Liquid cooling heat dissipation process for relieving tooth machining

Abstract

The invention relates to the technical field of relieved tooth machining, in particular to a liquid cooling heat dissipation relieved tooth machining process which comprises the steps that S1, through reasonable selection of a relieved tooth blank and a matched inner cooling tool, the structural adaptation and thermal stability in the machining process are ensured, and a reliable basis is provided for subsequent liquid cooling heat dissipation; s2, a high-pressure liquid cooling system is established on the machine tool, water-soluble cutting fluid with the temperature of 25 DEG C is conveyed to the tool, and a nozzle is aligned to a main cutting edge and the flow direction of cuttings at an angle of 60 degrees; s3, a special clamp is designed to ensure reliable fixation of the workpiece, an auxiliary cooling channel and a sealing backflow system are arranged in the clamp, and backflow liquid is recycled after being filtered by 25; according to the invention, efficient control and dynamic optimization of liquid cooling heat dissipation in the process of relieving teeth are realized. The machining stability is guaranteed through accurate preparation of a workpiece and a cutter before machining; the internal and external dual-channel liquid cooling system is combined with real-time temperature and flow monitoring to realize accurate regulation and control of the temperature of the cutter and a cutting area.

Description

Technical Field

[0001] This invention relates to the field of shovel tooth machining technology, and more specifically to a process for machining shovel teeth using liquid cooling. Background Technology

[0002] Shaving teeth are widely used in heavy machinery and transmission systems, and their machining quality directly affects the load-bearing capacity and service life of parts. In traditional machining processes, due to the large contact area between the shaving tooth tool and the workpiece, significant heat accumulation during cutting can easily lead to tool overheating, accelerated wear, and uneven workpiece surface temperature, thus affecting machining accuracy and surface quality. To reduce cutting temperature rise, external spraying or immersion in coolant is generally used. However, traditional liquid cooling methods often suffer from uneven cooling, difficulty in dynamically adjusting the flow rate, and lag in temperature control response, making it difficult to meet the requirements of high-speed, high-precision machining.

[0003] While research on internal channel cooling for cutting tools can improve local cutting edge temperature, in machining complex tooth shapes, improper liquid cooling flow distribution or suboptimal nozzle layout can still easily lead to excessively high local temperatures or coolant waste. Current technologies cannot achieve efficient, uniform, and controllable liquid cooling during tooth-shaping. There is an urgent need for a liquid cooling process that can dynamically adjust internal and external cooling flow, optimize nozzle layout, and achieve closed-loop temperature control to improve tool life and machining quality. Summary of the Invention

[0004] The purpose of this invention is to solve the problems in the existing technology where traditional liquid cooling methods often have uneven cooling, difficulty in dynamically adjusting the flow rate, and lag in temperature control response, making it difficult to meet the requirements of high-speed and high-precision machining.

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

[0006] This invention provides a process for machining shovel teeth with liquid cooling, including the following steps: S1. By reasonably selecting the shovel tooth blank and matching internal cooling tool, the structural compatibility and thermal stability of the machining process are ensured, providing a reliable foundation for subsequent liquid cooling.

[0007] S2. Establish a high-pressure liquid cooling system on the machine tool to deliver 25°C water-soluble cutting fluid to the tool, with the nozzle aimed at the main cutting edge and the direction of chip flow at a 60° angle;

[0008] S3. A specially designed fixture ensures reliable workpiece fixation. The fixture includes an auxiliary cooling channel and a sealed reflux system. The reflux fluid passes through a 25°... Filtered and reused;

[0009] S4. Liquid cooling cutting process starts a stable liquid flow, cuts in stages according to process parameters, and uses a combination of internal tool cooling and external high-pressure jet cooling. At the same time, the machining status is monitored in real time to reduce the cutting temperature.

[0010] S5. After processing, the coolant is recycled through reflux filtration. The nozzle angle, flow rate or tool parameters are dynamically adjusted by monitoring the concentration, temperature and contamination level.

[0011] Furthermore, in step S1, the process of ensuring structural compatibility and thermal stability during machining by rationally selecting the hoist tooth blank and matching internal cooling tool, thus providing a reliable foundation for subsequent liquid cooling heat dissipation, is as follows:

[0012] S1.1. Based on the operating environment and performance requirements of the shovel teeth, high-strength alloy steel or high-manganese wear-resistant steel with a hardness of HB320~HB450 is selected as the blank material. A workpiece geometry and material property dataset is established using a three-dimensional model database (such as a shovel tooth CAD model library). The blank is pre-cleaned (de-scaling, rust removal) and the positioning datum is machined to ensure that the flatness error of the datum surface is ≤ 0.02 mm. Workpiece posture recognition is achieved through a laser scanning positioning system. The actual clamping position of the workpiece is compared and corrected with the theoretical model, and the compensation amount is calculated. The formula for calculating the compensation amount is: ,in, For the theoretical reference point coordinates, These are the coordinates of the measured point;

[0013] S1.2. Based on the workpiece material's hardness, thermal conductivity, and cutting depth parameters, establish a tool selection decision model: ,in, For material type parameters, For material hardness, Thermal conductivity;

[0014] like For this purpose, carbide or indexable insert tools are recommended.

[0015] For this purpose, coated carbide or CBN tools are preferred.

[0016] If the thermal conductivity of the material is lower than Therefore, tools with enhanced cooling channel structures are recommended. The objective function expression for tool recommendation is: ,in, For cutting temperature rise, For tooling costs, Surface roughness index These are weighting coefficients. This model allows for the rapid selection of tool combinations from a tool library that offer the best thermal stability and cost-effectiveness, enabling parametric, data-driven tool selection.

[0017] Furthermore, in step S1, the process of ensuring structural compatibility and thermal stability during machining by rationally selecting the hoist tooth blank and matching internal cooling tool, thus providing a reliable foundation for subsequent liquid cooling heat dissipation, is as follows:

[0018] S1.3. Perform CFD (Computational Fluid Dynamics) simulation on the cutting tool with an internal cooling structure, establish a coolant flow field model for the cutting tool, and use [the following simulation method]... Turbulence model, input conditions are:

[0019] Coolant inlet pressure: 12 bar; temperature: 18 ℃; flow rate: 3 L / min; outlet boundary set as atmospheric pressure reflux. Simulation results show that the outlet velocity of the internal cooling channel can be maintained at 8–10 m / s, the coolant can effectively cover the root of the main cutting edge of the tool, the local temperature field is uniformly distributed, and the maximum temperature rise does not exceed 20 ℃.

[0020] Furthermore, in step S2, a high-pressure liquid cooling system is established on the machine tool to deliver 25°C water-soluble cutting fluid to the tool. The nozzle is aligned at a 60° angle with the main cutting edge and the chip flow direction.

[0021] S2.1, The liquid cooling system includes:

[0022] Liquid supply unit: includes a storage tank, a high-pressure pump, a temperature control device, and a flow sensor;

[0023] The distribution and injection unit consists of a high-pressure nozzle assembly, an internal cooling connector, and an angle adjustment mechanism.

[0024] Return and filtration unit: includes coolant recovery tank, coarse and fine filtration devices (filtration accuracy 5–25 μm), and circulation piping;

[0025] Control unit: Includes a PLC controller and monitoring sensor module, used to adjust coolant flow, temperature and pressure in real time;

[0026] S2.2 Based on the previous process experiments and simulation analysis, the initial parameters of the system are set as follows:

[0027] Coolant type: Water-soluble synthetic cutting fluid;

[0028] Temperature range: 10–25 ℃;

[0029] Pressure: 10–20 bar;

[0030] Total flow rate: 4–12 L / min (internal and external cooling flow rate ratio is approximately 3:7); the coolant temperature is controlled by a closed-loop temperature control device, which detects the liquid outlet temperature in real time through a thermocouple sensor. If the detected temperature exceeds the set threshold (e.g., 25 ℃), the controller automatically adjusts the pump speed or activates the auxiliary cooling unit to maintain the system operating within the steady-state temperature range.

[0031] Furthermore, in step S2, a high-pressure liquid cooling system is established on the machine tool to deliver 25°C water-soluble cutting fluid to the tool. The nozzle is aligned at a 60° angle with the main cutting edge and the chip flow direction.

[0032] S2.3. A three-nozzle structure is adopted: the main nozzle is aligned with the root of the main cutting edge; the auxiliary nozzles are aligned with the chip flow direction and the workpiece surface area respectively, and the nozzle angle is initially set to 45°.

[0033] Optimization is achieved through angle correction based on temperature gradients. Infrared temperature sensors are deployed in the machining experiment to obtain temperature distribution data of the cutting area. Minimize the temperature variance in the cutting zone using the gradient descent method: ,in, The nozzle angle parameter is used, and the control system automatically fine-tunes the nozzle angle by ±2° to 3° based on the calculation results to obtain the optimal cooling coverage effect.

[0034] S2.4 When the coolant pressure is too high, dynamic distribution control is achieved through a flow sensor and a proportional valve. The control logic is as follows:

[0035] When the tool cuts into the workpiece and the cutting load increases, the system automatically increases the internal cooling flow by about 10% to enhance the cooling of the cutting edge;

[0036] When the cutting load decreases or the tool is withdrawn, the internal cooling flow rate automatically drops to the reference value;

[0037] The external cooling flow rate remains stable for continuous chip removal and auxiliary heat dissipation; flow control is based on a PID regulation algorithm to implement closed-loop feedback.

[0038] ,in, For real-time coolant flow rate, As the baseline flow rate, This refers to the deviation in cutting temperature rise detected by the system.

[0039] Furthermore, in step S3, a special fixture is designed to ensure reliable workpiece fixation. The fixture is equipped with an auxiliary cooling channel and a sealed reflux system. The reflux fluid passes through 25... The process for recycling after filtration is as follows:

[0040] S3.1 For the complex shape and structure of the shovel tooth blank, the special fixture must meet the following requirements:

[0041] The workpiece clamping is highly rigid, ensuring that vibration during processing is less than 5μm.

[0042] Provide a reference positioning surface to ensure that the clamping accuracy error of the shovel tooth blank is ≤ 0.02 mm;

[0043] Supports liquid cooling channel layout, including main cooling pipe interface and auxiliary nozzle fixing position;

[0044] S3.2 The fixture has pre-set built-in cooling channels for introducing coolant to the side or bottom of the workpiece: A three-dimensional flow field model is established based on the workpiece geometry and tool path, and flow constraints are set for each channel node to ensure that the fluid velocity is not less than 5 m / s and not greater than 10 m / s.

[0045] An iterative flow distribution algorithm is used to optimize the coolant channels: the flow rate in each channel is initialized to be an equal distribution of the total flow rate; the temperature rise in the cooling zone is calculated. Calculate the variance of temperature rise ,like If the temperature exceeds the set threshold, the temperature rise of each channel will be considered. Traffic After adjustment, the iterative flow allocation expression is as follows:

[0046] ,in, To increase the temperature of each channel, For traffic, iterate until ;

[0047] S3.3 The interface between the internal cooling channel and the external nozzle of the fixture is sealed with an O-ring. The sealing surface pressure can withstand a fluid pressure of 20 bar. After the coolant absorbs heat through the workpiece, it enters the storage tank through the fixture return pipeline and is recycled after coarse and fine filtration. The return pipeline is designed with a flow detection port and a differential pressure monitoring point to detect the risk of blockage or leakage in real time.

[0048] S3.4 After the fixture and channel design is completed, conduct simulation verification before actual processing.

[0049] A finite element thermal field model was established for the fixture-workpiece-tool system;

[0050] The temperature field in the cutting zone is predicted by simulating coolant flow and heat transfer using CFD.

[0051] The temperature rise in the critical cutting area was verified to be ≤ 50 ℃ and the temperature difference to be ≤ 15 ℃, which meets the requirements for tool thermal stability.

[0052] Furthermore, in step S4, the liquid-cooled cutting process achieves its goal of reducing cutting temperature by initiating a stable liquid flow, cutting in stages according to process parameters, and employing a combination of internal tool cooling and external high-pressure jet cooling, while simultaneously monitoring the machining status in real time.

[0053] S4.1. Set the initial cutting parameters according to the workpiece material hardness, tool type and machine tool rigidity;

[0054] S4.2, The initial flow rate of the internal cooling channel of the tool is 3 L / min, and the pressure is 12 bar; as the cutting load increases or the tool temperature increases... When the temperature exceeds the set threshold (e.g., 80 ℃), the system automatically adjusts the internal cooling flow rate according to the temperature deviation.

[0055] Furthermore, in step S4, the liquid-cooled cutting process achieves its goal of reducing cutting temperature by initiating a stable liquid flow, cutting in stages according to process parameters, and employing a combination of internal tool cooling and external high-pressure jet cooling, while simultaneously monitoring the machining status in real time.

[0056] S4.3. Arrange an infrared temperature sensor on the tool shank or near the tool tip to collect temperature data in real time; monitor power changes to judge cutting load fluctuations and adjust the feed or cutting depth in time; use high-definition camera or laser detection to judge chip breakage; and conduct random inspections of the workpiece surface during machining to confirm that Ra ≤ 1.6 μm.

[0057] Furthermore, in step S5, after machining is completed, the coolant is recycled through reflux filtration. Simultaneously, the nozzle angle, flow rate, or tool parameters are dynamically adjusted by monitoring the concentration, temperature, and contamination level.

[0058] S5.1. After the coolant carries away heat through the tool's internal cooling channel, external spray nozzles, and fixture cooling channel, it is collected in the recovery tank through the return pipeline. A filtration system is installed at the inlet of the return pipeline, including coarse and fine filters. The filters are equipped with differential pressure monitoring. When the differential pressure... When this happens, the system automatically switches to the backup filter, and automatically detects the coolant concentration, pH value, and temperature.

[0059] S5.2. Utilize tool life prediction models or periodically inspect tool tip wear to determine whether tool replacement or re-grinding is necessary. Randomly inspect workpiece surface roughness. To ensure that the finishing process meets the requirements If the surface roughness exceeds the standard, the cutting speed, feed rate, or coolant spray direction can be adjusted.

[0060] Furthermore, in step S5, after machining is completed, the coolant is recycled through reflux filtration. Simultaneously, the nozzle angle, flow rate, or tool parameters are dynamically adjusted by monitoring the concentration, temperature, and contamination level.

[0061] S5.3 Utilize the tool temperature, cutting zone temperature and liquid cooling flow data recorded during machining to analyze the relationship between coolant flow and temperature control effect. Based on statistical analysis (such as standard deviation of temperature fluctuation and average temperature rise), adjust the internal and external cooling flow distribution or nozzle layout.

[0062] S5.4. By collecting multiple batches of processing data and using a simple weighted scoring algorithm, the optimal processing parameters are selected. The expression is as follows: ,in: This is the highest temperature of the cutting tool. This refers to the spindle power or cutting force indicators. For surface roughness, These are the weighting coefficients.

[0063] Beneficial effects

[0064] Compared with known public technologies, the technical solution provided by this invention has the following beneficial effects:

[0065] This invention achieves efficient control and dynamic optimization of liquid cooling heat dissipation during tooth-shaving machining. Specifically, it ensures machining stability through precise preparation of the workpiece and cutting tool before machining; the dual-channel internal and external liquid cooling system, combined with real-time temperature and flow monitoring, enables precise temperature control of the cutting tool and cutting zone; dynamic flow regulation and nozzle fine-tuning ensure uniform heat load distribution in the machining area, effectively reducing average temperature rise and temperature fluctuations; simultaneously, through statistical analysis and feedback correction of machining data, the internal and external cooling flow distribution and nozzle layout are optimized, enabling the liquid cooling system to achieve adaptive adjustment capabilities. Therefore, this invention can significantly improve tool life and machining quality, ensure thermal stability during tooth-shaving machining, and improve the energy efficiency and controllability of the liquid cooling system, demonstrating significant economic benefits and technical advantages. Attached Figure Description

[0066] Figure 1 This is a flowchart illustrating the process for machining liquid-cooled spade teeth according to the present invention. Detailed Implementation

[0067] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present invention.

[0068] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of the invention described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but includes other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0069] The present invention will now be described in further detail with reference to the accompanying drawings:

[0070] Example:

[0071] like Figure 1 As shown,

[0072] S1. By rationally selecting the hoisting tooth blank and matching internal cooling tool, the structural compatibility and thermal stability of the machining process are ensured, providing a reliable foundation for subsequent liquid cooling heat dissipation;

[0073] Furthermore, by rationally selecting the hoisting tooth blank and matching internal cooling tool, the process ensures structural compatibility and thermal stability during machining, providing a reliable foundation for subsequent liquid cooling heat dissipation.

[0074] S1.1. Based on the operating environment and performance requirements of the shovel teeth, high-strength alloy steel or high-manganese wear-resistant steel with a hardness of HB320~HB450 is selected as the blank material. A workpiece geometry and material property dataset is established using a three-dimensional model database (such as a shovel tooth CAD model library). The blank is pre-cleaned (de-scaling, rust removal) and the positioning datum is machined to ensure that the flatness error of the datum surface is ≤ 0.02 mm. Workpiece posture recognition is achieved through a laser scanning positioning system. The actual clamping position of the workpiece is compared and corrected with the theoretical model, and the compensation amount is calculated. The formula for calculating the compensation amount is: ,in, For the theoretical reference point coordinates, These are the coordinates of the measured point;

[0075] S1.2. Based on the workpiece material's hardness, thermal conductivity, and cutting depth parameters, establish a tool selection decision model: ,in, For material type parameters, For material hardness, Where is the thermal conductivity; if If the condition is unsuitable, carbide or indexable insert tools are recommended; otherwise, coated carbide or CBN tools are preferred.

[0076] If the thermal conductivity of the material is lower than Therefore, tools with enhanced cooling channel structures are recommended. The objective function expression for tool recommendation is: ,in, For cutting temperature rise, For tooling costs, Surface roughness index These are weighting coefficients. This model allows for the rapid selection of tool combinations from a tool library that offer the best thermal stability and cost-effectiveness, enabling parametric, data-driven tool selection.

[0077] S1.3. Perform CFD (Computational Fluid Dynamics) simulation on the cutting tool with an internal cooling structure, establish a coolant flow field model for the cutting tool, and use [the following simulation method]... The turbulence model was used with the following input conditions: coolant inlet pressure: 12 bar; temperature: 18℃; flow rate: 3 L / min; and the outlet boundary was set to normal pressure reflux. Simulation results show that the outlet velocity of the internal cooling channel can be maintained at 8–10 m / s, the coolant can effectively cover the root of the main cutting edge of the tool, the local temperature field is uniform, and the maximum temperature rise does not exceed 20℃.

[0078] In this embodiment, before liquid cooling of the shovel teeth, the workpiece and cutting tools are prepared first. A shovel tooth blank that meets the design requirements is selected, preferably made of high-strength alloy steel or wear-resistant steel. The blank surface is pre-cleaned and datum positioned to ensure clamping accuracy and machining stability. Subsequently, appropriate cutting tools are selected according to different machining stages: in the roughing stage, carbide or indexable insert tools are used to achieve efficient cutting and stable removal of allowance; in the finishing stage, carbide tools with high wear resistance and heat resistance coatings (such as TiAlN or AlCrN coatings) or cubic boron nitride (CBN) tools are selected to ensure surface quality and tool life. Preferably, the tool adopts a structure with internal cooling channels, allowing the liquid cooling medium to directly enter the cutting edge area during machining, achieving efficient heat conduction and dissipation, and providing good pathway matching and heat exchange conditions for the subsequent liquid cooling control system. Through this preparation step, the structural stability and thermal control accuracy of the machining process can be effectively improved, laying the foundation for the stable implementation of the liquid cooling process.

[0079] S2. Establish a high-pressure liquid cooling system on the machine tool to deliver 25°C water-soluble cutting fluid to the tool, with the nozzle aligned at a 60° angle with the main cutting edge and the direction of chip flow.

[0080] Furthermore, a high-pressure liquid cooling system is established on the machine tool to deliver water-soluble cutting fluid at 25°C to the cutting tool. The nozzle is aimed at the main cutting edge and the chip flow direction at a 60° angle. The process is as follows:

[0081] S2.1, The liquid cooling system includes:

[0082] Liquid supply unit: includes a storage tank, a high-pressure pump, a temperature control device, and a flow sensor;

[0083] The distribution and injection unit consists of a high-pressure nozzle assembly, an internal cooling connector, and an angle adjustment mechanism.

[0084] Return and filtration unit: includes coolant recovery tank, coarse and fine filtration devices (filtration accuracy 5–25 μm), and circulation piping;

[0085] Control unit: Includes a PLC controller and monitoring sensor module, used to adjust coolant flow, temperature and pressure in real time;

[0086] S2.2 Based on previous process experiments and simulation analysis, the initial system parameters are set as follows:

[0087] Coolant type: Water-soluble synthetic cutting fluid;

[0088] Temperature range: 10–25 ℃;

[0089] Pressure: 10–20 bar;

[0090] Total flow rate: 4–12 L / min (internal and external cooling flow ratio approximately 3:7); coolant temperature is controlled by a closed-loop temperature control device, which monitors the liquid outlet temperature in real time via thermocouple sensors. If the detected temperature exceeds a set threshold (e.g., 25 ℃), the controller automatically adjusts the pump speed or activates the auxiliary cooling unit to maintain the system operating within the steady-state temperature range. S2.3: A three-nozzle structure is adopted: the main nozzle is aligned with the root of the main cutting edge; the auxiliary nozzles are aligned with the chip flow direction and the workpiece surface area, respectively. The initial nozzle angle is set to 45°.

[0091] Optimization is achieved through angle correction based on temperature gradients. Infrared temperature sensors are deployed in the machining experiment to obtain temperature distribution data of the cutting area. Minimize the temperature variance in the cutting zone using the gradient descent method: ,in, The nozzle angle parameter is used, and the control system automatically fine-tunes the nozzle angle by ±2° to 3° based on the calculation results to obtain the optimal cooling coverage effect.

[0092] S2.4 When the coolant pressure is too high, dynamic distribution control is achieved through a flow sensor and a proportional valve. The control logic is as follows:

[0093] When the tool cuts into the workpiece and the cutting load increases, the system automatically increases the internal cooling flow by about 10% to enhance the cooling of the cutting edge;

[0094] When the cutting load decreases or the tool is withdrawn, the internal cooling flow rate automatically drops to the reference value;

[0095] The external cooling flow rate remains stable for continuous chip removal and auxiliary heat dissipation; flow control is based on a PID regulation algorithm to implement closed-loop feedback.

[0096] ,in, For real-time coolant flow rate, As the baseline flow rate, This refers to the deviation in cutting temperature rise detected by the system.

[0097] In this embodiment, based on the machining center structure and tool installation method, a dual-channel liquid cooling circuit is designed: the internal cooling channel guides coolant directly to the cutting edge through internal cooling holes in the tool, achieving directional cooling inside the tool; the external cooling channel consists of a nozzle array arranged along the cutting area of ​​the shaving teeth, used to cover the cutting zone and remove heat from the chips. The coolant system includes a circulating pump, a flow regulating valve, temperature and pressure sensors, and a two-stage filtration unit. A coarse filter is located at the outlet of the recovery tank to remove large particulate impurities, and a fine filter is located before the pump to prevent clogging of the internal cooling channel of the tool. The control unit automatically adjusts the pump speed and valve opening according to the set flow and temperature thresholds to ensure that the coolant is circulated and delivered at a stable flow and pressure. During the initial operation of the system, a low-flow pre-circulation is used to clean the passage and achieve stable startup, and then the flow is gradually increased to the working state to achieve real-time heat dissipation support for the shaving teeth machining process.

[0098] S3. A specially designed fixture ensures reliable workpiece fixation. The fixture includes an auxiliary cooling channel and a sealed reflux system. The reflux fluid passes through a 25°... Filtered and reused;

[0099] Furthermore, a specialized fixture is designed to ensure reliable workpiece fixation. The fixture incorporates an auxiliary cooling channel and a sealed reflux system, with the reflux fluid passing through a 25-degree arc. The process for recycling after filtration is as follows:

[0100] S3.1 For the complex shape and structure of the shovel tooth blank, the special fixture must meet the following requirements:

[0101] The workpiece clamping is rigid, ensuring that the vibration during processing is less than 5μm; a reference positioning surface is provided to ensure that the clamping accuracy error of the shovel tooth blank is ≤ 0.02 mm; liquid cooling channel arrangement is supported, including the main cooling pipe interface and the fixed position of the auxiliary nozzle;

[0102] S3.2 The fixture has pre-set built-in cooling channels for introducing coolant to the side or bottom of the workpiece: A three-dimensional flow field model is established based on the workpiece geometry and tool path, and flow constraints are set for each channel node to ensure that the fluid velocity is not less than 5 m / s and not greater than 10 m / s.

[0103] An iterative flow distribution algorithm is used to optimize the coolant channels: the flow rate in each channel is initialized to be an equal distribution of the total flow rate; the temperature rise in the cooling zone is calculated. Calculate the variance of temperature rise ,like If the temperature exceeds the set threshold, the temperature rise of each channel will be considered. Traffic After adjustment, the iterative flow allocation expression is as follows:

[0104] ,in, To increase the temperature of each channel, For traffic, iterate until ;

[0105] S3.3 The interface between the internal cooling channel and the external nozzle of the fixture is sealed with an O-ring. The sealing surface pressure can withstand a fluid pressure of 20 bar. After the coolant absorbs heat through the workpiece, it enters the storage tank through the fixture return pipeline and is recycled after coarse and fine filtration. The return pipeline is designed with a flow detection port and a differential pressure monitoring point to detect the risk of blockage or leakage in real time.

[0106] S3.4 After the fixture and channel design is completed, conduct simulation verification before actual processing.

[0107] A finite element thermal field model was established for the fixture-workpiece-tool system;

[0108] The temperature field in the cutting zone is predicted by simulating coolant flow and heat transfer using CFD.

[0109] The temperature rise in the critical cutting area was verified to be ≤ 50 ℃ and the temperature difference ≤ 15 ℃, meeting the tool thermal stability requirements.

[0110] In this embodiment, during the liquid cooling process of the shovel teeth, temperature sensors are installed at the tool, cutting zone, and coolant inlet and outlet to obtain key parameters such as tool temperature, cutting zone temperature, and coolant temperature in real time. At the same time, flow sensors and pressure sensors are installed in the internal and external cooling circuits to monitor the operating status of the liquid cooling system. The data acquisition module transmits the above signals to the controller in real time, and the controller records and processes the temperature, flow, and pressure data synchronously.

[0111] The controller can use a sliding window averaging algorithm to calculate the real-time temperature trend.

[0112] ,in For ambient temperature, By setting the number of sampling points and continuously calculating the rate of temperature change and the standard deviation of fluctuation, a dynamic assessment of the processing heat load can be achieved.

[0113] S4. Liquid cooling cutting process starts a stable liquid flow, cuts in stages according to process parameters, and uses a combination of internal tool cooling and external high-pressure jet cooling. At the same time, the machining status is monitored in real time to reduce the cutting temperature.

[0114] Furthermore, liquid-cooled cutting machining achieves its goal of reducing cutting temperature by initiating a stable liquid flow, cutting in stages according to process parameters, and employing a combination of internal tool cooling and external high-pressure jet cooling, while simultaneously monitoring the machining status in real time.

[0115] S4.1. Based on the workpiece material hardness, tool type, and machine tool rigidity, set the initial cutting parameters.

[0116]

[0117] S4.2, The initial flow rate of the internal cooling channel of the tool is 3 L / min, and the pressure is 12 bar; as the cutting load increases or the tool temperature increases... When the temperature exceeds a set threshold (e.g., 80°C), the system automatically adjusts the internal cooling flow rate according to the temperature deviation.

[0118]

[0119] When the tool temperature drops below the threshold, the flow rate automatically recovers to the initial value of 3 L / min;

[0120] S4.3. Arrange an infrared temperature sensor on the tool shank or near the tool tip to collect temperature data in real time; monitor power changes to judge cutting load fluctuations and adjust the feed or cutting depth in time; use high-definition camera or laser detection to judge chip breakage; and conduct random inspections of the workpiece surface during machining to confirm that Ra ≤ 1.6 μm.

[0121] In this embodiment, during the tooth-shaving process, the control system adjusts the tool temperature based on real-time data. Cutting zone temperature and coolant temperature difference The system uses data to comprehensively analyze the cooling effect and dynamically adjusts the distribution of internal and external cooling flow accordingly, setting a target temperature rise value. With temperature fluctuation threshold To maintain processing thermal stability, the controller calculates the cooling adjustment amount based on the real-time temperature error, using a proportional adjustment calculation formula: ,in, This is a correction value for the cooling flow rate. To adjust the coefficient, when the average temperature rise exceeds the set value, the system automatically increases the internal cooling flow. If the temperature fluctuation is large, the external cooling flow is increased first to improve temperature uniformity.

[0122] S5. After processing, the coolant is recycled through reflux filtration. At the same time, the nozzle angle, flow rate or tool parameters are dynamically adjusted by monitoring the concentration, temperature and contamination level.

[0123] Furthermore, after processing, the coolant is recycled through reflux filtration. Simultaneously, the nozzle angle, flow rate, or tool parameters are dynamically adjusted by monitoring concentration, temperature, and contamination levels.

[0124] S5.1. After the coolant carries away heat through the tool's internal cooling channel, external spray nozzles, and fixture cooling channel, it is collected in the recovery tank through the return pipeline. A filtration system is installed at the inlet of the return pipeline, including coarse and fine filters. The filters are equipped with differential pressure monitoring. When the differential pressure... When this happens, the system automatically switches to the backup filter, and automatically detects the coolant concentration, pH value, and temperature.

[0125] S5.2. Utilize tool life prediction models or periodically inspect tool tip wear to determine whether tool replacement or re-grinding is necessary. Randomly inspect workpiece surface roughness. To ensure that the finishing process meets the requirements If the surface roughness exceeds the standard, the cutting speed, feed rate or coolant spray direction can be adjusted. S5.3 Utilize the tool temperature, cutting zone temperature and coolant flow rate data recorded during machining to analyze the relationship between coolant flow rate and temperature control effect. Based on statistical analysis (such as temperature fluctuation standard deviation, average temperature rise), adjust the internal and external coolant flow rate distribution or nozzle layout.

[0126] The expression for comprehensively evaluating cooling using average temperature rise and temperature fluctuation is as follows:

[0127] ,in, Average temperature rise, The standard deviation of the temperature in the cutting zone. These are the weighting coefficients;

[0128] The relationship model between flow rate and temperature control is as follows:

[0129] when The smaller the value, the better the temperature control effect. The coefficient is obtained through regression. It can be determined whether internal or external cooling is more sensitive to temperature control;

[0130] S5.4. By collecting multiple batches of processing data and using a simple weighted scoring algorithm, the optimal processing parameters are selected. The expression is as follows: ,in: This is the highest temperature of the cutting tool. This refers to the spindle power or cutting force indicators. For surface roughness, These are weighting coefficients.

[0131] In this embodiment, the controller employs an adaptive correction algorithm based on temperature error trends to optimize the adjustment parameters in real time. When an abnormally high temperature or fluctuation is detected in a certain area, the system achieves localized cooling by slightly increasing the flow rate of the corresponding nozzle or adjusting the injection angle. After multiple processing cycles, the control system can gradually form an optimal flow distribution model and nozzle layout scheme, realizing the self-learning and iterative optimization of the liquid cooling system.

[0132] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions will not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A process for machining liquid-cooled spade teeth, characterized in that, Includes the following steps: S1. By rationally selecting the hoisting tooth blank and matching internal cooling tool, the structural compatibility and thermal stability of the machining process are ensured, providing a reliable foundation for subsequent liquid cooling heat dissipation; S2. Establish a high-pressure liquid cooling system on the machine tool to deliver 25°C water-soluble cutting fluid to the tool, with the nozzle aimed at the main cutting edge and the direction of chip flow at a 60° angle; S3. A specially designed fixture ensures reliable workpiece fixation. The fixture includes an auxiliary cooling channel and a sealed reflux system. The reflux fluid passes through a 25°... Filtered and reused; S4. Liquid cooling cutting process starts a stable liquid flow, cuts in stages according to process parameters, and uses a combination of internal tool cooling and external high-pressure jet cooling. At the same time, the machining status is monitored in real time to reduce the cutting temperature. S5. After processing, the coolant is recycled through reflux filtration. The nozzle angle, flow rate or tool parameters are dynamically adjusted by monitoring the concentration, temperature and contamination level.

2. The process for machining liquid-cooled heat dissipation shovel teeth according to claim 1, characterized in that, In step S1, the process of ensuring structural compatibility and thermal stability during machining by appropriately selecting the hoist tooth blank and matching internal cooling tool, thus providing a reliable foundation for subsequent liquid cooling heat dissipation, is as follows: S1.

1. Based on the operating environment and performance requirements of the shovel teeth, high-strength alloy steel or high-manganese wear-resistant steel with a hardness of HB320~HB450 is selected as the blank material. A workpiece geometry and material property dataset is established using a three-dimensional model database. The blank is pre-cleaned and the positioning datum is machined to ensure that the flatness error of the datum surface is ≤ 0.02 mm. The workpiece posture is recognized by a laser scanning positioning system. The actual clamping position of the workpiece is compared and corrected with the theoretical model, and the compensation amount is calculated. The formula for calculating the compensation amount is: ,in, For the theoretical reference point coordinates, These are the coordinates of the measured point; S1.

2. Based on the workpiece material's hardness, thermal conductivity, and cutting depth parameters, establish a tool selection decision model: ,in, For material type parameters, For material hardness, Thermal conductivity; like For this purpose, carbide or indexable insert tools are recommended. For this purpose, coated carbide or CBN tools are preferred. If the thermal conductivity of the material is lower than Therefore, tools with enhanced cooling channel structures are recommended. The objective function expression for tool recommendation is: ,in, For cutting temperature rise, For tooling costs, Surface roughness index These are the weighting coefficients.

3. The process for machining liquid-cooled heat dissipation shovel teeth according to claim 2, characterized in that, In step S1, the process of ensuring structural compatibility and thermal stability during machining by appropriately selecting the hoist tooth blank and matching internal cooling tool, thus providing a reliable foundation for subsequent liquid cooling heat dissipation, is as follows: S1.

3. Perform CFD (Computational Fluid Dynamics) simulation on the cutting tool with an internal cooling structure, establish a coolant flow field model for the cutting tool, and use [the following simulation method]... Turbulence model, input conditions are: Coolant inlet pressure: 12 bar; Temperature: 18 ℃; Flow rate: 3 L / min; Outlet boundary set to atmospheric pressure reflux.

4. The process for machining liquid-cooled heat dissipation shovel teeth according to claim 3, characterized in that, In step S2, a high-pressure liquid cooling system is established on the machine tool to supply water-soluble cutting fluid at 25°C to the cutting tool. The nozzle is aimed at the main cutting edge and the chip flow direction at a 60° angle. S2.1, The liquid cooling system includes: Liquid supply unit: includes a storage tank, a high-pressure pump, a temperature control device, and a flow sensor; The distribution and injection unit consists of a high-pressure nozzle assembly, an internal cooling connector, and an angle adjustment mechanism. Return and filtration unit: includes coolant recovery tank, coarse and fine filtration devices, and circulation piping; Control unit: Includes a PLC controller and monitoring sensor module, used to adjust coolant flow, temperature and pressure in real time; S2.2 Based on the previous process experiments and simulation analysis, the initial parameters of the system are set as follows: Coolant type: Water-soluble synthetic cutting fluid; Temperature range: 10–25 ℃; Pressure: 10–20 bar; Total flow rate: 4–12 L / min; The coolant temperature is controlled by a closed-loop temperature control device. The liquid outlet temperature is detected in real time by a thermocouple sensor. If the detected temperature exceeds the set threshold, the controller automatically adjusts the pump speed or activates the auxiliary cooling unit to maintain the system in a steady-state temperature range.

5. The process for machining liquid-cooled heat dissipation shovel teeth according to claim 4, characterized in that, In step S2, a high-pressure liquid cooling system is established on the machine tool to supply water-soluble cutting fluid at 25°C to the cutting tool. The nozzle is aimed at the main cutting edge and the chip flow direction at a 60° angle. S2.

3. A three-nozzle structure is adopted: the main nozzle is aligned with the root of the main cutting edge; the auxiliary nozzles are aligned with the chip flow direction and the workpiece surface area respectively, and the nozzle angle is initially set to 45°. Optimization is achieved through angle correction based on temperature gradients. Infrared temperature sensors are deployed in the machining experiment to obtain temperature distribution data of the cutting area. Minimize the temperature variance in the cutting zone using the gradient descent method: ,in, For nozzle angle parameters, S2.4 When the coolant pressure is too high, dynamic distribution control is achieved through a flow sensor and a proportional valve. The control logic is as follows: When the tool cuts into the workpiece and the cutting load increases, the system automatically increases the internal cooling flow by about 10% to enhance the cooling of the cutting edge; When the cutting load decreases or the tool is withdrawn, the internal cooling flow rate automatically drops to the reference value; The external cooling flow rate remains stable for continuous chip removal and auxiliary heat dissipation; flow control is based on a PID regulation algorithm to implement closed-loop feedback. ,in, For real-time coolant flow rate, As the baseline flow rate, This refers to the deviation in cutting temperature rise detected by the system.

6. The process for machining liquid-cooled heat dissipation shovel teeth according to claim 5, characterized in that, In step S3, a special fixture is designed to ensure reliable workpiece fixation. The fixture is equipped with an auxiliary cooling channel and a sealed reflux system. The reflux fluid passes through 25... The process for recycling after filtration is as follows: S3.1 For the complex shape and structure of the shovel tooth blank, the special fixture must meet the following requirements: The workpiece clamping is highly rigid, ensuring that vibration during processing is less than 5μm. Provide a reference positioning surface to ensure that the clamping accuracy error of the shovel tooth blank is ≤ 0.02 mm; Supports liquid cooling channel layout, including main cooling pipe interface and auxiliary nozzle fixing position; S3.2 The fixture has pre-set built-in cooling channels for introducing coolant to the side or bottom of the workpiece: A three-dimensional flow field model is established based on the workpiece geometry and tool path, and flow constraints are set for each channel node to ensure that the fluid velocity is not less than 5 m / s and not greater than 10 m / s. An iterative flow distribution algorithm is used to optimize the coolant channels: the flow rate in each channel is initialized to be an equal distribution of the total flow rate; the temperature rise in the cooling zone is calculated. Calculate the variance of temperature rise ,like If the temperature exceeds the set threshold, the temperature rise of each channel will be considered. Traffic After adjustment, the iterative flow allocation expression is as follows: ,in, To increase the temperature of each channel, For traffic, iterate until ; S3.3 The interface between the internal cooling channel and the external nozzle of the fixture is sealed with an O-ring. The sealing surface pressure can withstand a fluid pressure of 20 bar. After the coolant absorbs heat through the workpiece, it enters the storage tank through the fixture return pipeline and is recycled after coarse and fine filtration. The return pipeline is designed with a flow detection port and a differential pressure monitoring point to detect the risk of blockage or leakage in real time. S3.4 After the fixture and channel design is completed, conduct simulation verification before actual processing.

7. The process for machining liquid-cooled heat dissipation shovel teeth according to claim 6, characterized in that, In step S4, the liquid-cooled cutting process involves starting a stable liquid flow, cutting in stages according to process parameters, and using a combination of internal tool cooling and external high-pressure jet cooling, while simultaneously monitoring the machining status in real time. This process aims to reduce the cutting temperature. S4.

1. Set the initial cutting parameters according to the workpiece material hardness, tool type and machine tool rigidity; S4.2, The initial flow rate of the internal cooling channel of the tool is 3 L / min, and the pressure is 12 bar; as the cutting load increases or the tool temperature increases... When the set threshold is exceeded, the system automatically adjusts the internal cooling flow rate according to the temperature deviation.

8. The process for machining liquid-cooled heat dissipation shovel teeth according to claim 7, characterized in that, In step S4, the liquid-cooled cutting process involves starting a stable liquid flow, cutting in stages according to process parameters, and using a combination of internal tool cooling and external high-pressure jet cooling, while simultaneously monitoring the machining status in real time. This process aims to reduce the cutting temperature. S4.

3. Arrange an infrared temperature sensor on the tool shank or near the tool tip to collect temperature data in real time; monitor power changes to judge cutting load fluctuations and adjust the feed or cutting depth in time; use high-definition camera or laser detection to judge chip breakage; and conduct random inspections of the workpiece surface during machining to confirm that Ra ≤ 1.6 μm.

9. The process for machining liquid-cooled heat dissipation shovel teeth according to claim 8, characterized in that, In step S5, after machining is completed, the coolant is recycled through reflux filtration. Simultaneously, the nozzle angle, flow rate, or tool parameters are dynamically adjusted by monitoring the concentration, temperature, and contamination level. S5.

1. After the coolant carries away heat through the tool's internal cooling channel, external spray nozzles, and fixture cooling channel, it is collected in the recovery tank through the return pipeline. A filtration system is installed at the inlet of the return pipeline, including coarse and fine filters. The filters are equipped with differential pressure monitoring. When the differential pressure... When this happens, the system automatically switches to the backup filter, and automatically detects the coolant concentration, pH value, and temperature. S5.

2. Utilize tool life prediction models or periodically inspect tool tip wear to determine whether tool replacement or re-grinding is necessary. Randomly inspect workpiece surface roughness. To ensure that the finishing process meets the requirements If the surface roughness exceeds the standard, the cutting speed, feed rate, or coolant spray direction can be adjusted.

10. The process for machining liquid-cooled heat dissipation shovel teeth according to claim 9, characterized in that, In step S5, after machining is completed, the coolant is recycled through reflux filtration. Simultaneously, the nozzle angle, flow rate, or tool parameters are dynamically adjusted by monitoring the concentration, temperature, and contamination level. S5.3 Utilize the tool temperature, cutting zone temperature and liquid cooling flow data recorded during machining to analyze the relationship between coolant flow and temperature control effect, and adjust the internal and external cooling flow distribution or nozzle layout based on statistical analysis. S5.

4. By collecting multiple batches of processing data and using a simple weighted scoring algorithm, the optimal processing parameters are selected. The expression is as follows: ,in: This is the highest temperature of the cutting tool. This refers to the spindle power or cutting force indicators. For surface roughness, These are the weighting coefficients.

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