MQL Tool Priming by Passage Complexity to Cut Downtime
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Solution Overview
Problem
Conventional MQL tool priming processes result in significant downtime and cleanliness issues due to the need for prolonged oil mist application, which can lead to dimensional errors and tool breakage, especially during frequent tool changes.
Innovation Solution
A method categorizes MQL tools based on internal passage complexity and fluid resistance, applying either a short-prime or long-prime MQL dosage during tool changes, with flowrates between 50-200 milliliters per hour for durations less than or greater than 2 seconds, depending on the tool category and usage timeframe.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional baptism priming process is used with prolonged oil mist application, then adequate lubrication is ensured, but significant downtime and cleanliness issues occur
Solution Approach 1:
The patent changes the parameters of oil mist application by categorizing tools into different groups based on their internal passage complexity and specifying different flow rates (5-10 mL/hr for group 1, 10-15 mL/hr for group 2) and durations (5-10 seconds for group 1, 10-15 seconds for group 2). This parameter optimization ensures adequate lubrication while significantly reducing priming time compared to conventional prolonged application.
Solution Approach 2:
The patent applies different priming parameters to different tool categories based on their specific characteristics. Group 1 tools (simpler internal passages) receive shorter, lower-flow priming, while group 2 tools (more complex internal passages) receive longer, higher-flow priming. This localized approach ensures each tool receives appropriate lubrication without unnecessary prolonged priming.
2Reliability
If conventional baptism priming process is used with prolonged oil mist application, then adequate lubrication is ensured, but cleanliness issues and oily removed material chips occur
Solution Approach 1:
By optimizing the flow rate and duration parameters of oil mist application, the patent reduces the total volume of oil introduced into the machining workspace. The controlled application ensures sufficient lubrication while minimizing oil contamination that causes cleanliness issues and clogging of washers and other systems.
Solution Approach 2:
The patent converts the potential harm of oil mist into a beneficial controlled application. By using precise flow rate control and timing, the oil mist that would otherwise cause contamination is instead delivered in optimized doses that ensure lubrication while minimizing waste and cleanliness issues.
3Ease of operation
If uniform priming cycle is applied to all MQL tools regardless of size or complexity, then simplified operation is achieved, but considerable downtime occurs
Solution Approach 1:
The patent divides tools into two groups based on internal passage complexity and applies different priming parameters to each group. This categorization approach maintains operational simplicity while optimizing priming time for each tool type, avoiding the excessive downtime caused by applying a uniform prolonged priming cycle to all tools.
Solution Approach 2:
The patent segments the tool population into distinct categories (group 1 with simpler passages, group 2 with complex passages) and applies tailored priming strategies to each segment. This segmentation enables optimized priming times for each category, reducing overall downtime while maintaining ease of operation through clear categorization.
4Reliability
If prolonged oil mist application is used for priming, then adequate lubrication is ensured, but oil usage increases
Solution Approach 1:
The patent optimizes oil usage by controlling the flow rate and duration parameters of priming application. Group 1 tools receive 5-10 mL/hr for 5-10 seconds, while group 2 tools receive 10-15 mL/hr for 10-15 seconds. These optimized parameters ensure adequate lubrication of internal passages while significantly reducing oil consumption compared to conventional prolonged application.
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 reduces priming time and oil usage, minimizing downtime and cleanliness issues while ensuring adequate lubrication, thereby improving machining efficiency and reducing the risk of tool damage.
Implementation Method 1
minimum quantity lubrication ('MQL') machining uses lubrication supplied to the cutting edges of a tool through a lean air-oil mist
Implementation Method 2
The MQL mist typically flows through internal passages of the tool to reach the cutting edges
Implementation Method 3
the initial volume of oil can end up coating (e.g., 'wetting') the internal passage surfaces instead of being expelled and lubricating the cutting edges
Implementation Method 4
minimum quantity lubrication ('MQL') machining uses lubrication supplied to the cutting edges of a tool
Data Source
AI summary
A method of priming a minimum quantity lubrication (MQL) tool includes determining a category of the tool, supplying a short-prime MQL dosage if the tool is a first category or if both a second category and lubricated within a first predetermined timeframe, and supplying a long-prime MQL dosage if the tool is the second category and has not been lubricated within the predetermined timeframe. The category is based on internal passage complexity of the tool.