航空機アルミ部品加工における逐次乳化形切削液供給システムの実用可能性(機械要素,潤滑,工作,生産管理など)

概要

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It is an urgent subject to reduce environmental burden in manufacturing processes. In a machining process, although an MQL (Minimal Quantity Lubrication) system has been utilized in the past few years, its application to aluminum alloy machining is difficult because of its cooling capability. To overcome this obstacle, we developed an S.S.E. (Supersonic Emulsification) system which uses a water soluble cutting liquid for semi-dry machining. By applying supersonic O/W emulsification just before the supply to cutting point, we were able to create an O/W emulsion without using an emulsifier which has a high environmental burden. One of the advantages of this process is to create emulsion with only using a very small amount of energy. Another is ease of retrofitting conventional machine tools with this system. When performing a cutting test using this S.S.E for semi-dry machining the cutting force was reduced by 15% compared to that by using the conventional "flood type emulsion machining". This could bring out approximately 4% reduction in power consumption for axis rotation. In a feasibility cutting test for machining air craft parts could also observe 2.3〜5.4% reduction in power consumption. The required quality of the machined part was also maintained. Finally, when using a 10% Rape Seed Emulsion supplied at 12ml/min, 30% reduction in oil cost could be achieved.
2006-05-25