Plasma-activated atomization for sustainable metalworking fluid delivery

Abstract

The present invention describes a system and method for enhancing metalworking operations by integrating an atmospheric pressure cold dielectric barrier discharge (DBD) plasma jet with a fluid atomizer. The system generates atomized liquid droplets that are electrostatically activated by the plasma jet and directed onto a workpiece or tool with the help of a carrier gas. The electrostatic charge on the atomized liquid droplets allows enhanced adhesion and penetration of the metalworking fluid to the tool and workpiece interface, resulting in improved lubrication, cooling, and operator safety. The system features a DBD plasma jet with a movable ring electrode for precise control of plasma jet characteristics, enabling the use of various fluids and carrier gases without extensive modifications. Additionally, the plasma offers disinfection and decontamination of the metalworking fluid, improving its recyclability and reuse. This novel fluid delivery system reduces environmental hazards caused by frequent disposal of contaminated metalworking fluid and contributes to sustainable metalworking operations. The invention also finds applications in spray painting, where it enhances paint adhesion and coverage on substrates. FIGURE 1

Description

FIELD OF THE INVENTIONThe present invention relates to the field of metalworking operations, specifically to systems and methods for delivering metalworking fluids. More particularly, it pertains to an innovative system that integrates an atmospheric pressure cold dielectric barrier discharge (DBD) plasma jet with a fluid atomizer to enhance the delivery and performance of metalworking fluids. This system aims to improve lubrication, cooling, and operator safety while promoting sustainability through fluid disinfection and recyclability. Additionally, the invention finds applications in spray painting, where it enhances paint adhesion and coverage on substrates.BACKGROUND OF THE INVENTION AND PRIOR ARTIn metalworking operations, the delivery of metalworking fluids is critical for lubrication, cooling, and the overall efficiency of the process. Traditional methods of fluid delivery, such as flood cooling and minimum quantity lubrication (MQL), have been widely used. However, these methods have several limitations and challenges.Flood cooling involves the continuous application of large volumes of coolant to the tool-workpiece interface. While effective in cooling and lubrication, this method results in significant fluid wastage and environmental concerns due to the disposal of contaminated fluids. Additionally, the high volume of fluid can cause issues such as mist formation, which poses health risks to operators.Minimum quantity lubrication (MQL) is an alternative approach that uses a small amount of lubricant delivered in the form of a fine mist. MQL aims to reduce fluid consumption and environmental impact. However, the atomization process in MQL systems often generates fog, which can disperse into the surrounding environment, creating safety hazards and reducing the efficiency of the lubrication process. Moreover, MQL systems do not address the issue of bacterial contamination and biofilm formation in metalworking fluids, which can lead to frequent fluid changes and maintenance.Various attempts have been made to improve the delivery and performance of metalworking fluids. For example, some systems have incorporated electrostatic forces to enhance fluid adhesion to the tool and workpiece. Others have explored the use of plasma technology for fluid activation. However, these solutions often require complex setups and extensive modifications when switching between different fluids and carrier gases.Technical Problem:The primary technical problem addressed by the present invention is the inefficiency and safety hazards associated with traditional metalworking fluid delivery methods. Specifically, the invention aims to overcome the following issues:1. Fluid Wastage and Environmental Impact: Traditional flood cooling methods result in significant fluid wastage and environmental concerns due to the disposal of contaminated fluids.2. Fog Formation and Safety Hazards: MQL systems often generate fog during the atomization process, which can disperse into the surrounding environment, creating safety hazards for operators and reducing the efficiency of the lubrication process.3. Bacterial Contamination and Biofilm Formation: Traditional fluid delivery methods do not address the issue of bacterial contamination and biofilm formation in metalworking fluids, leading to frequent fluid changes and maintenance.4. Complexity and Lack of Versatility: Existing solutions that incorporate electrostatic forces or plasma technology often require complex setups and extensive modifications when switching between different fluids and carrier gases.CN107105566A relates to a tube-ring type electrode atmospheric pressure surface dielectric barrier discharge jet source device. The high-voltage electrode of the device is a stainless steel tube, which is 7 mm in inside diameter, 7.9 mm in outside diameter, and 125 mm in length; a quartz glass tube, which is 9 mm in inside diameter, 15 mm in outside diameter and 103 mm in length, tightly covers the outer layer of the stainless steel tube; a cone structure is at the lower end of the quartz glass tube; and furthermore, a gas outlet, the aperture of which is 1.5 mm, is at the lower end of the quartz glass tube. The effective power and the gas temperature of the device are relatively low; furthermore, the effective power, the gas molecule rotation temperature and vibration temperature for detection, the electro-excitation temperature, the gas atomic density for detection, and the gas molecule density and the average electron density for detection are increased along with increasing of peak voltage; simultaneously, the working peak voltage of a plasma jet source can be reduced through the device; therefore, the plasma jet source can work under the 1.98 KV peak voltage; gas can be broken down; and simultaneously, the active oxygen atomic density can be increased. The lower end of the device described as a quartz glass tube is a fixed cone shape, and there is an aperture to be a 1.5 mm gas vent. CN107750087A discloses a bare electrode and dielectric barrier dual-purpose plasma jet- generating device that belongs to the plasma discharge reactor technology field. An atmospheric pressure cold plasma jet can be used to carry out surface modification on a metal material or a non-metallic material.CN212752708U discloses a handheld medical device that generates a low-temperature plasma jet using dielectric barrier discharge, ideal for medical applications like disinfection and wound treatment. The device features a plastic shell for insulation, a quartz discharge tube for gas ionization, and a high-voltage electrode for plasma generation. By ionizing argon gas with high voltage, the device creates a controlled plasma jet that is safe for human tissue, offering a portable and user-friendly solution for various medical treatments.CN206422966U describes a plasma jet device with a specialized electrode design, including a stainless-steel spiral high-voltage electrode and a copper foil ring-shaped grounding electrode. By flowing gas through the device and applying an electric field, the gas is ionized to create a plasma jet. The device allows for control of active oxygen density and jet length by adjusting the voltage, achieving a stable plasma jet at a low voltage (around 2 kV). Key components include a quartz glass tube for insulation and visibility, with applications in processes requiring precise plasma control.CN109317922B discloses a method for enhancing cutting processes by combining a cold plasma jet with an atomized cooling lubricating medium. The atomized medium improves heat transfer and surface modification, leading to reduced cutting temperatures, lower cutter wear, and enhanced surface quality. The system uses a cold plasma generator and an atomized cooling medium device to mix and apply these elements effectively, improving cutting performance and extending tool life.CN102601677B describes an atmospheric cold plasma jet auxiliary cutting method that uses a cold plasma jet as a cooling and lubricating medium during material cutting. The method involves directing a working gas through a cold plasma jet generator, where its flow and high-voltage output are adjusted to produce a uniform plasma jet at or slightly above room temperature. This jet continuously cools and lubricates the tool-workpiece and tool-chip interfaces during cutting. The plasma can be generated using dielectric barrier discharge, suspension electrode discharge, or bare electrode discharge modes. The method offers environmental benefits and enhances cutting efficiency by reducing cutting force, extending tool life, and improving workpiece surface quality. Reference is further made to Xu, W., Liu, X., Song, J., Wu, L. and Sun, J., 2012. Friction and wear properties of Ti6Al4V / WC- Co in cold atmospheric plasma jet. Applied Surface Science, 259, pp.616-623, in which friction and wear properties of Ti6Al4V / WC-Co friction pair have been studied using an autonomous atmospheric pressure bare electrode cold plasma jet generating device and block-on-ring friction / wear tester. The investigations have been performed with different atmospheres such as air, air jet, nitrogen jet, air cold plasma jet, and nitrogen cold plasma jet. In the results section, coefficient of friction, friction temperature and surface roughness were examined and discussed appropriately.In Mustafa, G., Liu, J., Zhang, F., Wang, G., Yang, Z., Harris, M., Liu, S., Liu, X., Jin, Z. and Sun, J., 2019. Atmospheric pressure plasma jet assisted micro-milling of Inconel 718. The International, Journal of Advanced Manufacturing Technology, 103, pp.4681-4687, the amalgamation of plasma jet and minimum quantity lubrication has been used during micro-milling of Inconel 718. The influence of plasma jet on machinability has been examined under different atmospheric conditions including dry, nitrogen gas, plasma jet, minimum quantity lubrication, and plasma with minimum quantity lubrication. The upshots of the present study have been discussed thoroughly in terms of surface roughness, cutting forces, and residual stress against the different conditions.In Liu, J., Chen, Y., Zhang, J., Wu, L., Yang, Z., Zhang, F., Sun, J., Liu, X., Jin, Z. and Zhao, D., 2020. Atmospheric pressure plasma jet and minimum quantity lubrication assisted micro-grinding of quenched GCr15. The International Journal of Advanced Manufacturing Technology, 106, pp.191-199, the combined effect of atmospheric pressure plasma jet (APPJ) and minimum quantity lubrication (MQL) has been investigated during the micro-grinding of Quenched GCr15 workpieces to alleviate the problems associated with micro-grinding process. The cooling and lubricating performance have been analyzed under five different environments such as dry micro- grinding, nitrogen jet assisted micro-grinding, APPJ assisted micro-grinding, MQL assisted micro- grinding, and APPJ+MQL assisted micro-grinding. The outcomes of the present study have been explained appropriately by pointing out the different parameters including grinding temperature, grinding force, surface roughness, and surface morphology of workpieces.In Liu, J., Song, J., Chen, Y., Zhang, J., Wu, L., Wang, G., Zhang, F., Liu, Z., Sun, J., Liu, S. and Liu, X., 2021. Atmospheric pressure cold plasma jet–assisted micro-milling TC4 titanium alloy. The International Journal of Advanced Manufacturing Technology, 112, pp.2201-2209, the authors performed micro-milling using atmospheric pressure cold plasma jet for the machining of Titanium alloy to improve the machinability and surface quality of machined surface. The authors have compared the upshots with different working conditions (dry, nitrogen jet, plasma jet, minimum quantity lubrication, and plasma jet with minimum quantity lubrication) regarding cutting force, cutting temperature, and surface quality.In Liu, J., Li, Y., Chen, Y., Zhou, Y., Wang, S., Yuan, Z., Jin, Z. and Liu, X., 2023. A review of low- temperature plasma-assisted machining: from mechanism to application. Frontiers of Mechanical Engineering, 18(1), p.18., the authors explored and reviewed the low temperature plasma assisted machining based on action mechanism, applications, characteristics, and classifications. Moreover, low- temperature plasma was classified as hot plasma and cold plasma according to the different equilibrium states. Additionally, hybrid machining methods combining the merits of low temperature plasma and other energy fields like ultrasonic vibration, liquid nitrogen, and minimum quantity lubrication have also been explained and analyzed.Disadvantages of Prior Art:The prior art methods and systems for metalworking fluid delivery have several disadvantages:1. High Fluid Consumption: Flood cooling methods consume large volumes of coolant, leading to increased costs and environmental impact due to the disposal of contaminated fluids.2. Health Risks: The mist and fog generated by MQL systems can pose health risks to operators, including respiratory issues and skin irritation.3. Frequent Maintenance: Bacterial contamination and biofilm formation in metalworking fluids necessitate frequent fluid changes and maintenance, increasing downtime and operational costs.4. Limited Versatility: Existing systems that use electrostatic forces or plasma technology often require complex setups and are not easily adaptable to different fluids and carrier gases, limiting their versatility and applicability.Technical Solution:The present invention provides a novel system and method that integrates an atmospheric pressure cold dielectric barrier discharge (DBD) plasma jet with a fluid atomizer to address the limitations and challenges of traditional fluid delivery methods. The technical solution offered by the invention includes the following features:1. Enhanced Fluid Delivery: The system generates atomized liquid droplets that are electrostatically activated by the plasma jet and directed onto the workpiece or tool with the help of a carrier gas. This enhances the adhesion and penetration of the metalworking fluid at the tool-workpiece interface, resulting in better lubrication and cooling.2. Fog Reduction: The invention reduces the fog generated during the atomization process, producing a more concentrated and dense mist. This minimizes safety hazards associated with fog dispersion and enhances the efficiency of the lubrication process.3.Disinfection Capability: The plasma-generated radical and reactive species disinfect the metalworking fluid, addressing issues of bacterial contamination, microorganism growth, and biofilm formation. This extends the usability of the metalworking fluid and reduces the need for frequent changes and maintenance.4. Sustainability: The system promotes sustainability by improving the recyclability and reuse of metalworking fluids, thereby reducing environmental hazards associated with their frequent disposal.5. Versatility and Adaptability: The adjustable position of the movable ring electrode allows for precise control over the plasma plume characteristics, making the system easily adaptable to different fluids and carrier gases without requiring extensive modifications.6. Spray Painting Applications: The system can be adapted for spray painting applications, where it improves paint adhesion and coverage on substrates, making it suitable for various industrial applications such as aerospace, automotive, biomedical, marine, and electronics.Overall, the present invention offers a comprehensive solution for enhancing metalworking operations and other industrial processes, providing significant benefits in terms of efficiency, safety, sustainability, and versatility.OBJECT OF THE INVENTIONThe primary object of the present invention is to provide a system for enhancing metalworking operations by integrating an atmospheric pressure cold dielectric barrier discharge (DBD) plasma jet with a fluid atomizer, thereby improving the delivery and performance of metalworking fluids.Another object of the invention is to reduce the fog generated during the atomization process in minimum quantity lubrication (MQL) systems, producing a more concentrated and dense mist that minimizes safety hazards and enhances the efficiency of the lubrication process.A further object of the invention is to enhance the penetration of metalworking fluids at the tool-workpiece interface, resulting in better lubrication and cooling, which are critical for the efficiency of metalworking operations and the longevity of the tools used.Yet another object of the invention is to incorporate disinfection capabilities into the system, using plasma-generated radical and reactive species to disinfect the metalworking fluid, thereby addressing issues of bacterial contamination, microorganism growth, and biofilm formation.An additional object of the invention is to promote sustainability in metalworking operations by improving the recyclability and reuse of metalworking fluids, thus reducing the environmental hazards associated with their frequent disposal.A further object of the invention is to provide a system that is easily adaptable to different fluids without requiring extensive modifications, achieved by adjusting the position of the movable ring electrode to control the plasma plume characteristics.Another object of the invention is to extend its application to spray painting, where the system can improve paint adhesion and coverage on substrates, making it suitable for various industrial applications such as aerospace, automotive, biomedical, marine, and electronics.Another object of the present invention is to provide a method and device for enhancing metalworking operations by integrating an atmospheric pressure cold dielectric barrier discharge (DBD) plasma jet with a fluid atomizer, thereby improving the delivery and performance of metalworking fluids.SUMMARY OF THE INVENTIONThe summary of the invention provided herein is intended to introduce the reader to the general principles and features of the invention. It is not intended to be an exhaustive or comprehensive description of the invention. The summary is not intended to limit the scope of the invention, which is defined by the claims and their equivalents.The specific embodiments and examples provided in the summary are illustrative and not intended to limit the scope of the invention. Various modifications, changes, and improvements can be made to the invention without departing from the spirit and scope of the invention. The invention is intended to cover all such modifications, changes, and improvements that fall within the scope of the claims and their equivalents.The present invention provides a novel system and method for enhancing metalworking operations by integrating an atmospheric pressure cold dielectric barrier discharge (DBD) plasma jet with a fluid atomizer. This innovative approach addresses multiple challenges in metalworking fluid delivery, including lubrication, cooling, and operator safety, while promoting sustainability through fluid disinfection and recyclability.The system comprises a high-voltage power supply, a dielectric barrier hollow tube, a movable ring electrode, a working gas source, a pressure gauge, a rotameter, a needle atomizer, a mixing chamber, a needle valve, a fluid tank, a lead nut, a tool, a tool holder, a dynamometer, and a workpiece which can be grounded. The dielectric tube serves as a conduit for gas flow and a barrier for controlling the current of discharge. The needle atomizer generates atomized liquid droplets, which are electrostatically activated by the plasma jet and directed onto the workpiece or tool with the help of a carrier gas.The movable ring electrode allows precise control over the plasma plume characteristics by varying the interelectrode distance between the needle atomizer and the movable ring electrode. This control enables the system to work with different fluids and carrier gases without requiring extensive modifications. The plasma plume contains electrically charged atomized liquid droplets that are attracted to the tool or workpiece due to electrostatic forces, enhancing adhesion and penetration of the metalworking fluid at the tool-workpiece interface.The invention also incorporates disinfection capabilities, using plasma-generated radical and reactive species to disinfect the metalworking fluid, addressing issues of bacterial contamination, microorganism growth, and biofilm formation. This feature significantly extends the usability of the metalworking fluid, reducing the need for frequent changes and maintenance.Additionally, the system promotes sustainability by improving the recyclability and reuse of metalworking fluids, thereby reducing environmental hazards associated with their frequent disposal. The system can also be adapted for spray painting applications, where it improves paint adhesion and coverage on substrates, making it suitable for various industrial applications such as aerospace, automotive, biomedical, marine, and electronics.In an aspect, the present invention provides a system for enhancing metalworking operations, comprising:a high-voltage power supply;a dielectric barrier hollow tube;a movable ring electrode;a working gas source;a pressure gauge;a rotameter;a needle atomizer;a mixing chamber;a needle valve;a fluid tank;a lead nut;a tool;a tool holder;a dynamometer;a workpiece which can be grounded;wherein one end of the dielectric tube is inserted by the needle atomizer and is connected with the high-voltage power supply through a metallic wire;wherein the working gas source is connected to the pressure gauge through a pipeline;wherein the pressure gauge is connected to the rotameter through a pipeline;wherein the rotameter is connected to the mixing chamber through a pipeline;wherein the fluid tank is connected to the mixing chamber through a pipeline;wherein the outlet of the mixing chamber is connected to the needle valve through a pipeline;wherein the needle valve is connected to the needle atomizer through a pipeline;wherein the needle atomizer is inserted into the dielectric tube;wherein the movable ring electrode is arranged on the outer wall of the dielectric tube and is connected to the power supply through the metallic wire;wherein the plasma plume is controlled at the lead nut by varying the interelectrode distance between the needle atomizer and the movable ring electrode; andwherein the fluid remaining in the treated zone being collected in a collector tank, pumped through a pipeline to a filter zone, and returned to the fluid tank as recycled fluid.In another aspect, the present invention provides a device for enhancing metalworking operations, comprising:a high-voltage power supply;a dielectric barrier hollow tube;a movable ring electrode arranged on the outer wall of the dielectric tube;a working gas source connected to a pressure gauge through a pipeline;a rotameter connected to the pressure gauge through a pipeline;a needle atomizer inserted into one end of the dielectric tube and connected to the high-voltage power supply through a metallic wire;a mixing chamber connected to the rotameter and a fluid tank through pipelines;a needle valve connected to the outlet of the mixing chamber through a pipeline;a lead nut for adjusting the interelectrode distance between the needle atomizer and the movable ring electrode;a tool and a tool holder;a dynamometer;a workpiece which can be grounded;wherein the device generates a plasma plume controlled by the lead nut by varying the interelectrode distance between the needle atomizer and the movable ring electrode.wherein the fluid remaining in the treated zone being collected in a collector tank, pumped through a pipeline to a filter zone, and returned to the fluid tank as recycled fluid.In another aspect, the present invention provides a method for enhancing metalworking operations in the system as described hereinabove, comprising the steps of:providing a high-voltage power supply;inserting a needle atomizer into one end of a dielectric barrier hollow tube and connecting the needle atomizer to the high-voltage power supply through a metallic wire;arranging a movable ring electrode on the outer wall of the dielectric tube and connecting the movable ring electrode to the high-voltage power supply through a metallic wire;connecting a working gas source to a pressure gauge through a pipeline;connecting the pressure gauge to a rotameter through a pipeline;connecting the rotameter to a mixing chamber through a pipeline;connecting a fluid tank to the mixing chamber through a pipeline;connecting the outlet of the mixing chamber to a needle valve through a pipeline;connecting the needle valve to the needle atomizer through a pipeline;adjusting the interelectrode distance between the needle atomizer and the movable ring electrode using a lead nut to control the plasma plume;generating a plasma plume by activating the high-voltage power supply, causing electron collisions with neutral gas molecules and atomized liquid droplets between the needle atomizer and the movable ring electrode;directing the plasma plume containing electrically charged atomized liquid droplets toward a tool or workpiece;enhancing the adhesion and penetration of the metalworking fluid to the tool and workpiece interface using electrostatic forces;improving lubrication and cooling at the tool-workpiece interface during metalworking operations.Overall, the present invention offers a versatile and efficient solution for enhancing metalworking operations, providing better lubrication, cooling, and safety, while promoting environmental sustainability and extending its applicability to other industrial processes.BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGSThe figures provided in the present invention disclosure are for illustrative purposes only and are not intended to limit the scope of the invention. The figures are simplified representations and may not be drawn to scale. They are included to facilitate understanding of the principles and methods described in the invention and to provide a visual aid for the accompanying description.Figure 1 illustrates a schematic diagram of the system for enhancing metalworking operations, showing the integration of the atmospheric pressure cold dielectric barrier discharge (DBD) plasma jet with the fluid atomizer. The figure includes the high-voltage power supply, dielectric barrier hollow tube, movable ring electrode, working gas source, pressure gauge, rotameter, needle atomizer, mixing chamber, needle valve, fluid tank, lead nut, tool, tool holder, dynamometer, and workpiece.Figure 2 depicts an alternative configuration of the system with two movable ring electrodes positioned around the dielectric tube, allowing for enhanced control over the plasma plume characteristics by adjusting the interelectrode distance between the needle atomizer and the ring electrodes.Figure 3 shows a configuration where the workpiece is connected to the high-voltage power supply, illustrating the adjustable interelectrode distance between the ring electrode and the needle atomizer, and the plasma atomizer distance between the tube outlet and the workpiece or tool.Figure 4 presents a single electrode dielectric configuration, where the high-voltage power is connected to the needle atomizer, and the inter-electrode distance between the needle atomizer and the workpiece or tool is adjustable and movable.Figure 5 illustrates the system with a gas compressor machine substituted for the working gas source, showing the various types of compressors that can be used to supply gas to the mixing chamber, including reciprocating, rotary screw, rotary vane, scroll, diaphragm, turbo, and hydraulic air compressors. Additionally, the system is designed for sustainability by recycling the working fluid, with the fluid remaining in the treated zone being collected in a collector tank, pumped through a pipeline to a filter zone, and returned to the fluid tank as recycled fluid.Therefore, the figures should be viewed as illustrative examples and not as limitations on the scope of the invention. The scope of the invention should be determined by the claims and their equivalents, and not by the specific examples or figures provided herein.DETAILED DESCRIPTION OF THE INVENTIONDefinition of Technical Terms:Dielectric Barrier Discharge (DBD) Plasma Jet: A type of plasma generated at atmospheric pressure using a dielectric barrier to separate the electrodes, which helps in producing a stable and uniform plasma jet. It is used in the present invention to activate and charge the atomized liquid droplets.Needle Atomizer: A device that generates fine liquid droplets through various atomization techniques such as pressure, rotary disc, gas, ultrasonic, and thermal atomization. In the present invention, it is used to create atomized liquid droplets that are subsequently activated by the plasma jet.Dielectric Tube: A hollow tube made from insulating materials such as quartz glass, Pyrex, ceramic, PTFE, PI, PMMA, PC, PEEK, TPU, POM, PET, FEP, PPVE, ETFE, or PVDF. It serves as a conduit for gas flow and a barrier for controlling the current of discharge in the plasma generation process.Movable Ring Electrode: An electrode positioned on the outer wall of the dielectric tube, which can be adjusted to vary the interelectrode distance between itself and the needle atomizer. This adjustment controls the characteristics of the plasma plume, such as its length and intensity.Plasma Plume: A stream of ionized gas containing charged particles, including ions, electrons, and excited species, generated by the DBD plasma jet. In the present invention, the plasma plume activates and charges the atomized liquid droplets, enhancing their adhesion and penetration at the tool-workpiece interface.Working Gas Source: A source of gas used to generate the plasma jet. The gas can be one or more combinations of nitrogen, argon, helium, carbon dioxide, oxygen, and dried air. The gas is supplied to the mixing chamber and subsequently to the needle atomizer.Mixing Chamber: A chamber where the working gas and fluid from the fluid tank are combined before being passed to the needle atomizer. The mixing chamber ensures a homogeneous mixture of gas and fluid for efficient atomization and plasma activation.Lead Nut: A component used to adjust the interelectrode distance between the needle atomizer and the movable ring electrode. By varying this distance, the lead nut controls the intensity and length of the plasma jet plume, allowing the system to work with different fluids and carrier gases.Electrostatic Forces: Forces that arise due to the presence of electrically charged particles. In the present invention, these forces cause the charged atomized liquid droplets to be attracted to and accumulate on the tool or workpiece, enhancing fluid adhesion and penetration.Tool-Workpiece Interface: The contact area between the tool and the workpiece during metalworking operations. Effective lubrication and cooling at this interface are critical for the efficiency of metalworking operations and the longevity of the tools used.Disinfection: The process of eliminating or reducing harmful microorganisms, such as bacteria, fungi, and viruses. In the present invention, plasma-generated radical and reactive species are used to disinfect the metalworking fluid, addressing issues of bacterial contamination and biofilm formation.Recyclability: The ability to reuse a material or product after its initial use. The present invention promotes the recyclability of metalworking fluids by incorporating disinfection capabilities, thereby extending the usability of the fluids and reducing environmental hazards associated with their disposal.Spray Painting: An application of the present invention where the system is used to improve paint adhesion and coverage on substrates. The system can handle various paint formulations, including water-based, oil-based, enamel, epoxy, specialty formulations, elastomeric, powder-based, anti-fouling, conductive, and smart paints.The present invention provides a system and method for enhancing metalworking operations by integrating an atmospheric pressure cold dielectric barrier discharge (DBD) plasma jet with a fluid atomizer. This innovative approach addresses multiple challenges in metalworking fluid delivery, including lubrication, cooling, and operator safety, while promoting sustainability through fluid disinfection and recyclability.Figure 1 illustrates a schematic diagram of the system. The system comprises a high-voltage power supply (4), a dielectric barrier hollow tube (1), a movable ring electrode (2), a working gas source (11), a pressure gauge (12), a rotameter (18), a needle atomizer (3), a mixing chamber (9), a needle valve (17), a fluid tank (15), a lead nut (16), a tool (5), a tool holder (7), a dynamometer (8), and a workpiece (6) which can be grounded (24). The dielectric tube (1) serves as a conduit for gas flow and a barrier for controlling the current of discharge.One end of the dielectric tube (1) is inserted by the needle atomizer (3) and connected to the high-voltage power supply (4) through a metallic wire (14). The working gas source (11) is connected to the pressure gauge (12) through a pipeline (13), which is further connected to the rotameter (18) through a pipeline (13). The rotameter (18) is connected to the mixing chamber (9) through a pipeline (13). The fluid tank (15) is connected to the mixing chamber (9) through a pipeline (13), and the outlet of the mixing chamber (9) is connected to the needle valve (17) through a pipeline (13). The needle valve (17) is connected to the needle atomizer (3) through a pipeline (13).The needle atomizer (3) generates atomized liquid droplets, which are electrostatically activated by the plasma jet and directed onto the workpiece (6) or tool (5) with the help of a carrier gas. The movable ring electrode (2) is arranged on the outer wall of the dielectric tube (1) and connected to the power supply (4) through the metallic wire (14). The plasma plume (10) is controlled at the lead nut (16) by varying the interelectrode distance between the needle atomizer (3) and the movable ring electrode (2).Figure 2 depicts an alternative configuration of the system with two movable ring electrodes (2) positioned around the dielectric tube (1). This configuration allows for enhanced control over the plasma plume characteristics by adjusting the interelectrode distance between the needle atomizer (3) and the ring electrodes (2) using the lead nut (16).Figure 3 shows a configuration where the workpiece (6) is connected to the high-voltage power supply (4). The interelectrode distance between the ring electrode (2) and the needle atomizer (3) is adjustable by the lead nut (16), and the plasma atomizer distance between the tube outlet (19) and the workpiece (6) or tool (5) is adjustable and movable.Figure 4 presents a single electrode dielectric configuration, where the high-voltage power is connected to the needle atomizer (3), and the interelectrode distance between the needle atomizer (3) and the workpiece (6) or tool (5) is adjustable and movable.Figure 5 illustrates the system with a gas compressor machine (23) substituted for the working gas source (11). The compressor can be any type of machine, including reciprocating, rotary screw, rotary vane, scroll, diaphragm, turbo, and hydraulic air compressors, to supply gas to the mixing chamber (9).The dielectric tube (1) is constructed from insulating materials such as quartz glass, Pyrex, ceramic (aluminum oxide or zirconium oxide), PTFE (polytetrafluoroethylene), PI (polyimides), PMMA (polymethyl methacrylate), PC (polycarbonate), PEEK (poly ether-ether ketone), TPU (thermoplastic polyurethane elastomer rubber), POM (polyformaldehyde), PET (polyethylene terephthalate), FEP (Fluorinated ethylene propylene), PPVE (Perfluoro propyl vinyl ether), ETFE (ethylene tetrafluoroethylene copolymerization), or PVDF. The dielectric tube (1) serves as a conduit for gas flow and a barrier for controlling the current of discharge.Upon activation of the high-voltage power supply (4), which can deliver direct current, square, sinusoidal, or pulse wave voltage independently adjustable within the range of 400 V to 100 kV, and a frequency range of 500 Hz to 50 MHz, the voltage is applied to the needle atomizer (3) and the movable ring electrode (2) via a high-voltage wire (14). The mixed fluid passes through the needle atomizer (3), creating a mist or atomized liquid droplets that drive the upstream central axis of the dielectric tube (1) downward. Simultaneously, the high voltage from the power supply (4) induces electron collisions with neutral gas molecules and atomized liquid droplets between the needle atomizer (3) and the movable ring electrode (2) located on the outer wall near the tube outlet (19).The electron impact collisions trigger chain reactions, resulting in the production of ions, excited species, and electrons, forming a quasi-neutral medium known as plasma. The plasma gas then flows through the dielectric tube (1) and is controlled by the lead nut (16) connected to the movable ring electrode (2) to change the interelectrode distance with the needle atomizer (3). This process generates a variable length of plasma plume (10) and plasma filament intensity, making it possible to use different fluids from the fluid tank (15) and different carrier gases from the working gas source (11) without necessitating changes to the flow rate, input power, or dielectric tube (1).The plasma plume (10) exiting the tube outlet (19) contains electrically charged atomized liquid droplets that are attracted to the tool (5) or workpiece (6) due to electrostatic forces. These forces arise from the negative charge of the droplets, induced by the plasma plume (10), and the electric field between the workpiece, which can also be grounded (24), causing the droplets to be drawn to and accumulate on the tool (5) or workpiece (6). This process ensures that the atomized liquid droplets are concentrated, reducing fog, enhancing operator safety by reducing exposure to airborne particles, and ensuring that the spray is accurately directed onto the tool (5) or workpiece (6).In metalworking fluid delivery, fog formation resulting from a minimum quantity lubrication (MQL) atomizer is undesirable. It is essential to reduce the fog size to produce a more concentrated mist, which is denser and minimizes safety hazards by preventing its dispersion into the surrounding environment. This precision may improve the film formation, affecting the thickness, spread, velocity, and splashing after impingement. Moreover, by focusing the atomized liquid droplets into the tool (5) or workpiece (6) and controlling the characteristics of the film formed, the plasma atomizer can effectively penetrate the tool-chip interface during metalworking operations. This results in better lubrication and cooling for metalworking operations efficiency and tool (5) life.In another embodiment, plasma gas leads to disinfection, fungus removal, bacterial destruction, and microorganism decontamination. Plasma generates reactive and radical species, which are highly reactive and can damage bacterial cell walls, membranes, and cellular structures in fungi and microorganisms. The UV radiation produced in the plasma dielectric tube (1) can damage the DNA of microorganisms, inhibiting their replication. The high electric fields in the plasma between the needle atomizer (3) and the movable ring electrode (2) can disrupt the membranes of bacteria and other microorganisms, leading to leakage of cellular contents and eventual cell death. The plasma plume (10) and plasma filament during the metalworking operation decontaminate the fluid from the fluid tank (15), enhancing operator safety by disinfecting the fluid and reducing the need for frequent changes and maintenance.The system is designed for sustainability by recycling the working fluid. The fluid remaining in the treated zone is collected in a collector tank (20) and then pumped (21) through a pipeline (13) to a filter zone (22). After filtration, the fluid is returned to the fluid tank (15) via the pipeline (13) as a recycled fluid.Additionally, the system can be adapted for spray painting applications, where it improves paint adhesion and coverage on substrates. The paint can be a single type or a combination of various formulations, including water-based options such as latex, acrylic, tempera, and watercolor; oil-based varieties like alkyd, linseed oil, and stand oil paints; enamel and epoxy paints; specialty formulations such as rust-inhibiting, heat-resistant, magnetic, and ceramic paints; elastomeric paints; powder-based and solid-mixed paints; anti-fouling paints for marine applications; conductive paints; and smart paints such as thermochromic and photochromic paints.In another embodiment the present invention describes a method for enhancing metalworking operations by integrating an atmospheric pressure cold dielectric barrier discharge (DBD) plasma jet with a fluid atomizer. This method improves the delivery and performance of metalworking fluids, addressing challenges such as lubrication, cooling, and operator safety, while promoting sustainability through fluid disinfection and recyclability.Step 1: Providing a High-Voltage Power SupplyThe method begins by providing a high-voltage power supply capable of delivering direct current, square, sinusoidal, or pulse wave voltage independently adjustable within the range of 400 V to 100 kV, and a frequency range of 500 Hz to 50 MHz. This power supply is essential for generating the plasma jet.Step 2: Inserting the Needle AtomizerA needle atomizer is inserted into one end of a dielectric barrier hollow tube. The needle atomizer is connected to the high-voltage power supply through a metallic wire. The needle atomizer is responsible for generating fine liquid droplets through various atomization techniques such as pressure, rotary disc, gas, ultrasonic, and thermal atomization.Step 3: Arranging the Movable Ring ElectrodeA movable ring electrode is arranged on the outer wall of the dielectric tube and connected to the high-voltage power supply through a metallic wire. The position of the movable ring electrode can be adjusted to vary the interelectrode distance between the needle atomizer and the ring electrode, thereby controlling the characteristics of the plasma plume.Step 4: Connecting the Working Gas SourceA working gas source is connected to a pressure gauge through a pipeline. The pressure gauge is further connected to a rotameter through a pipeline. The rotameter is connected to a mixing chamber through a pipeline. The working gas can be one or more combinations of nitrogen, argon, helium, carbon dioxide, oxygen, and dried air.Step 5: Connecting the Fluid TankA fluid tank is connected to the mixing chamber through a pipeline. The fluid tank provides the fluid for metalworking operations, which can be one or a combination of water, oil fluid, pure vegetable oil, synthetic ester, oil-water emulsions, solid lubricant mixed water or oil, nanoparticle-enhanced water-based fluids, nanoparticle-enhanced oil-based lubricant, and oil-water emulsions with nanoparticles.Step 6: Mixing the Gas and FluidThe working gas and fluid from the fluid tank are combined in the mixing chamber to form a homogeneous mixture. The outlet of the mixing chamber is connected to a needle valve through a pipeline, and the needle valve is connected to the needle atomizer through a pipeline.Step 7: Adjusting the Interelectrode DistanceThe interelectrode distance between the needle atomizer and the movable ring electrode is adjusted using a lead nut. This adjustment controls the intensity and length of the plasma jet plume, allowing the system to work with different fluids and carrier gases.Step 8: Generating the Plasma PlumeThe high-voltage power supply is activated, causing electron collisions with neutral gas molecules and atomized liquid droplets between the needle atomizer and the movable ring electrode. These collisions trigger chain reactions, resulting in the production of ions, excited species, and electrons, forming a quasi-neutral medium known as plasma. The plasma gas flows through the dielectric tube and is controlled by the lead nut to change the interelectrode distance with the needle atomizer, generating a variable length of plasma plume and plasma filament intensity.Step 9: Directing the Plasma PlumeThe plasma plume containing electrically charged atomized liquid droplets is directed toward a tool or workpiece. The electrostatic forces cause the charged droplets to be attracted to and accumulate on the tool or workpiece, enhancing fluid adhesion and penetration at the tool-workpiece interface.Step 10: Enhancing Lubrication and CoolingThe method ensures that the atomized liquid droplets are concentrated, reducing fog and enhancing operator safety by minimizing exposure to airborne particles. The precise direction of the spray onto the tool or workpiece improves film formation, affecting the thickness, spread, velocity, and splashing after impingement. This results in better lubrication and cooling for metalworking operations efficiency and tool life.Step 11: Disinfecting the FluidThe plasma gas leads to disinfection, fungus removal, bacterial destruction, and microorganism decontamination. Plasma generates reactive and radical species that damage bacterial cell walls, membranes, and cellular structures in fungi and microorganisms. The UV radiation produced in the plasma dielectric tube can damage the DNA of microorganisms, inhibiting their replication. The high electric fields in the plasma can disrupt the membranes of bacteria and other microorganisms, leading to leakage of cellular contents and eventual cell death. This disinfection process enhances operator safety by disinfecting the fluid and reducing the need for frequent changes and maintenance.Step 12: Recycling the Working FluidThe method promotes sustainability by recycling the working fluid. The fluid remaining in the treated zone is collected in a collector tank and then pumped through a pipeline to a filter zone. After filtration, the fluid is returned to the fluid tank via the pipeline as recycled fluid.Step 13: Adapting for Spray Painting ApplicationsThe method can be adapted for spray painting applications, where it improves paint adhesion and coverage on substrates. The paint can be a single type or a combination of various formulations, including water-based options such as latex, acrylic, tempera, and watercolor; oil-based varieties like alkyd, linseed oil, and stand oil paints; enamel and epoxy paints; specialty formulations such as rust-inhibiting, heat-resistant, magnetic, and ceramic paints; elastomeric paints; powder-based and solid-mixed paints; anti-fouling paints for marine applications; conductive paints; and smart paints such as thermochromic and photochromic paints.Overall, the present invention offers a versatile and efficient solution for enhancing metalworking operations, providing better lubrication, cooling, and safety, while promoting environmental sustainability and extending its applicability to other industrial processes.In another embodiment a device for enhancing metalworking operations by integrating an atmospheric pressure cold dielectric barrier discharge (DBD) plasma jet with a fluid atomizer. This device addresses multiple challenges in metalworking fluid delivery, including lubrication, cooling, and operator safety, while promoting sustainability through fluid disinfection and recyclability.Device Components:High-Voltage Power Supply (4): The device includes a high-voltage power supply capable of delivering direct current, square, sinusoidal, or pulse wave voltage independently adjustable within the range of 400 V to 100 kV, and a frequency range of 500 Hz to 50 MHz. This power supply is essential for generating the plasma jet.Dielectric Barrier Hollow Tube (1): The dielectric tube is constructed from insulating materials such as quartz glass, Pyrex, ceramic (aluminum oxide or zirconium oxide), PTFE (polytetrafluoroethylene), PI (polyimides), PMMA (polymethyl methacrylate), PC (polycarbonate), PEEK (poly ether-ether ketone), TPU (thermoplastic polyurethane elastomer rubber), POM (polyformaldehyde), PET (polyethylene terephthalate), FEP (Fluorinated ethylene propylene), PPVE (Perfluoro propyl vinyl ether), ETFE (ethylene tetrafluoroethylene copolymerization), or PVDF. The dielectric tube serves as a conduit for gas flow and a barrier for controlling the current of discharge.Needle Atomizer (3): The needle atomizer is inserted into one end of the dielectric tube and connected to the high-voltage power supply through a metallic wire. The needle atomizer generates fine liquid droplets through various atomization techniques such as pressure, rotary disc, gas, ultrasonic, and thermal atomization.Movable Ring Electrode (2): The movable ring electrode is arranged on the outer wall of the dielectric tube and connected to the high-voltage power supply through a metallic wire. The position of the movable ring electrode can be adjusted to vary the interelectrode distance between the needle atomizer and the ring electrode, thereby controlling the characteristics of the plasma plume.Working Gas Source (11): The working gas source is connected to a pressure gauge (12) through a pipeline (13). The pressure gauge is further connected to a rotameter (18) through a pipeline (13). The rotameter is connected to a mixing chamber (9) through a pipeline (13). The working gas can be one or more combinations of nitrogen, argon, helium, carbon dioxide, oxygen, and dried air.Mixing Chamber (9): The mixing chamber combines the working gas and fluid from the fluid tank to form a homogeneous mixture. The outlet of the mixing chamber is connected to a needle valve (17) through a pipeline (13), and the needle valve is connected to the needle atomizer (3) through a pipeline (13).Fluid Tank (15): The fluid tank provides the fluid for metalworking operations, which can be one or a combination of water, oil fluid, pure vegetable oil, synthetic ester, oil-water emulsions, solid lubricant mixed water or oil, nanoparticle-enhanced water-based fluids, nanoparticle-enhanced oil-based lubricant, and oil-water emulsions with nanoparticles. Also, the fluid remaining in the treated zone is collected in a collector tank (20) and then pumped (21) through a pipeline (13) to a filter zone (22). After filtration, the fluid is returned to the fluid tank (15) via the pipeline (13) as recycled fluid.Lead Nut (16): The lead nut is used to adjust the interelectrode distance between the needle atomizer and the movable ring electrode. This adjustment controls the intensity and length of the plasma jet plume, allowing the system to work with different fluids and carrier gases.Tool (5) and Tool Holder (7): The tool and tool holder are components of the metalworking setup where the plasma-activated fluid is directed. The tool is used for various metalworking operations such as drilling, milling, grinding, and turning.Dynamometer (8): The dynamometer is used to measure the forces and torques during the metalworking operations, providing data on the efficiency and effectiveness of the lubrication and cooling provided by the plasma-activated fluid.Workpiece (6): The workpiece is the material being processed in the metalworking operation. It can be grounded (24) to enhance the electrostatic attraction of the charged atomized liquid droplets.Device Operation:Upon activation of the high-voltage power supply (4), the voltage is applied to the needle atomizer (3) and the movable ring electrode (2) via a high-voltage wire (14). The mixed fluid passes through the needle atomizer (3), creating a mist or atomized liquid droplets that drive the upstream central axis of the dielectric tube (1) downward. Simultaneously, the high voltage from the power supply (4) induces electron collisions with neutral gas molecules and atomized liquid droplets between the needle atomizer (3) and the movable ring electrode (2) located on the outer wall near the tube outlet (19).The electron impact collisions trigger chain reactions, resulting in the production of ions, excited species, and electrons, forming a quasi-neutral medium known as plasma. The plasma gas then flows through the dielectric tube (1) and is controlled by the lead nut (16) connected to the movable ring electrode (2) to change the interelectrode distance with the needle atomizer (3). This process generates a variable length of plasma plume (10) and plasma filament intensity, making it possible to use different fluids from the fluid tank (15) and different carrier gases from the working gas source (11) without necessitating changes to the flow rate, input power, or dielectric tube (1).The plasma plume (10) exiting the tube outlet (19) contains electrically charged atomized liquid droplets that are attracted to the tool (5) or workpiece (6) due to electrostatic forces. These forces arise from the negative charge of the droplets, induced by the plasma plume (10), and the electric field between the workpiece, which can also be grounded (24), causing the droplets to be drawn to and accumulate on the tool (5) or workpiece (6). This process ensures that the atomized liquid droplets are concentrated, reducing fog, enhancing operator safety by reducing exposure to airborne particles, and ensuring that the spray is accurately directed onto the tool (5) or workpiece (6).In metalworking fluid delivery, fog formation resulting from a minimum quantity lubrication (MQL) atomizer is undesirable. It is essential to reduce the fog size to produce a more concentrated mist, which is denser and minimizes safety hazards by preventing its dispersion into the surrounding environment. This precision may improve the film formation, affecting the thickness, spread, velocity, and splashing after impingement. Moreover, by focusing the atomized liquid droplets into the tool (5) or workpiece (6) and controlling the characteristics of the film formed, the plasma atomizer can effectively penetrate the tool-chip interface during metalworking operations. This results in better lubrication and cooling for metalworking operations efficiency and tool (5) life.In another aspect, plasma gas leads to disinfection, fungus removal, bacterial destruction, and microorganism decontamination. Plasma generates reactive and radical species, which are highly reactive and can damage bacterial cell walls, membranes, and cellular structures in fungi and microorganisms. The UV radiation produced in the plasma dielectric tube can damage the DNA of microorganisms, inhibiting their replication. The high electric fields in the plasma can disrupt the membranes of bacteria and other microorganisms, leading to leakage of cellular contents and eventual cell death. This disinfection process enhances operator safety by disinfecting the fluid and reducing the need for frequent changes and maintenance.The device is designed for sustainability by recycling the working fluid. The fluid remaining in the treated zone is collected in a collector tank (20) and then pumped (21) through a pipeline (13) to a filter zone (22). After filtration, the fluid is returned to the fluid tank (15) via the pipeline (13) as recycled fluid.Additionally, the device can be adapted for spray painting applications, where it improves paint adhesion and coverage on substrates. The paint can be a single type or a combination of various formulations, including water-based options such as latex, acrylic, tempera, and watercolor; oil-based varieties like alkyd, linseed oil, and stand oil paints; enamel and epoxy paints; specialty formulations such as rust-inhibiting, heat-resistant, magnetic, and ceramic paints; elastomeric paints; powder-based and solid-mixed paints; anti-fouling paints for marine applications; conductive paints; and smart paints such as thermochromic and photochromic paints.Overall, the present invention offers a versatile and efficient device for enhancing metalworking operations, providing better lubrication, cooling, and safety, while promoting environmental sustainability and extending its applicability to other industrial processes.Advantages:The present invention offers several significant advantages in the field of metalworking operations, as well as in other industrial applications such as spray painting and coating. These advantages include:1. Enhanced Lubrication and Cooling:The integration of the atmospheric pressure cold dielectric barrier discharge (DBD) plasma jet with the fluid atomizer improves the delivery and performance of metalworking fluids. The plasma-activated mist enhances the penetration of the fluid at the tool-workpiece interface, resulting in better lubrication and cooling. This leads to increased efficiency in metalworking operations and extends the life of the tools used.2. Fog Reduction and Safety:The invention reduces the fog generated during the atomization process in minimum quantity lubrication (MQL) systems. By producing a more concentrated and dense mist, the system minimizes safety hazards associated with the dispersion of fog into the surrounding environment. This enhances operator safety by reducing exposure to airborne particles that could cause respiratory issues and other health problems.3. Disinfection Capability:The plasma-generated radical and reactive species in the system disinfect the metalworking fluid, addressing issues of bacterial contamination, microorganism growth, and biofilm formation. This significantly extends the usability of the metalworking fluid, reducing the need for frequent changes and maintenance, and enhancing operator safety.4. Sustainability and Environmental Benefits:The invention promotes sustainability by improving the recyclability and reuse of metalworking fluids. The system's disinfection capabilities allow for the recycling of fluids, reducing environmental hazards associated with their frequent disposal. This contributes to more sustainable metalworking operations and minimizes the environmental impact.5. Versatility and Adaptability:The system is designed to be easily adaptable to different fluids and carrier gases without requiring extensive modifications. The adjustable position of the movable ring electrode allows for precise control over the plasma plume characteristics, making the system versatile and suitable for various applications.6. Improved Paint Adhesion and Coverage:In addition to metalworking operations, the invention can be used for spray painting applications. The plasma-activated mist improves paint adhesion and coverage on substrates, making it suitable for various industrial applications such as aerospace, automotive, biomedical, marine, and electronics. This results in higher quality coatings and more efficient painting processes.7. Enhanced Process Efficiency:The precise direction of the plasma-activated mist onto the tool or workpiece improves film formation, affecting the thickness, spread, velocity, and splashing after impingement. This leads to more efficient metalworking operations, reducing waste and optimizing the use of fluids.8. Health and Safety Benefits:By reducing fog and disinfecting the fluid, the system minimizes health risks to operators, such as skin irritation, respiratory issues, and chemical exposure. This creates a safer working environment and reduces the likelihood of occupational health problems.Overall, the present invention offers a comprehensive solution for enhancing metalworking operations and other industrial processes, providing significant benefits in terms of efficiency, safety, sustainability, and versatility.The present invention has been described in terms of specific embodiments and applications. However, it will be understood by those skilled in the art that various modifications and changes can be made without departing from the spirit and scope of the invention. The embodiments and examples provided are illustrative and not intended to limit the scope of the invention. The scope of the invention is defined by the appended claims and their equivalents.The invention is not limited to the specific configurations, materials, or processes described herein. For example, the dielectric tube can be made from various insulating materials, and the working gas source can include different combinations of gases. The high-voltage power supply can deliver different types of voltage and frequency ranges, and the needle atomizer can utilize various atomization techniques. Additionally, the invention can be adapted for other applications beyond metalworking operations, such as spray painting and coating.The invention is intended to cover all alternatives, modifications, and equivalents that fall within the scope of the claims. Any specific features or steps disclosed in the description are not to be construed as limiting the invention but rather as illustrative examples. The claims should be interpreted broadly to encompass all such variations and modifications. Furthermore, the use of terms such as "comprising," "including," "having," and similar terms in the claims is intended to be inclusive and open-ended, indicating that additional elements or steps may be included. The use of singular terms also includes the plural, and vice versa, unless specifically stated otherwise. The present invention is not limited by the specific embodiments described herein but is defined by the following claims and their legal equivalents.

Claims

1. A system for enhancing metalworking operations, comprising: a high-voltage power supply; a dielectric barrier hollow tube; a movable ring electrode; a working gas source; a pressure gauge; a rotameter; a needle atomizer; a mixing chamber; a needle valve; a fluid tank; a lead nut; a tool; a tool holder; a dynamometer; a workpiece which can be grounded; wherein one end of the dielectric tube is inserted by the needle atomizer and is connected with the high-voltage power supply through a metallic wire; wherein the working gas source is connected to the pressure gauge through a pipeline; wherein the pressure gauge is connected to the rotameter through a pipeline; wherein the rotameter is connected to the mixing chamber through a pipeline; wherein the fluid tank is connected to the mixing chamber through a pipeline; wherein the outlet of the mixing chamber is connected to the needle valve through a pipeline; wherein the needle valve is connected to the needle atomizer through a pipeline; wherein the needle atomizer is inserted into the dielectric tube; wherein the movable ring electrode is arranged on the outer wall of the dielectric tube and is connected to the power supply through the metallic wire; wherein the plasma plume is controlled at the lead nut by varying the interelectrode distance between the needle atomizer and the movable ring electrode; and wherein the fluid remaining in the treated zone being collected in a collector tank, pumped through a pipeline to a filter zone, and returned to the fluid tank as recycled fluid.

2. The system of claim 1, wherein the dielectric tube has an inner diameter of 0.02 mm to 50 mm and an outer diameter of 0.03 mm to 100 mm, and is constructed from materials selected from the group consisting of quartz glass, Pyrex, ceramic, PTFE, PI, PMMA, PC, PEEK, TPU, POM, PET, FEP, PPVE, ETFE, and PVDF.

3. The system of claim 1, wherein the discharge form of the cold plasma discharge unit is selected from the group consisting of corona discharge, single electrode dielectric barrier discharge, double dielectric barrier discharge, piezoelectric pen discharge, glow discharge, radio frequency discharge, micro-wave plasma, sliding arc discharge, and jet stream electric discharge.

4. The system of claim 1, wherein the high voltage power supply is selected from the group consisting of a DC high-voltage power supply, low-frequency high-voltage power supply, radio-frequency power supply, piezoelectric power supply, microwave high-pressure power supply, and pulse high voltage power supply, with a discharge voltage amplitude controlled from 400 V to 100 KV, and a pulse frequency controlled from 500 Hz to 50 MHz.

5. The system of claim 1, wherein the discharge form of the cold plasma is characterized by a single electrode dielectric configuration, wherein the high voltage power is connected to the needle atomizer with an outer diameter from 3 mm to 50 mm and an inner diameter from 0.01 mm to 10 mm, and the high-voltage power is connected to the workpiece, with the inter-electrode distance between the needle atomizer and the workpiece or tool being adjustable and movable.

6. The system of claim 1, wherein the discharge form of the cold plasma is characterized by a double electrode dielectric configuration, wherein the high-voltage power is connected to a movable ring electrode with a length of 0.5 mm to 50 mm positioned around the dielectric tube, and the inter-electrode distance between the ring electrode and the needle atomizer is adjustable by the lead nut, with the plasma atomizer distance between the tube outlet and the workpiece or tool being adjustable and movable.

7. The system of claim 1, wherein the tube outlet directed toward the workpiece or tool is adjustable and allows for free movement, and the plasma plume can operate in either contact or non-contact mode with the workpiece or tool, with the tool requiring grounding in the contact configuration.

8. The system of claim 1, wherein the lead nut possesses the ability to control the intensity and length of the plasma jet plume by adjusting the interelectrode distance between the needle atomizer and the movable ring electrode, allowing for the use of various fluids or carrier gases.

9. The system of claim 1, wherein the plasma atomizer can control the intensity of the plasma jet plume, and the lead nut is constructed from insulator materials selected from the group consisting of quartz glass, Pyrex, ceramic, PTFE, PI, PMMA, PC, PEEK, TPU, POM, PET, FEP, PPVE, ETFE, PVDF, or metallic material with a coating of insulator paint.

10. The system of claim 1, wherein the working gas source to generate the plasma atomizer can be one or more combinations of nitrogen, argon, helium, carbon dioxide, oxygen, and dried air.

11. The system of claim 1, wherein the atomizer needle, which generates atomized liquid droplets, can utilize one or a combination of various atomization techniques, including pressure, rotary disc, gas, ultrasonic, and thermal atomization.

12. The system of claim 1, wherein the fluid tank provides the fluid for metalworking operations as a lubricant and coolant, and the fluid can be one or a combination of water, oil fluid, pure vegetable oil, synthetic ester, oil-water emulsions, solid lubricant mixed water or oil, nanoparticle-enhanced water-based fluids, nanoparticle-enhanced oil-based lubricant, and oil-water emulsions with nanoparticles.

13. The system of claim 1, wherein the fluid tank supplies fluid paint for coating objects, improving process efficiency by reducing mist size, concentrating the fine paint droplets onto the substrate, and enhancing adhesion of the paint to the substrate, with the paint being a single type or a combination of various formulations, including water-based, oil-based, enamel, epoxy, specialty formulations, elastomeric, powder-based, anti-fouling, conductive, and smart paints.

14. The system of claim 1, wherein the working gas source can be substituted with a gas compressor machine to supply gas to the mixing chamber, with the compressor being any type of machine, including reciprocating, rotary screw, rotary vane, scroll, diaphragm, turbo, and hydraulic air compressors.

15. The system of claim 1, wherein the fluid tank supplies the fluid paint, coolant, or lubricant, and the metalworking operation is designed for sustainability by recycling the working fluid, with the fluid remaining in the treated zone being collected in a collector tank, pumped through a pipeline to a filter zone, and returned to the fluid tank as recycled fluid.

16. A device for enhancing metalworking operations, comprising: a high-voltage power supply; a dielectric barrier hollow tube; a movable ring electrode arranged on the outer wall of the dielectric tube; a working gas source connected to a pressure gauge through a pipeline; a rotameter connected to the pressure gauge through a pipeline; a needle atomizer inserted into one end of the dielectric tube and connected to the high-voltage power supply through a metallic wire; a mixing chamber connected to the rotameter and a fluid tank through pipelines; a needle valve connected to the outlet of the mixing chamber through a pipeline; a lead nut for adjusting the interelectrode distance between the needle atomizer and the movable ring electrode; a tool and a tool holder; a dynamometer; a workpiece which can be grounded; wherein the device generates a plasma plume controlled by the lead nut by varying the interelectrode distance between the needle atomizer and the movable ring electrode; and wherein the fluid remaining in the treated zone being collected in a collector tank, pumped through a pipeline to a filter zone, and returned to the fluid tank as recycled fluid.

17. The device of claim 16, wherein the dielectric tube has an inner diameter of 0.02 mm to 50 mm and an outer diameter of 0.03 mm to 100 mm, and is constructed from materials selected from the group consisting of quartz glass, Pyrex, ceramic, PTFE, PI, PMMA, PC, PEEK, TPU, POM, PET, FEP, PPVE, ETFE, and PVDF.

18. The device of claim 16, wherein the discharge form of the cold plasma discharge unit is selected from the group consisting of corona discharge, single electrode dielectric barrier discharge, double dielectric barrier discharge, piezoelectric pen discharge, glow discharge, radio frequency discharge, micro-wave plasma, sliding arc discharge, and jet stream electric discharge.

19. The device of claim 16, wherein the high voltage power supply is selected from the group consisting of a DC high-voltage power supply, low-frequency high-voltage power supply, radio-frequency power supply, piezoelectric power supply, microwave high-pressure power supply, and pulse high voltage power supply, with a discharge voltage amplitude controlled from 400 V to 100 KV, and a pulse frequency controlled from 500 Hz to 50 MHz.

20. The device of claim 16, wherein the discharge form of the cold plasma is characterized by a single electrode dielectric configuration, wherein the high voltage power is connected to the needle atomizer with an outer diameter from 3 mm to 50 mm and an inner diameter from 0.01 mm to 10 mm, and the high-voltage power is connected to the workpiece, with the inter-electrode distance between the needle atomizer and the workpiece or tool being adjustable and movable.

21. The device of claim 16, wherein the discharge form of the cold plasma is characterized by a double electrode dielectric configuration, wherein the high-voltage power is connected to a movable ring electrode with a length of 0.5 mm to 50 mm positioned around the dielectric tube, and the inter-electrode distance between the ring electrode and the needle atomizer is adjustable by the lead nut, with the plasma atomizer distance between the tube outlet and the workpiece or tool being adjustable and movable.

22. The device of claim 16, wherein the tube outlet directed toward the workpiece or tool is adjustable and allows for free movement, and the plasma plume can operate in either contact or non-contact mode with the workpiece or tool, with the tool requiring grounding in the contact configuration.

23. The device of claim 16, wherein the lead nut possesses the ability to control the intensity and length of the plasma jet plume by adjusting the interelectrode distance between the needle atomizer and the movable ring electrode, allowing for the use of various fluids or carrier gases.

24. The device of claim 16, wherein the plasma atomizer can control the intensity of the plasma jet plume, and the lead nut is constructed from insulator materials selected from the group consisting of quartz glass, Pyrex, ceramic, PTFE, PI, PMMA, PC, PEEK, TPU, POM, PET, FEP, PPVE, ETFE, PVDF, or metallic material with a coating of insulator paint.

25. The device of claim 16, wherein the working gas source to generate the plasma atomizer can be one or more combinations of nitrogen, argon, helium, carbon dioxide, oxygen, and dried air.

26. The device of claim 16, wherein the atomizer needle, which generates atomized liquid droplets, can utilize one or a combination of various atomization techniques, including pressure, rotary disc, gas, ultrasonic, and thermal atomization.

27. The device of claim 16, wherein the fluid tank provides the fluid for metalworking operations as a lubricant and coolant, and the fluid can be one or a combination of water, oil fluid, pure vegetable oil, synthetic ester, oil-water emulsions, solid lubricant mixed water or oil, nanoparticle-enhanced water-based fluids, nanoparticle-enhanced oil-based lubricant, and oil-water emulsions with nanoparticles.

28. The device of claim 16, wherein the fluid tank supplies fluid paint for coating objects, improving process efficiency by reducing mist size, concentrating the fine paint droplets onto the substrate, and enhancing adhesion of the paint to the substrate, with the paint being a single type or a combination of various formulations, including water-based, oil-based, enamel, epoxy, specialty formulations, elastomeric, powder-based, anti-fouling, conductive, and smart paints.

29. The device of claim 16, wherein the working gas source can be substituted with a gas compressor machine to supply gas to the mixing chamber, with the compressor being any type of machine, including reciprocating, rotary screw, rotary vane, scroll, diaphragm, turbo, and hydraulic air compressors.

30. The device of claim 16, wherein the fluid tank supplies the fluid paint, coolant, or lubricant, and the metalworking operation is designed for sustainability by recycling the working fluid, with the fluid remaining in the treated zone being collected in a collector tank, pumped through a pipeline to a filter zone, and returned to the fluid tank as recycled fluid.

31. A method for enhancing metalworking operations in the system of claim 1, said method comprising the steps of: providing a high-voltage power supply; inserting a needle atomizer into one end of a dielectric barrier hollow tube and connecting the needle atomizer to the high-voltage power supply through a metallic wire; arranging a movable ring electrode on the outer wall of the dielectric tube and connecting the movable ring electrode to the high-voltage power supply through a metallic wire; connecting a working gas source to a pressure gauge through a pipeline; connecting the pressure gauge to a rotameter through a pipeline; connecting the rotameter to a mixing chamber through a pipeline; connecting a fluid tank to the mixing chamber through a pipeline; connecting the outlet of the mixing chamber to a needle valve through a pipeline; connecting the needle valve to the needle atomizer through a pipeline; adjusting the interelectrode distance between the needle atomizer and the movable ring electrode using a lead nut to control the plasma plume; generating a plasma plume by activating the high-voltage power supply, causing electron collisions with neutral gas molecules and atomized liquid droplets between the needle atomizer and the movable ring electrode; directing the plasma plume containing electrically charged atomized liquid droplets toward a tool or workpiece; enhancing the adhesion and penetration of the metalworking fluid to the tool and workpiece interface using electrostatic forces; improving lubrication and cooling at the tool-workpiece interface during metalworking operations.

32. The method of claim 31, further comprising the step of adjusting the intensity and length of the plasma jet plume by varying the interelectrode distance between the needle atomizer and the movable ring electrode using the lead nut.

33. The method of claim 31, further comprising the step of selecting the dielectric tube from materials including quartz glass, Pyrex, ceramic, PTFE, PI, PMMA, PC, PEEK, TPU, POM, PET, FEP, PPVE, ETFE, and PVDF.

34. The method of claim 31, further comprising the step of selecting the working gas source from one or more combinations of nitrogen, argon, helium, carbon dioxide, oxygen, and dried air.

35. The method of claim 31, further comprising the step of utilizing various atomization techniques for the needle atomizer, including pressure, rotary disc, gas, ultrasonic, and thermal atomization.

36. The method of claim 31, further comprising the step of providing the fluid for metalworking operations from the fluid tank, wherein the fluid can be one or a combination of water, oil fluid, pure vegetable oil, synthetic ester, oil-water emulsions, solid lubricant mixed water or oil, nanoparticle-enhanced water-based fluids, nanoparticle-enhanced oil-based lubricant, and oil-water emulsions with nanoparticles.

37. The method of claim 31, further comprising the step of supplying fluid paint from the fluid tank for coating objects, wherein the paint can be a single type or a combination of various formulations, including water-based, oil-based, enamel, epoxy, specialty formulations, elastomeric, powder-based, anti-fouling, conductive, and smart paints.

38. The method of claim 31, further comprising the step of substituting the working gas source with a gas compressor machine to supply gas to the mixing chamber, wherein the compressor can be any type of machine, including reciprocating, rotary screw, rotary vane, scroll, diaphragm, turbo, and hydraulic air compressors.

39. The method of claim 31, further comprising the step of recycling the working fluid by collecting the fluid remaining in the treated zone in a collector tank, pumping the fluid through a pipeline to a filter zone, and returning the filtered fluid to the fluid tank as recycled fluid.

40. A system for enhancing metalworking operations, substantially as described and illustrated in the specification and drawings.

41. A device for enhancing metalworking operations, substantially as described and illustrated in the specification and drawings.

42. A method for enhancing metalworking operations, substantially as described and illustrated in the specification and drawings.