Fluidostatic Rolling Device Pneumatic Lubrication
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing hydrostatic rolling devices are limited in processing speed due to the use of hydraulic fluids, which attenuate movement and require significant lubricant usage, especially on non-cylindrical workpieces and free-formed surfaces, restricting the maximum achievable processing speed.
Innovation Solution
The use of a pressurized gas as the hydrostatic fluid, which increases in viscosity with temperature, allowing for higher processing speeds and reducing the need for cooling lubricants, with the gas containing lubricant particles that cool and increase viscosity near the rolling element, providing effective lubrication with minimal fluid usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydraulic fluid is used as pressurised fluid, then secure hydrostatic mounting is achieved, but processing speed is limited due to fluid attenuation
Solution Approach 1:
The patent replaces hydraulic fluid with pressurised gas (pneumatic system) to eliminate the attenuation effect that limits processing speed. The gas is introduced through supply channels to the rolling element mounting, providing hydrostatic support without the viscous drag that characterizes liquid-based systems, thereby enabling higher processing speeds while maintaining mounting security.
2Reliability
If hydraulic fluid is used as pressurised fluid, then rolling element is supported, but lubricant usage and disposal costs increase
Solution Approach 1:
The patent transitions from a hydraulic system requiring lubricant to a pneumatic system using pressurised gas. The gas is supplied through dedicated channels to support the rolling element, eliminating the need for lubricant application and subsequent disposal, thereby reducing substance loss and associated costs while maintaining reliable element support.
3Productivity
If processing speed is increased, then productivity improves, but tracking accuracy decreases due to discrete steps
Solution Approach 1:
The pneumatic system provides continuous, smooth support to the rolling element through pressurised gas, eliminating the discrete step movements inherent in hydraulic systems. This continuous support mechanism allows the tool to track the workpiece contour more accurately at higher speeds, maintaining manufacturing precision while improving productivity.
4Speed
If gas is used as pressurised fluid, then processing speed increases, but viscosity stability decreases with temperature changes
Solution Approach 1:
The patent acknowledges that gas viscosity changes with temperature but operates within controlled parameters where this effect is manageable. The pressurised gas system is designed to maintain sufficient viscosity stability for hydrostatic mounting under normal operating conditions, allowing high processing speeds to be achieved while accepting minor viscosity variations as a trade-off for the significant speed improvement.
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
This approach enables faster processing speeds and maintains surface property changes in materials like certain steels for a longer time, reducing lubricant costs and eliminating the need for cooling lubricant disposal, while ensuring secure lubrication and minimal fluid usage.
Implementation Method 1
the temperature and the pressure of the gas, which contains lubricant particles, can be selected in such a way that the gas containing lubricant particles close to the rolling element cools down during expansion
Implementation Method 2
the rolling element can be pressed against a workpiece surface to be processed by means of the pressurised fluid
Implementation Method 3
a lubricant must be applied. For the most part an oil is used as a pressurised fluid, which has a double function; namely raising the hydrostatic pressure on the rolling element on the one hand, and on the other hand lubricating the rolling element relative to its mounting
Data Source
AI summary
A fluidostatic tool with at least one rolling element uses a pressurized lubricant mist or aerosol to apply force against a metal workpiece surface that is flat, curved or cylindrical. The rolling element, such as a ball, is held within a tubular borehole of the tool and cushioned on the pressurized lubricant mist during machining of the metal surface. Viscosity of the lubricant mist increases and reduces friction between the ball and the metal surface as it exits the tool, thereby reducing or eliminating the need for other lubricants during the machining process. The pressure of the lubricant mist against the ball seals the borehole of the tool and prevents leakage of the pressurized lubricant mist when the tool is not engaged with a metal workpiece surface. The lubricant mist can be an oil-free lubricant or a mixture of oil-free lubricant and oil components.