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中國地質(zhì)大學長城學院畢業(yè)設計
外文資料翻譯譯文
從生態(tài)加工技術對攻絲的研究
摘 要
這項研究是關于攻螺紋（扭矩，攻絲，磨損，工作硬度等）的加工特性。在生態(tài)加工技術操作下，涂有TiN的MMC（鋁合金金屬復合材料）攻螺絲形成的攻絲得到了調(diào)查，并與沒有涂層的特性進行了比較。下面的結果就是從這份研究中得到的：1.TiN涂層攻絲的刀具壽命是沒有攻絲的四倍；2.有TiN涂層的攻絲形成的螺紋比沒有的加工硬化要低。
關鍵詞：攻絲； 攻螺絲； 螺紋； 生態(tài)加工； 鉆孔
1．引言
螺栓、螺釘機械連接中的螺紋是機械部件的最重要緊固系統(tǒng)之一。螺紋制造有很多種方法，特別攻螺絲是用來生產(chǎn)內(nèi)螺紋的有效的技術。
最近，每年都強調(diào)增加生產(chǎn)力。據(jù)說現(xiàn)在的車間里，最重要和最嚴重的問題是提高生產(chǎn)力。怎樣改善孔加工（鉆/鉸孔和攻絲）已成為一個嚴重的問題。傳統(tǒng)的刀具材料限制了生產(chǎn)力的提高，如高速鋼刀具加工鋁合金金屬復合材料（MMC）時刀具壽命很短由于碳化硅粒子的腐蝕天性。因此，刀具的磨損和破壞阻礙了生產(chǎn)力的提高。為了實現(xiàn)理想的生產(chǎn)力，攻絲已經(jīng)吸引了車間工程師的注意。
在這項研究中，用攻絲加工MMC，利用攻絲（扭矩，攻絲磨損，工作硬度等）的切割特點， 有TiN涂層和沒有涂層的都進行了調(diào)查。
2. 實驗方法
2.1實驗裝置
攻絲試驗在辛辛那提5’NC-MC (5HP)進行。該（鉆孔和攻絲） 儀器和數(shù)據(jù)采集系統(tǒng)如圖2.1。切削力（推力和扭矩）測定使用三個類型9273 壓電電力測功器和相應的場所用5007電荷放大器放大。得到的信號，然后傳遞到A / D轉(zhuǎn)換器AZI-16-12 ，連接到個人電腦。切削力測量安裝如圖2.2。
2.2工件，鉆及塔
在本實驗中使用的工件是鋁合金（2618 MMC）的增強，15％碳化硅顆粒。形成無槽絲錐的螺紋是M10如圖2.3和兩種類型的攻絲被用來在調(diào)查過程中。
攻絲的形狀類似于螺釘?shù)男螤睿∕10，孔距1.5），無論有沒有氮化鈦涂層。
定位孔的直徑9.3mm，用于所有試驗和聚晶金剛石攻絲鉆孔（高速鋼硬質(zhì)合金碳化鎢和聚晶金剛石鉆孔）用在所有測試。本實驗中用的鉆頭如圖2.4。
圖2.1 竊聽器和數(shù)據(jù)采集儀器 圖2.2 Schmatic圖?的竊聽系統(tǒng) 圖2.3 水龍頭用于這項工作
2.3儀表和檢測方法的線程
線程的估計是用螺紋規(guī)來衡量。結果被分為A等和B等[ 1 ]。硬鋁合金[ 2 ]螺紋深度是攻絲直徑的1.4倍。
甲等-質(zhì)量：直徑通過整個螺紋測量。
乙等-質(zhì)量：直徑至少15毫米。
圖2.5是顯示的直徑指標(M10×1.5 ISO 6H)。
2.4實驗特性
攻絲試驗時，切削速度（攻絲的轉(zhuǎn)速）是215 rpm和進給速度0.1mm/rev （322.5mm/min）。冷卻油（氯和硫免費熱切割石油）手動供應。
3.實驗結果與討論
在M10攻絲操作的推力和扭矩信號顯示在圖3.1 。結果表明，隨著螺紋扣數(shù)的形成，扭矩增大，離開孔時減小。然而，可以看到幾乎沒有推力的增加。
圖2.4 形狀的聚晶金剛石鉆頭 圖2.5 螺紋規(guī)
3.1轉(zhuǎn)矩比較
圖3.2顯示是先前所提到的有TiN涂層和沒有涂層的第1孔和第8孔攻絲的扭矩信號。
圖2.1 參數(shù)確定
圖3.1 圖切削力信號根據(jù)竊聽測試扭矩 圖3.2 比較扭矩信號（第1洞和第8洞）與扭矩
在攻絲操作的初始階段顯示推力和扭矩的增加。然而，當螺紋成形進入全速時，推力顯示出下降的趨勢伴隨著扭矩的增加和攻絲縮回，在螺紋孔口也可以看到負扭矩的出現(xiàn)。
圖3.1負推力值是攻絲偏離中心的結果是因為一方不正當?shù)墓ぜ?，刀具的安裝或定位空的表面粗糙度。 上述不確定的因素是定位孔的表面粗糙度。
當有TiN涂層第一孔的攻螺紋的攻絲扭矩值8.7 Nm而沒有涂層的值是11.2Nm，得到扭矩信號。因而，第一孔有涂層的相比沒有涂層的扭矩減少了28 ％。而對第8孔有TiN涂層的扭矩相比沒有涂層減少了52 ％。
初始階段和在攻絲突破點前扭矩信號的比較表明，沒有涂層的攻絲扭矩減少要明顯于有TiN涂層的攻絲?？梢哉f，就形成的攻絲而言，在車螺紋時工作是均勻分布在刮削端。扭矩的比較結果總結在圖3.3 。結果表明，有TiN涂層的攻絲扭矩一般低于那些沒有涂層的攻絲。
3.2螺紋形式的比較
有TiN涂層和沒有涂層的攻絲的螺紋形式如圖3.4 。在螺紋孔①，②，③ ，④位置的橫截面的放大圖像以及1，4，8號孔作了比較。
圖3.4是不同位置螺紋的照片模型，而圖3.5是八號孔放大的圖像。
可以從圖3.5 中看出，有TiN涂層攻絲形成的螺紋的側面① ②沒有異常。相反，沒有涂層表明孔的進口和出口相應的①號和④號位置無規(guī)律。
圖3.3 比較扭矩信號同類型 圖3.4 闡明的軸向截面建制線程
為了驗證上述的意見，對孔①和②進行詳細的分析進行。結果總結在圖3.6 。圖3.6（a）和（b）給出了1號和8號螺紋孔各自的①和②位置的結果?？梢杂^察圖3.6（a），有TiN涂層的攻絲齒形遠遠優(yōu)于沒有涂層的。
3.3比較加工硬化
當采用有TiN涂層和沒有涂層的攻絲車螺紋時，研究比較加工硬化的嚴重性。
本研究結果歸納于圖3.7 。選用了兩種類型中1號攻絲。
有TiN涂層和沒有涂層的結果分別在圖3.7（a）和（b）。用能受100 gw的硬度測量硬度儀測量硬度。
結果表明，有TiN涂層的攻螺紋的硬度低于沒有涂層的。上述結果表明，在以下幾個方面，如螺紋形式和加工硬化等，有TiN涂層的攻絲優(yōu)于沒有涂層的攻絲。
圖3.5 比較線程形式 圖3.6 比較擴大線程形式
3.4刀具壽命的比較
有TiN涂層和沒有涂層的攻絲被用來調(diào)查性能和攻絲的刀具壽命一樣高。每種類型的攻絲反復進行3次試驗，。結果總結在圖3.8 。
螺紋規(guī)讀數(shù)用A,B值評估。結果表明，在刀具壽命達到限制前，螺紋孔的平均數(shù)，是沒有TiN涂層攻絲的X = 13和有涂層攻絲的X = 49。有TiN涂層攻絲的刀具壽命是沒有涂層的3.8倍。
3.5比較塔磨損
圖3.9顯示各種類型攻絲的刀具磨損，在實驗中車螺紋后如圖3.8所示。應當指出的是，所有用于比較的攻絲已充分達到刀具壽命。有TiN涂層和沒有涂層的攻絲分別如圖3.9（a）和（b），?？梢钥闯?，所有攻絲的刀具磨損點。此外，可以看到大量的磨損在分界線上。有TiN涂層和沒有涂層攻絲的比較，如放大點，結果表明，后者的磨損明顯高于前者。就有TiN涂層攻絲來說，在刀具磨損區(qū)可以看到覆蓋的TiN涂層。
圖3.7 比較硬度分布
圖3.8 用攻絲的刀具壽命的比較 圖3.9 用攻絲的刀具磨損比較
4.結論
4.1有TiN涂層的刀具的壽命大約是沒有涂層的刀具壽命的4倍。
4.2和沒有TiN涂層的刀具相比，有涂層刀具的扭轉(zhuǎn)力下降了28 ％。
4.3和沒有TiN涂層的刀具相比，帶有涂層的齒形螺紋刀具則顯示出更少的不規(guī)則性。
4.4有TiN涂層的刀具的硬度低于沒有涂層的刀具。
4.5從以上結果顯示， 有TiN涂層的刀具在以下方面優(yōu)于沒有涂層的刀具：刀具壽命，螺紋樣式和加工硬化等。
參考文獻
[1] WOLFGANGSTRACHE : Alternative Strategies for the Production of Threads in Aluminum-based SIC
Reinforced Metal Matrix Composite (MMC) Alloy,1993.
[2] Beitz.W : Dubbel-Taschhenbuch fuer den Maschinenbau. ISBN 3-540-52381-2, (1990), G15.
外文原文
A Study on Tapping Viewed from Eco-Machining Technology
Abstract
This study deals with machining characteristics of thread tapping (torque, tap, wear, workhardness etc.) The tapping of MMC (aluminum alloy metal matrix composite) with TiN coated forming taps under eco-machining technology operation, where chips are not produced and ejected from the tap flute, was investigated and compared with the characteristics during uncoated tapping. The following results are obtained from this study. 1.The tool life of TiN coated taps was 4 times longer than that of uncoated tap；2.Threads formed with the TiN coated taps exhibit lower work hardening than those formed with uncoated taps.
Keywords: Tap； Tapping； Thread； Eco-Machining； Drilling
1. Introduction
Threads form the mechanical joint of a bolt–screw connection, which is one of the most important fastening systems for mechanical components. There are many ways of thread making, especially that of tapping which has been employed as an efficient technique for the production of internal threads.
Recently, the rise of productivity has been emphasized year by year. Also it is said that the improvement of productivity is one of the most important and serious problem in today’s machine shops. The improvement of hole making production (drilling/reaming and tapping) has become a serious matter. One factor limiting productivity gains has been that conventional tool materials such as HSS exhibit very short tool lives when machining an aluminum alloy metal matrix composite (MMC) due to the abrasive nature of the SiC particles. Therefore, the improvement has been obstructed by various problems as rapid tool wear and failure. As a mean of achieving the desired productivity gains, forming taps have caught the attention of machine shop engineers.
In this study, cutting characteristics of tapping (torque, taps wear, work hardness, etc.) during the tapping of MMC with forming taps, both TiN coated and uncoated was investigated.
2. Experimental Methods
2.1 Experimental Equipment
The tapping tests were conducted on a Cincinati 5’NC-MC (5HP). The (drilling and tapping) apparatus and data acquisition system are presented in Figure 2.1. The cutting forces (thrust and torque) were measured using a three component Kistler Type 9273 Piezo-electric dynamometer and the corresponding locus was amplified by a Kistler type 5007 charge amplifier. The signal obtained was then passed to a Towa A/D converter type AZI-16-12, connected to a personal computer. A schematic diagram of the cutting force measuring setup is presented in Figure 2.2.
2.2 Workpiece, Drill and Tap
The workpiece used in this experiment is aluminum alloy (2618 MMC) reinforced with 15 vol% silicon carbide (SiC) particulate. The thread forming fluteless taps were M10 as shown in Figure 2.3 and two types of taps were used during the course of the investigation.
The shape of the taps was similar to the shape of a screw (M10, Pitch:1.5), either uncoated or coated with Titanium nitride (TiN).
Pilot holes of 9.3mm diameter were used for all trials and PCD tipped drills (HSS cemented tungsten carbide and polycrystalline diamond drilling) were employed in all the tests. The shape of drill used in this test is shown in Figure 2.4.
2.3 Gauge and Inspection Method of Thread
The estimate of threads was performed with a thread gauge (Go-NoGo gauge).The results were classified as A and B quality[1]. Where, 1.4×tapped diameter is Diameter is the recommended depth of thread of hard Aluminum alloy[2].
A – quality : Gauge can be turned through the whole thread.
B – quality : Gauge can be turned in at least 15mm.
Figure 2.5 shows the appearance of gauge (M10×1.5 ISO 6H).
2.4 Experimental Characteristics
Tapping tests were conducted at a cutting speed (rotational speed of tap) of 215 rpm and feed rate of 0.1mm/rev (322.5mm/min). Coolant oil (Chlorine and sulphur free heat cutting oil) was supplied manually.
3. Experimental Results And Discussion
Cutting Forces in Tapping (thrust, torque) The thrust and torque signals produced in this tapping operation with a M10 tap are shown in Figure 3.1. The results show that torque increases with number of threads formed and decreases at the instant that the tap is about to break through the outlet of the hole. Whereas, little increase in thrust can be observed.
3.1 Comparison of Torque
Figure 3.2 shows torque signals of tap in the 1st hole and 8th holes for the TiN-coated and uncoated taps mentioned in the previous section.
At the initial stage of the tapping operation both thrust and torque show an increase in magnitude. However, when the thread forming operation enters full gear, the thrust force shows a decreasing trend accompanied with in increase in torque and as the tap retracts after breakthrough, a negative torque of 5N magnitude can be observed across a few threads at hole outlet.
The negative thrust value observed in Figure 3.1 is the outcome of the deflection of the tap from the center due to either improper workpiece, tool setup or poor finish of the pilot holes. The inconclusive results observed above led to the investigating of the factors responsible for the poor finish of the pilot holes.
The torque signals derived while threading taps for the 1st hole show tapping torque values of 8.7 Nm for the TiN coated tap and11.2 Nm for the uncoated and tap respectively. Thus, for the 1st hole, the TiN coated tap exhibits a 28% reduction in torque compared to the uncoated tap. While for the 8th hole the reduction in torque for the TiN coated tap is approximately 52% as compared to uncoated tap.
Comparison of the torque signals at the initial phase and prior to breakthrough of the taps shows that the uncoated tap exhibits a sharper decrease in torque than the TiN coated tap. It can be said that, in the case of forming taps, work is evenly distributed at the scrape point during threading. A comparison of the torque results is summarized in Figure 3.3. Results indicate that tapping torque of the TiN coated tap is generally lower than those of the un-coated tap.
3.2 Comparison of Thread Forms
The thread forms for the TiN coated and uncoated taps are shown in Figure 3.4. Magnified images of the axial cross-section of the formed threads at position No.①,②③ and ④ in holes and 1.4 and 8 were used in the comparison.
Figure 3.4 is a model of the photographed threads at the various positions, while Figure 3.5 shows magnified images for hole No.8
As it can be seen from Figure 3.5, the thread profile at position No.① to ② of threads formed with the TiN coated tap show no abnormalities. On the contrary, with the uncoatedtaps the root shows irregularities at position No.① and ④ corresponding to the hole inlet and outlet.
In order to validate the observations mentioned above, a detailed analysis was performed on holes No.① and ②. Results are summarized in Figure 3.6. Figure 3.6(a) and (b) give results for hole No.① and 8 at thread position No.① and ② respectively. As it can be observed in Figure 3.6(a), the tooth profile of the TiN coated is far superior to the uncoated tap.
3.3 Comparison of Work Hardening
A comparative study was performed to investigate the magnitude of work hardening when using the TiN coated and uncoated taps to form threads.
Results of this study are summarized in Figure 3.7. Tap No.1 of both tap types were used. Results for the TiN coated and uncoated tap are given in Figure 3.7(a) and (b) respectively. Hardness was measured on a hardness tester loaded with a 100 gw.
The results show that the hardness of the TiN coated tapping thread is lower than the
uncoated tapping thread. The above results show that the TiN coated tap is superior to the uncoated tap in the following aspects, thread form and work hardening etc,.
3.4Comparison of Tool Life
The TiN coated and uncoated taps were used to investigate the performance level with respect to tool life of taps. Tests were repeatedly performed three times with each type of tap. The results are summarized in Figure 3.8.
Thread gauge readings were evaluated using A, B values. The results indicate that the average number of thread holes before tool life limit is reached are uncoated X =13 and TiN coated tap X =49 hole tap. The tool life of the TiN coated tap is 3.8 times longer than that of uncoated tap.
3.5 Comparison of Tap Wear
Figure 3.9 shows the tool wear of the various taps after threading in the experiments indicated in Figure 3.8. It should be noted that all the taps used for this comparison have already attained full tool life. TiN coated and uncoated taps are shown in Figure 3.9(a) and (b), respectively. It can be seen that the point of all the taps show tool wear. In addition, extensive wear can be observed at the boundary between the full thread form with the chamfer thread run-out of same 3～5 threads from the scrape point. A comparison of the TiN coated and the uncoated tap, as exemplified by the magnified point, shows that wear of the latter is more pronounced than the former. In the case of the TiN coated tap, an overlay of TiN coating can be observed at the tool wear zone.
4. Conclusions
4.1The tool life of the TiN coated tap was approximately 4 times longer than that of the uncoated tap.
4.2The TiN coated tap (for the 1st hole) exhibits 28% reduction in torque compared to the uncoated tap.
4.3The tooth profile of the thread produced by the TiN coated tap shows fewer irregularities than for the uncoated tap.
4.4 The hardness of the TiN coated tapping thread is lower than the uncoated tapping thread.
4.5From the above results, the TiN coated tap is superior to the uncoated tap in the following aspects, tool life, thread forms and work hardening etc,.
References
[1] WOLFGANGSTRACHE : Alternative Strategies for the Production of Threads in Aluminum-based SIC Reinforced Metal
Matrix Composite (MMC) Alloy,1993.
[2] Beitz.W : Dubbel-Taschhenbuch fuer den Maschinenbau. ISBN 3-540-52381-2, (1990), G15.
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