Design And Atomization Mechanism Of Electrostatic Atomization Minimum Quantity Lubrication Device And Evaluation Of Milling Performance Of Nickel Base Alloys

Nickel-based alloys and other high-strength,high-modulus,high toughness materials in aerospace and other key national development areas are widely used without the support of such basic processes as milling,efficient and green cooling and lubrication is to improve the performance of its milling difficult-to-machine materials to meet the aerospace quality use requirements of the guarantee.Compared to pouring type cutting fluid dosage,high cost and the disadvantages of the environment and unfriendly,minimum quantity lubrication is an iterative processing process to achieve green manufacturing clean production of parts from the source.However,the phenomenon of droplet bounce and liquid crown splash broken when droplets impact the liquid film will produce a large number of small droplets spread to the surrounding environment,the health of workers and the workshop environment threatening at the same time reduce the effective utilization of lubricants and lubrication performance.The proposed electrostatically enabled atomization technology can effectively regulate the performance of pneumatic atomization,so that the minimum quantity lubricant can be delivered to the cutting area with high effective flow rate to improve the cooling and lubrication performance.However,the technology is still in the experimental research stage,the application scope is small,and there are still gaps in the research of electrostatic atomization minimum quantity lubrication technology and related devices safety,stability and other application performance.In this regard,the research work on electrostatic atomization mechanism and field parameter synergistic regulation of milling performance was carried out in this paper.The integrated electrostatic atomization minimum quantity lubrication process equipment was designed,the electrostatically enabled bio-lubricant fragmentation atomization mechanism was analyzed,the experimental study of atomization performance and milling performance of nickel-based alloy under multi-field coupling was conducted,and the field parameter co-regulation process system was developed.The specific research is as follows.(1)Design integrated electrostatic atomization minimum quantity lubrication device.Analyze high voltage electrostatic generation,input-output linear adjustment of the drive circuit and the characteristics of the gas-liquid delivery device.The controlled output of gas,liquid and electric parameters is realized by means of mechanicalelectronic design and embedded program compilation.(2)Explore the mechanism of lubricant atomization under needle electrode.Based on the spatial electrostatic dynamics,a numerical difference model of the electric field in the spatial domain was established to obtain the electric field distribution law in the domain of the needle electrode,a theoretical model of electrostatically enabled lubricant cone jet atomization was proposed,experimental verification of the atomization performance of electrostatic atomization two-phase flow was carried out,and the influence law of the field parameters on the droplet size distribution was analyzed,and the experimental results were consistent with the atomization model.(3)Explore the milling lubrication performance of electrostatic atomized minimum quantity lubrication system.Analyze the composition of the micro-element force on the cutting edge of the end mill and the law of change of the combined force,and to conduct experimental research on the performance of the electrostatic atomization minimum quantity lubrication system for milling nickel-based alloys by combining surface roughness,specific energy and other evaluation and analysis methods,and to further analyze the mechanism of electrostatic atomization minimum quantity lubrication at the milling tool-workpiece interface and the mechanism of increase and decrease of the electrostatic field,and to arrive at the ratio of air pressure-voltage parameters that can obtain the best surface quality under fixed working conditions.(4)Conduct experimental studies on optimization of electrostatic atomization minimum quantity lubrication process parameters.Analyze the influence of multiple factors such as position,injection flow rate on the quality of minimum quantity lubrication milling process,and design an orthogonal experimental scheme for milling nickel-based alloy GH4169 with electrostatic atomization minimum quantity lubrication of bio-lubricants,the experimental study was conducted on milling force,surface roughness,etc.using six factors(flow rate,air pressure,voltage,incidence angle,elevation angle,target distance)and three levels.The best combination of electrostatic atomization minimum quantity lubrication process parameters was determined by combining signal-to-noise ratio analysis and validation experimental analysis.(5)Establish the electrostatic atomization field parameters cooperative regulation milling process system.Combined with the milling nickel-based alloy performance experiments to establish a genetic algorithm to optimize the mapping relationship between electrostatic atomization minimum quantity lubrication process parameters and application scenarios under the BP neural network vision,complete the electrostatic atomization minimum quantity lubrication device remote cooperative coupling control optimization strategy,realize the electrostatic atomization minimum quantity lubrication process multi-scene,high matching industrial application technology upgrade.