The present disclosure relates to the field of milling lubrication, and in particular to an internal cooling/external cooling-switching milling minimum-quantity-lubrication intelligent nozzle system and method.
The description in this section merely provides background information related to the present disclosure, and does not necessarily constitute the prior art.
In machining, the cooling and lubrication manners used at the milling machine machining center include internal cooling and external cooling. In the cooling and lubrication manner of internal cooling, generally, the cutting fluid is supplied by a cutting fluid supply system, flows into a rotary joint of a machine tool spindle through a cutting fluid pipe, and flows into an internal cooling pipe of the machine tool spindle from the rotary joint. The cutting fluid is transmitted to an internal cooling pipe in a cutting tool to realize cooling and lubrication of the cutting tool in the cutting machining process. The cooling and lubrication manner of internal cooling can satisfy the cooling and lubrication under machining conditions such as holes and grooves of a large milling depth. But it has the disadvantage that it is only suitable for cutting machining under specific machining conditions, and because an internal cooling system is a built-in system in the machine tool, the price is higher, and it will cause economic waste under the machining conditions where internal cooling is not required. The cooling and lubrication manner of external cooling includes pouring and minimum quantity lubrication (MQL) technique. For the pouring, generally, the cutting fluid is supplied by a cutting fluid supply system, and flows into an external cooling nozzle through an external cooling pipe, so as to perform cooling and lubrication on a cutting tool-a machining region of a workpiece from the outside. This manner of cooling and lubrication can effectively cool and lubricate the machining region, and can also perform functions of chip removal and cutting tool cleaning. Compared with the cooling and lubrication manner of internal cooling, the cooling and lubrication manner of pouring cannot satisfy the cooling and lubrication under machining conditions such as holes and grooves of a large milling depth. In addition, in this manner, the cooling and lubrication efficiency of the cutting fluid is very low, so a large amount of cutting fluid is wasted. This will not only cause economic losses, but also affect the life and health of operators because the cutting fluid contains substances that are harmful to human health.
Compared with the traditional cooling and lubrication manner of external cooling by pouring, the MQL is more suitable for the concept of green manufacturing and sustainable development in the field of machining. The MQL refers to a technique in which a small amount of lubricating fluid, water and a gas with a certain pressure are mixed and atomized, and then sprayed to the cutting region for cooling and lubrication. The water and the high-pressure gas perform the function of cooling, and oil performs the functions of lubricating the cutting region and prolonging the service life of the cutting tool.
As a green quasi-dry machining technique, the MQL has the following advantages:
(1) As an effective green manufacturing technique, there is no need to replace MQL oil during machining, and it is only required to periodically incorporate, that is, add a small amount of pollution-free lubricating oil into the compressed gas. In the entire operation process, no waste liquid is discharged. The generated oil mist can be directly discharged after being purified by equipment, thereby effectively avoiding the environmental pollution caused by industrial production.
(2) The cutting conditions of the cutting tool are improved, the cutting heat generated in the machining process are suppressed and reduced, and the service life of the cutting tool is prolonged. The cutting fluid is supplied in the form of high-velocity mist particles, thereby increasing the permeability of the lubricant, enhancing the cooling and lubrication effect, and improving the surface machining quality of the workpiece.
(3) By implementing the MQL technique, the consumption of the lubricating medium is extremely low. In normal cases, the consumption per hour is only 0.05-0.1 L. In contrast, the consumption of emulsion per hour in traditional wet machining is about 1000 L, and the actual consumption of cutting fluid in the former is only one ten thousandth of that in the traditional case, so the cost of coolant is greatly reduced.
MQL supply systems can be roughly classified into two categories, single-channel type and double-channel type. The difference between the two is that air and lubricating oil are mixed to form aerosols at different positions, that is, the MQL supply systems are classified into two forms according to the differences in transmission and atomization of the small amount of cutting fluid. The characteristic of the single-channel type is that: air and lubricating oil have been mixed to form an aerosol in the generating equipment, and then the aerosol is delivered to the machining region through a track inside the nozzle. The characteristic of the double-channel type is that: air and lubricating oil are delivered to a mixing cavity near the machining spindle nose in different tracks to form an aerosol, and the aerosol is then delivered to the machining region. Compared with the double-channel system, although the single-channel system is easier to manufacture, oil mist is easily dispersed when the cooling and lubricating mist is delivered, especially in a rotating spindle with strong centrifugal action, which often leads to uneven distribution of oil mist in the machining region, thereby affecting the machining quality. However, in the double-channel type MQL system, because after the aerosol is formed, the distance of its delivery to the machining region is shorter, the lubricating droplets are smaller than those in the single-channel type system, and the lubricating effect is better, so the application range is wider. The MQL technique has higher cutting fluid utilization rate and less environmental pollution. However, as with the pouring, the MQL technique still has the problem of insufficient cooling and lubrication for the machining region under conditions such as when machining holes and grooves of a large milling depth. For the improvement of the cooling and lubrication manners of internal cooling and external cooling, researchers have made great progress, but there are still many deficiencies in application.
Although the existing devices have made outstanding contributions in the aspects of resource saving, lubrication performance and the like, when workpieces with holes of a large depth and with grooves of a small depth are simultaneously machined on the machine tool, the external cooling still has the problem of insufficient cooling and lubrication. The use of the internal cooling machine tool is not cost effective. The researchers thought that by changing the tool holder structure of the cutting tool, external cooling can be converted into internal cooling while keeping the original external cooling and lubrication mechanism unchanged. When the actual machining conditions require the internal cooling and lubrication manner, external cooling can be converted into internal cooling by transforming the tool holder, so that the machine tool has the cooling and lubrication manner of internal cooling while maintaining external cooling, thereby satisfying the demands for actual machining conditions. Researchers have now conducted research in this aspect and have achieved remarkable results.
At present, the cooling and lubrication manner of external cooling has been transformed to the cooling and lubrication manner of internal cooling, so that the machine tool has the cooling and lubrication manners of both internal cooling and external cooling, and can realize the transformation between external cooling and internal cooling by a special structure, thereby satisfying the demands for machining workpieces with holes and grooves of a large depth, and also satisfying the demands for machining workpieces with holes of a small depth or with flat surfaces. However, in the actual machining of a machine tool, the operator needs to judge which cooling and lubrication manner is needed for the machining conditions at this time based on his own experience before transforming the cooling and lubrication manner between internal cooling and external cooling, so there are large limitations. Furthermore, these inventions need manual operation in transforming the cooling and lubrication manner between internal cooling and external cooling, failing in intelligent switching between internal cooling and external cooling, thereby wasting lots of human resources.
In view of the defects in the prior art, the present disclosure provides an internal cooling/external cooling-switching milling MQL intelligent nozzle system and method.
Milling depth data of a machine tool is collected; the milling depth data is transmitted to a control center for data analysis and processing; the data is compared with an initially set internal cooling/external cooling switching threshold to obtain the most suitable cooling and lubrication manner under current machining conditions of the machine tool; and the control center controls internal cooling and external cooling systems according to the obtained result to realize intelligent switching of the cooling and lubrication manner between internal cooling and external cooling.
A first objective of the present disclosure is to provide an internal cooling/external cooling-switching milling MQL intelligent nozzle system, which adopts the following technical solution:
The system includes:
a vision system, configured to acquire a real-time milling depth of a workpiece and send the real-time milling depth to a lubrication manner controller for processing;
a lubrication system, including an internal cooling system and an external cooling system connected together to a cutting fluid supply source through a reversing device; and
the lubrication manner controller, configured to communicate with the vision system and the lubrication system respectively, and control the reversing device to act according to a set milling depth threshold and data acquired by the vision system, so as to adjust and switch to the internal cooling system or the external cooling system to work.
When the external cooling system works, droplets sprayed from a nozzle device of the external cooling system impact a heat source surface and spread to form a liquid film along the heat source surface.
Further, the vision system includes an image collection device and a cradle head; the image collection device is mounted on the self-stabilizing cradle head; and the image collection device is configured to be mounted on a machine tool and acquire a real-time milling depth image of the workpiece.
Further, the reversing device includes a reversing base; a reversing channel is arranged inside the reversing base; an inlet of the reversing channel is butted with the cutting fluid supply source through a pipeline; a first outlet of the reversing channel communicates with the internal cooling system; a second outlet of the reversing channel communicates with the external cooling system; a reversing block is mounted in the reversing channel; and the reversing block is capable of blocking the first outlet and/or the second outlet by rotation.
Further, the reversing base is provided with a pressure regulating structure and a pressure relieving structure, and both the pressure regulating structure and the pressure relieving structure communicate with the reversing channel.
Further, the external cooling system includes the nozzle device, a telescopic arm module and a nozzle angle module; the nozzle device is mounted on the telescopic arm module through the nozzle angle module; and the nozzle device is capable of changing a relative position to the workpiece through the telescopic arm module and changing a direction of an output end of the nozzle device through the nozzle angle module.
Further, the telescopic arm module includes a telescopic arm support, an X-axis action arm, a Y-axis action arm and a Z-axis action arm; the X-axis action arm is mounted on the telescopic arm support through the Z-axis action arm; the Y-axis action arm is mounted on the telescopic arm support; and the nozzle angle module is mounted at an output end of the Y-axis action arm by magnetic force.
Further, the nozzle device includes a gas pipe, a liquid pipe and a gas-liquid pipe; one end of the gas pipe communicates with a gas source, and the other end communicates with the gas-liquid pipe with an axis forming a set included angle with an axis of the gas-liquid pipe; one end of the liquid pipe communicates with the cutting fluid supply source through the reversing device, and the other end is coaxially butted with the gas-liquid pipe; a gas-liquid mixing cavity is formed inside the gas-liquid pipe, and the gas-liquid mixing cavity communicates with the outside through an opening at one end of the gas-liquid pipe away from the liquid pipe.
Further, the nozzle angle module includes a first rotation module and a second rotation module; the nozzle device is mounted at an output end of the second rotation module; the second rotation module is mounted at an output end of the first rotation module; and the nozzle angle module is configured to change the direction of the output end of the nozzle device, so as to enable the droplets sprayed from the nozzle device to impact the heat source surface and spread to form the liquid film along the heat source surface.
A second objective of the present disclosure is to provide an internal cooling/external cooling-switching milling MQL method using the internal cooling/external cooling-switching milling MQL intelligent nozzle system as described above, which includes the following steps:
The method includes the following steps:
acquiring, by a vision system, a real-time milling depth image of a workpiece and transmitting the real-time milling depth image to a lubrication manner controller for processing;
determining a lubrication manner under current conditions and controlling a reversing device to act according to a set milling depth threshold of the lubrication manner controller to make an internal cooling system or an external cooling system work;
delivering, by the internal cooling system, a lubricating fluid to an internal cooling pipe of a cutting tool for cyclic heat transfer to realize cooling and lubrication; and
mixing, by the external cooling system, the lubricating fluid with a gas, and spraying the mixture to a machining position of the workpiece through a nozzle device to realize cooling and lubrication.
Further, droplets output from the external cooling system impact a heat source surface and spread to form a liquid film along the heat source surface to perform heat transfer on the heat source surface.
Compared with the prior art, the present disclosure has the following advantages and beneficial effects:
(1) The milling depth data of the machine tool is collected; the milling depth data is transmitted to the control center for data analysis and processing; the data is compared with the initially set internal cooling/external cooling switching threshold to obtain the most suitable cooling and lubrication manner under current machining conditions of the machine tool; and the control center controls internal cooling and external cooling systems according to the obtained result to realize intelligent switching of the cooling and lubrication manner between internal cooling and external cooling.
(2) The lubrication manner control center can send a corresponding lubrication manner signal to a motor control center according to the most suitable cooling and lubrication manner under current milling conditions, and the motor control center controls angular rotation of a stepping motor in the reversing device by controlling the number of pulse signals, so as to realize intelligent switching between internal cooling and external cooling.
(3) By regulating a pressure regulating handle 1, a preload of a pressure regulating spring 1 is regulated, so that a cutting fluid pressure at a pressure relieving port, that is, a pressure of an internal cooling channel and an external cooling channel, can be regulated. By regulating a preload of a pressure regulating spring 2, a current pressure of the cutting fluid, that is, an overflow pressure, is regulated. By regulating the overflow pressure, the overflow pressure can be made less than the maximum pressure that the reversing device can withstand, thereby protecting the system.
(4) In the nozzle gas-liquid pipeline of an external cooling mechanism of the system, a detailed mechanical analysis is performed on droplet atomization in the selected nozzle gas-liquid pipeline, and a computational analysis is performed on the effective droplet ratio when the atomized droplets reach the workpiece surface, so that a most suitable nozzle structure is selected.
(5) The telescopic arm module of the external cooling mechanism of the system can realize the positional movement in the directions of X, Y and Z, and the nozzle angle module can realize the angular rotation around the Y-axis and the Z-axis. The switching between internal cooling and external cooling is intelligent, and does not need the operator to manually operate in the working process of the machine tool, thereby greatly saving the labor.
The accompanying drawings constituting a part of the present disclosure are used to provide further understanding of the present disclosure. Exemplary embodiments of the present disclosure and descriptions thereof are used to explain the present disclosure, and do not constitute an improper limitation to the present disclosure.
In the figures, I vision system, II internal cooling system, III external cooling system, II-1 internal cooling and external cooling cutting fluid storage device, II-2 reversing device; III-1 external cooling compressed air storage device.
The vision system includes I-1 camera, I-2 lighting device, I-3 self-stabilizing cradle head, I-4 image collection control center, I-5 image collection control center wireless transmission device, I-6 lubrication manner control center, I-7 lubrication manner control center wireless transmission device, I-8 motor control center, I-9 motor control center wireless transmission device, I-10 support, and I-11 vision system bolt.
II-2-1 reversing device upper seat, II-2-2 reversing device lower seat, II-2-3 reversing block, II-2-4 regulating sleeve 1, II-2-5 regulating sleeve 2, II-2-6 pressure regulating nut 1, II-2-7 pressure regulating nut 2, II-2-8 regulating screw 1, II-2-9 regulating screw 2, II-2-10 spring seat 1, II-2-11 spring seat 2, II-2-12 pressure regulating spring 1, II-2-13 pressure regulating spring 2, II-2-14 spring base 1, II-2-15 spring base 2, II-2-16 valve core 1, II-2-17 valve core 2, II-2-18 reversing motor, II-2-3-1 reversing block bearing, II-2-2-1 reversing device bolt gasket, II-2-2-2 reversing device bolt, II-2-18-1 reversing motor bolt gasket, II-2-18-2 reversing motor bolt, II-2-18-3 reversing motor coupling.
II-2-2-3 reversing device bolt hole, A internal cooling device pipe, B external cooling device pipe, II-2-18-4 reversing motor bolt hole, III-2-1 X, Y, Z telescopic arm module, III-2-2 nozzle angle module, III-2-1-1 X direction telescopic arm, III-2-1-2 Y direction telescopic arm, III-2-1-3 Z direction telescopic arm, III-2-1-4 X and Z direction telescopic arm connector, III-2-1-5 Z and Y direction telescopic arm connector, III-2-1-6 X direction telescopic arm motor, III-2-1-7 Y direction telescopic arm motor, III-2-1-8 Z direction telescopic arm motor,
III-2-1-1-1 telescopic arm support, III-2-1-1-2 telescopic arm end cover, III-2-1-1-3 moving slider, III-2-1-1-4 lead screw, III-2-1-1-5 bolt, III-2-1-1-6 coupling, III-2-1-1-7 coupling bolt, III-2-1-1-8 telescopic arm bearing, III-2-1-1-9 support gasket, III-2-1-1-10 support bolt,
III-2-2-1 nozzle first pedestal right pedestal, III-2-2-2 nozzle first pedestal left pedestal, III-2-2-3 nozzle second pedestal right pedestal, III-2-2-4 nozzle second pedestal left pedestal, III-2-2-5 nozzle support, III-2-2-6 nozzle device, III-2-2-7 first pedestal motor, III-2-2-8 second pedestal motor, III-2-2-9 nozzle first pedestal bolt, III-2-2-10 nozzle second pedestal bolt, III-2-2-11 first pedestal bearing, III-2-2-12 support bearing, III-2-2-13 first pedestal bolt, III-2-2-14 second pedestal bolt, III-2-2-15 first pedestal coupling, III-2-2-16 second pedestal coupling, III-2-2-6-1 nozzle housing, III-2-2-6-2 nozzle gas-liquid pipeline.
1 cutting fluid storage tank, 2 hydraulic pump, 3 pressure regulating valve, 4 throttle valve, 5 overflow valve, 6 cutting fluid recycling bin, 7 air compressor, 8 filter, 9 gas storage tank, 10 pressure gauge, 11 pressure regulating valve, 12 throttle valve, 13 overflow valve, 14 compressed air recycling bin.
It should be noted that the following detailed descriptions are all exemplary and are intended to provide a further description of the present disclosure. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by a person of ordinary skill in the technical field to which the present disclosure belongs.
It should be noted that terms used herein are only for describing specific implementations and are not intended to limit exemplary implementations according to the present disclosure. As used herein, the singular form is intended to include the plural form, unless the context clearly indicates otherwise. In addition, it should be further understood that terms “include” and/or “comprise” used in this specification indicate that there are features, steps, operations, devices, assemblies, and/or combinations thereof;
For ease of description, words “up”, “down”, “left”, and “right” appearing in the present disclosure only mean that they are consistent with the up, down, left, and right directions of the drawings themselves, and do not limit the structure. It is for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation of the present disclosure.
As described in the background art, the transformation of the cooling and lubrication manner between internal cooling and external cooling needs manual operation in the prior art, failing in intelligent switching between internal cooling and external cooling. In view of the above problem, the present disclosure provides an internal cooling/external cooling-switching milling minimum-quantity-lubrication intelligent nozzle system and method.
In a typical implementation of the present disclosure, as shown in
The distribution of the system on a machine tool is shown in
The vision system I is configured to perform real-time monitoring on a milling state of a cutting tool of the machine tool, collect a real-time milling depth image of a workpiece milled by the cutting tool, and transmit the collected real-time milling depth image of the workpiece milled by the cutting tool to a control system through a wireless transmission device.
The overall structure of the vision system is shown in
The camera I-1 is configured to shoot a real-time image of the workpiece milled by the cutting tool, and aims to collect milling depth information of the cutting tool. The lighting device I-2 is configured to illuminate the conditions, and aims to make the image shot by the camera I-1 clearer or to meet the requirements for image shooting under dark conditions. The self-stabilizing cradle head I-3 can automatically adjust an absolute horizontal attitude of the camera I-1, and can realize the high stability of the camera I-1 under a proper swing, so that the camera I-1 always remains relatively stable to a target, thereby ensuring the stability of image shooting. On the one hand, the image collection control center I-4 receives through the image collection control center wireless transmission device I-5 a start shooting instruction sent by the lubrication manner control center I-6, such that the camera I-1 is controlled to shoot the image. On the other hand, the image collection control center is configured to store image information shot by the camera I-1, and the image information is wirelessly transmitted to the lubrication manner control center I-6 via the image collection control center wireless transmission device I-5.
The lubrication manner control center I-6 is mounted on the self-stabilizing cradle head I-3; the lubrication manner control center wireless transmission device I-7 receives the real-time image of the workpiece milled by the cutting tool; and the lubrication manner control center I-6 obtains real-time milling depth data of the cutting tool by analyzing and processing the real-time image of the workpiece milled by the cutting tool. A milling depth threshold for internal cooling/external cooling lubrication manner transformation is set in the lubrication manner control center I-6. The lubrication manner control center I-6 compares the obtained real-time milling depth data of the cutting tool with the set milling depth threshold, obtains the lubrication manner under current machining conditions according to the comparison result, and transmits the result to the motor control center I-8 in the form of an analog semaphore through the lubrication manner control center wireless transmission device I-7.
The motor control center I-8 is mounted on the self-stabilizing cradle head I-3; the motor control center wireless transmission device I-9 receives the analog semaphore containing the lubrication manner required under the current milling conditions sent by the lubrication manner control center I-6; the motor control center I-8 analyzes and processes the analog semaphore; the motor control center wireless transmission device I-9 performs angular regulation on a reversing motor II-2-18 in a reversing device in a manner of controlling the number of pulse signals; and the reversing motor II-2-18 realizes the switching of the cutting fluid flowing to an internal cooling device pipe A or an external cooling device pipe B by controlling the angle of a reversing block II-2-3 in the reversing device II-2, so as to realize the switching between the internal cooling system and the external cooling system, thereby realizing the transformation of the most suitable lubrication manner of the machine tool for the workpiece under the current milling conditions.
The internal cooling system II and the external cooling system III are mechanisms configured to execute internal cooling and external cooling transformation commands sent by the control system. The internal cooling system includes an internal cooling and external cooling cutting fluid storage device II-1, the reversing device II-2 and an internal cooling device II-3. The external cooling system includes the internal cooling and external cooling cutting fluid storage device II-1, an external cooling compressed air storage device III-1, the reversing device II-2 and an external cooling device III-2.
The internal cooling and external cooling cutting fluid storage device II-1 is configured to transport the cutting fluid to the internal cooling device II-3 and the external cooling device III-2 through the reversing device II-2, and the external cooling compressed air storage device III-1 is configured to transmit a compressed gas to the external cooling device III-2 through a pipeline. As shown in
An exploded view of the reversing device II-2 is shown in
An internal assembly of the reversing device II-2 is shown in
The regulating sleeve 1 II-2-4, the pressure regulating nut 1 II-2-6, the regulating screw 1 II-2-8, the spring seat 1 II-2-10, the pressure regulating spring 1 II-2-12, the spring base 1 II-2-14 and the valve core 1 II-2-16 form a cutting fluid pressure relieving device in the cavity of the reversing device upper seat II-2-1, and a pressure of the cutting fluid in the cavity is regulated by regulating a preload of the regulating screw 1 II-2-8. The regulating sleeve 2 II-2-5, the pressure regulating nut 2 II-2-7, the regulating screw 2 II-2-9, the spring seat 2 II-2-11, the pressure regulating spring 2 II-2-13, the spring base 2 II-2-15 and the valve core 2 II-2-17 form a cutting fluid overflow device in the reversing device upper seat II-2-2, and the maximum pressure of the cutting fluid in the cavity is controlled by regulating a preload of the regulating screw 2 II-2-9, thereby protecting the reversing device.
The reversing motor II-2-18 is a stepping motor, and is mounted on an outer side of the reversing device lower seat through a reversing motor bolt gasket II-2-18-1, a reversing motor bolt II-2-18-2 and a reversing motor bolt hole II-2-18-3. The reversing motor II-2-18 is connected with one end of the reversing block II-2-3 through a reversing motor coupling II-2-18-3. The reversing motor II-2-18 serves as an actuating mechanism of the motor control center I-8, and performs angular rotation by the number of received pulse signals. The reversing motor II-2-18 provides power for the reversing block II-2-3, so as to drive the reversing block II-2-3 to rotate in the reversing device II-2, thereby realizing the switching between the internal cooling device pipe A and the external cooling device pipe B by the reversing block II-2-3.
An overall structure of the external cooling device III-2 is shown in FIG. II. The external cooling device III-2 is configured to deliver the cutting fluid to a nozzle device III-2-2-6 through a pipeline, and spray the cutting fluid through a nozzle to cool the cutting tool and the machined workpiece. The external cooling device includes an X, Y, Z telescopic arm module III-2-1 and a nozzle angle module III-2-2.
The structure of the telescopic arm module III-2-1 is shown in
An exploded view of the telescopic arm III-2-1-1 is shown in
An exploded view of the nozzle angle module III-2-2 is shown in
An assembly diagram of the nozzle support III-2-2-5 is shown in
Three views of the nozzle angle module III-2-2 are shown in
An assembly diagram of the nozzle device III-2-2-6 is shown in
The vision system is connected to and mounted on the nozzle second pedestal left pedestal III-2-2-4 through the support via the vision system bolt I-11 and a bolt hole III-2-2-17, and the nozzle second pedestal left pedestal III-2-2-4 mounts the nozzle angle module III-2-2 onto the telescopic arm module III-2-1 through magnetic connection.
Milling depth data of the machine tool is collected; the milling depth data is transmitted to the control center for data analysis and processing; the data is compared with the initially set internal cooling/external cooling switching threshold to obtain the most suitable cooling and lubrication manner under the current machining conditions of the machine tool; and the control center controls the internal cooling and external cooling systems according to the obtained result to realize intelligent switching of the cooling and lubrication manner between internal cooling and external cooling.
In another typical implementation of the present disclosure, as shown in
The method includes the following steps:
a real-time milling depth image of a workpiece is acquired by the vision system and the real-time milling depth image is transmitted to the lubrication manner controller for processing;
a lubrication manner under current conditions is determined and the reversing device is controlled to act according to a set milling depth threshold of the lubrication manner controller to make the internal cooling system or the external cooling system work;
a lubricating fluid is delivered to the internal cooling pipe of the cutting tool by the internal cooling system for cyclic heat transfer to realize cooling and lubrication; and
the lubricating fluid is mixed with a gas by the external cooling system, and the mixture is sprayed to a machining position of the workpiece through the nozzle device to realize cooling and lubrication, such that droplets output from the external cooling system impact a heat source surface and spread to form a liquid film along the heat source surface to perform heat transfer on the heat source surface.
Specifically, in conjunction with Embodiment 1, the detailed steps are described:
A block diagram of information transmission is shown in
The switching between the internal cooling lubrication system and the external cooling lubrication system is realized by the rotation angle of the reversing block II-2-3 in the reversing device II-2. In terms of the angular regulation of the reversing block II-2-3, the angular rotation of the reversing motor II-2-18 is performed according to the number of pulse signals of the motor control center I-8 received by a driver of the reversing motor II-2-18, so as to control the angular regulation of the reversing block II-2-3, thereby realizing the switching of the lubrication system between internal cooling and external cooling.
Each type of stepping motor has its fixed step angle θ. The step angle θ is a mechanical angle that a rotor rotates when the stepping motor receives a pulse signal without a reduction gear. The step angle is specifically calculated as:
nc is the number of rotor teeth of the stepping motor, and np is the number of operating beats of the stepping motor.
When the stepping motor rotates one cycle, the required number of pulse signals N306°is calculated as:
When the stepping motor rotates by an arbitrary angle, the required number of pulse signals Nr is calculated as:
θr is the arbitrary angle that the stepping motor rotates.
The above formula can be transformed into: θr=Nr×θ
In this way, the rotation angle of the reversing block II-2-3 in the reversing device II-2 can be regulated by regulating the magnitude of the number of pulse signals Nr given by the motor control center I-8 to the driver of the reversing motor stepping motor of the reversing device II-2, thereby realizing the switching between the internal cooling lubrication system and the external cooling lubrication system.
According to the shape of the reversing block designed in this embodiment, the reversing device II-2 has four working states as shown in
(1) As shown in
(2) As shown in
(3) As shown in
(4) As shown in
When N is equal to 0°, N180° or N360°, the internal cooling and external cooling lubrication systems are in a stop state. When N is equal to N90°, the internal cooling and external cooling lubrication systems are in the internal cooling working state. When N is equal to N270°, the internal cooling and external cooling lubrication systems are in the external cooling working state. The number of pulse signals given by the motor control center respectively to the stepping motor driver of the reversing device: 0°, (N180° or N360°), N90° or N270° can be controlled to realize the free switching between internal cooling and external cooling in this embodiment.
The working principle of the reversing device II-2 of this embodiment is shown in
In addition, after passing through the pressure relieving port, the cutting fluid with the pressure of p2 will flow leftward, and flow through the valve core 2 II-2-17 and a damping hole 2 to a lower end of the valve core 2 II-2-17, which generates an upward thrust p2A2, where A2 is the effective working area of the lower end of the valve core 2 II-2-17. A preload of the pressure regulating spring 2 II-2-13 at the upper end of the valve core 2 II-2-17 is Fs2. When the axial thrust p2A2 generated by the pressure p2 of the cutting fluid is less than the spring preload Fs2, a self-weight G of the valve core 2 II-2-17 and a friction force Ff between the valve core 2 II-2-17 and an inner cavity of the reversing device, the left outlet is closed, and the overflow device does not work.
When the internal cooling pipe A or the external cooling pipe B is open and when the pressure p2 of the cutting fluid passing through the pressure relieving port is greater than the preload Fs1 of the pressure regulating spring 1 II-2-12, that is: p2≥Fs1, the valve core 1 II-2-16 overcomes the preload of the pressure regulating spring 1 II-2-12 and moves rightward under the action of the pressure of the cutting fluid in the left cavity, so that the pressure relieving port is reduced, as shown in
According to the balance relationship between the outlet pressure and pressure regulating spring 1 II-2-12: p2A1=k1(x01+Δx).
The pressure p2 of the cutting fluid passing through the pressure relieving port can be obtained as:
k1 is the spring stiffness of the pressure regulating spring 1 II-2-12, x01 is the precompression amount of the pressure regulating spring 1 II-2-12, and Δx is the displacement variation of the pressure relieving port.
It can be seen from the above formula that when the displacement variation Δx of the pressure relieving port is much less than the precompression amount x01 of the pressure regulating spring 1 II-2-12, the pressure p2 of the cutting fluid passing through the pressure relieving port can basically remain stable. The preload Fs1 of the pressure regulating spring 1 II-2-12 can be regulated by regulating the pressure regulating nut 1 II-2-6, so that the pressure p2 of the cutting fluid passing through the pressure relieving port can be regulated.
At this time, the axial thrust p2A2 generated by the pressure p2 of the cutting fluid is less than the spring preload Fs2, the self-weight G of the valve core 2 II-2-17 and the friction force Ff between the valve core 2 II-2-17 and the inner cavity of the reversing device, the left outlet is closed, and the overflow device does not work.
As shown in
(1) The pressure p2 of the cutting fluid increases, so that the thrust p2A2 of the cutting fluid acting on the bottom end of the valve core 2 II-2-17 increases to be just enough to overcome the spring preload Fs2, the self-weight G of the valve core 2 II-2-17 and the friction force Ff between the valve core 2 II-2-17 and the inner cavity of the reversing device, and the valve core 2 II-2-17 will start to move upward under the action of the thrust of the cutting fluid. According to the force balance relationship of the valve core 2 II-2-17: pkA2=Fs2+G.
A critical opening pressure of the valve port is
k2 is the spring stiffness of the pressure regulating spring 2 II-2-13, and x02 is the spring preload of the pressure regulating spring 2 II-2-13.
(2) The pressure p2 of the cutting fluid continues increasing, the valve core 2 II-2-17 will move upward, the valve port will be open, and the cutting fluid will flow into the cutting fluid storage device through the left outlet, that is, start to generate overflow. When the valve core 2 II-2-17 moves upward and is at a certain balance position, the pressure regulating spring 2 II-2-13 will be compressed by a certain distance x. At this time, the force balance equation of the valve core 2 II-2-17 becomes: p2A2=k2(x02+x)+G+Ff.
That is, the pressure p2 of the cutting fluid at this time is:
It can be seen from the above formula that when the overflow is generated, the pressure p2 of the cutting fluid at this time is not affected by the change in the flow rate, but is affected by the spring stiffness and preload of the pressure regulating spring 2 II-2-13, the self-weight of the valve core 2 II-2-17 and the sliding friction force. The spring stiffness of the pressure regulating spring 2 II-2-13, the self-weight of the valve core 2 II-2-17 and the sliding friction force are constant after the reversing device is established, so the pressure p2 of the cutting fluid at this time, that is, the overflow pressure, can be regulated by regulating the preload Fs2 of the pressure regulating spring 2 II-2-13. By regulating the overflow pressure, the overflow pressure can be made less than the maximum pressure that the reversing device can withstand, thereby protecting the reversing device.
The nozzle device includes the nozzle housing and the nozzle gas-liquid pipeline. The nozzle gas-liquid pipeline is mounted in the nozzle housing, and includes the hollow pipe, the gas pipe and the liquid pipe. As shown in
Form I: As shown in
(1) The frictional pressure loss of the cutting fluid in the liquid pipe can be divided into two parts. As shown in
λ is the frictional resistance coefficient. The liquid pipe in this embodiment is made of metal, so the frictional resistance coefficient is
l1 is the length of the horizontal straight pipe of the liquid pipe before the bend; v1 is the flow velocity of the cutting fluid before the bend; l2 is the length of the inclined pipeline of the liquid pipe after the bend and before the gas-liquid mixing point P; v2 is the flow velocity of the cutting fluid after the bend, and v1 is approximately equal to v2; d1 is the diameter of the liquid pipe; and ρ1 is the density of the cutting fluid.
(2) When the cutting fluid passes through the bend part in the liquid pipe, the bend will lead to an increase in the motion resistance of the liquid, causing a pressure loss, as shown in
where ξ is the local resistance coefficient. ξ is 0.13.
According to the above analysis, it can be known that the total pressure loss of the cutting fluid in the nozzle gas-liquid pipeline is:
In the process of flowing in the gas pipe, the gas may have a certain heat exchange with the outside through the pipe, and since the temperature is relatively uniform, it is often treated as an isothermal process. In order to simplify the calculation, the gas is often used as an incompressible fluid when considering the flow resistance. The pressure loss of gas per meter of pipe length in the gas pipe can be calculated by the following formula:
qm is the mass flow rate of the gas, λ is the frictional resistance coefficient, and d2 is the diameter of the gas pipe. ρ2 is the gas density.
Then the total pressure loss is:
The total pressure loss caused by the nozzle gas-liquid pipeline shown in Form I is:
Form II: As shown in
(1) The frictional pressure loss of the cutting fluid in the liquid pipe can be divided into two parts. As shown in
(2) When the cutting fluid passes through the bend part in the liquid pipe, the bend will lead to an increase in the motion resistance of the liquid, causing a pressure loss, as shown in
ξ is the local resistance coefficient.
According to the above analysis, it can be known that the total pressure loss of the cutting fluid in the nozzle gas-liquid pipeline is:
The pressure loss of the gas in the gas pipe is:
Then the total pressure loss is:
The total pressure loss caused by the nozzle gas-liquid pipeline shown in Form II is:
Form III: As shown in
The frictional pressure loss of the cutting fluid in the liquid pipe can be calculated by the following formula:
The pressure loss of the gas in the gas pipe is:
Then the total pressure loss is:
The total pressure loss caused by the nozzle gas-liquid pipeline shown in Form III is:
Comparing the total pressure loss of the three forms of nozzle gas-liquid pipeline structure, it is easy to see ΔP2>ΔP1>ΔP3.
Therefore, in this embodiment, the following structure is preferred: the tail end of the gas pipe is set as a 30° bend; the liquid pipe is a horizontal straight pipe; and the tail end of the gas pipe is inserted into the liquid pipe and connected into the left end of the hollow pipe along with the liquid pipe.
After the cutting fluid and the high-pressure gas merge at Point P, the cutting fluid is atomized under the action of the high-pressure gas. The atomization of the cutting fluid can be classified into two manners: jet atomization and breaking atomization.
The jet atomization means that when lubricating oil is sprayed out in the form of a continuous liquid through an oil spray hole, the disturbance of the outside gas will cause vibration waves on the jet surface. As the amplitude of the vibration waves increases, the jet will be cracked into liquid flakes and large-diameter droplets. When the droplet diameter exceeds a critical value, the droplet will fragment into lots of small droplets. The size of droplets depends on the nozzle structure, gas flow state, external conditions and the like.
The breaking atomization is shown as
In the nozzle gas-liquid pipeline structure of Form III, the force of the cutting fluid droplet is shown in
{right arrow over (F)}
Σ
={right arrow over (F)}
D
+{right arrow over (F)}
P
+{right arrow over (F)}
Q
+{right arrow over (F)}
W.
{right arrow over (F)}Σ is the resultant force received by the droplet; {right arrow over (F)}D is the viscous force of the gas flow on the mist droplet; {right arrow over (F)}P is the acting force of the pressure gradient on the mist droplet; {right arrow over (F)}Q is the force received by the cutting fluid droplet itself under pressure; and {right arrow over (F)}W is the gravity.
For {right arrow over (F)}D, in any case, there is a relative velocity {right arrow over (v)}2−{right arrow over (v)}1 in the movement between the surrounding gas flow and the mist droplet, and the viscous force is:
Ap is the face area of the mist droplet; ρf is the gas density; {right arrow over (v)}1 is the mist droplet velocity; {right arrow over (v)}2 is the gas flow velocity; and CD is the resistance coefficient.
The Reynolds number is defined as
then FD=3πμfde({right arrow over (v)}2−{right arrow over (v)}1)f(Re).
μf is the kinematic viscosity coefficient of the fluid; and de is the diameter of the oil droplet.
Assuming that there is a pressure gradient ∂p/∂n along the direction of the gas flow velocity {right arrow over (v)}2, then
Since the oil droplet is a sparse suspended phase, assuming that the gas flow field is not disturbed by the presence of the mist droplet, the Navier-Stokes equation is still satisfied:
Since de is very small, the above formula can be simplified as
then
As shown in
Then p2′=p2+ρ1g(h1−h2)−Δpw.
p2 is the pressure of the cutting fluid just entering the liquid pipe, for Form III: h1−h2=0.
Then:
and the direction is the same as the direction of the droplet velocity.
The magnitude of the weight of the droplet is:
mp is the mass of the droplet, and the direction of the weight of the droplet is vertically downward.
Then the total resultant force received by the droplet is
{right arrow over (i)} the unit vector, which forms an angle of 30° downward with the positive half of the x-axis. {right arrow over (j)} is the unit vector, and the direction points to the negative half of the y-axis.
For the droplet of Form III, force analysis in the x and y directions is respectively performed, and the result is shown in
According to the formula, it can be known that the direction of {right arrow over (F)}D forms an η angle with the horizontal coordinate X. The magnitude of the η angle is related to the gas flow velocity {right arrow over (v)}2 and the velocity of the cutting fluid droplet {right arrow over (v)}1. The force direction diagram is shown in
The direction of {right arrow over (F)}P is the same as that of the gas flow velocity {right arrow over (v)}2, the direction of {right arrow over (F)}Q is the same as that of the velocity of the cutting fluid droplet {right arrow over (v)}1, and the gravity {right arrow over (F)}W is vertically downward.
F
3yPositive
=F
DyPositive
+F
PyPositive
=F
D sin η°+FP sin 30°
F
3yNegative
=F
W
F
3xPositive
=F
DxPositive
+F
PxPositive
+F
Q
=F
D cos η°+FP cos 30°+FQ
Then the magnitude of the resultant force {right arrow over (F)}Σ is
Then the direction of the resultant force {right arrow over (F)}Σ is
For the cutting fluid droplet, the received resultant force {right arrow over (F)}Σ causes the droplet to rupture. Assuming that the magnitude of the critical force of the cutting fluid droplet at the critical rupture point is FL, then the magnitude of the difference FA between the magnitude of the resultant force {right arrow over (F)}Σ and the force of the droplet at the critical rupture point reflects the rupture effect of the droplet:
F
A
=|F
Σ
−F
L|
As shown in
Pq is the pressure of the gas just entering the gas pipe, h3−h2=−l2 sin 30°.
p
q
′=p
q−ρ2gl2 sin 30°−Δq.
After Point P, the gas will drive the broken cutting fluid droplets to flow into the hollow pipe, and the pressure of the gas-liquid mixture is
p
3
=p
2
′+p
q
′=p
2
−Δp
w
+p
q−ρ2gl2 sin 30°−Δq=p2+pq−ρ2gl2 sin 30°−ΔP3.
It is assumed that the flow velocity of the gas-liquid mixture is v3.
When the gas-liquid two-phase flow flows to the nozzle orifice, since the pipe diameter is sharply reduced, an orifice throttling phenomenon will occur. As shown in
h2=h4; v4 is much greater than v3, so v3 is ignored. ρ is the density of the gas-liquid two-phase flow, ρ=ρ2(1−ε)+ρ1ε. The flow of the necked-down section is turbulent, and p4 is the pressure after the orifice; α2 is 1; and Δpw1 is the local loss, being
Then the velocity of the gas-liquid two-phase flow at the nozzle outlet is:
The velocity of the droplet is also v4.
The researchers have found according to the Bernoulli's equation that before the droplet impacts the micro-grinding region, the weight of the droplet appears very small as compared to the resistance of the surrounding air it receives. Therefore, the gravity of the droplet can be ignored, and it is only necessary to consider the influence of the viscous resistance of the surrounding air on the droplet. According to the principle of aerodynamics, the resistance of the surrounding air around the droplet to the droplet can be known:
In the formula, va is the velocity of the surrounding air; ya is the volumetric weight of the air; Sf is the face area of the droplet; CD is the air resistance coefficient; and g is the gravitational acceleration.
In view of the fact that the flow velocity of the surrounding air of the droplet is much less than the velocity of the high-velocity droplet, the surrounding air is approximately regarded as in a static state, and thereby the formula can be expressed as
When the spray boundary is of a closed ellipse, the coverage area of the droplet group reaches the maximum. The total number of droplets Nt is:
In the formula, Qf is the liquid supply flow rate of a spray device; f is the liquid supply frequency of the minimum-quantity-lubrication device; and Vd32 is the volume of the droplet with a particle size of d32. d32 is the Sauter average particle size, which has the physical meaning of a ratio of the volume mean of all droplets generated by the spray to the area mean of all droplets. Researchers generally replaces the original droplet group with a droplet group with the particle size of d32, which has the same total volume and surface area as the original droplet group. The general expression of d32 is:
In the formula, σt is the surface tension coefficient of the droplet; μ is the dynamic viscosity of the spray medium; ρa is the density of the environmental medium at the nozzle outlet; and d0 is the nozzle diameter.
Assuming that the spray droplets uniformly fall on the surface of the workpiece, then the number of droplets falling in the machining region is:
In the formula, sg is the cutting machining area; and Se is the ellipse area of the spray boundary.
The description of the initial droplet size adopts x2-distribution:
In the formula,
Weber criterion number (We number for short) and Laplace number (La number) are used to control the result after the droplet collides with the heat source surface:
In the formula, ρf is the density of the spray cooling medium; v6 is the vertical velocity component of the droplet on the heat source surface; σ is the flow stress in the first deformation region corresponding to the minimum chip thickness; μ is the dynamic viscosity of the spray medium; and D is the particle size of the spray droplet.
The positional relationship between the nozzle and the workpiece is shown in
After velocity analysis, the vertical velocity v6 of the droplet falling on the surface of the workpiece is
As shown in
2.0×104×La−0.2≤We≤2.0×104×La−1.4.
From the above formula, the range of the particle size D of the droplet that spreads, that is, the droplet capable of realizing effective heat transfer, can be obtained: Dmin≤D≤Dmax. Therefore, the proportion of the droplets capable of realizing effective heat transfer is:
In the formula,
distribution.
The number of droplets capable of realizing effective heat transfer is:
N
e
=N
z
·P(D).
The base fluid and the high-pressure gas sprayed by the nozzle to the heat source surface are regarded as a fluid jet and a high-pressure gas jet. According to the droplets capable of realizing effective heat transfer in the machining region above, probability statistical analysis is performed, and a heat transfer coefficient of a single fluid droplet is calculated, thereby obtaining a heat transfer coefficient of the fluid. The heat transfer coefficient of the fluid plus the heat transfer coefficient of the high-pressure gas jet is the convective heat transfer coefficient of the external cooling minimum-quantity-lubrication jet in the internal cooling and external cooling systems under conditions of spray cooling.
For a single fluid droplet, the heat transfer coefficient hs satisfies:
In the formula, J is the heat transfer amount of a single droplet; cf is the specific heat capacity of the droplet; ΔT is the heat transfer temperature difference; qs is the heat flux density of a single drop at heat transfer; ts is the heat transfer time; md is the mass of the droplet; and A′ is the spreading area of the droplet.
Based on the calculation of the number of effective droplets in the machining region, the heat transfer coefficient of all droplets capable of realizing effective heat transfer can be known:
The convective heat transfer coefficient ha of the high-pressure gas jet to the heat source surface is:
In the formula, Nu is the Nusselt number, which has the following relationship with Reynolds number (Re) and Prandtl number
In the formula, ka is the thermal conductivity of air; μa is the dynamic viscosity of the gas; and ca is the specific heat capacity of air at constant pressure.
The convective heat transfer coefficient of the external cooling minimum-quantity-lubrication jet in the internal cooling and external cooling systems under conditions of spray cooling is: h=hn+ha.
The information transmission manners are all wireless transmission, and the Internet, for example, GPRS, 2G, 3G, 4G and the like, can be used for transmission. The above wireless transmission techniques are all mature techniques, all have complete working modules, and thus, can be used directly.
The foregoing descriptions are merely preferred embodiments of the present disclosure, but are not intended to limit the present disclosure. A person skilled in the art may make various alterations and variations to the present disclosure. Any modification, equivalent replacement, or improvement made and the like within the spirit and principle of the present disclosure shall fall within the protection scope of the present disclosure.
Number | Date | Country | Kind |
---|---|---|---|
2020112401605 | Nov 2020 | CN | national |