimum cutting speed for dry cutting is 90 m/min while 120 m/min is for wet cutting.Cost as a function of speed is presented in Figure 3-16A and Figure 3-16B for sandwich coating (KC732) under dry and wet conditions. Again, as wear criteria increases, cost decreases. Furthermore, the optimum speed of 260 m/min of dry cutting, increased to 360 m/min in cases of wet cutting. This indicates the importance of coolant with this material not only decreases cost but also increases productivity.Figure 3-17A and Figure 3-17B summarize the relationship of cost and speed for coated tools with TiALN (KC5010) under dry and wet cutting conditions. As the cutting speed increases the cost increases and as the wear criteria increases the cost decreases. The optimum cost was at the lowest speed (210 m/min) in both machining conditions.A cost comparison between KC732 and KC5010 at different wear criteria and machining conditions is presented in Figures 3-18A and 3-18B. It can be seen that KC732 responded positively to coolant in terms of extended tool life, and increased the optimum cutting speed from 260m/min to 360 nn/min. Nonetheless, coolant introduction to KC5010 at high speed cutting lowered the tool life and increased machining cost. The data presented in the aforementioned figures shows that dry cutting is more cost effective than wet cutting within speed range of 210 m/min-310 m/min for KC732 and vise versa at any speed higher than 310m/min. Cutting tool material KC5010 is cost effective at dry and 210 m/min. Therefore, in spite of the cost of the KC732; it is proven to be superior over KC313 (uncoated) and KC5010 in wear cost. Table 3-10 summarizes the optimum values of cost and speed under wet and dry cutting.Figures 3-19A, and 3-19B for KC313 (uncoated) show the relationship between costs and wear criterion at different cutting speeds under dry and wet conditions. Figure 3-20A, and Figure 3-20B are plotted for KC732 presenting cutting cost as a function of wear criteria for dry and wet conditions. Figure 3-21A and Figure 3-21B are plotted for KC5010. The curves show that for the same cutting velocity, by increases the selected wear criterion, the cost decreases.The improved performance of (KC313) under wet over dry cutting in terms off tool life is presented in Figure 3-22A. The results of the two coatings testing methods, of flank wear for the KC732 and KC5010 are shown in Figure 3-2B. Clearly this indicates improvement in cutting inserts life with TiN-TiCN-TiN coatings (KC732) under wet over dry cutting, and reduction in tool life of TiALN coating (KC5010) on wet cutting. Finally, KC732 provides superior performance under all cutting conditions over KC5010.(a) The variation of cost versus cutting speed at different wear criteria (dry ).(b) The variation of cost versus cutting speed at different wear criteria (wet).Figure 3-14 Cost variation with speed for KC313, (a) The variation of cost versus cutting speed at different wear criteria (dry), (b) The variation of cost versus cutting speed at different wear criteria (wet).(a) The variation of cost versus cutting s