直接加熱轉(zhuǎn)筒式干燥機設(shè)計

直接加熱轉(zhuǎn)筒式干燥機設(shè)計,直接加熱轉(zhuǎn)筒式干燥機設(shè)計,直接,加熱,轉(zhuǎn)筒式,干燥機,設(shè)計 第 V 頁 鞍山科技大學(xué)本科生畢業(yè)設(shè)計（論文） 直接加熱轉(zhuǎn)筒式干燥機 摘 要 時代在發(fā)展，人類在進步。環(huán)境保護已經(jīng)越來越多的被人們所重視。解決煤燃燒產(chǎn)生的大氣污染問題是目前一個很重要也很緊迫的問題，隨著人類對煤的研究，發(fā)現(xiàn)原煤和生物量的混合物燃燒后幾乎不含有污染性氣體。本設(shè)計的目的是為無污染生物煤的生產(chǎn)提供低成本的原煤干燥設(shè)備，為生物煤的推廣打下堅實的基礎(chǔ)，同時也為環(huán)保事業(yè)做出貢獻(xiàn)。 本設(shè)計采用如下方案：采用轉(zhuǎn)筒式，直接傳熱方式，主要靠對流傳熱，采取并流操作，使用高溫?zé)煹罋庾鳛檩d體。由一般異步電動機，圓柱齒輪減速器和齒輪齒圈傳動組成動力傳動裝置。由重油燃燒產(chǎn)生煙道氣，石棉做保溫層，尾氣除塵設(shè)備選擇旋風(fēng)分離器。物料進、出傳送均采用皮帶傳輸機。密封方式頸向迷宮式密封。 在設(shè)計任務(wù)給定后，確定了設(shè)計所需的基本參數(shù)。進行了物料衡算和熱量衡算，解決了需要消耗多少干燥介質(zhì)和熱量的問題。依據(jù)物料衡算和熱量衡算的結(jié)果計算并確定了設(shè)備的規(guī)格參數(shù)。對干燥設(shè)備作了結(jié)構(gòu)設(shè)計的詳細(xì)計算和必要的強度校核。并選擇配套的附屬裝置，如物料的傳輸方式選擇、熱風(fēng)系統(tǒng)加熱方式選擇、引風(fēng)機選型等，更加完善了設(shè)計的完整性。 關(guān) 鍵 詞：直接傳熱，轉(zhuǎn)筒式，干燥，原煤 Direct heating transfers the cylinder drying machine Abstract As the time going ,the environmental protection is getting more and more important in the new century. The output of coal burns is one kind of the things that course the environments pollution. However, scientists find that the output of the mixture burns ,which is the raw coal and creature s mixture, hardly doesnt contains pollutions. The purpose of this design is to study out one kind of dry equipments for raw coal, which makes the first step from the raw coal to creature coal. This design adopted the tube type dehydrator ,and transmitting heat directly by the main way of convection .and in this design adopted the parallel flow operation ,used the heat flue gas to carry the heat .the general asynchronous motor, cylinder gear speed reducer and tooth ring transmission composite the power transmission apparatus .the bure of the heavy oil create the flue gas and the heat preservation lamella is made by asbestos .the same time tornado separator can remove the dust tail gases. The strap delivers, machine carries out the in and out transmissions of the material. The seal method is diameter faces the maze type seal. After the design mission given ,I made out all the data that must be compute out. To resole the problem how much medium for dry and the calorific value would be consumed, I have done the material calculates and the sum calorific value calculates. And according them I work out the specification parameter of the equipment. And more I have made some additional deal design, such as hot blast system and the breeze machine etc ,which made the design more perfect the complete. Key Words:Transmit heat directly , cylinder ,Dry , Raw coal 目 錄 1 緒論……………………………………………………………………………………1 1.1干燥技術(shù)的概況………………………………………………………………1 1.2干燥技術(shù)發(fā)展的總趨勢………………………………………………………2 1.3干燥器的分類和選型…………………………………………………………3 1.3.1干燥器的分類…………………………………………………………3 1.3.2干燥器的選型…………………………………………………………3 1.4回轉(zhuǎn)圓筒干燥器的特性………………………………………………………4 1.5回轉(zhuǎn)圓筒干燥器在工業(yè)上的應(yīng)用……………………………………………5 1.6回轉(zhuǎn)圓筒干燥器的設(shè)計概論…………………………………………………5 2 設(shè)計初始參數(shù)的確定…………………………………………………………………7 2.1已知參數(shù)………………………………………………………………………7 2.2其他所需參數(shù)的確定…………………………………………………………7 2.2.1并流適用于下列物料的干燥…………………………………………7 2.2.2逆流方式適用于下列物料……………………………………………7 2.3混合氣的參數(shù)計算……………………………………………………………12 3 物料衡算和熱量衡算…………………………………………………………………14 3.1水分蒸發(fā)量……………………………………………………………………14 3.2空氣消耗量……………………………………………………………………14 4 設(shè)備規(guī)格參數(shù)的設(shè)計和確定…………………………………………………………16 4.1筒體直徑………………………………………………………………………16 4.2容積散熱系數(shù)…………………………………………………………………16 4.3筒體長度………………………………………………………………………16 4.3.1預(yù)熱段長度……………………………………………………………16 4.3.2蒸發(fā)段長度……………………………………………………………18 4.3.3加熱段長度……………………………………………………………18 4.4轉(zhuǎn)筒得轉(zhuǎn)速喝傾斜度得選擇…………………………………………………19 4.4.1轉(zhuǎn)速……………………………………………………………………19 4.4.2筒體地斜度……………………………………………………………19 4.5停留時間………………………………………………………………………19 4.6填充系數(shù)………………………………………………………………………20 4.7熱風(fēng)系統(tǒng)加熱形式的選擇……………………………………………………21 4.8鼓風(fēng)機或引風(fēng)機的選型………………………………………………………21 4.9旋風(fēng)分離器和進、出料裝置…………………………………………………22 5 回轉(zhuǎn)圓筒干燥器的結(jié)構(gòu)設(shè)計與計算…………………………………………………24 5.1筒體設(shè)計………………………………………………………………………24 　　　 5.1.1筒體結(jié)構(gòu)組成…………………………………………………………24 　　　5.1.2筒體載荷計算…………………………………………………………29 　　 5.1.3筒體彎矩與應(yīng)力計算…………………………………………………32 　　　5.1.4筒體變形計算…………………………………………………………35 5.2滾圈設(shè)計………………………………………………………………………38 5.2.1滾圈的結(jié)構(gòu)型式………………………………………………………38 5.2.2滾圈的設(shè)計與計算……………………………………………………39 5.3托輪及軸承設(shè)計………………………………………………………………41 　 　　5.3.1結(jié)構(gòu)設(shè)計………………………………………………………………41 　　　5.3.2托輪及軸承的計算……………………………………………………42 5.4擋輪及軸的設(shè)計………………………………………………………………46 5.4.1擋輪……………………………………………………………………46 5.4.2擋輪受力………………………………………………………………46 5.4.3擋輪參數(shù)的確定………………………………………………………47 5.4.4擋輪軸及軸承的選擇…………………………………………………48 5.5傳動裝置的確定設(shè)計依據(jù)……………………………………………………49 　　 5.5.1電動機選型……………………………………………………………49 5.5.2齒輪配置………………………………………………………………49 5.5.3傳動裝置計算…………………………………………………………50 5.6減速器的選型…………………………………………………………………53 　　 5.6.1按強度選用減速器……………………………………………………53 　　 5.6.2校核熱功率……………………………………………………………53 5.7聯(lián)軸器的選型…………………………………………………………………54 5.7.1聯(lián)軸器的計算轉(zhuǎn)矩……………………………………………………54 5.7.2聯(lián)軸器的工作轉(zhuǎn)速……………………………………………………54 5.7.3軸孔直徑………………………………………………………………54 5.8進、出料端設(shè)計………………………………………………………………54 6 回轉(zhuǎn)圓筒干燥器的密封………………………………………………………………56 7 回轉(zhuǎn)圓筒干燥器的安裝、調(diào)整和運轉(zhuǎn)………………………………………………57 8 經(jīng)濟性分析……………………………………………………………………………58 結(jié)論與思考……………………………………………………………………………60 致謝……………………………………………………………………………………61 參考文獻(xiàn)………………………………………………………………………………62 第 3 頁 鞍山科技大學(xué)本科生畢業(yè)設(shè)計（論文） 轉(zhuǎn)筒式干燥機結(jié)構(gòu)改進 鞍山科技大學(xué)機械工程及其自動化機械設(shè)計02.3 吳大永 摘要 本文介紹了對老式干燥機密封結(jié)構(gòu)進行的幾項技術(shù)改造，并與國內(nèi)使用的同類型干燥設(shè)備進行了對比。改進后的干燥機應(yīng)用應(yīng)該較為廣泛并且不因該發(fā)生漏料現(xiàn)象。 工作原理： 濕物料由皮帶運輸機或斗式提升機送到料斗，由進料口加入。轉(zhuǎn)筒干燥器主體是略帶傾斜并能回轉(zhuǎn)的筒圓體。物料進入圓筒內(nèi)部時，與通過筒內(nèi)的熱風(fēng)成順流接觸或逆流或與加熱壁面進行有效接觸而被干燥，干燥后產(chǎn)品從另一端下部出料。在干燥過程中，物料借助于圓筒的緩慢轉(zhuǎn)動，在重力作用下從高的一端向較低一端移動。筒體內(nèi)壁上裝有順向抄板，它不斷把物料抄起又灑下，使物料的熱接觸面大大增強，提高了干燥速度率并促使物料向前移動。熱載體（熱空氣、煙道氣）干燥物料后，通過旋風(fēng)除塵器收集其夾帶的粉塵后排空。 產(chǎn)品特點： （1）生產(chǎn)能力大，可連續(xù)操作； （2）結(jié)構(gòu)簡單，故障少，操作方便，維修費用低，運行穩(wěn)定； （3）適用范圍廣，可干燥粉狀、顆粒狀、條、塊狀物料、操作彈性大，生產(chǎn)上允許產(chǎn)品產(chǎn)量有較大波動，而不影響產(chǎn)品的質(zhì)量； （4）設(shè)備龐大，安裝、拆卸困難 熱容量系數(shù)小，熱效率相對較低（但蒸汽管式轉(zhuǎn)筒干燥器熱效率較高）。 關(guān)鍵詞：干燥設(shè)備，技術(shù)改造 具資料，大慶30萬噸/年乙烯工程高密度聚乙烯裝置的兩臺間接式干燥機（筒體外徑φ2400mm，筒體長21000mm），具資料記載，系由日本三井造船玉野工廠1981年制造。該機經(jīng)過一年零五個月的運行，從未發(fā)生漏料現(xiàn)象。其主要原因是日方對該機的密封結(jié)構(gòu)進行了幾項技術(shù)改造。本文將該設(shè)備與國內(nèi)幾家工廠使用的同類型干燥機進行比較，以分析其密封性能得到改善的主要原因。并進一步進行設(shè)備完善。 常用的間接式轉(zhuǎn)筒式干燥機，它的主要部件為一個與水平線略成傾斜旋轉(zhuǎn)圓筒。這種結(jié)構(gòu)的干燥機的出料箱密封處尺寸很大（與筒體外徑相等），密封不可靠。填料的使用壽命不足一年，長因漏料而被迫停車檢修。北京一家名為燕山石化公司長征化工廠從聯(lián)邦德國兩臺干燥機即屬同類型機。 老式干燥機結(jié)構(gòu)示意圖見圖1。本文在其基礎(chǔ)上對其密封結(jié)構(gòu)做了如下改進： 1、出料的改進 由于轉(zhuǎn)筒的旋轉(zhuǎn)和重力的作用，轉(zhuǎn)筒底部的物料（見圖1）隨徑向葉片一起旋轉(zhuǎn)，當(dāng)上升到轉(zhuǎn)筒上半部后便滑向反向螺旋葉片，經(jīng)反向螺旋葉片止逆之后，連續(xù)均勻的排出物料箱。由于物料不是從轉(zhuǎn)筒底部排出，從而密封尺寸大大減?。ū緳C密封尺寸縮小到φ1150），使密封可靠性大大增加。 2、出料箱支承的改進 如圖1所示，出料箱和轉(zhuǎn)筒之間設(shè)有大型滾動軸承出料箱的另一側(cè)則采用彈簧支撐，彈簧的固定為鉸支連接，以保證筒體的伸縮這樣轉(zhuǎn)筒在懸轉(zhuǎn)過程中，密封填料的兩側(cè)接觸面相對偏心較小，所以密封就比較容易。另外，與出料箱相連的所有管線均采用撓性管，以減小管線對出料箱的作用力。具資料，上海石化中廠滌綸二廠的兩臺干燥器與本文的尺寸基本相同，本文干燥機除未采用大型滾動軸承外。其余結(jié)構(gòu)、操作參數(shù)基本與日方基本相同，所以密封效果較日方的能更理想一些。密封性會更強。 3、密封填料的改進 通常，往復(fù)運動的密封采用V型填料。該填料除具有密封作用外，還具有抗震動力強、容易安裝、壽命長和兩密封面相對偏心要求不嚴(yán)等優(yōu)點。因本廠干燥機轉(zhuǎn)速低（0.21rad/s），故能獲得良好的密封效果。然而V型填料的摩擦阻力大，還需采用如下改進措施：⑴在密封的外環(huán)和第二環(huán)之間加入潤滑脂，每兩個月補充一次；⑵出料箱與填料接觸的環(huán)面噴3/100mm的鍍鉻層，以減小摩擦阻力；⑶在填充的支承環(huán)處加氮氣（0.29Mpa）沖洗，以免粉料進入V型填料內(nèi)，同時也加強了填料的自封作用（筒內(nèi)壓力0.0049Mpa），這也是實現(xiàn)密封的重要措施之一。另外為使V型填料始終保持一定的預(yù)緊力，還在填料壓蓋處有補償彈簧，見圖2。 同樣，對進料處也進行了上述（2、3項）改進。本文研制的兩臺轉(zhuǎn)筒式干燥機，由于進行了上述改造，基本解決了該設(shè)備的密封問題，從而充分發(fā)揮了這一老式干燥機的生產(chǎn)能力 第15頁 鞍山科技大學(xué)本科生畢業(yè)設(shè)計（論文） 附錄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 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 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 10"5 Pa 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) 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 < Vc < 100 m/min, e.g. (i = 0.8. For Vc > 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. 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 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 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. 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: aizawa@odin.hpm.rcast.u-tokyo.ac.jp. Mail address: 4-6-1 Komaba, Tokyo 153-8904, Japan. Tel & Fax: +81-3-5452-5116 材 料 沙 的 加 熱 處 理 2004年10月 經(jīng)氯離子注入進行機械干燥機工具設(shè)計 Tatsuhiko Aizawa1, Atsushi Mitsuo2, Shigeo Yamamoto2, Shinji Muraishi3, Taro Sumitomo1 1. 合作研究中心、位于日本東京的東京大學(xué) 2. 位于日本東京的東京工業(yè)研究所 3. 位于日本東京的東京技術(shù)學(xué)院，材料科學(xué)技術(shù)系 摘要:干燥機已成為一個關(guān)鍵問題,它可大大減少潤滑油及清潔劑使用過程中所產(chǎn)生的廢物，并提高醫(yī)療及食品應(yīng)用方面特殊工具的環(huán)保意識。 由于工具和金屬產(chǎn)品在干燥條件下直接接觸，機器嚴(yán)重受損，即使具有良好的保護涂層也會被氧化。自動注油機械原理使用lubricous氧化機制是對干燥機行之有效的處理。 通過將氯離子注入工具，在工具表面形成鈦氧化合物的保護層。這一氧化物毀壞ELAS，形成塑膠，即使在高速切割的條件下，配戴量及摩擦系數(shù)都會大大減少。 關(guān)鍵詞：干燥機，氯離子注入，自動注油，鑄工具，錫涂層，TICN涂層 機械干燥是一個關(guān)鍵詞,在21世紀(jì), 對于制造業(yè)生產(chǎn)科學(xué)是一個關(guān)鍵詞。必須大幅度減少環(huán)境負(fù)擔(dān),Cqi放射物11在現(xiàn)代高速潮濕和半干燥機械運轉(zhuǎn)過程中，清洗劑、潤滑油在日常生產(chǎn)中巨額浪費。各提案旨在機械干燥, Tribo-Filrns的原址形成重要概念在于必須使用干燥機工具。 作者指出,in-situ的重要作用在于形成lubricious氧化物以減少摩擦及配戴量。自動注油原理在于將氯離子注入到鈦材料、鈦陶瓷中。 本文自動注油將氯離子注入應(yīng)用于機械干燥。 利用各種工具和材料,了解干燥機械以設(shè)計出高速切削工具。 對于水泥碳化物為基礎(chǔ)的干燥機,只有減少摩擦,才能實現(xiàn)自動注油過程。 具有CL-植入陶瓷保護層的工具，即使在高切削速度范圍也可大大減少摩擦。 1. 干燥工具的機械設(shè)計 （曾在1910年至1911年討論）,兩次關(guān)鍵項目必須考慮干切削工具設(shè)計。 首先,工具的表面涂層或保護區(qū)將改成lubricous薄膜——單一氧化物薄膜。當(dāng)在表面形成鈦的單一氧化物薄膜，在高壓正常切割條件下，通過塑料變形，實現(xiàn)低摩擦低損耗。此外,單一鈦氧化物在干燥切割過程中被轉(zhuǎn)化成中級氧化物或氧化物Magneli。這些薄膜也有氧化塑料變形的潛能,使低摩擦, 即使提高切割速度，也可保持低摩擦低損耗。 為了實現(xiàn)上述的自動注油過程，必須有足夠的可供選擇的工具和材料，同時優(yōu)化氯離子注入條件。 其次,優(yōu)化刀具形狀不僅減少摩擦及損耗,而且延長工具的使用壽命。 很難描述干燥機中各工件的相互聯(lián)系。工具表面形狀優(yōu)化還是依靠技術(shù).可以利用Tribo片涂層減少形狀優(yōu)化上的困難。因為Tribo形成于切割邊緣附近，所以刀具形狀略有修改就可以實現(xiàn)干燥狀態(tài)下高速切割。 原址基礎(chǔ)組建鈦氧化物tribofilms需要鈦原料在干燥機中通過tribo化學(xué)物的表面反應(yīng)產(chǎn)生氧化物。一是煉鋼中的鈦。后面會加以解釋。由于鈦用于非氧化過程,它的carbides作為工作材料被分配。 另一種是列入工具材料中的鈦基陶瓷材料。通常包括靜態(tài)碳化物工具。錫是典型的作為切割工具陶瓷保護涂層薄膜的成分。（曾在1911年至1913年被討論）,前者鈦源往往對于控制在工具表面上形成的低摩擦薄膜起著非常重要的作用。 2. 實驗程序 如何準(zhǔn)備工具及工作材料,如何解釋,以及氯植入試驗. 2.1準(zhǔn)備工具 擲掉膠結(jié)碳化物工具被選為樣本。 在磨損表面，他們沒有芯片破裂而形成的三角形。這兩種形式與P10和P30膠結(jié)碳化物被當(dāng)作單純的工具材料。 為了調(diào)查陶瓷保護涂層在機器加工改進方面的效果，TICN涂層替代錫層和Tic層作為多面超薄型被儲存。此點在后面的膠結(jié)碳化物P10型號中將被提到。 請注意 TiC應(yīng)固定于水泥涂抹層carbides中。 2.2氯植入 圖表1對氯離子注入切割工具過程進行了描述。 工具標(biāo)本被裝在一個目標(biāo)操作中，并通過氯離子束的掃描。 離子束在自由離子源中由a1c13Freeman產(chǎn)生，通過蒸發(fā)器進行大量的收集產(chǎn)生單一的容易控制的氯離子束。氯離子劑量經(jīng)常是ions/cm21.0X1017100，具有100keV的移入能源。氯離子植入到樣本側(cè)面和邊緣。 這一角度被正常的固定在工具表面，移入過程中，控制真空低于210X"5PA。 加熱離子束,束密度目前只限于 0.03-0.05A/m2全過程. 圖表1:氯離子注入切割工具。 2.3轉(zhuǎn)數(shù)測試 測驗用于對干燥機加工能力的評定。切割的深度及強度都是固定不變的：深度為1.0毫米，強度為0.1毫米 / 轉(zhuǎn)，切割速度范圍為10米 / 分至500米 / 分。圖2說明工件和工具間的機械內(nèi)部運作。車床裝有傳感器，可準(zhǔn)確測量出化學(xué)反應(yīng)及強度。兩種磨損表面在試驗中被觀察：側(cè)翼寬(VB)和坑口寬（KT）。 s45c型號的鋼鐵，通過加入鈦進行非氧化處理后用于做工具材料。其主要化學(xué)成份是0.44mass%C、0.34mass%Si, 0.80mass% Mn及0.01mass%Ti, 氧含量被控制在0.0011 mass %，其他成分磷、硫、銅、鎳、鉻被控制在低于0.001mass% 。 2.4定性 首次用激光顯微鏡觀察工具表面Tribo薄膜的形成. 工具表面各氧化物的形成通過EDS (能量色散光譜)進行對照觀察。 圖表 2:該轉(zhuǎn)數(shù)測試中工件及工具間的機械互動。 3. 針對基本的鑄工具和TICN鍍鑄工具實驗結(jié)果及討論內(nèi)容，調(diào)查干燥機氯離子注入工具材料的效果。 3.1基本鑄工具的氯離子注入 試驗中，F(xiàn)c和Fs被測試用以估計摩擦系數(shù)。 圖3將基本的鑄工具及注入氯離子的鑄工具進行對比，展示了經(jīng)提升的切割速度（Vc）?；镜蔫T工具的摩擦系數(shù)(U)界于40米 / 分和100米 / 分之間。例如 (I=0.8. Vc 大于100米 / 分時，Vc將穩(wěn)定下降。而注入氯離子的鑄工具Vc=300米 / 分 時達(dá)到最低速。例如,i=0.58而^ = 0.65為基本的鑄工具。高速切割范圍內(nèi)的較低摩擦系數(shù)可通過如今的氯離子注入方法實現(xiàn)。 3.2 氯離子注入到TICN涂層 在鈦的軸承工作試驗中,自動注油過程較高的切割速度狀態(tài)下進行。鈦氧化物的保護膜很難在工具材料上形成。由于鈦數(shù)量來源少。 另一方面,經(jīng)氯離子注入的陶瓷涂層鈦表面卻容易形成保護膜,像TICN。在CL-植入到TICN鍍工具的情況下，自動注油過程可以在所有切削速度中很好的工作. 圖表3: 基本的鑄工具與注入氯離子的鑄工具之間摩擦系數(shù)的對比 圖4對切割了500米長度后的TICN涂層及注入氯離子TICN涂層的鑄工具在各種切割速度下側(cè)面磨損寬度進行對比。通過氯離子注入TICN涂層可大大減少側(cè)面磨損。Vc>300 米 / 分時，側(cè)面磨損將提供給TICN鍍鑄工具更多的Vc。干燥狀態(tài)下較高的切割速度，TICN涂層將會發(fā)生嚴(yán)重的氧化。而對于氯注入的TICN鑄工具，隨著切割速度的提高，側(cè)面磨損僅僅增加了其長度。尤其VB=55Jim, 在切割速度Vc=500米 / 分， 切割長度為500米。 圖表 4: TICN涂層及注入氯離子TICN涂層的鑄工具之間側(cè)面磨損度的對比 3.3形成Tribo薄膜 即使在較高切割速度下，側(cè)面磨損的大幅度減小很好的證明了自動注油過程在鈦氧化物薄膜上很有效的發(fā)揮了其作用。 圖表5顯示了在Vc=400米 / 分，切割長度達(dá)500米狀態(tài)后注入氯離子TICN的側(cè)表面的微觀結(jié)構(gòu)。側(cè)翼表面的切割邊緣表面形成薄膜。理論上, Belag可作為工具的保護層使用。一般來講，該類保護膜包括多種氧化物；工具的部分金屬成分在相對較高溫度下進行切割時會被氧化。工件材料的組成部分，如鐵件容易氧化，而形成具有氧化薄膜的赤鐵礦。 圖表5:通過激光顯微鏡對工具表面進行精確測量. 圖表6:Si, Mil, Ti Fe, anil O 在微觀圖表中的區(qū)別 本干燥\機所形成的薄膜,絕不是一個簡單的混合或氧化物的化合物.圖6描述了矽、錳、鈦、鐵和氧各成分在微觀圖表中的區(qū)分。圖5中所形成的薄膜分成兩個區(qū)域: 一區(qū)域薄膜主要由TiOX組成，而二區(qū)域薄膜主要由SiO2和MnO組成。一區(qū)域二區(qū)域都包含少量的鐵成分。在干燥機械過程中不存在側(cè)翼表面，因此通過激光顯微鏡所測試的側(cè)翼磨損寬度只包括一區(qū)。二區(qū)被認(rèn)為與經(jīng)氯離子注入TICN保護層而減少摩擦及損耗無關(guān)。在干燥機中通過氯離子的注入，原基礎(chǔ)鈦氧化物的形成與自動注油過程緊密相關(guān)。 4. 結(jié)論 氯離子注入切割工具。 干燥機的表現(xiàn)已通過干燥條件下，切割速度達(dá)500 米/分的范圍下經(jīng)轉(zhuǎn)數(shù)測試加以驗證。氯離子注入基本的鑄工具后，摩擦系數(shù)及磨損度大大降低。在較高的切割速度范圍內(nèi)，側(cè)翼寬度遠(yuǎn)遠(yuǎn)超出100lim, Vc=500m / min, 而氯離子的注入可使VB達(dá)55Jim,干燥機tribological方面的改善應(yīng)歸功于形成的鈦氧化物薄膜的自動注油系統(tǒng)。 作者要感謝泰國的博士TAkhadejdamrong,MTech實驗中對她的幫助. 這項研究部分項目得到了國家資助，是在無障礙過程中，無危險環(huán)境狀態(tài)下進行的。