Gas-Dissolved Machining Fluid for Low-Loss Micro Hole Machining
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional machining technologies face inefficiencies in forming micro hole structures due to high pressure loss and increased energy consumption when using pressurized machining fluids through narrow pipelines, leading to reduced machining precision and increased costs.
Innovation Solution
A machining fluid comprising a first phase fluid and a second phase gas dissolved under high pressure, which reduces dynamic viscosity and friction, allowing for improved flow and increased precision, and potentially includes flammable gases for high-temperature cutting effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If conventional pressure pump is used to increase machining fluid pressure through narrow pipelines, then machining fluid pressure can be increased, but pressure loss increases and energy consumption increases
Solution Approach 1:
The patent changes the physical parameters of the machining fluid by dissolving gas (such as nitrogen or air) into the liquid machining fluid under high pressure to create a pressurized fluid containing dissolved gas bubbles. This parameter change reduces the liquid's viscosity and increases its compressibility, allowing the fluid to be pumped more efficiently through narrow pipelines with reduced pressure loss. The gas-saturated fluid maintains adequate pressure for machining while consuming less energy.
Solution Approach 2:
The dissolved gas acts as an intermediary substance that modifies the properties of the liquid machining fluid. The gas bubbles serve as a mediator between the pump and the narrow pipeline, reducing the direct friction between the liquid and pipe walls. This intermediary presence allows for more efficient energy transfer and reduced pressure loss during pumping through constricted passages.
2Stress or pressure
If conventional pressure pump is used to increase machining fluid pressure through narrow pipelines, then machining fluid pressure can be increased, but energy consumption increases
Solution Approach 1:
The patent modifies the energy parameters of the machining system by introducing gas-saturated liquid instead of pure liquid. The dissolved gas reduces the effective density and viscosity of the fluid, decreasing the power required by the pump to achieve the same pressure. This parameter modification directly reduces energy consumption while maintaining the necessary machining fluid pressure.
Solution Approach 2:
The patent applies pneumatic-hydraulic principles by saturating the liquid machining fluid with gas under pressure. This creates a two-phase fluid system that combines the incompressibility of liquid for pressure transmission with the low viscosity and compressibility of gas for reduced pumping resistance. The resulting gas-saturated liquid requires less energy to pump while maintaining adequate pressure for the machining process.
3Productivity
If gas is dissolved into liquid under high pressure, then viscosity is reduced and flow is improved, but device complexity increases
Solution Approach 1:
The patent merges the functions of the gas supply system and the liquid machining fluid system into a single integrated pressurized fluid delivery system. By combining gas and liquid into a unified gas-saturated fluid mixture, the system eliminates the need for separate gas injection mechanisms during machining, thereby reducing overall device complexity despite the initial saturation process. The combined fluid delivers both cooling and lubrication functions through a single delivery path.
Solution Approach 2:
The patent performs the gas dissolution action in advance before the machining operation begins. The liquid machining fluid is pre-saturated with gas under high pressure in a separate preparation stage, creating a ready-to-use pressurized fluid mixture. This preliminary action eliminates the need for complex real-time gas injection systems during machining, simplifying the overall device while maintaining improved flow characteristics throughout the machining process.
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 enhances machining precision and efficiency by reducing pressure loss and friction, lowering abrasion and energy consumption, while enabling high-temperature cutting effects for improved debris removal and machining speed.
Implementation Method 1
a second phase fluid, which is a gas, that is dissolved into the first phase fluid through high pressure
Implementation Method 2
According to Henry's Law, since the solubility of gas in the solvent is very low, the solution that the gas dissolved in belongs to the dilute solution and the quantity of the solved gas inside the solvent, either Mole number or Molality, is approximately proportional to the gas pressure
Implementation Method 3
according to the Hagne-Poiseuille's equation listed as equation (1) shown below, the ΔP represents the pressure loss, L represents length of the pipeline where the flow, e.g. machining fluid, flowing therein, μ represents dynamic viscosity, Q represents volume flow rate, r represents radius of the pipeline
Implementation Method 4
the second phase fluid can be a combustion gas, a flammable gas or a combination of flammable gas and combustion gas such that the second phase fluid can be acted as the fuel or combustion adjuvant during the machining process whereby, in addition to the merit of traditional machining fluids, the addition of flammable gas or combustion-supporting gas properties can help produce high-temperature cutting effects during machining
Implementation Method 5
The machining fluid is injected to a work piece by an injection head, so that the machining fluid can effectively flow into the machining position thereby achieving cooling, discharging and removing the machining debris
Data Source
AI summary
The present invention provides a machining fluid comprising a first phase fluid and a second phase fluid pressurized to be dissolved in the first phase fluid. The present invention further provides a machining device comprising an injecting head having a nozzle and a flow channel communicating with the nozzle for guiding the machining fluid to the nozzle injecting the machining fluid to an object. Alternatively, the present invention further provides a machining device comprising a light source for generating a laser beam and an injecting head having a nozzle and a flow channel communicating with the nozzle. The flow channel guides a machining fluid having a first phase fluid and a second phase fluid such that the machining fluid is injected to an object by the nozzle. The injecting head also receives the laser beam and guides the laser beam to the object through the nozzle.