Dual-Channel CO2 Tool Cooling to Prevent Dry Ice Blockage
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Solution Overview
Problem
Current cooling and lubrication systems for machining processes, particularly for difficult-to-cut materials, are either ineffective or require specific ad-hoc designs that cannot be adapted to various machining processes and machine tools, and they often face issues with dry ice formation in CO2 regulation systems.
Innovation Solution
A portable device that simultaneously injects CO2 in liquid state and cutting fluid micro-particles, or either alone, into the machining area, using a CO2 regulation system that prevents dry ice formation and is controlled by a Programmable Logic Controller (PLC) for flexible operation in milling, lathing, and drilling processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If CO2 is used as cutting fluid in machining processes, then cooling capacity is improved, but dry ice formation obstructs the conduits
Solution Approach 1:
The conduit is divided into two separate channels: an inner channel for liquid CO2 injection and an outer channel for gaseous CO2 injection. This segmentation allows the gaseous CO2 to counteract the formation of dry ice particles in the inner channel, preventing conduit obstruction while maintaining high cooling capacity
Solution Approach 2:
Gaseous CO2 acts as an intermediary substance that interacts with the liquid CO2 in the inner channel. The gaseous CO2 provides a protective atmosphere that prevents the phase transition of liquid CO2 to solid dry ice particles, thereby preventing conduit blockage
2Reliability
If a regulation system is designed to prevent dry ice formation, then reliability is improved, but device complexity increases
Solution Approach 1:
The regulation system merges the cooling function (liquid CO2 injection) and the anti-obstruction function (gaseous CO2 injection) into a single integrated device. The two channels are joined at the exit to form a unified injection system, simplifying the overall structure while maintaining reliability
Solution Approach 2:
The dual-channel conduit serves multiple functions: the inner channel provides cryogenic cooling, the outer channel prevents dry ice formation, and together they create a universal regulation system that can be applied to various machining operations without requiring separate systems
3Manufacturing precision
If a cooling and lubrication device is designed for specific machining processes, then manufacturing precision is improved, but adaptability decreases
Solution Approach 1:
The device is designed with independent control of cooling (liquid CO2) and lubrication (cutting fluid) functions, allowing it to be adapted to various machining processes such as milling, turning, and drilling. The system can operate in different modes (cooling only, lubrication only, or combined) to suit different machining requirements
4Reliability
If cooling and lubrication are provided separately, then reliability is improved, but device complexity increases
Solution Approach 1:
The device merges the separately controllable cooling and lubrication functions into a single integrated system. The cooling subsystem (liquid CO2) and lubrication subsystem (cutting fluid injection) are combined in one device with a unified injection mechanism, reducing overall system complexity while maintaining the ability to operate independently or simultaneously
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The device provides continuous and controlled cooling and lubrication, adaptable to different machining operations, preventing dry ice obstruction and allowing simultaneous use of cryogenic cooling and minimum quantity lubrication (MQL), resulting in efficient temperature control and extended machine tool life.
Implementation Method 1
The gases that are normally injected in the cutting area are liquid nitrogen (LN 2 ) and liquid carbon dioxide (CO 2 ). The reasons for using LN 2 as cutting fluid are that it is an inert gas that is found in large amounts in the atmosphere and has high cooling capacity (-196°C)
Implementation Method 2
Both conduits are joined just at the exit of the system, so the CO 2 in gaseous state generates a Venturi effect that drags the dry ice particles to the outside, thereby obtaining the cutting fluid to inject in the cutting area
Implementation Method 3
CO 2 has lower cooling capacity (-78°C), can be stored in liquid state at room temperature in pressurised containers at 5.5 - 6 MPa and can dissolve oils when it is in supercritical state, which makes it more attractive from an industrial point of view
Implementation Method 4
The device has been designed so it can adapt to the most common machining processes... using a CO2 regulation system that prevents the formation of dry ice
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
A device (100) for cooling and lubricating a tool during a chip removal machining process, which comprises: a first subsystem (110) for cryogenic cooling that comprises: a first entry (1) configured to introduce CO2 in liquid state in a first conduit (a) of the device (100); a first exit (18) configured to supply CO2 in liquid state from a second conduit (g) of the device (100); a third conduit (b) located between said first (a) and second conduit (g); and means (2, 7, 8, 4, 11, 13, 14, 15, 16, d, h, c) for preventing the formation of dry ice in said first, second and third conduits (a, g, b); and a second subsystem (120) for lubrication that comprises means (3, 5, 6, 9, 10, 12, 19, i, j, f, k, e, 20) for supplying micro-particles of a cutting oil in liquid state; wherein said first subsystem (110) and second subsystem (120) are independent from each other, and wherein said first subsystem (110) and second subsystem (120) are configured to act either simultaneously or either one alone (110, 120). Method of operation of the device.