A profile grinding device for grinding a thin-walled gear

Abstract

The present application relates to a kind of forming grinding device for grinding thin-walled gear, belong to the lubrication cooling technical field in grinding processing, including electrostatic spraying module, temperature regulation module and grinding wheel;Grinding wheel has inner runner, electrostatic spraying module sprays liquid gallium to the workpiece surface ground by grinding wheel;Electrostatic spraying module includes pressurizing module, charge application module and conveying module;After liquid gallium is transported to detachable closed gallium delivery box, part is pressurized after entering uniform electric field conduit by pressurizing pipeline, part enters the electric field particle charging by detachable closed gallium storage cavity, and is sent to uniform electric field conduit, under the action of electric field, all liquid gallium in uniform electric field conduit is uniformly charged, and is sprayed to workpiece surface by conveying module;The temperature regulation module adjusts workpiece surface temperature, maintains liquid gallium solid-liquid conversion.The present application effectively solves the problem that coolant is difficult to penetrate to the depth of tooth surface in thin-walled gear forming grinding, and improves the quality and efficiency of forming grinding.

Description

Technical Field

[0001] This invention relates to the field of lubrication and cooling technology in grinding processes, and more particularly to a forming grinding apparatus for grinding thin-walled gears. Background Technology

[0002] Thin-walled gears are susceptible to thermal and force deformation during machining, leading to problems such as tooth profile error, tooth pitch error, and roundness deviation of the gear ring. Traditional grinding processes, due to the complex structure and deep tooth grooves of thin-walled gears, and the influence of the air barrier layer on the grinding wheel, make it difficult for coolant to effectively penetrate deep into the tooth surface. This results in excessively high temperatures in the grinding zone, affecting the surface quality of the workpiece and making it difficult to guarantee high precision. This is especially true in the machining of gears made of large module or high-hardness materials (such as titanium alloys and high-strength alloy steels), which easily generates cutting vibration and grinding wheel wear.

[0003] Gallium, as a highly efficient lubricant, possesses an excellent low coefficient of friction and good thermal conductivity, making it widely used in precision machining and grinding. Gallium effectively reduces grinding temperature during the grinding process, thereby minimizing temperature fluctuations in the heat-affected zone and reducing the impact of grinding forces on the workpiece surface. By introducing gallium into the grinding process, more efficient thermal management and lubrication can be achieved, preventing problems such as workpiece surface burning and deformation caused by excessively high temperatures.

[0004] Liquid metals, due to their unique physical properties, offer an emerging solution for precision cooling and lubrication. Gallium, with its extremely low melting point, can rapidly transform from a solid to a liquid state under high-temperature grinding environments. It also possesses excellent thermal conductivity and lubrication properties for metal parts, with a thermal conductivity far exceeding that of traditional cutting fluids or gaseous coolants. However, the practical application of gallium still faces numerous technical challenges, such as overcoming the uneven distribution caused by gravity and centrifugal force, ensuring precise spraying onto complex geometric surfaces, and controlling the stability of liquid gallium during the spraying process. Therefore, designing an auxiliary device that can safely and efficiently utilize the properties of liquid metals is of profound significance for achieving localized heat management of workpieces and efficient grinding. Summary of the Invention

[0005] To address the problem of coolant difficulty penetrating deep into the tooth surface during thin-walled gear forming grinding, this invention provides a forming grinding device for grinding thin-walled gears. Through the synergistic effect of an innovative electrostatic spraying module and a temperature control module, it solves the problem that coolant is difficult to effectively penetrate deep into the tooth surface due to the complex structure and deep tooth grooves of thin-walled gears, as well as the influence of the grinding wheel air barrier layer, thereby improving the quality and efficiency of thin-walled gear forming grinding.

[0006] To achieve the above objectives, the present invention adopts the following specific technical solution:

[0007] A forming grinding device for grinding thin-walled gears, the forming grinding device comprising an electrostatic spraying module, a temperature control module, and a grinding wheel;

[0008] The grinding wheel has an inner flow channel, and the electrostatic spraying module is placed inside the inner flow channel for spraying liquid gallium onto the surface of the workpiece being ground by the grinding wheel; the electrostatic spraying module includes a pressure module, a charge application module, and a delivery module;

[0009] The pressurization module includes a detachable sealed gallium delivery box and a pressurization pipeline, and the charge application module includes an electric field application cavity, a detachable sealed gallium storage cavity, and a uniform electric field conduit.

[0010] The detachable sealed gallium delivery box is connected to the input end of the pressurization pipeline and the detachable sealed gallium storage cavity, respectively; the detachable sealed gallium storage cavity is connected to the uniform electric field conduit through the electric field application cavity, and the output end of the pressurization pipeline is connected to the uniform electric field conduit; the uniform electric field conduit is located in the electric field set in the inner channel of the grinding wheel;

[0011] After the liquid gallium is delivered to the detachable sealed gallium delivery box, a portion is pressurized through the pressurization pipeline and enters the uniform electric field conduit, while another portion enters the electric field application chamber through the detachable sealed gallium storage cavity. The electric field application chamber has an electrostatic field, which charges the passing liquid gallium particles and delivers them into the uniform electric field conduit. Under the action of the electric field, all the liquid gallium particles in the uniform electric field conduit are uniformly charged and then sprayed onto the workpiece surface through the delivery module.

[0012] The temperature control module is located in the grinding area and is used to adjust the surface temperature of the workpiece to maintain the dynamic conversion state of liquid gallium between solid and liquid.

[0013] Furthermore, the pressurization pipeline includes a pressurization pipe, a guide pipe, a liquid inlet pipe, and a liquid flow valve;

[0014] The detachable sealed gallium delivery box is connected to the guide pipe through the pressurization pipe, and the liquid flow valve is installed at the end of the guide pipe and is connected through the liquid inlet pipe;

[0015] The guide tube is equipped with a liquid-pushing assembly, which includes a pressure compensation element. The liquid-pushing assembly is activated or deactivated according to the trigger signal of the pressure compensation element to intermittently deliver liquid gallium.

[0016] Furthermore, the liquid pushing assembly also includes an elastic element, a push block, a control switch, and a drive element; the push block is installed inside the guide tube, and the push block is connected to the drive element and the elastic element respectively; the drive element drives the push block to push the liquid gallium forward; the elastic element is used to pull the push block to reset; the drive element is connected to the central control unit through the control switch, and the control switch starts or stops the drive element under the control of the central control unit.

[0017] Furthermore, the pressurizing tube has a tapered structure, with a low-pressure section, an active section, and a high-pressure section sequentially arranged along the conveying direction inside; the pressure in each section of the low-pressure section, the active section, and the high-pressure section increases sequentially, and the part from the active section to the high-pressure section has a tapered structure.

[0018] Furthermore, the charge application module also includes a high-voltage electrical energy source and electrode plates;

[0019] The high-voltage electric energy source is installed on the electric field application cavity, with one end connected to the upper end of the electric field application cavity and the other end connected to the electrode plate disposed on the lower side inside the electric field application cavity; the high-voltage electric energy source provides a stable voltage to the electric field application cavity, and the electrode plate generates a uniform electrostatic field.

[0020] Furthermore, the high-voltage electrical energy source includes a power source and a capacitor energy storage device; the power source and the capacitor energy storage device are connected in parallel at the upper end of the electric field application cavity via conductive lines.

[0021] Furthermore, the charge application module also includes a voltage detector, a voltage regulating valve, an electrode access tube, a current valve, and a voltage sensing switch;

[0022] The current valve is installed at the upper end of the electric field application cavity through the electrode access tube and is connected to the voltage regulating valve through the conductive line; the electrode plate is connected to the voltage sensing switch through the conductive line; the voltage regulating valve is connected to the voltage sensing switch through the high-voltage power source;

[0023] The voltage detector is installed on the electric field application cavity and, together with the voltage sensing switch, monitors the electric field strength in real time and adjusts the voltage through the voltage regulating valve.

[0024] Furthermore, the conveying module includes a rotary motor, an angle adjuster, a transmission gear, a rotary shaft, a flexible connector, an electrostatic nozzle, a flow rate regulating valve, a guide tube, and an end nozzle;

[0025] The output shaft of the rotary motor is connected to the transmission gear via the rotary shaft. The angle adjuster is meshed with the transmission gear. The outer end of the angle adjuster is connected to the flexible connector. The upper and lower ends of the flexible connector are respectively sealed to the electrostatic nozzle and the guide tube. The electrostatic nozzle is connected to the uniform electric field conduit via the flow rate regulating valve. The end nozzle is installed at the output end of the guide tube.

[0026] The rotary motor drives the angle adjuster to rotate via the transmission gear, thereby adjusting the rotation angle and direction of the guide tube so that the end nozzle faces the surface of the workpiece.

[0027] Furthermore, a flow monitor is installed at the end of the electrostatic nozzle; the electrostatic nozzle monitors and adjusts the flow rate and velocity of the liquid gallium in real time through the flow monitor and the flow rate regulating valve.

[0028] Furthermore, the temperature control module includes a liquid-cooled fan, a duct, a high-pressure airflow generator, a temperature sensor, a controller, a flow regulating valve, a buffer chamber, a diverter, a flow guide plate, an airflow regulator, a pressure monitor, and a feedback regulating switch;

[0029] The liquid cooling fan delivers concentrated air to the buffer chamber through the duct. The output end of the buffer chamber is connected to multiple branch pipes arranged around the grinding area through the flow guide adjustment plate. The outlet ends of the branch pipes are respectively directed towards different positions of the workpiece.

[0030] The high-pressure airflow generator is used to pressurize the airflow blown by the liquid cooling fan to generate high-pressure airflow. The high-pressure airflow is blown by the liquid cooling fan in sequence through the duct, the buffer chamber and the splitter pipe toward the workpiece surface in the grinding area.

[0031] The flow regulating valve is installed at the end of the duct and is used to regulate the flow rate of the high-pressure airflow output from the duct; the feedback regulating switch, the airflow direction regulator, and the pressure monitor are sequentially installed on the diverter pipe along the airflow direction; the airflow direction regulator is used to regulate the airflow direction; the pressure monitor is used to monitor the output pressure of the high-pressure airflow in the diverter pipe; the feedback regulating switch controls the flow guide plate to regulate the flow rate of the high-pressure airflow in the diverter pipe according to the difference between the airflow output pressure monitored by the pressure monitor and the set pressure;

[0032] The temperature sensor is installed in the grinding area to monitor the workpiece temperature in real time and feeds it back to the controller through the feedback adjustment switch; the controller is connected to the liquid cooling fan, the high-pressure airflow generator, the flow regulating valve, the airflow direction regulator, the pressure monitor and the feedback adjustment switch respectively;

[0033] After the temperature sensor detects an abnormal temperature, the controller activates the flow regulating valve to adjust the airflow, activates the feedback regulating switch and the pressure monitor, and adjusts the flow guide plate and the wind direction regulator to control the airflow, pressure and wind direction to regulate the workpiece temperature.

[0034] The beneficial effects of this invention are:

[0035] The forming grinding device for grinding thin-walled gears of the present invention achieves precise spraying of liquid gallium and efficient cooling and lubrication through the synergistic effect of an innovative electrostatic spraying module and a temperature control module. It effectively solves the problem that the coolant is difficult to effectively penetrate deep into the tooth surface during forming grinding of thin-walled gears due to their complex structure and deep tooth grooves, as well as the influence of the grinding wheel air barrier layer. This improves grinding quality and efficiency and is in line with the development concept of high efficiency and energy saving.

[0036] The low melting point of liquid gallium allows it to rapidly absorb heat and lower the workpiece temperature in the grinding zone during high-temperature grinding environments, quickly transitioning from a solid to a liquid state. It also exhibits excellent low friction coefficient and good thermal conductivity. This invention utilizes the phase transition characteristics of liquid gallium at high temperatures to absorb some heat, effectively reducing the workpiece surface temperature. Simultaneously, the high thermal conductivity of liquid gallium rapidly conducts the heat generated during grinding, thereby reducing temperature fluctuations in the heat-affected zone, improving the thermal stability of the workpiece surface, and minimizing thermal damage and deformation. Furthermore, the lubricating properties of liquid gallium effectively lubricate the workpiece surface, reducing damage from grinding forces and further improving grinding quality.

[0037] This invention utilizes precise liquid gallium spraying and efficient cooling via a temperature control module to rapidly absorb and dissipate heat generated during grinding, reducing thermal damage to the workpiece surface. Simultaneously, the cooled liquid gallium forms a uniform solid protective film, minimizing the impact of grinding forces on the workpiece surface and improving surface quality and machining accuracy. This innovative design provides a new technical means for high-precision grinding of thin-walled gears and has broad application prospects.

[0038] The pressurization module of this invention provides stable and reliable pressure for liquid gallium. Through the transmission of pressure waves, the liquid gallium is propelled forward, overcoming the effects of gravity and centrifugal force, and smoothly reaching the charge application module, ensuring the stability and continuity of the entire spraying process. Furthermore, through the cooperation of elastic elements, push blocks, and pressure compensation elements, intermittent delivery of liquid gallium is achieved, avoiding blockages.

[0039] In this invention, the power supply and capacitor energy storage unit in the charge application module constitute a high-voltage electrical energy source, providing a stable voltage to the electric field application cavity. The electrode plates generate a uniform electrostatic field, uniformly charging the liquid gallium particles. A voltage detector and voltage sensing switch monitor the electric field strength in real time, and adjust the voltage via a voltage regulating valve to ensure the stability of the electric field. A uniform electric field conduit further homogenizes the electric field distribution, enabling the liquid gallium to achieve a uniform charged state and maintain a stable trajectory for precise application to the target area. Thus, this invention, by precisely controlling the electrostatic field strength and distribution of the charge application module, ensures that the liquid gallium particles are uniformly charged, guaranteeing that the liquid gallium can be uniformly sprayed onto the workpiece surface in a stable state during transport, forming a uniform protective layer. This uniformity not only improves grinding quality but also reduces liquid gallium waste and increases material utilization. This uniformity control is crucial for improving grinding quality and reducing thermal damage.

[0040] The delivery module of this invention ensures that charged liquid gallium is accurately sprayed onto the surface of the workpiece by adjusting the rotation angle and direction of the electrostatic nozzle. The flow rate and velocity of the liquid gallium are monitored and adjusted in real time by a flow monitor and a flow rate regulating valve to ensure the uniformity of the spraying. The spraying effect is further optimized by a nozzle regulator and a charge matching device to improve the adhesion efficiency of liquid gallium and reduce waste.

[0041] The temperature control module of this invention provides the necessary high-pressure airflow for cooling the grinding area through a liquid-cooled fan and a high-pressure airflow generator. A temperature sensor monitors the workpiece surface temperature in real time, and a controller adjusts the operating frequency of the liquid-cooled fan and the high-pressure airflow generator to regulate the temperature of the workpiece grinding area and maintain it within a reasonable range, enabling dynamic conversion between liquid gallium and solid-liquid states. A buffer chamber and a diversion pipe further optimize the airflow distribution, ensuring the airflow's sealing and stability during transmission. An airflow adjuster and a flow guide plate precisely control the airflow direction, improving the cooling effect.

[0042] This invention integrates the electrostatic spraying module and the temperature control module into a single, compact auxiliary device. This integrated design not only improves the device's portability and ease of installation but also enhances the collaborative working effect between the modules. By optimizing the layout and connection methods of each module, the overall performance and reliability of the device are ensured. This compact design allows the device to be easily integrated into existing grinding equipment without requiring large-scale modifications to the original equipment.

[0043] This invention optimizes the internal flow channel structure of the grinding wheel, ensuring stable flow of liquid gallium during transportation, avoiding blockages and uneven flow, improving the reliability and service life of the device, and reducing maintenance costs. Attached Figure Description

[0044] Figure 1This is a schematic diagram of the forming grinding device for grinding thin-walled gears according to the present invention;

[0045] Figure 2 This is a detailed view of the grinding wheel in this invention;

[0046] Figure 3 This is a structural diagram of the pressurization module in this invention;

[0047] Figure 4 This is a structural diagram of the charge application module in this invention;

[0048] Figure 5 This is a structural diagram of the conveying module in this invention;

[0049] Figure 6 This is a schematic diagram illustrating the principle of electrostatic spraying onto the workpiece surface in this invention;

[0050] Figure 7 This is a diagram of the temperature control structure in this invention.

[0051] Wherein: 1-Grinding wheel, 1.1-Cooling section, 1.1.1-Inner flow channel inlet, 1.1.2-Cathode conductive wire, 1.1.3-Anode conductive wire, 1.1.4-Electric field, 1.1.5-Inner flow channel outlet, 1.2-Grinding section, 2-Reservoir tank, 3-Miniature high-pressure pump, 4-Ring electrode, 5-Slip ring, 6-Workpiece, 7-Pressure regulating valve, 8-Pressure pipe, 8.1-Low pressure range, 8.2-Active range, 8.3-High pressure range, 9-Removable sealed gallium feeding box, 10-Gallium inlet switch, 11-Guide pipe, 1 2-Inlet pipe, 13-Elastic element, 14-Push block, 15-Flow valve, 16-Pressure compensation element, 17-Control switch, 18-Power supply, 19-Conductive wire, 20-Voltage detector, 21-Capacitor energy storage, 22-Voltage regulating valve, 23-Electric field application cavity, 23.1-Low electric field intensity range, 23.2-Buffer zone, 23.3-High electric field intensity range, 24-Removable sealed gallium storage cavity, 25-Uniform electric field conduit, 26-Electrode access pipe, 27-Insulating elastic element, 28-Electrode plate, 29- 30-Current valve, 31-Voltage sensing switch, 32-Control switch, 33-Electrostatic field, 34-Rotating motor, 35-Angle adjuster, 36-Transmission gear, 37-Rotating shaft, 38-Fixed bracket, 39-Flexible connector, 39-Electrostatic nozzle, 39.1-Starting range, 39.2-Uniform speed range, 39.3-Spraying range, 40-Flow monitor, 41-Flow rate regulating valve, 42-Nozzle adjuster, 43-Charge matching device, 44-Guide tube, 45-End nozzle, 46-High-pressure airflow duct interface. 47-Cooling air mechanism, 48-Liquid cooling fan, 49-Duct, 50-High pressure airflow generator, 51-Temperature sensor, 52-Controller, 53-Flow regulating valve, 54-Buffer chamber, 54.1-Inlet section, 54.2-Pressure stabilization section, 54.3-Outlet section, 55-Diverter pipe, 56-Flow guide plate, 57-Airflow direction adjuster, 58-Pressure monitor, 59-Feedback adjustment switch, 60-Support base, 61-Top tip, 62-Negative pressure nozzle, 63-Centrifugal filter module, 64-Return pipe. Detailed Implementation

[0052] To enable those skilled in the art to better understand the technical solutions of this application, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments.

[0053] The directional terms such as above, below, left, right, front, and back used in this application are based on the positional relationships shown in the attached drawings. Different attached drawings may result in different positional relationships, therefore they should not be interpreted as limitations on the scope of protection.

[0054] In this invention, the terms "installation," "connection," "interlocking," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, an integral connection, a mechanical connection, an electrical connection, or a connection that allows communication between components. They can also refer to a direct connection or an indirect connection through an intermediate medium. Furthermore, they can refer to the internal connection of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of these terms in this invention based on the specific circumstances.

[0055] In traditional grinding processes, due to the complex structure and deep tooth grooves of thin-walled gears, and the influence of the air barrier layer of the grinding wheel, the coolant cannot effectively penetrate into the depth of the tooth surface, resulting in excessively high workpiece surface temperature and affecting workpiece surface quality.

[0056] This embodiment discloses a forming grinding device for grinding thin-walled gears. It innovatively utilizes the synergistic effect of an electrostatic spraying module and a temperature control module to solve the problem that due to the complex structure and deep tooth grooves of thin-walled gears, and the influence of the grinding wheel air barrier layer, the coolant is difficult to effectively penetrate deep into the tooth surface. This effectively improves the grinding quality, is highly efficient and energy-saving, and provides a new technical means for high-precision grinding of thin-walled gears.

[0057] In this embodiment, liquid gallium is used as the coolant. Gallium has a low melting point, approximately 29.8°C. When gallium is solid, it can form a support coating on the workpiece surface during grinding, reducing workpiece surface deformation. When solid gallium absorbs heat and turns into liquid gallium, it can lower the grinding temperature, providing a cooling effect. Furthermore, the liquid gallium forms a protective film on the workpiece surface, effectively lubricating the grinding area, reducing damage to the workpiece from grinding forces, and improving grinding quality.

[0058] like Figure 1 As shown, the forming grinding device includes a grinding wheel 1, an electrostatic spraying module, a temperature control module, a liquid storage tank 2, a micro high-pressure pump 3, a ring electrode 4, and a slip ring 5.

[0059] In this embodiment, the grinding wheel 1 is a diamond grinding wheel with an internal flow channel structure, including a cooling part 1.1 and a grinding part 1.2. The cooling part 1.1 and the grinding part 1.2 are coaxially arranged, and the drive mechanism drives the grinding part 1.2 to rotate and grind the workpiece 6 through the output shaft.

[0060] Cooling section 1.1 is used to spray liquid gallium onto workpiece 6. It is made of metal matrix composite material and has internal flow channels designed with a gradient pore structure, such as... Figure 2As shown, the inner flow channel is divided into three layers from the inside to the outside along the radial direction: inner, middle, and outer. The inner layer is the axial main liquid supply pipe, which is used to pressurize and transport liquid gallium to the middle layer. The inner layer has an inner flow channel inlet 1.1.1 in the center. The middle layer is an annular pressure stabilizing cavity. Liquid gallium particles are uniformly charged in this annular pressure stabilizing cavity. Cathode conductive wires 1.1.2 and anode conductive wires 1.1.3 are arranged at intervals on the outer side of the annular pressure stabilizing cavity. After the anode conductive wires 1.1.3 and cathode conductive wires 1.1.2 are energized, an electric field 1.1.4 is formed in the annular pressure stabilizing cavity. The outer layer has at least one output channel embedded in it. The output channel is located on the side of the grinding wheel 1 close to the workpiece 6, and its outlet faces the surface of the workpiece 6. In this embodiment, two output channels are symmetrically arranged to ensure that the spray area of ​​liquid gallium covers the entire surface of the workpiece 6. The outer end of the output channel is the inner flow channel outlet 1.1.5. The charged liquid gallium is atomized and sprayed through the output channel.

[0061] The grinding section 1.2 consists of a grinding wheel base and an abrasive layer. The abrasive layer is fixed on the outer circumference of the grinding wheel base. The grinding wheel base rotates under the drive of a drive mechanism, and the workpiece 6 is ground by the abrasive layer. Preferably, the grinding wheel base is made of a metal matrix composite material, and the abrasive layer is a diamond grinding layer. The abrasive layer forms a metallurgical bond with the grinding wheel base through a high-temperature sintering process, ensuring that the abrasive layer is firmly attached when the grinding wheel base rotates at high speed. When grinding the workpiece 6, the abrasive layer contacts and grinds the surface of the workpiece 6.

[0062] The electrostatic spraying module is installed in the inner flow channel of the cooling section 1.1. The electrostatic spraying module is used to accurately and uniformly spray liquid gallium onto the surface of the workpiece 6 being ground by the grinding wheel 1, forming a protective layer on the surface of the workpiece 6 and reducing the damage to the workpiece 6 caused by the grinding force.

[0063] The electrostatic spraying module of this embodiment includes a pressurization module, a charge application module, and a delivery module. The pressurization module, charge application module, and delivery module are respectively disposed in the inner layer, middle layer, and outer layer of the inner flow channel.

[0064] The pressurization module is used to pressurize liquid gallium, enabling it to overcome gravity and reach the charge application module. For example... Figure 3 As shown, the pressurization module includes a pressure regulating valve 7, a pressurization pipe 8, a detachable sealed gallium delivery box 9, a gallium inlet switch 10, a guide pipe 11, a liquid inlet pipe 12, an elastic element 13, a push block 14, a flow valve 15, a pressure compensation element 16, and a control switch 17. The pressure regulating valve 7, the gallium inlet switch 10, the flow valve 15, the pressure compensation element 16, and the control switch 17 are all connected to the central control unit.

[0065] Pressure regulating valve 7 is located at the inlet 1.1.1 of the inner flow channel. Its inlet is connected to the liquid gallium delivery device, and its outlet is connected to the inlet pipe of the removable sealed gallium delivery box 9, which is mainly used for storing and delivering liquid gallium. Pressure regulating valve 7 is used to adjust the pressure of liquid gallium entering the removable sealed gallium delivery box 9, ensuring that the liquid gallium enters the pressurization module stably at a predetermined initial pressure.

[0066] The first output port of the detachable sealed gallium delivery box 9 is connected to the guide pipe 11 via the pressurization pipe 8, and the second output port of the detachable sealed gallium delivery box 9 is connected to the detachable sealed gallium storage cavity 24 of the charge application module via the gallium inlet switch 10. The gallium inlet switch 10 is used to switch the connection between the detachable sealed gallium delivery box 9 and the detachable sealed gallium storage cavity 24. In this embodiment, the detachable sealed gallium delivery box 9 is made of plastic or other materials that do not react with gallium.

[0067] In this embodiment, the pressurizing pipe 8, the detachable sealed gallium delivery box 9, and the guide pipe 11 can be connected by flange sealing, which facilitates disassembly and assembly while ensuring a sealed connection between the pressurizing pipe 8, the detachable sealed gallium delivery box 9, and the guide pipe 11, thus forming a closed liquid gallium delivery channel to prevent the liquid from being disturbed by external factors or leaking during the delivery process.

[0068] A liquid-pushing assembly, consisting of an elastic element 13, a pusher block 14, a pressure compensation element 16, a control switch 17, and a drive element, is installed in the middle of the guide tube 11. The pusher block 14 is installed inside the guide tube 11, and its upper end is connected to the drive element. Under the action of the drive element, the pusher block 14 pushes the liquid gallium inside the guide tube 11 forward. The drive element is connected to the central control unit via the control switch 17, which starts or stops the drive element under the control of the central control unit. The elastic element 13 is installed on the guide tube 11 and connected to the front side of the pusher block 14 (i.e., near the pressure pipe 8). When delivery needs to be stopped, the drive element stops, and the elastic element 13 pulls the pusher block 14 back to its original position for the next pushing action. The pressure compensation element 16 is installed on the guide tube 11 near the pusher block 14 and is used to monitor pressure changes inside the guide tube 11 in real time and feed the pressure difference back to the central control unit. When the pressure reaches the set threshold, the pressure compensation element 16 is triggered. The central control unit controls the drive element to start or stop via the control switch 17, thereby controlling the movement of the pusher block 14. This causes the pusher block 14 to periodically squeeze the liquid gallium, forming a pulsed pressure wave within the pressurization pipe 8, which drives the liquid gallium to flow, thus achieving intermittent delivery of liquid gallium and preventing subsequent pipeline blockage. In addition, a safety pressure relief valve is installed on the guide pipe 11 to release pressure when the internal pressure of the guide pipe 11 exceeds the limit, ensuring the safety of the device.

[0069] The flow valve 15 is installed at the end of the guide pipe 11. The flow valve 15 is connected to the uniform electric field conduit 25 of the charge application module through the inlet pipe 12. The flow valve 15 is used to control the flow rate of liquid gallium flowing into the uniform electric field conduit 25 from the pressurization module.

[0070] The pressurizing tube 8 has a tapered structure, meaning its inner diameter on the input side is larger than its inner diameter on the output side. A first movable partition in the input side cavity divides the cavity along the conveying direction into a low-pressure zone 8.1 and an active zone 8.2, while the output side cavity is a high-pressure zone 8.3. Liquid gallium conveyed by the detachable, sealed gallium delivery box 9 sequentially passes through the low-pressure zone 8.1, active zone 8.2, and high-pressure zone 8.3. Under the periodic pushing of the liquid pushing component, the liquid gallium generates pressure waves in the low-pressure zone 8.1, active zone 8.2, and high-pressure zone 8.3. The liquid pushing component, along with the pressure regulating valve 7, pressure compensation element 16, control switch 17, and flow valve 15, works in concert to propel the liquid gallium forward. In this embodiment, the pressurizing tube 8, through its tapered structure, can increase the pressure within the high-pressure zone 8.3, thereby enhancing the transmission efficiency of the pressure waves. The guide tube 11 has the same diameter as the output side of the pressurizing tube 8.

[0071] In this embodiment, the first movable partition is a movable piston partition. When liquid gallium flows in a directional manner, a pressure difference is generated in the adjacent intervals. When the pressure difference exceeds a threshold, the piston of the movable partition is moved by the pressure difference, which can open the channel with the adjacent interval and allow the liquid gallium to flow to the next interval.

[0072] After the pressurization module is activated, the pressure regulating valve 7 is opened, and liquid gallium enters the detachable sealed gallium delivery box 9. The liquid gallium then enters the pressurization pipe 8 through the first output port, and sequentially passes through the low-pressure zone 8.1, the active zone 8.2, and the high-pressure zone 8.3 before entering the guide pipe 11. Under the combined effects of the gradually narrowing structure of the pressurization pipe 8 accelerating the liquid gallium flow, the intermittent delivery of liquid gallium by the liquid pushing component, and the dynamic pressure adjustment by the pressure compensation element 16, a "specific guiding effect" is formed in the guide pipe 11, ultimately achieving efficient and stable delivery of liquid gallium, providing a uniform and controllable fluid basis for subsequent electrostatic spraying. In addition, after the gallium inlet switch 10 is turned on, a portion of the liquid gallium in the detachable sealed gallium delivery box 9 simultaneously enters the detachable sealed gallium storage cavity 24 of the charge application module for charge loading.

[0073] The charge application module is set in the annular voltage stabilizing cavity and is connected to the detachable sealed gallium delivery box 9 through the gallium inlet switch 10. It uses an electrostatic field to make the liquid gallium particles delivered by the detachable sealed gallium delivery box 9 to the charge application module uniformly charged and atomized, ensuring that the liquid gallium can be sprayed onto the surface of the workpiece 6 in a stable charged atomized state.

[0074] like Figure 4As shown, the charge application module includes a power supply 18, a conductive line 19, a voltage detector 20, a capacitor energy storage device 21, a voltage regulating valve 22, an electric field application cavity 23, a detachable sealed gallium storage cavity 24, a uniform electric field conduit 25, an electrode access pipe 26, an insulating elastic element 27, an electrode plate 28, a current valve 29, a voltage sensing switch 30, and a control switch 31. The power supply 18 can be connected to an external power supply circuit via a power line, and can also be a storage element. The voltage detector 20, voltage regulating valve 22, current valve 29, voltage sensing switch 30, and control switch 31 are respectively connected to the central control unit via wires.

[0075] Electrode access pipe 26 is installed at the upper end of the electric field application cavity 23 and is connected to one end of voltage regulating valve 22 via current valve 29 and conductive line 19. The other end of voltage regulating valve 22 is connected to one end of a high-voltage power source consisting of power supply 18 and capacitor energy storage device 21 connected in parallel. The other end of the high-voltage power source is connected to electrode plate 28 located on the lower side of the electric field application cavity 23 via conductive line 19 after passing through voltage sensing switch 30. Voltage sensing switch 30 is used to control the on / off state of the circuit. In this embodiment, power supply 18 and capacitor energy storage device 21 constitute a high-voltage power source. When power supply 18 supplies power, capacitor energy storage device 21 stores electrical energy, providing a stable high-voltage current for the generation of electrostatic field 23, making electrostatic field 32 stable and uniform, which is beneficial for achieving uniform charging of liquid gallium particles. Voltage regulating valve 22 and current valve 29 are used to regulate the voltage and current released by the high-voltage power source, respectively.

[0076] The voltage detector 20 is installed on the electric field application cavity 23 to monitor the voltage in real time. The voltage detector 20 and the voltage sensing switch 30 monitor the electric field strength in real time and feed the electric field strength back to the voltage regulating valve 22. The voltage regulating valve 22 adjusts the output voltage of the high voltage power source. At the same time, the current valve 29 works with the voltage regulating valve 22 to control the current transmission, thereby adjusting the strength of the electrostatic field 32 and ensuring the stability of the electric field.

[0077] The electric field application cavity 23 is divided into a low electric field intensity zone 23.1, a buffer zone 23.2, and a high electric field intensity zone 23.3 in sequence along the charge transport direction by two second movable partitions.

[0078] The second movable partition used in this embodiment is a pressure-responsive elastic diaphragm or a sliding partition. As the liquid gallium flows in a directional manner, the liquid gallium pressure increases. Through the pressure difference, the channel closed by the diaphragm can be opened, or the partition can be pushed to move and open the channel, allowing the liquid gallium to flow to the next zone.

[0079] The detachable sealed gallium storage cavity 24 and the uniform electric field conduit 25 are respectively connected to the inlet and outlet of the electric field application cavity 23 by flange sealing. The detachable sealed gallium storage cavity 24 is connected to the detachable sealed gallium delivery box 9 by the gallium inlet switch 10. The detachable sealed gallium storage cavity 24 is used to store the liquid gallium delivered into the charge application module by the detachable sealed gallium delivery box 9 and to deliver the liquid gallium to the electric field application cavity 23.

[0080] The uniform electric field conduit 25 is located within the electric field 1.1.4 set in the inner flow channel of the grinding wheel 1. It includes two inlets and one outlet. One inlet is connected to the electric field application cavity 23, and the other inlet is connected to the liquid inlet pipe 12. This allows the charged liquid gallium in the electric field application cavity 23 and the high-pressure liquid gallium introduced by the guide pipe 11 to enter the uniform electric field conduit 25 through the inlets. Under the action of the electric field 1.1.4, the uniform electric field conduit 25 in this embodiment makes the liquid gallium inside it uniformly charged and uniformly distributed, which plays a uniform field effect. At the same time, it increases the pressure of the liquid gallium inside the uniform electric field conduit 25. Under the action of the electric field 1.1.4, the charge application module can also guide the flow of liquid gallium to maintain a stable movement trajectory, and further enhance the stability of the charged atomization of liquid gallium particles. The output port of the uniform electric field conduit 25 is connected to at least one control switch 31. The number of control switches 31 corresponds to the number of output channels in the grinding wheel 1. The uniform electric field conduit 25 is connected to the input terminal of the electrostatic nozzle 39 of the delivery module through the control switch 31. The control switch 31 is used to control the on / off state of the charge application module and the electrostatic nozzle 39.

[0081] An insulating elastic element 27 is provided below the electrode plate 28 inside the electric field application cavity 23 to prevent high voltage leakage. The insulating elastic element 27 can be composed of multiple small insulating elastic elements or can be a ring-shaped insulating elastic element.

[0082] The voltage regulating valve 22, voltage sensing switch 30, and current valve 29 are opened sequentially to establish an electrostatic field 32 in the electric field application chamber 23. After the electrostatic field 32 stabilizes, the gallium inlet switch 10 is turned on, and the liquid gallium in the detachable sealed gallium delivery box 9 enters the low electric field strength zone 23.1 through the detachable sealed gallium storage chamber 24. The electric field force generated in the electric field application chamber 23 pushes the liquid gallium from the low electric field strength zone 23.1 into the buffer zone 23.2 and the high electric field strength zone 23.3 in sequence, and moves towards the uniform electric field conduit 25. When the liquid gallium moves in the electric field application chamber 23, the liquid gallium particles are charged and atomized under the action of the electrostatic field 32. After the liquid gallium enters the uniform electric field conduit 25, it is uniformly charged and maintains a stable movement trajectory due to the uniform field effect of the uniform electric field conduit 25. The control switch 31 is turned on to send the liquid gallium into the delivery module so that it can be accurately applied to the target area in the future.

[0083] The conveying module further atomizes the liquid gallium through the electrostatic nozzle 39 and precisely sprays it onto the surface of the workpiece 6 with the opposite charge. Under the high-pressure airflow generated by the high-speed grinding of the grinding wheel 1, the atomized liquid gallium quickly forms a uniform coating on the surface of the workpiece 6. After being converted into a solid, it effectively suppresses the local deformation of the workpiece 6 during the grinding process.

[0084] like Figure 5 and Figure 6 As shown, the conveying module includes a rotary motor 33, an angle adjuster 34, a transmission gear 35, a rotating shaft 36, a fixed bracket 37, a flexible connector 38, an electrostatic nozzle 39, a flow monitor 40, a flow rate regulating valve 41, a nozzle adjuster 42, a charge matching device 43, a guide tube 44, and an end nozzle 45.

[0085] The output shaft of the rotary motor 33 is coaxially and fixedly connected to the transmission gear 35 via the rotary shaft 36. The angle adjuster 34 is meshed with the transmission gear 35, and its outer end is connected to the flexible connector 38. The rotary motor 33 drives the transmission gear 35 to rotate via the rotary shaft 36, and the transmission gear 35 drives the angle adjuster 34 to rotate through meshing transmission, thus forming the power transmission system of the angle adjuster 34. The upper and lower ends of the flexible connector 38 are respectively connected to the output end of the electrostatic nozzle 39 and the input end of the guide tube 44 with the end nozzle 45 through a sealing sleeve. The sealing sleeve ensures the sealing and stability of the liquid gallium during the conveying process. The power transmission system drives the guide tube 44 to rotate to a specific angle and direction through the angle adjuster 34, so that the end nozzle 45 can accurately spray the charged liquid gallium onto the surface of the workpiece 6. That is, the power transmission system can provide the rotational power required by the guide tube 44 to adjust the spray angle of the end nozzle 45 during the conveying of liquid gallium.

[0086] A mounting bracket 37 is fixedly installed on the top of the rotating shaft 36 above the angle adjuster 34 to prevent the angle adjuster 34 and the transmission gear 35 from moving up and down.

[0087] In addition, the rotary motor 33 is connected to the power supply device (which can be an external power source or a battery or other energy storage device) via the charge matching device 43 to ensure that the power supply device supplies power to the rotary motor 33 with a predetermined voltage and a predetermined current, so as to ensure that the electrostatic nozzle 39 rotates stably at a predetermined angle.

[0088] In this embodiment, the electrostatic nozzle 39 is a flexible nozzle. A flow rate regulating valve 41 and a flow rate monitor 40 are respectively installed at the upper and lower ends of the electrostatic nozzle 39. The electrostatic nozzle 39 is connected to the control switch 31 on the uniform electric field conduit 25 via the flow rate regulating valve 41. The electrostatic nozzle 39 can monitor and adjust the flow rate and velocity of the liquid gallium in real time through the flow rate monitor 40 and the flow rate regulating valve 41, ensuring the stability of the pressure and speed of the liquid gallium spray, thereby ensuring the uniformity of the coating onto the surface of the workpiece 6.

[0089] In this embodiment, the end nozzle 45 is installed at the output end of the guide tube 44 via the nozzle adjuster 42, and is located at the outlet 1.1.5 of the inner flow channel of the cooling section 1.1 of the grinding wheel 1, i.e., at the outlet of the output channel. The guide tube 44 is a straight tube used to specifically guide the jet of liquid gallium, and the nozzle adjuster 42 can be used to adjust the opening size of the end nozzle 45.

[0090] The end nozzle 45 has multiple small-diameter outlets and a wear-resistant surface, which can atomize liquid gallium and uniformly cover the surface of the workpiece 6 during the grinding process. Preferably, in this embodiment, the outlet diameter of the end nozzle 45 is 0.05-0.15 mm, and the surface of the end nozzle 45 is coated with a titanium nitride wear-resistant layer.

[0091] In addition, the flexible connector 38 has a high-pressure airflow duct interface 46, which is connected to the flow channel 44.1 in the guide tube 44. The high-pressure airflow duct interface 46 is connected to the cooling air mechanism 47 through the pipeline. The cooling air mechanism 47 blows high-pressure airflow into the flow channel 44.1 through the high-pressure airflow duct interface 46 to accelerate the ejection speed of liquid gallium.

[0092] A ring electrode 4 is installed at the end of the guide tube 44 to further stabilize the electrical stability of liquid gallium.

[0093] The interior of the electrostatic nozzle 39 consists of, from top to bottom, the initial zone 39.1, the constant speed zone 39.2, and the spray zone 39.3.

[0094] During the injection process, the flow monitor 40, the flow rate regulating valve 41, the nozzle regulator 42, and the charge matching device 43 operate and adjust in a predetermined sequence to control the flow rate and velocity of liquid gallium in the electrostatic nozzle 39, ensuring that the liquid gallium can be accurately and stably delivered to the target location.

[0095] Specifically:

[0096] When liquid gallium enters the electrostatic nozzle 39, as it moves from the initial zone 39.1 to the uniform velocity zone 39.2, the flow monitor 40 detects the flow rate in real time, and the flow rate regulating valve 41 dynamically adjusts the flow rate. Under the coordinated action of the power transmission system, the flow monitor 40, and the flow rate regulating valve 41, the electrostatic nozzle 39 smoothly moves the liquid gallium in a predetermined direction. The direction is calibrated by the guide tube 44, ensuring that the liquid gallium in the guide channel 44.1 is precisely sprayed onto the surface of the workpiece 6 through the end nozzle 45. During grinding of the workpiece 6, the end nozzle 45, under the action of the angle adjuster 34, maintains the atomization angle between 15° and 30°, further improving the adhesion efficiency of the liquid gallium. In this embodiment, the nozzle adjuster 42 adjusts the opening of the end nozzle 45 to further optimize the atomization angle, and the charge matching device 43 ensures the stability of the power supply to the rotary motor 33 to stabilize the electric field, forming a closed-loop linkage control. This ensures the stability of the liquid gallium spray posture, further optimizing the spray effect, improving the adhesion efficiency of the liquid gallium, and reducing waste.

[0097] The temperature control module is located in the grinding area and is used to regulate the surface temperature of workpiece 6, keeping it within a reasonable range. For example... Figure 7 As shown, the temperature control module includes a liquid-cooled fan 48, a duct 49, a high-pressure airflow generator 50, a temperature sensor 51, a controller 52, a flow regulating valve 53, a buffer chamber 54, a diverter 55, a flow guide plate 56, an airflow direction adjuster 57, a pressure monitor 58, a feedback adjustment switch 59, and an air supply duct. The controller 52 is installed on the air supply duct and is connected to the liquid-cooled fan 48, the high-pressure airflow generator 50, the flow regulating valve 53, the flow guide plate 56, the airflow direction adjuster 57, the pressure monitor 58, the feedback adjustment switch 59, and the central control unit, respectively.

[0098] The liquid-cooled fan 48 and the duct 49 are respectively installed inside the air supply duct. The air outlet of the liquid-cooled fan 48 faces one end of the duct 49, and the other end of the duct 49 is connected to the input end of the buffer chamber 54, so that the liquid-cooled fan 48 can concentrate and blow cold air into the buffer chamber 54 through the duct 49. The output end of the buffer chamber 54 is connected to multiple branch pipes 55 arranged around the grinding area through the flow guide adjustment plate 56. The outlet ends of the branch pipes 55 face different positions of the workpiece 6. The flow guide adjustment plate 56 is used to control the on / off state and the opening size of the inlet of each branch pipe 55.

[0099] A high-pressure airflow generator 50 is installed on the air supply duct to pressurize the airflow within the duct, generating a high-pressure airflow. This high-pressure airflow, propelled by the liquid-cooled fan 48, is blown along the duct 49, buffer chamber 54, and splitter pipe 55 towards the grinding area. Thus, the liquid-cooled fan 48 and the high-pressure airflow generator 50 constitute a high-pressure airflow source, providing the necessary high-pressure airflow for cooling the grinding area and consequently the workpiece 6. The operating frequencies of the liquid-cooled fan 48 and the high-pressure airflow generator 50 can be adjusted under the control of the controller 52 to ensure that the temperature of the workpiece 6 in the grinding area is controlled within a reasonable range.

[0100] In this embodiment, the buffer chamber 54 is connected to the conduit 49 and the diverter 55 by a sealed sleeve to ensure the airtightness and stability of the airflow during transmission. The design of the buffer chamber 54 and the diverter 55 can further optimize the airflow distribution and ensure the airtightness and stability of the airflow during transmission.

[0101] A flow regulating valve 53 is installed at the end of the conduit 49 to regulate the flow rate of the high-pressure airflow output from the conduit 49. Along the airflow direction, the splitter pipe 55 is sequentially equipped with a feedback regulating switch 59, an airflow direction regulator 57, and a pressure monitor 58. The airflow direction regulator 57 is used to regulate the airflow direction; it works in conjunction with the flow guide plate 56 to adjust the direction of the high-pressure airflow within the grinding area, thereby precisely controlling the airflow direction and improving the cooling effect on the workpiece 6. The pressure monitor 58 is used to monitor the output pressure of the high-pressure airflow within the splitter pipe 55. The feedback regulating switch 59 can control the flow guide plate 56 to adjust the flow rate of the high-pressure airflow within the splitter pipe 55 based on the difference between the airflow output pressure monitored by the pressure monitor 58 and the set pressure.

[0102] Multiple temperature sensors 51 are installed on the grinding area and matched with the cooling area of ​​each shunt pipe 55 (such as the detection positions on the surface of the workpiece 6) to monitor the temperature of the workpiece 6 in the grinding area in real time. The temperature is fed back to the controller 52 through the feedback adjustment switch 59 so that the controller 52 can adjust the working status of each component of the temperature control module in a timely manner to ensure the temperature control effect.

[0103] In this embodiment, the buffer chamber 54 is divided into an air inlet section 54.1, a pressure stabilizing section 54.2, and an air outlet section 54.3 by two second movable partitions along the airflow direction. Under the action of airflow pressure difference, the second movable partitions can sequentially open the pressure stabilizing section 54.2 and the air outlet section 54.3.

[0104] In this embodiment, after the temperature sensor 51 detects a temperature anomaly, the controller 52 activates the flow regulating valve 53 to adjust the airflow. Simultaneously, it controls the airflow direction adjuster 57 to correct the airflow angle, directing the high-pressure airflow towards the high-temperature area. The greater the temperature difference, the greater the adjustment range of the airflow or airflow direction. Finally, the feedback regulating switch 59, in conjunction with the pressure monitor 58, detects the airflow pressure and fine-tunes the guide plate 56 to ensure that the airflow accurately covers the high-temperature area. While adjusting the airflow and airflow direction, the controller also controls the airflow and pressure in each section of the buffer chamber 54, thereby generating suitable airflow to regulate the temperature of the grinding area.

[0105] In addition, in this embodiment, liquid gallium can be supplied to the grinding wheel 1 via a storage tank 2 and a miniature high-pressure pump 3. The output port of the storage tank 2 is connected to the input port of the miniature high-pressure pump 3. The miniature high-pressure pump 3 is installed on the cooling section 1.1 of the grinding wheel 1, and its output port is connected to the inlet of the pressure regulating valve 7, pumping the liquid gallium in the storage tank 2 into the removable, sealed gallium delivery box 9 inside the cooling section 1.1. In this embodiment, a semiconductor heating system is installed inside the storage tank 2 to maintain the metallic gallium in a liquid state.

[0106] The data cables, power cables, etc. used in the cooling section 1.1 are connected to the central control unit, power supply device, etc. outside the device through the slip ring 5 set at the inlet of the inner flow channel 1.1.1.

[0107] The workpiece 6 is ground using the forming grinding apparatus for grinding thin-walled gears according to this embodiment. Taking a roller screw as an example, the forming grinding process of the external thread of the roller screw by the forming grinding apparatus of this embodiment is explained. The distance between the end nozzle 45 and the surface of the workpiece 6 is 5mm-10mm, and the temperature control module is located below the workpiece 6.

[0108] In this embodiment, the forming grinding apparatus supports the workpiece 6 in the grinding area below the grinding wheel 1 via a platform assembly consisting of a servo motor, a push rod, and a support base 60. Two servo motors are symmetrically arranged on the support base 60, with their output shafts connected to the push rod. A center 61 is mounted on the outer end of the push rod. Both ends of the workpiece 6 abut against the center 61. After the two centers 61 clamp the workpiece 6, the two servo motors rotate synchronously in opposite directions at the same speed, driving the workpiece 6 to rotate via the push rod and center 61. This allows the grinding wheel 1 to grind the surface of the workpiece 6 and for liquid gallium to uniformly cover the surface of the workpiece 6.

[0109] In addition, the forming grinding apparatus of this embodiment is also equipped with a recovery module for recovering liquid gallium. The recovery module includes a negative pressure suction nozzle 62, a centrifugal filter 63, and a return pipe 64. The negative pressure suction nozzle 62 is located on one side of the grinding wheel 1. The output end of the negative pressure suction nozzle 62 is connected to the input end of the centrifugal filter 63 through a pipe. The output end of the centrifugal filter 63 is connected to the storage tank 2 through the return pipe 64. The negative pressure suction nozzle 62 is used to suck up the mixture of liquid gallium and grinding debris, powder, etc., that are thrown up by the high-pressure airflow generated by the grinding wheel 1. The negative pressure suction nozzle 62 conveys the mixture to the centrifugal filter 63 for centrifugal filtration. The filtered liquid gallium flows back to the storage tank 2 through the return pipe 64 and can continue to participate in the cooling operation to reduce losses. In addition, the mixture of liquid gallium and debris, powder, etc., that flows onto the support base 60 can also be conveyed to the centrifugal filter 63 through a pipe for centrifugal filtration to improve the recovery rate of liquid gallium.

[0110] The forming grinding device utilizes electrostatic spraying to uniformly cover the surface of the workpiece 6, which carries an opposite charge (e.g., the workpiece 6 can be charged by the electric field at the end of the conveying module, electrostatic induction, or electron beam irradiation). Under the impact of the high-pressure airflow from the temperature control module, the liquid gallium rapidly transforms from liquid to solid, providing support on the surface of the workpiece 6. This effectively suppresses local deformation during grinding, improving the tooth profile machining accuracy and surface quality of thin-walled gears. As the grinding wheel 1 grinds the workpiece 6, it generates a large amount of heat, causing the solid gallium to transform back into liquid gallium at high temperatures. This heat is then carried away, reducing the grinding temperature and achieving efficient cooling and lubrication.

[0111] The specific steps are as follows:

[0112] a. Workpiece 6 is mounted on the platform assembly to ensure that the servo motor can drive workpiece 6 to rotate at a predetermined speed;

[0113] The semiconductor heating system of the storage tank 2 is activated to maintain the metallic gallium in the storage tank 2 in a liquid state and pressurize it to a predetermined pressure; at the same time, the micro high-pressure pump 3 pumps the liquid gallium in the storage tank 2 into the detachable sealed gallium delivery box 9 at a pressure of 10-50 MPa; the control switch 17 is activated to maintain the pressure fluctuation of the pressure tube 8 in the active range 8.2 of <±5% through the liquid pushing component, the working pressure in the high pressure range 8.3 is 20-50 MPa, and the working pressure in the low pressure range 8.1 is 5-15 MPa;

[0114] b. Turn on the gallium inlet switch 10 and the liquid flow valve 15. Under the drive of the high-pressure liquid, a portion of the liquid gallium is pressurized through the pressurization pipeline and enters the uniform electric field conduit 25. The other portion enters the electric field application chamber 23 through the detachable sealed gallium storage chamber 24. Under the action of the electrostatic field 32 of the electric field application chamber 23, the particles are charged and sent to the uniform electric field conduit 25.

[0115] Before the gallium-inlet switch 10 is turned on, the power supply 18 is started, and the capacitor energy storage device 21 provides a stable high-voltage current for the subsequent electric field generation. The electrode plate 28 generates a uniform electrostatic field 32 in the electric field application cavity 23. At the same time, the electric field 1.1.4 of the uniform electric field conduit 25 is activated.

[0116] To ensure stable atomization and spraying of liquid gallium under the influence of an electric field, the control switch 17 is temporarily closed before opening the flow valve 15. This prevents liquid gallium from flowing into the uniform electric field conduit 25 before the electric field has stabilized, thus ensuring the stability of the electric field and the uniform charging of the liquid gallium. After confirming that the liquid gallium has been stably delivered to the electric field region, the control switch 17 is restarted, and the flow valve 15 is opened simultaneously. The electric field 1.1.4 is used to uniformly charge all the liquid gallium in the uniform electric field conduit 25.

[0117] During the liquid gallium transport process, the pressure compensation element 16 monitors the pressure in real time to ensure that the pressure in the active zone 8.2, high pressure zone 8.3 and low pressure zone 8.1 within the pressurization tube 8 all meet the predetermined standards.

[0118] c. Turn on control switch 31, and the delivery module sprays liquid gallium onto the surface of workpiece 6. Under the combined action of high-pressure liquid flow and uniform electric field, the liquid gallium is atomized at electrostatic nozzle 39, decomposed into tiny particles, and then sprayed out from end nozzle 45 after passing through electrostatic nozzle 39. The electrostatic field causes the atomized liquid gallium particles to be oriented by Coulomb force, accurately and uniformly sprayed onto the surface of workpiece 6.

[0119] d. While the grinding wheel 1 is grinding the surface of the workpiece 6, the temperature control module is activated.

[0120] Under the action of the high-pressure airflow blown by the temperature control module, the atomized liquid gallium sprayed onto the surface of workpiece 6 quickly changes from liquid to solid, forming a uniform support coating on the surface of workpiece 6, thereby effectively suppressing local deformation of workpiece 6 during the grinding process. As the grinding wheel 1 rotates at high speed to grind workpiece 6 and generates a large amount of heat, the solid gallium locally liquefies again, and takes away the heat with its good thermal conductivity, thereby reducing the grinding temperature.

[0121] e. The fallen liquid gallium and debris enter the recycling module together. After centrifugation, the liquid gallium is recycled and reused.

[0122] Although the principles of the present invention have been described in detail above with reference to preferred embodiments, those skilled in the art should understand that the above embodiments are merely illustrative explanations of the implementation of the present invention and are not intended to limit the scope of the present invention. The details in the embodiments do not constitute a limitation on the scope of the present invention. Any obvious changes, such as equivalent transformations or simple substitutions, based on the technical solutions of the present invention without departing from the spirit and scope of the present invention fall within the protection scope of the present invention.

Claims

1. A forming grinding apparatus for grinding thin-walled gears, characterized in that, The forming grinding device includes an electrostatic spraying module, a temperature control module, and a grinding wheel (1); The grinding wheel (1) has an inner flow channel, and the electrostatic spraying module is placed inside the inner flow channel for spraying liquid gallium onto the surface of the workpiece (6) being ground by the grinding wheel (1); the electrostatic spraying module includes a pressure module, a charge application module and a transport module; The pressurization module includes a detachable sealed gallium delivery box (9) and a pressurization pipeline, and the charge application module includes an electric field application cavity (23), a detachable sealed gallium storage cavity (24), a uniform electric field conduit (25), a high-voltage electric energy source, and an electrode plate (28). The detachable sealed gallium delivery box (9) is connected to the input end of the pressurized pipeline and the detachable sealed gallium storage cavity (24) respectively; the detachable sealed gallium storage cavity (24) is connected to the uniform electric field conduit (25) through the electric field application cavity (23), and the output end of the pressurized pipeline is connected to the uniform electric field conduit (25); the uniform electric field conduit (25) is located in the electric field (1.1.4) set in the inner channel of the grinding wheel (1); After the liquid gallium is delivered to the detachable sealed gallium delivery box (9), a portion of it is pressurized through the pressurization pipeline and enters the uniform electric field conduit (25), while a portion of the liquid gallium enters the electric field application cavity (23) through the detachable sealed gallium storage cavity (24). The high-voltage electric energy source is installed in the electric field application cavity (23), with one end connected to the upper end of the electric field application cavity (23) and the other end connected to the electrode located on the lower side inside the electric field application cavity (23). The plates (28) are connected; the high-voltage electric energy provides a stable voltage to the electric field application cavity (23), and the electrode plate (28) generates a uniform electrostatic field (32) in the electric field application cavity (23). The electrostatic field (32) charges the passing liquid gallium particles and sends them into the uniform electric field conduit (25); under the action of the electric field (1.1.4), all the liquid gallium particles in the uniform electric field conduit (25) are uniformly charged and sprayed onto the surface of the workpiece (6) through the conveying module; The temperature control module is located in the grinding area and is used to adjust the surface temperature of the workpiece (6) to maintain the dynamic conversion state of liquid gallium between solid and liquid.

2. The forming grinding apparatus for grinding thin-walled gears according to claim 1, characterized in that, The pressurization pipeline includes a pressurization pipe (8), a guide pipe (11), an inlet pipe (12), and a flow valve (15); The detachable sealed gallium delivery box (9) is connected to the guide pipe (11) through the pressurization pipe (8), the liquid flow valve (15) is installed at the end of the guide pipe (11), and the liquid flow valve (15) is connected to the uniform electric field conduit (25) through the liquid inlet pipe (12); The guide tube (11) is equipped with a liquid pushing assembly, which includes a pressure compensation element (16). The liquid pushing assembly is started or stopped according to the trigger signal of the pressure compensation element (16) to intermittently deliver liquid gallium.

3. The forming grinding apparatus for grinding thin-walled gears according to claim 2, characterized in that, The liquid propulsion assembly further includes an elastic element (13), a push block (14), a control switch (17), and a drive element; the push block (14) is installed inside the guide tube (11), and the push block (14) is connected to the drive element and the elastic element (13) respectively. The drive element drives the push block (14) to push the liquid gallium forward; the elastic element (13) is used to pull the push block (14) to reset; the drive element is connected to the central control unit through the control switch (17), and the control switch (17) starts or stops the drive element under the control of the central control unit.

4. The forming grinding apparatus for grinding thin-walled gears according to claim 2, characterized in that, The pressurizing pipe (8) has a tapered structure, and its interior is provided with a low-pressure section (8.1), an active section (8.2), and a high-pressure section (8.3) in sequence along the conveying direction. The pressure in each section of the low-pressure section (8.1), the active section (8.2), and the high-pressure section (8.3) increases sequentially. The part from the active section (8.2) to the high-pressure section (8.3) has a tapered structure.

5. The forming grinding apparatus for grinding thin-walled gears according to claim 1, characterized in that, The high-voltage electric energy source includes a power source (18) and a capacitor storage device (21); the power source (18) and the capacitor storage device (21) are connected in parallel at the upper end of the electric field application cavity (23) via a conductive line (19).

6. The forming grinding apparatus for grinding thin-walled gears according to claim 5, characterized in that, The charge application module also includes a voltage detector (20), a voltage regulating valve (22), an electrode access tube (26), a current valve (29), and a voltage sensing switch (30); The current valve (29) is installed on the upper end of the electric field application cavity (23) through the electrode access pipe (26) and is connected to the voltage regulating valve (22) through the conductive line (19); the electrode plate (28) is connected to the voltage sensing switch (30) through the conductive line (19); the voltage regulating valve (22) is connected to the voltage sensing switch (30) through the high voltage power source; The voltage detector (20) is installed on the electric field application cavity (23) and, together with the voltage sensing switch (30), monitors the electric field strength in real time and adjusts the voltage through the voltage regulating valve (22).

7. The forming grinding apparatus for grinding thin-walled gears according to claim 1, characterized in that, The conveying module includes a rotary motor (33), an angle adjuster (34), a transmission gear (35), a rotating shaft (36), a flexible connector (38), an electrostatic nozzle (39), a flow rate regulating valve (41), a guide tube (44), and an end nozzle (45); The output shaft of the rotary motor (33) is connected to the transmission gear (35) through the rotary shaft (36). The angle adjuster (34) is meshed with the transmission gear (35). The outer end of the angle adjuster (34) is connected to the flexible connector (38). The upper and lower ends of the flexible connector (38) are respectively sealed to the electrostatic nozzle (39) and the guide tube (44). The electrostatic nozzle (39) is connected to the uniform electric field conduit (25) through the flow rate regulating valve (41). The end nozzle (45) is installed at the output end of the guide tube (44). The rotary motor (33) drives the angle adjuster (34) to rotate through the transmission gear (35) to adjust the rotation angle and direction of the guide tube (44) so ​​that the end nozzle (45) faces the surface of the workpiece (6).

8. The forming grinding apparatus for grinding thin-walled gears according to claim 7, characterized in that, The electrostatic nozzle (39) is equipped with a flow monitor (40) at its end; the electrostatic nozzle (39) monitors and adjusts the flow rate and velocity of the liquid gallium in real time through the flow monitor (40) and the flow rate regulating valve (41).

9. The forming grinding apparatus for grinding thin-walled gears according to claim 1, characterized in that, The temperature control module includes a liquid-cooled fan (48), a duct (49), a high-pressure airflow generator (50), a temperature sensor (51), a controller (52), a flow regulating valve (53), a buffer chamber (54), a diverter (55), a flow regulating plate (56), a wind direction regulator (57), a pressure monitor (58), and a feedback regulating switch (59). The liquid cooling fan (48) delivers concentrated air to the buffer chamber (54) through the duct (49). The output end of the buffer chamber (54) is connected to multiple diversion pipes (55) arranged around the grinding area through the flow guide adjustment plate (56). The outlet ends of the diversion pipes (55) are respectively facing different positions of the workpiece (6). The high-pressure airflow generator (50) is used to pressurize the airflow blown by the liquid cooling fan (48) to generate high-pressure airflow. The high-pressure airflow is blown by the liquid cooling fan (48) through the duct (49), the buffer chamber (54) and the diversion pipe (55) to the surface of the workpiece (6) in the grinding area. The flow regulating valve (53) is installed at the end of the duct (49) and is used to regulate the flow rate of the high-pressure airflow output by the duct (49); the feedback regulating switch (59), the wind direction regulator (57), and the pressure monitor (58) are installed sequentially on the diverter (55) along the airflow direction; the wind direction regulator (57) is used to regulate the wind direction; the pressure monitor (58) is used to monitor the output pressure of the high-pressure airflow in the diverter (55); the feedback regulating switch (59) controls the flow guide plate (56) to regulate the flow rate of the high-pressure airflow in the diverter (55) according to the difference between the airflow output pressure monitored by the pressure monitor (58) and the set pressure; The temperature sensor (51) is installed in the grinding area to monitor the temperature of the workpiece (6) in real time and feeds it back to the controller (52) through the feedback adjustment switch (59); the controller (52) is connected to the liquid cooling fan (48), the high-pressure airflow generator (50), the flow regulating valve (53), the airflow regulator (57), the pressure monitor (58) and the feedback adjustment switch (59) respectively; After the temperature sensor (51) detects an abnormal temperature, the controller (52) activates the flow regulating valve (53) to adjust the airflow, activates the feedback regulating switch (59) and the pressure monitor (58), and adjusts the flow guide plate (56) and the wind direction regulator (57) to control the airflow, pressure and wind direction to regulate the temperature of the workpiece (6).

Images