Electrostatic Nozzle Micro-Texture for Stable MQL Droplet Control
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Solution Overview
Problem
Current MQL technologies face issues with uncontrollable droplet movement, environmental pollution, health risks for operators, noise from compressed air, and pipeline blockage due to nanoparticle adsorption, which affect the efficiency and safety of machining processes.
Innovation Solution
The development of a micro-texture electrostatic nozzle with micro-bulges on the inner surface of the acceleration chamber, which enhances oleophilic performance, improves droplet control, reduces noise, and prevents pipeline blockage by increasing contact area and time with the MQL liquid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional MQL technology is used, then lubrication and cooling effects are achieved, but droplet movement is uncontrollable causing environmental pollution and health risks
Solution Approach 1:
The patent replaces the traditional mechanical/compressed air-based droplet delivery system with an electrostatic field-based system. By applying high voltage to the nozzle, droplets are charged and guided along electric field lines to the workpiece, enabling precise control of droplet trajectories and preventing uncontrolled diffusion and drift into the working environment.
Solution Approach 2:
The patent changes the electrical parameter (applying high voltage) to the nozzle system, transforming it from a passive spray device to an active electrostatic atomization device. This parameter change enables the droplets to be charged and controlled by electric fields, fundamentally improving droplet delivery precision and control.
2Productivity
If compressed air is used for atomization, then MQL delivery is achieved, but noise is generated affecting operator health
Solution Approach 1:
The patent replaces the compressed air mechanical atomization system with an electrostatic field-based atomization system. Instead of using high-velocity gas flow to break up liquid, the system uses electrostatic forces to atomize and guide the lubrication droplets, eliminating the noise source while maintaining atomization efficiency.
3Temperature
If nanofluid is used for enhanced cooling, then heat transfer capacity is improved, but pipeline blockage occurs due to nanoparticle adsorption
Solution Approach 1:
The patent extracts the nanoparticles from the MQL fluid system by using electrostatic atomization to deliver only the lubrication oil droplets to the workpiece. The electrostatic field selectively charges and transports the oil droplets, leaving nanoparticles behind in the delivery system, thereby preventing pipeline blockage while maintaining effective lubrication.
4Quantity of substance
If corona discharge is used for droplet breakup, then droplet size is reduced, but energy consumption increases due to small corona region
Solution Approach 1:
The patent uses a porous or textured nozzle surface that, when combined with electrostatic charging, creates an extended corona discharge region. This increases the effective charging area compared to traditional needle-tip corona discharge, improving droplet breakup efficiency while reducing energy consumption through more uniform charge distribution across the nozzle surface.
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 solution results in uniform droplet distribution, reduced noise exposure, and stable operation by enhancing droplet control and preventing pipeline blockage, thereby improving the safety and efficiency of the machining process.
Implementation Method 1
a corona charging technology is adopted to charge the MQL liquid at a nozzle outlet; the droplets will be further broken up under the action of a high-voltage electric field
Implementation Method 2
a corona charging technology is adopted to charge the MQL liquid at a nozzle outlet
Implementation Method 3
a series of micro-bulges are arranged on an inner side surface of an acceleration chamber to greatly improve oleophilic performance of the inner surface of the acceleration chamber
Implementation Method 4
Droplets produced by a nanofluid minimal quantity lubrication (NMQL) technology enter the grinding region under the carrying action of high-pressure gas
Data Source
AI summary
The present disclosure provides an electrostatic nozzle and a controllable jet minimal quantity lubrication (MQL) grinding system. The electrostatic nozzle comprises a nozzle core; an upper nozzle body is connected above the nozzle core; a free space is formed between the upper nozzle body and the nozzle core for storing compressed air and reducing pressure; a lower nozzle body is connected below the nozzle core; a gas-liquid mixing chamber, an acceleration chamber and a nozzle outlet are sequentially arranged inside the nozzle core from top to bottom; and micro-bulges are uniformly distributed on an inner wall of the acceleration chamber.