RU2349430C2 - Cutting method of semi-finished product made of aluminium alloy - Google Patents

Abstract

FIELD: metallurgy.

SUBSTANCE: invention concerns metal cutting field. Particularly it concerns cutting methods of semi-finished products made of aluminium alloys. For cutting there is used cutting-off tool, implementing lubrication of cutting area and removal of wastes during the cutting process. For lubricating there is used foam-cleaning agent which is fed to the cutting area to tool nose in amount 1-10 g per one cut.

EFFECT: consequently it is excluded contamination of chips by mineral oil during the process of cutting and it is reduced cost price of manufacturing of semi-finished products made of aluminium alloys while providing of specified requirements for cooling of cutting tool.

1 tbl, 3 ex

Description

The invention relates to the field of metal cutting, in particular to methods for cutting semi-finished products (ingots, rods, rolled products and others) from aluminum alloys.

In the process of manufacturing billets from ingots of aluminum alloys, an operation is used to cut them into measured billets. As a result of this, a large amount of chips is formed, contaminated with mineral oil used as cutting fluid (coolant) in the above operation. The resulting chips are used as working material for the smelting of aluminum alloys, which, according to Safety Rules PB 11-242-98, must be completely degreased and briquetted before entering the melting furnace. However, the degreasing of contaminated aluminum chips requires significant additional costs, which lead to an increase in the cost of manufacturing semi-finished products from aluminum alloys.

Known methods of cutting a large semi-finished product from aluminum alloys with various cutting tools, such as circular saws, milling cutters, cutting discs located on the faceplate, and other tools.

A known method of cutting a round billet with smooth disks located on a rotating faceplate, including feeding the billet to a cutting tool and cutting the billet by rolling it with disks while guiding them to the center (A. C. USSR No. 203431, Cl. 49C 12/01, publ. September 28, 1967).

The known method of cutting does not exclude contamination of the chips with mineral oil during the cutting process and is characterized by the relatively high cost of manufacturing semi-finished products from aluminum alloys due to the need for additional costs for degreasing the chips contaminated with mineral oil for subsequent processing by remelting them into ingots.

A known method of cutting rolled metal with at least one disk, including feeding the disk to the cut steel and rotating the disk with a change in angular velocity during the cutting process, wherein the ratio of the disk speed at the time of cutting to the nominal speed of the disk before cutting starts is selected from the following expression:

where V ₁ is the nominal frequency of rotation of the disk before it begins to feed, rpm;

V ₂ - frequency of rotation of the disk at the time of cutting, rpm;

(Patent RU No. 2036752 C1, B23D 23/00, B23D 45/00, published on September 6, 1995).

The known method of cutting rolled metal does not exclude contamination of the chips with mineral oil during the cutting process and is characterized by the relatively high cost of manufacturing semi-finished products from aluminum alloys due to the need for additional costs for degreasing the chips contaminated with mineral oil for subsequent processing by remelting them into ingots.

The closest analogue to the claimed technical solution is a well-known method of cutting aluminum pipes into measured billets, including cutting with a cutting tool, lubricating the cutting zone and removing waste during cutting (A. S. USSR No. 1296322 A1, B23D 45/00, B23Q 11/02 , published on March 15, 1987).

The known method of cutting does not exclude contamination of chips with mineral oil during the cutting process and is characterized by the relatively high cost of manufacturing semi-finished products from aluminum alloys due to the need for additional costs for degreasing oil-contaminated chips for its subsequent processing by remelting into ingots.

The objective of the invention is to eliminate contamination of the chips with mineral oil during the cutting process and reduce the cost of manufacturing semi-finished products from aluminum alloys while ensuring established requirements for cooling the cutting tool.

The technical result is achieved in that, in contrast to the closest analogue, which includes cutting with a cutting tool, lubricating the cutting zone and removing waste during the cutting process, according to the claimed technical solution, a foaming agent is used for lubrication, which is supplied to the cutting zone on the cutting edge of the tool in an amount 1-10 g per cut.

When analyzing patent and scientific and technical sources, no technical solutions have been identified that possess the entire set of essential features of the claimed technical solution. Comparison of the proposed method not only with the closest analogue, but also with other technical solutions in the art showed that it is known to use foaming agents, for example, an aqueous washing solution for cleaning metal chips from grease in the process of preparing it for processing (Patent RU No. 2238171 C1 , B22F 8/00, C22B 34/00, published on October 20, 2004).

Known lubricant supply to the cutting edges of the tool. However, the identified technical solutions only partially contain essential features, but do not possess the entire set of essential features of the claimed technical solution. In the inventive method, only the entire claimed combination of known and unknown significant features allows to obtain a new, previously unknown positive effect, which consists in eliminating contamination of the shavings of aluminum alloys with mineral oil during the cutting process and a significant reduction in the cost of manufacturing semi-finished products from aluminum alloys.

The use in the inventive method of cutting foaming agents, for example, liquid technical soap for lubricating the cutting zone instead of coolant containing mineral oil, eliminates the contamination of the chips generated by the cutting oil with mineral oil and the additional cost of degreasing the chips before they are processed by remelting into ingots. At the same time, sticking of chips to the cutting tool is stably eliminated and its cooling is ensured in accordance with established standards. The absence of additional costs for degreasing chips before its processing by remelting into ingots can significantly reduce the cost of manufacturing semi-finished products from aluminum alloys.

To verify the claimed technical solution, the following work was carried out. An ingot of aluminum alloy B1T according to TU 95.2222-90 with a diameter of 150 mm and a length of about 5 meters was cut into measuring billets on an MP-36 cutting machine using a circular saw. The chips from the cutting zone were removed by transporting it on an inclined surface under the action of its weight in a container.

Example 1

According to the claimed technical solution, the ingot cutting zone was lubricated with Onega household laundry soap in accordance with TU 6-36-216-93, which was applied to the cutting edges of a circular saw. The amount of liquid soap supplied to the cutting zone was varied in the following ranges: 0.5; one; 5; 10; 12 g per cut.

Example 2

According to the claimed technical solution, the lubrication of the cutting zone of the ingot was carried out with Prim-Exi liquid soap according to TU 3281-001-18431309-98. The amount of liquid soap supplied to the cutting zone of the ingot was 1 and 10 g per cut.

Example 3

According to the closest analogue, the ingot cutting zone was lubricated with Vapor cylinder oil in accordance with TU.

For each option, 3 cuts of the ingot were performed. For comparison, according to the claimed technical solution, the ingots of aluminum alloy B1T were cut with a diameter of 154 and 185 mm, as well as ingots of aluminum alloy AMSN1 according to TU 95.2222-90 and S-80 according to TU 001.309-89 with a diameter of 150 mm.

In the course of this work, the relative cost of manufacturing 1 kg of semi-finished product from aluminum alloys was determined by standard methods.

To assess the effect of a significant amount of sodium and potassium contained in foaming agents in the form of the corresponding salts of fatty acids (0.79-7.6 g / l sodium and 0.15-1.5 g / l potassium) on their content in aluminum alloy ingots conducted experimental melting of ingots from shavings formed by the claimed technical solution. At the same time, chips were used for smelting ingots according to two options: with washing chips with water after cutting ingots and without washing. It was found that the content of sodium and potassium in the smelted ingots from the above chips does not exceed their values for regular ingots of aluminum alloys, because the sodium and potassium contained in the foaming agents passes into the slag during the smelting process and significantly increases the content of the above elements in it.

The research results are shown in the table.

Analysis of the data presented in the table shows that the claimed method differs from the closest analogue in the absence of contamination of the chips with mineral oil during the cutting process and the lower cost of manufacturing 1 kg of semi-finished product from aluminum alloys (81.9-87.5% by the present method instead of 100 % by the closest analogue).

Moreover, in the entire claimed range of the amount of foaming agent supplied to the cutting zone, no sticking of chips to the cutting tool occurs while meeting the established requirements for cooling the cutting tool.

The optimal parameters of the proposed method are the following (experiments No. 1-12):

- the amount of foaming agent supplied to the cutting zone on the cutting edge of the tool is 1-10 g per cut.

A decrease in the amount of foaming agent supplied to the cutting zone of less than 1 g per cut leads to the sticking of chips to the cutting tool and its overheating.

An increase in the amount of foaming agent supplied to the cutting zone of more than 10 g per cut leads to a significant increase in the cost of manufacturing a semi-finished product from aluminum products without further improving the quality of the cut.

The inventive method is tested with a positive result in the production conditions of OAO ChMZ during the experimental cutting of ingots of aluminum alloy B1T with a diameter of 150 mm on a cutting machine MP-36. Currently, work is underway to introduce the proposed method into production.

Table Comparative data of the proposed method and the closest analogue No. Technical Solution Option Prefabricated material Ingot Diameter, mm Brand of lubricant The amount of lubricant per 1 cut, g Test results experience Chip sticking to the tool Oil contaminated chips Compliance of cutting tool cooling with specified requirements The relative cost of manufacturing 1 kg of semi-finished product,% Rel. one The inventive method B1T 150 Onega one no no Yes 81.9 2 - "- B1T 150 - "- 10 no no Yes 84.7 3 - "- B1T 154 - "- one no no Yes 82.5 four - "- B1T 154 - "- 10 no no Yes 86.1 5 - "- B1T 185 - "- one no no Yes 82,4 6 - "- B1T 185 - "- 10 no no Yes 86.4 7 - "- AMSN1 150 - "- one no no Yes 83,2 8 - "- AMSN1 150 - "- 10 no no Yes 87.5 9 - "- S-80 150 - "- one no no Yes 84.3 10 - "- S-80 150 - "- 10 no no Yes 87.1 eleven - "- B1T 150 Prim ex one no no Yes 82.5 12 - "- B1T 150 Prim ex 10 no no Yes 87.4 13 The closest analogue B1T 150 Vapor cylinder oil no there is Yes one hundred

Claims (1)

A method of cutting semi-finished products from aluminum alloys with a cutting tool, including lubricating the cutting zone and removing waste during the cutting process, characterized in that a foaming agent is used as a lubricant, which is fed to the cutting zone on the cutting edge of the cutting tool in an amount of 1-10 g per cut .