Milling MQL Nozzle Switching by Real-Time Depth Detection
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Solution Overview
Problem
Existing milling technologies face challenges in efficiently cooling and lubricating machining regions, particularly when dealing with large milling depths and grooves, as traditional internal and external cooling methods are either cost-inefficient or result in insufficient lubrication, and manual operation is required for switching between cooling modes, leading to resource wastage and operator reliance.
Innovation Solution
An internal cooling/external cooling-switching milling minimum-quantity-lubrication (MQL) intelligent nozzle system that collects real-time milling depth data to automatically switch between internal and external cooling modes using a vision system, lubrication controller, and reversing device, ensuring optimal cooling and lubrication based on current machining conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If internal cooling system is used, then cooling and lubrication under large milling depth conditions is satisfied, but the price is higher and it causes economic waste under machining conditions where internal cooling is not required
Solution Approach 1:
The system dynamically switches between internal cooling mode and external cooling mode based on real-time milling depth detection. When milling depth exceeds a threshold, internal cooling is activated; otherwise, external cooling is used. This dynamic adaptation resolves the contradiction by ensuring reliable cooling when needed while avoiding the cost penalty when not needed.
Solution Approach 2:
The system changes the cooling delivery parameter (internal vs. external) based on machining conditions. By detecting milling depth and switching the cooling mode accordingly, the system optimizes the balance between cooling effectiveness and economic cost, using the expensive internal cooling only when necessary.
2Ease of operation
If external cooling by pouring is used, then cooling and lubrication can be performed from outside, but the cooling and lubrication efficiency of the cutting fluid is very low, causing large amount of cutting fluid to be wasted
Solution Approach 1:
The system dynamically selects between external pouring cooling and MQL based on milling depth. For shallow machining, external pouring provides flexibility and ease of operation. For deep machining, MQL delivers cutting fluid directly to the cutting zone, dramatically improving efficiency and reducing fluid consumption. This dynamic switching resolves the contradiction between operational flexibility and fluid waste.
Solution Approach 2:
The MQL system applies cutting fluid locally and precisely to the cutting zone through targeted delivery, rather than general pouring. This localized application dramatically improves cutting fluid efficiency and reduces waste, while the system maintains the option for external pouring when appropriate for the machining conditions.
3Ease of operation
If manual switching between cooling modes is required, then operator control is maintained, but resource wastage occurs and operator reliance is increased
Solution Approach 1:
The system performs self-service by automatically detecting milling depth through the vision system and autonomously switching between internal and external cooling modes without operator intervention. This eliminates resource wastage from manual delays and removes dependence on operator judgment, while maintaining full operational control through automated decision-making.
Solution Approach 2:
The vision system provides real-time feedback on milling depth to the control system, which automatically adjusts the cooling mode in response. This closed-loop feedback mechanism eliminates manual switching delays and ensures optimal cooling is applied continuously, resolving the contradiction between operator control and machining efficiency.
4Loss of energy
If MQL technique is used, then green manufacturing concept is achieved with reduced cutting fluid consumption, but it cannot satisfy the cooling and lubrication under machining conditions such as holes and grooves of a large milling depth
Solution Approach 1:
The system achieves multi-functionality by integrating both external cooling (pouring and MQL) and internal cooling capabilities into a single system. The vision-guided switching enables the system to adapt to different machining conditions: MQL for shallow machining to minimize fluid consumption, and internal cooling for deep holes and grooves where high-pressure direct delivery is required. This universal approach resolves the contradiction between fluid efficiency and adaptability.
Solution Approach 2:
The system dynamically adapts its cooling delivery method based on detected milling depth and machining geometry. For large milling depth conditions, it switches to internal cooling to ensure adequate penetration and cooling effectiveness. For shallow machining, it uses MQL to minimize fluid consumption. This dynamic adaptability resolves the contradiction between green manufacturing goals and versatility across different machining scenarios.
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 system enables intelligent and efficient switching between internal and external cooling, optimizing lubrication for various machining conditions without manual intervention, reducing resource consumption and improving machining quality and safety.
Implementation Method 1
a vision system, configured to acquire a real-time milling depth of a workpiece
Implementation Method 2
The MQL refers to a technique in which a small amount of lubricating fluid, water and a gas with a certain pressure are mixed and atomized
Implementation Method 3
The water and the high-pressure gas perform the function of cooling, and oil performs the functions of lubricating the cutting region
Implementation Method 4
The cutting fluid is transmitted to an internal cooling pipe in a cutting tool to realize cooling and lubrication of the cutting tool
Data Source
AI summary
The present disclosure provides an internal cooling/external cooling-switching milling minimum-quantity-lubrication intelligent nozzle system and method, relating to the field of milling lubrication. The system includes: a vision system, configured to acquire a real-time milling depth of a workpiece and send the real-time milling depth to a lubrication manner controller for processing; a lubrication system, including an internal cooling system and an external cooling system connected together to a cutting fluid supply source through a reversing device; and the lubrication manner controller, configured to communicate with the vision system and the lubrication system respectively, and control the reversing device to act according to a set milling depth threshold and data acquired by the vision system, so as to adjust and switch to the internal cooling system or the external cooling system to work. Milling depth data of a machine tool is collected, the milling depth data is transmitted to a control center for data analysis and processing, the data is compared with an initially set internal cooling/external cooling switching threshold to obtain the most suitable cooling and lubrication manner under current machining conditions of the machine tool, and the control center controls the internal cooling and external cooling systems according to the obtained result to realize intelligent switching of the cooling and lubrication manner between internal cooling and external cooling.