Air Mist Quantitative Control Of The Cooling Device

Spray cooling is one of the cooling methods for high-speed machining. Cutting with spray cooling, combining the advantages of dry cutting and wet processing, belongs to near dry cutting. It applies to many fields because of the many advantages. Although now, many imported high-speed cutting machines have spray cooling device, which are produced by foreign specialized lubrication companies, its structure is closed and the technology is confidential. Therefore, it's difficult for domestic machine companies to imitate. If it is bought as purchased components, it will improve the cost of machines for its high price. So, it's not suitable for most of the domestic enterprises. To solve this problem, the research on a cooling device, which uses economical modular pneumatic components instead of special devices to realize the quantitative control of air and oil mist, is important to match advanced cooling technology with domestic high-speed cutting machines and improve market competitiveness.The main contents and achievements in this dissertation are summarized as follows:(1) Now, imported high-speed cutting machines are expensive and the technology is confidential. Combined with characteristics of spray cooling, the research and analysis on atomization mechanism of droplet and structure of atomizer has been done. Then, a new, economical modular spray cooling device using modular pneumatic components to realize the quantitative control of air and oil mist has been constituted.(2) In order to do research on the test of the spray cooling device, the analysis on relationship of the cooling effect and flow's state parameters is done. On this basis, in order to judge the atomization effect of the cooling device to get the best control parameter, the measure standard of atomization effect is defined. A simple and scientific magnesia indentation method is used to judge the atomization effect. The test experiment is done to determine the best control parameter (nozzle and mass ratio of air-oil mist).(3) Cutting test using the cooling device has been done to test the cooling effect of the cooling device controlling air and oil mist quantitatively. The test results show that when the nozzle's diameter is 1.7mm and the mass ratio of air-oil mist varies from 215 to 252, workpiece surface roughness Ra is the least, and the cooling effect of air-oil mist is the best which is equivalent to the cooling effect of oil cooling on the machining center. A machining center with traditional wet processing needs cutting fluid 20-100L/min. Oil quantity used for the cooling device controlling air and oil mist quantitatively is less than 0.026L/h, about one to fifty thousand of wet cutting. The results show that, the economical modular spray cooling device controlling air and oil mist quantitatively can not only get expected cooling effect, but also greatly reduce production cost. It can improve market competitiveness of domestic mid-low gear high-speed machines, and has great application prospect in machine tool industry.