A method of form grinding for thin-walled gears

Abstract

The present application relates to a kind of forming grinding method for thin-walled gear, belong to the lubrication cooling technical field in grinding processing, method as follows: liquid gallium is transported to the detachable sealed gallium delivery box of electrostatic spraying module, part of liquid gallium in detachable sealed gallium delivery box enters pressurized pipeline pressurization;Part of liquid gallium enters electric field application cavity, realizes particle charging atomization under the action of electrostatic field and is sent to uniform electric field duct.Switch off control switch at the same time, after the electric field in uniform electric field duct is stable, liquid gallium in pressurized pipeline flows into uniform electric field duct.In the uniform field effect, liquid gallium in uniform electric field duct is uniformly charged atomization, and charged liquid gallium after atomization is sprayed to workpiece surface.Grinding workpiece surface, temperature control module adjusts workpiece surface temperature in real time, maintains the state of dynamic conversion between liquid gallium and solid liquid.The present application effectively solves the problem that cooling liquid 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 specifically to a forming grinding method for thin-walled gears. Background Technology

[0002] Thin-walled gears are susceptible to thermal coupling during machining, leading to problems such as tooth profile errors, tooth pitch deviations, and out-of-tolerance roundness of the gear ring. Traditional grinding processes, due to the complex structure and deep tooth grooves of thin-walled gears, coupled with the air barrier created by the high-speed rotation of the grinding wheel, make it difficult for coolant to penetrate deep into the tooth surface. This results in surface burns caused by heat accumulation in the grinding area, especially in the machining of hard and brittle materials such as titanium alloys and high-strength alloy steels. Furthermore, this is accompanied by increased cutting vibration and excessively rapid grinding wheel wear, severely restricting machining accuracy. Traditional grinding cooling technology mainly relies on externally sprayed grinding fluid for cooling, but this has significant limitations: uneven cooling effect, high grinding fluid consumption, and potential environmental pollution; more importantly, the airflow generated by the rotating grinding wheel repels the grinding fluid, making it difficult to accurately cover the grinding area, resulting in low cooling efficiency.

[0003] For example, the gear forming grinding wheel with internal cooling structure disclosed in the invention patent with publication number CN210819179U delivers coolant through a reservoir and a network of bifurcated polygonal flow channels, but it still fails to overcome the core bottleneck—the coolant is easily displaced by the airflow of the rotating grinding wheel, and cannot penetrate the air barrier layer in deep tooth groove scenarios. It is difficult to penetrate deep into the tooth surface and cannot evenly cover the complex tooth surface, thus limiting the cooling and lubrication effect. Summary of the Invention

[0004] 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 method for thin-walled gears. Through the synergistic effect of an innovative electrostatic spraying module and a temperature control module, the method solves the problem that coolant cannot 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.

[0005] To achieve the above objectives, the present invention adopts the following specific technical solution:

[0006] A forming grinding method for thin-walled gears, wherein during the grinding process of a grinding wheel, liquid gallium is sprayed onto the workpiece surface in a uniformly charged state through an electrostatic spraying module in the inner channel of the grinding wheel, and the workpiece surface temperature is adjusted using a temperature control module. The steps are as follows:

[0007] A. Install the workpiece; transfer the liquid gallium into the detachable sealed gallium delivery box of the electrostatic spraying module, and adjust the end nozzle to the appropriate position;

[0008] B. Start the electrostatic spraying module to uniformly charge and atomize the liquid gallium particles and spray them onto the workpiece surface;

[0009] B1. A portion of the liquid gallium in the detachable, sealed gallium delivery box enters the pressurization pipeline for pressurization;

[0010] B2. A portion of the liquid gallium in the detachable sealed gallium delivery box enters the electric field application chamber through the detachable sealed gallium storage chamber. Under the action of the electrostatic field in the electric field application chamber, the particles are charged and atomized and sent to the uniform electric field conduit; at the same time, the control switch on the pressurization pipeline is turned off.

[0011] B3. After the electric field inside the uniform electric field conduit stabilizes, the control switch is turned on, and the liquid gallium in the pressurized pipeline flows into the uniform electric field conduit. Under the uniform field effect, the liquid gallium inside the uniform electric field conduit is uniformly charged and atomized.

[0012] B4. The conveying module sprays the atomized charged liquid gallium onto the surface of the workpiece.

[0013] C. Start the grinding wheel to grind the workpiece surface, turn on the temperature control module to adjust the workpiece surface temperature in real time, and repeat step B to continuously replenish liquid gallium to the workpiece surface until the grinding process is completed.

[0014] D. Recycling and reuse of liquid gallium.

[0015] Further, in step B1, the operation process of the pressurization pipeline is as follows: the liquid gallium in the detachable sealed gallium delivery box enters the guide tube through the pressurization tube, and the control switch is activated. The liquid gallium is pushed forward by the liquid pushing component, so that the pressure fluctuation in the active range of the pressurization tube is maintained at <±5%, the working pressure in the high pressure range is 20~50MPa, and the working pressure in the low pressure range is 5~15MPa.

[0016] In step B3, after the electric field inside the uniform electric field conduit stabilizes, the liquid flow valve is opened while the control switch is restarted, and the high-pressure liquid gallium in the guide tube is intermittently transported into the uniform electric field conduit through the liquid pushing component.

[0017] Furthermore, the operation of the liquid delivery assembly is as follows: the central control unit controls the start of the drive element through the control switch, and the drive element drives the pusher block to push the liquid gallium forward in the guide tube; when it is necessary to stop the delivery, the drive element stops working, and the elastic element pulls the pusher block to reset; the pressure compensation element monitors the pressure in the guide tube in real time, and when the pressure reaches the set threshold, the pressure compensation element triggers a signal, and the central control unit controls the opening and closing of the control switch according to the trigger signal of the pressure compensation element to realize the start or stop of the drive element, thereby realizing the intermittent delivery of liquid gallium.

[0018] Furthermore, the pressurizing tube adopts a tapered structure, with the inner diameter on the input side being larger than that on the output side. The inner cavity on the input side is divided into a low-pressure zone and an active zone by a first movable partition, while the inner cavity on the output side is a high-pressure zone. Liquid gallium passes through the low-pressure zone, the active zone, and the high-pressure zone sequentially along the conveying direction in the pressurizing tube, with the pressure in each zone increasing sequentially. The pressure increase from the active zone to the high-pressure zone is achieved through a tapered structure.

[0019] Further, in step B2, the process of generating an electrostatic field in the electric field application cavity is as follows: a high-voltage electric energy source is installed on the electric field application cavity. One end of the high-voltage electric energy source is connected to the upper end of the electric field application cavity, and the other end is connected to the electrode plate 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. After it releases the high-voltage current, the electrode plate generates a uniform electrostatic field.

[0020] Furthermore, the high-voltage electric energy source, the power supply, and the capacitor energy storage device are connected in parallel via conductive wires. The power supply provides power, and the capacitor energy storage device stores electrical energy, providing a stable high-voltage current for the generation of the electrostatic field.

[0021] Furthermore, the monitoring and regulation process of the electrostatic field is as follows: one end of the high-voltage electric energy source is connected to the current valve through a voltage regulating valve. The current valve is installed at the upper end of the electric field application cavity through an electrode access tube. The other end of the high-voltage electric energy source is connected to the electrode plate through a voltage sensing switch. A voltage detector is installed on the electric field application cavity. The voltage detector and the voltage sensing switch monitor the electric field strength in the electric field application cavity in real time and feed the electric field strength back to the voltage regulating valve. The voltage regulating valve adjusts the output voltage of the high-voltage electric energy source. The current valve cooperates with the voltage regulating valve to control the current transmission, thereby realizing the regulation of the electrostatic field strength.

[0022] Further, in step B4, the operation process of the conveying module is as follows: the rotary motor is started, and its output shaft drives the transmission gear to rotate through the rotary shaft. The transmission gear drives the meshing angle adjuster to rotate. The angle adjuster adjusts the rotation angle and direction of the guide tube through the flexible connector so that the end nozzle faces the workpiece surface. Liquid gallium enters the electrostatic nozzle from the uniform electric field conduit through the flow rate regulating valve, and then enters the guide tube through the flexible connector. Finally, it is sprayed onto the workpiece surface by the end nozzle.

[0023] Furthermore, in step B4, the flow rate of liquid gallium is monitored in real time by a flow monitor installed at the end of the electrostatic nozzle, and the flow rate of liquid gallium is adjusted in conjunction with a flow rate regulating valve to ensure that the liquid gallium jet flow rate meets the grinding requirements.

[0024] Further, in step C, the operation process of the temperature control module is as follows: the liquid cooling fan and the high-pressure airflow generator are started. The liquid cooling fan sends air to the buffer chamber through the duct. After being pressurized by the high-pressure airflow generator, the high-pressure airflow is concentrated in the buffer chamber and then distributed to multiple distribution pipes around the grinding area through the flow guide adjustment plate. The airflow direction adjuster on the distribution pipe adjusts the airflow direction so that the high-pressure airflow blows to different positions on the workpiece surface. The temperature sensor monitors the workpiece temperature in real time and feeds it back to the controller. The controller adjusts the flow rate of the high-pressure airflow output from the duct through the flow regulating valve. The pressure monitor monitors the airflow output pressure in the distribution pipe. The feedback adjustment switch controls the flow guide adjustment plate according to the pressure difference to further adjust the airflow of each distribution pipe, thereby achieving precise adjustment of the workpiece surface temperature and maintaining the dynamic conversion state of liquid gallium between solid and liquid.

[0025] The beneficial effects of this invention are:

[0026] The present invention discloses a forming grinding method for thin-walled gears, which achieves precise atomization and directional delivery of lubricating fluid by coupling the inner flow channel of the grinding wheel with electrostatic spraying technology, accurately covering the workpiece surface, improving the lubrication and cooling effect, and solving the problem that the coolant cannot penetrate the air barrier layer of the grinding wheel and uniformly cover the complex tooth surface and the distribution is uneven.

[0027] This invention employs electrostatic field-assisted high-voltage electrostatic atomization technology to achieve directional and refined spraying of liquid gallium, forming a dense and uniform support coating on the workpiece surface. This significantly reduces the impact of grinding force on the workpiece surface and extends the service life of thin-walled gears. At the same time, through real-time pressure monitoring and automatic adjustment mechanisms, the stability and uniformity of liquid gallium during the spraying process are ensured.

[0028] This invention utilizes liquid gallium, which has a low melting point of approximately 29.8°C. Taking advantage of the phase transition properties of liquid gallium at high temperatures in the grinding zone, it rapidly transforms from a liquid to a solid state under the impact of a high-pressure gas flow. This process not only provides cooling but also forms a uniform support coating on the workpiece surface, offering reliable support for the gear teeth. This effectively suppresses localized deformation during grinding, improving the machining accuracy and surface quality of thin-walled gears. As a large amount of heat is generated in the grinding zone, the solid gallium transforms back into a liquid state at high temperatures, effectively lubricating the grinding zone, carrying away heat, and reducing the grinding temperature, thus achieving efficient cooling and lubrication.

[0029] This invention achieves micro-power regulation and rapid heating response through semiconductor heating technology. The semiconductor heating element has excellent thermal conductivity with liquid gallium and can adjust the heat output in a very short time to cope with changes in ambient temperature or instantaneous heat fluctuations generated during the process, ensuring that the liquid gallium is always maintained within the set temperature range and maintaining the dynamic transition state between solid and liquid states.

[0030] This invention efficiently recovers residual gallium through a recycling module, avoiding resource waste and achieving closed-loop utilization. Attached Figure Description

[0031] Figure 1 A schematic diagram of the apparatus structure for implementing the forming grinding method for thin-walled gears according to the present invention;

[0032] Figure 2 This is a detailed view of the grinding wheel in this invention;

[0033] Figure 3 This is a structural diagram of the pressurization module in this invention;

[0034] Figure 4 This is a structural diagram of the charge application module in this invention;

[0035] Figure 5 This is a structural diagram of the conveying module in this invention;

[0036] Figure 6 This is a schematic diagram illustrating the principle of electrostatic spraying onto the workpiece surface in this invention;

[0037] Figure 7 This is a structural diagram of the temperature control module in this invention.

[0038] 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, 12- 13-Inlet pipe, 14-Elastic element, 15-Push block, 16-Flow valve, 17-Pressure compensation element, 18-Control switch, 19-Power supply, 20-Conductive wire, 21-Voltage detector, 22-Capacitor energy storage, 23-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-Current valve, 3 0-Voltage sensing switch, 31-Control switch, 32-Electrostatic field, 33-Rotating motor, 34-Angle adjuster, 35-Transmission gear, 36-Rotating shaft, 37-Fixed bracket, 38-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 regulator, 43-Charge matching device, 44-Guide tube, 44.1-Flow guide channel, 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

[0039] 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.

[0040] 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.

[0041] 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.

[0042] 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.

[0043] This embodiment discloses a forming grinding method for 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.

[0044] 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.

[0045] 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.

[0046] In this embodiment, the grinding wheel 1 is a diamond grinding wheel with an internal flow channel structure, including a cooling section 1.1 and a grinding section 1.2. The cooling section 1.1 and the grinding section 1.2 are coaxially arranged, and the drive mechanism drives the grinding section 1.2 to rotate and grind the workpiece 6 through the output shaft.

[0047] 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.

[0048] The grinding wheel 1.2 consists of a wheel matrix, an abrasive layer, and a bronze binder. The wheel matrix is ​​preferably made of a metal-based composite material. The abrasive layer is composed of diamond abrasive grains randomly dispersed in the bronze binder, forming an integral structure that is metallurgically bonded to the outer circumference of the wheel matrix through a high-temperature sintering process. During grinding, the wheel matrix rotates under the drive mechanism, which in turn drives the abrasive layer on the outer circumference to move synchronously. When the abrasive layer contacts the surface of the workpiece 6, the grinding of the workpiece 6 is completed through the cutting action of the abrasive grains.

[0049] 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.

[0050] 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.

[0051] 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.

[0052] 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.

[0053] 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.

[0054] 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.

[0055] 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.

[0056] 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.

[0057] 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.

[0058] 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.

[0059] 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.

[0060] 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.

[0061] 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.

[0062] 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.

[0063] 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.

[0064] 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.

[0065] 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.

[0066] 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.

[0067] 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.

[0068] 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.

[0069] 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.

[0070] The delivery 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 microscopic damage to the surface of the workpiece 6 caused by the grinding force during the grinding process.

[0071] 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.

[0072] 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.

[0073] 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.

[0074] 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.

[0075] 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.

[0076] 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.

[0077] 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.

[0078] 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.

[0079] A ring electrode 4 is installed at the end of the guide tube 44 to further stabilize the electrical stability of liquid gallium.

[0080] 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.

[0081] 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.

[0082] Specifically:

[0083] 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 moves the liquid gallium smoothly in the predetermined direction. The direction is calibrated by the guide tube 44, so that the liquid gallium in the guide channel 44.1 is accurately sprayed onto the surface of the workpiece 6 to be processed through the end nozzle 45.

[0084] When grinding workpiece 6, the end nozzle 45, under the action of the angle adjuster 34, maintains the atomization angle between 15° and 30°, which is more conducive to improving the adhesion efficiency of liquid gallium. In this embodiment, the nozzle adjuster 42 is used to adjust the opening of the end nozzle 45 to further optimize the atomization angle, and the charge matching device 43 is used to ensure the stability of the power supply of the rotary motor 33 to stabilize the electric field, forming a closed-loop linkage control, ensuring the stability of the liquid gallium spray posture, further optimizing the spray effect, improving the adhesion efficiency of liquid gallium, and reducing waste.

[0085] 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.

[0086] 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.

[0087] 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.

[0088] 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.

[0089] 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.

[0090] 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.

[0091] 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.

[0092] 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.

[0093] In addition, this embodiment can deliver liquid gallium 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 keep the metallic gallium in a liquid state, preventing solid gallium from clogging the delivery pipes at low temperatures.

[0094] 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.

[0095] The above-described apparatus is used to grind workpiece 6. Taking workpiece 6 as a thin-walled gear as an example, the forming grinding method for thin-walled gears is explained. The distance from the end nozzle 45 to the surface of workpiece 6 is 5mm to 10mm, and the temperature control module is located below workpiece 6.

[0096] A platform assembly consisting of servo motors, push rods, and a support base 60 supports the workpiece 6 in the grinding area below the grinding wheel 1. Two servo motors are symmetrically arranged on the support base 60, and the output shafts of the servo motors are connected to the push rods. A center 61 is mounted on the outer end of the push rod. The two ends of the workpiece 6 abut against the center 61 respectively. After the two center 61s clamp the workpiece 6, the two servo motors rotate synchronously in opposite directions and at the same speed. The push rods and center 61 drive the workpiece 6 to rotate, so that the grinding wheel 1 grinds the surface of the workpiece 6 and the liquid gallium evenly covers the surface of the workpiece 6.

[0097] In addition, this embodiment utilizes a recovery module to recover 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 positioned 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 via a pipe. The output end of the centrifugal filter 63 is connected to the storage tank 2 via the return pipe 64. The negative pressure suction nozzle 62 is used to collect the mixture of liquid gallium and grinding debris, powder, etc., that is propelled by the high-pressure airflow generated during grinding by the grinding wheel 1. The negative pressure suction nozzle 62 transports 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 process, reducing losses. Furthermore, the mixture of liquid gallium and debris, powder, etc., flowing onto the support base 60 can also be transported to the centrifugal filter 63 for centrifugal filtration via a pipe, thereby improving the recovery rate of liquid gallium.

[0098] Electrostatic spraying is used to uniformly cover the surface of workpiece 6, which carries an opposite charge (workpiece 6 can acquire an opposite charge due to the influence of 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 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 generates a large amount of heat while grinding workpiece 6, the solid gallium transforms back into liquid gallium at high temperatures, carrying away the heat, reducing the grinding temperature, and achieving efficient cooling and lubrication.

[0099] The specific steps are as follows:

[0100] A. Install workpiece 6, send liquid gallium into the detachable sealed gallium delivery box 9 of the electrostatic spraying module, and adjust the position and orientation of the end nozzle 45 to make it into a suitable position;

[0101] A1. The workpiece 6 is mounted on the platform assembly via the tip 61, ensuring that the servo motor can drive the workpiece 6 to rotate at a predetermined speed; the rotary motor 33 is started to adjust the atomization angle of the end nozzle 45 relative to the surface of the workpiece 6 to 15° to 30°, and the distance from the end nozzle 45 to the surface of the workpiece 6 is adjusted to 5mm to 10mm; the nozzle adjuster 42 is started to adjust the nozzle size of the end nozzle 45.

[0102] A2. Start the semiconductor heating system of the storage tank 2 to keep the metallic gallium in the storage tank 2 in a liquid state and pressurize it to a predetermined pressure; open the pressure regulating valve 7, and the micro high pressure pump 3 pumps the liquid gallium in the storage tank 2 into the detachable sealed gallium delivery box 9 at 10-50MPa.

[0103] B. Start the electrostatic spraying module to uniformly charge and atomize the liquid gallium particles and spray them onto the surface of workpiece 6.

[0104] B1. A portion of the liquid gallium in the detachable sealed gallium delivery box 9 flows sequentially into the pressurizing tube 8 and the guide tube 11. The control switch 17 is activated, and the liquid gallium is pushed forward by the liquid pushing component, so that the pressure fluctuation in the active range 8.2 of the pressurizing tube 8 is maintained at <±5%, the working pressure in the high pressure range 8.3 is 20~50MPa, and the working pressure in the low pressure range 8.1 is 5~15MPa.

[0105] B2. Start the power supply 18 and use the capacitor storage device 21 to provide a stable high-voltage current for the subsequent electric field generation. Sequentially open the voltage regulating valve 22, the voltage sensing switch 30, and the current valve 29. The high-voltage current is transmitted to the electrode access tube 26 through the conductive wire 19, and then forms a uniform electrostatic field 32 in the electric field application cavity 23 through the electrode plate 28.

[0106] Turn on the gallium inlet switch 10 and the electric field 1.1.4 to allow a portion of the liquid gallium in the detachable sealed gallium delivery box 9 to enter the electric field application chamber 23 through the detachable sealed gallium storage chamber 24. The liquid gallium passes sequentially through the low electric field intensity zone 23.1, the buffer zone 23.2, and the high electric field intensity zone 23.3 within the electric field application chamber 23, and is atomized under the action of the electrostatic field 32 during the flow. The atomized liquid gallium then flows into the uniform electric field conduit 25.

[0107] To ensure that liquid gallium can be stably atomized and sprayed under the action of an electric field, the control switch 17 is temporarily turned off to prevent liquid gallium from flowing into the uniform electric field conduit 25 before the electric field is stable, thereby ensuring the stability of the electric field and the uniform charging of the liquid gallium.

[0108] B3. After the electric field inside the uniform electric field conduit 25 is stabilized, the liquid flow valve 15 and the control switch 17 are opened. The high-pressure liquid gallium in the pressurization module is intermittently transported into the uniform electric field conduit 25 through the liquid pushing component. Under the uniform field effect, the liquid gallium inside the uniform electric field conduit 25 is uniformly charged.

[0109] During the liquid gallium transport process, the pressure compensation element 16 monitors the pressure changes in real time to ensure that the pressure in the active range 8.2, high pressure range 8.3 and low pressure range 8.1 within the pressurized tube 8 all meet the predetermined standards.

[0110] B4. By activating control switch 31, flow monitor 40, flow rate regulating valve 41, nozzle regulator 42, and charge matching device 43, under the combined action of high-pressure liquid flow and a uniform electric field, the liquid gallium is further atomized at the electrostatic nozzle 39, decomposing into tiny particles, which are then ejected from the end nozzle 45 after passing through the electrostatic nozzle 39. The electrostatic field causes the atomized liquid gallium particles to be directed by Coulomb force, accurately and uniformly sprayed onto the surface of workpiece 6.

[0111] C. Start grinding wheel 1 to grind the surface of workpiece 6, and turn on the temperature control module to adjust the surface temperature of workpiece 6 in real time. At this time, repeat step B to continuously replenish liquid gallium to the surface of workpiece 6 until the grinding process is completed.

[0112] C1. Start grinding wheel 1 to grind the surface of workpiece 6; at the same time, turn on the servo motor to drive workpiece 6 to rotate, and the rotation speed matches the grinding speed of grinding wheel 1.

[0113] C2. Simultaneously with the start of grinding wheel 1, the temperature control module is activated. 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 rapidly 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. When the temperature drops to the predetermined minimum threshold, the temperature control module reduces the amount of high-pressure airflow. As grinding wheel 1 rotates at high speed and grinds workpiece 6, a large amount of heat is generated, and the solid gallium partially liquefies again. Its excellent thermal conductivity carries away the heat, thereby reducing the grinding temperature. When the temperature rises to the predetermined maximum threshold, the temperature control module increases the amount of high-pressure airflow. This maintains the surface temperature of workpiece 6 within the predetermined temperature range, allowing the liquid gallium to dynamically transition between solid and liquid states.

[0114] When the temperature control module is working, the pressure monitor 58 monitors the output pressure of the high-pressure airflow in the diversion pipe 55 in real time. The liquid cooling fan 48 and the high-pressure airflow generator 50 adjust their working frequency under the control of the controller 52 to ensure that the surface temperature of the workpiece 6 is within a reasonable range.

[0115] D. Recycling and reuse of liquid gallium.

[0116] The negative pressure suction nozzle 62 picks up splashed and fallen liquid gallium and debris, and sends them into the centrifugal filtration module 63. After centrifugation, the liquid gallium enters the storage tank 2 through the return pipe 64 for recycling.

[0117] 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 method for forming and grinding thin-walled gears, characterized in that, The forming grinding method is to spray liquid gallium in a uniformly charged state onto the surface of the workpiece (6) through an electrostatic spraying module set in the inner channel of the grinding wheel (1) during the grinding process of the workpiece (6) by grinding wheel (1), and to adjust the surface temperature of the workpiece (6) by using a temperature control module. The electrostatic spraying module includes a pressurization module, a charge application module, and a delivery module; the pressurization module includes a detachable sealed gallium delivery box (9) and a pressurization pipe (8), a flow guide pipe (11), and a liquid inlet pipe (12) connected in sequence; the charge application module includes an electric field application cavity (23), a detachable sealed gallium storage cavity (24), and a uniform electric field conduit (25). The detachable sealed gallium delivery box (9) is connected to the pressurization tube (8) 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 electric field application cavity (23) has an electrostatic field (32); the liquid inlet tube (12) is connected to the uniform electric field conduit (25); the guide tube (11) is provided with a liquid pushing assembly consisting of a push block (14), a control switch (17) and a driving element; the push block (14) is placed in the guide tube (11), and its upper end is connected to the control switch (17) through the driving element; The temperature control module includes a high-pressure airflow source, a conduit (49), 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 high-pressure airflow source delivers concentrated air to 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) are respectively facing different positions of the workpiece (6). The temperature sensor (51) is installed in the grinding area, the flow regulating valve (53) is installed at the end of the conduit (49), and the feedback regulating switch (59), the airflow regulator (57), and the pressure monitor (58) are installed sequentially on the diverter (55) along the airflow direction; 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 controller (52) is connected to the high-pressure airflow source, the flow regulating valve (53), the airflow regulator (57), the pressure monitor (58), and the feedback regulating switch (59) respectively; The profile grinding steps are as follows: A. Install the workpiece (6); transfer the liquid gallium to the detachable sealed gallium delivery box (9) of the electrostatic spraying module, and adjust the end nozzle (45) to the appropriate position; B. Start the electrostatic spraying module to atomize the liquid gallium particles evenly and spray them onto the surface of the workpiece (6); B1. A portion of the liquid gallium in the detachable sealed gallium delivery box (9) is pressurized into the pressurization pipeline; B2. A portion of the liquid gallium in the detachable sealed gallium delivery box (9) 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 atomized and sent to the uniform electric field conduit (25). At the same time, the control switch (17) on the pressurization pipeline is turned off. B3. After the electric field in the uniform electric field conduit (25) is stabilized, the control switch (17) is turned on, and the liquid gallium in the pressurized pipeline flows into the uniform electric field conduit (25). Under the uniform field effect, the liquid gallium in the uniform electric field conduit (25) is uniformly charged and atomized. B4. The conveying module sprays the atomized charged liquid gallium onto the surface of the workpiece (6); C. Start the grinding wheel (1) to grind the surface of the workpiece (6), turn on the temperature control module to adjust the surface temperature of the workpiece (6) in real time, repeat step B, and continuously replenish liquid gallium to the surface of the workpiece (6) until the grinding process is completed. D. Recycling and reuse of liquid gallium.

2. The forming grinding method for thin-walled gears according to claim 1, characterized in that, In step B1, the operation of the pressurization pipeline is as follows: the liquid gallium in the detachable sealed gallium delivery box (9) enters the guide pipe (11) through the pressurization pipe (8), and the control switch (17) is activated. The liquid gallium is pushed forward by the liquid pushing component, so that the pressure fluctuation of the active range (8.2) of the pressurization pipe (8) is maintained at <±5%, the working pressure of the high pressure range (8.3) is 20~50 MPa, and the working pressure of the low pressure range (8.1) is 5~15 MPa. In step B3, after the electric field in the uniform electric field guide pipe (25) is stabilized, the liquid flow valve (15) is opened while the control switch (17) is restarted. The high pressure liquid gallium in the guide pipe (11) is intermittently transported into the uniform electric field guide pipe (25) through the liquid pushing component.

3. The forming grinding method for thin-walled gears according to claim 2, characterized in that, The operation mode of the liquid delivery component is as follows: the central control unit controls the start of the drive element through the control switch (17), and the drive element drives the push block (14) to push the liquid gallium forward in the guide tube (11); when it is necessary to stop the delivery, the drive element stops working, and the elastic element (13) pulls the push block (14) to reset; the pressure compensation element (16) monitors the pressure in the guide tube (11) in real time. When the pressure reaches the set threshold, the pressure compensation element (16) triggers a signal. The central control unit controls the opening and closing of the control switch (17) according to the trigger signal of the pressure compensation element (16) to realize the start or stop of the drive element, thereby realizing the intermittent delivery of liquid gallium.

4. The forming grinding method for thin-walled gears according to claim 2, characterized in that, The pressurizing tube (8) adopts a tapered structure, with the inner diameter of the input side being larger than that of the output side. The inner cavity of the input side is divided into a low-pressure zone (8.1) and an active zone (8.2) by a first movable partition, while the inner cavity of the output side is a high-pressure zone (8.3). The liquid gallium passes through the low-pressure zone (8.1), the active zone (8.2), and the high-pressure zone (8.3) in the pressurizing tube (8) along the conveying direction. The pressure in each zone increases sequentially, and the pressure increase from the active zone (8.2) to the high-pressure zone (8.3) is achieved through a tapered structure.

5. The forming grinding method for thin-walled gears according to claim 1, characterized in that, In step B2, the process of generating an electrostatic field (32) in the electric field application cavity (23) is as follows: a high-voltage electric energy source is installed on the electric field application cavity (23). One end of the high-voltage electric energy source is connected to the upper end of the electric field application cavity (23), and the other end is connected to the electrode plate (28) on the lower side inside the electric field application cavity (23). The high-voltage electric energy source provides a stable voltage to the electric field application cavity (23). After it releases the high-voltage current, the electrode plate (28) generates a uniform electrostatic field (32).

6. The forming grinding method for thin-walled gears according to claim 5, characterized in that, The high-voltage electric energy source is a power source (18) and a capacitor energy storage device (21) connected in parallel through a conductive line (19). The power source (18) supplies power and the capacitor energy storage device (21) stores electrical energy, providing a stable high-voltage current for the generation of the electrostatic field (32).

7. The forming grinding method for thin-walled gears according to claim 6, characterized in that, The monitoring and adjustment process of the electrostatic field (32) is as follows: one end of the high voltage power source is connected to the current valve (29) through the voltage regulating valve (22), and the current valve (29) is installed on the upper end of the electric field application cavity (23) through the electrode access pipe (26); the other end of the high voltage power source is connected to the electrode plate (28) through the voltage sensing switch (30); the voltage detector (20) is installed on the electric field application cavity (23); the voltage detector (20) and the voltage sensing switch (30) monitor the electric field strength in the electric field application cavity (23) 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, and the current valve (29) cooperates with the voltage regulating valve (22) to control the current transmission, thereby realizing the adjustment of the electrostatic field (32) strength.

8. The forming grinding method for thin-walled gears according to claim 1, characterized in that, In step B4, the operation of the conveying module is as follows: the rotary motor (33) is started, and its output shaft drives the transmission gear (35) to rotate through the rotary shaft (36). The transmission gear (35) drives the meshing angle adjuster (34) to rotate. The angle adjuster (34) adjusts the rotation angle and direction of the guide tube (44) through the flexible connector (38) so that the end nozzle (45) faces the surface of the workpiece (6). Liquid gallium enters the electrostatic nozzle (39) from the uniform electric field conduit (25) through the flow rate regulating valve (41), and then enters the guide tube (44) through the flexible connector (38), and is finally sprayed onto the surface of the workpiece (6) by the end nozzle (45).

9. The forming grinding method for thin-walled gears according to claim 8, characterized in that, In step B4, the flow rate of liquid gallium is monitored in real time by a flow monitor (40) installed at the end of the electrostatic nozzle (39), and the flow rate of liquid gallium is adjusted by a flow rate regulating valve (41) to ensure that the liquid gallium jet flow rate meets the grinding requirements.

10. The forming grinding method for thin-walled gears according to claim 1, characterized in that, In step C, the operation of the temperature control module is as follows: the liquid cooling fan (48) and the high-pressure airflow generator (50) are started. The liquid cooling fan (48) sends air to the buffer chamber (54) through the duct (49). After being pressurized by the high-pressure airflow generator (50), the high-pressure airflow is concentrated in the buffer chamber (54) and then distributed to multiple distribution pipes (55) around the grinding area through the flow guide adjustment plate (56). The airflow direction adjuster (57) on the distribution pipe (55) adjusts the airflow direction so that the high-pressure airflow blows to different positions on the surface of the workpiece (6). The temperature sensor (51) monitors the temperature of the workpiece (6) in real time and feeds it back to the controller (52). The controller (52) adjusts the high-pressure airflow output from the conduit (49) through the flow regulating valve (53). The pressure monitor (58) monitors the airflow output pressure in the diverter (55). The feedback regulating switch (59) controls the flow regulating plate (56) according to the pressure difference, further adjusting the airflow of each diverter (55) to achieve precise adjustment of the surface temperature of the workpiece (6) and maintain the dynamic conversion state of liquid gallium between solid and liquid.

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