Helical-Passage Thread Tap for MQL Backpressure Reduction
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Solution Overview
Problem
Conventional thread taps designed for liquid lubricant flow experience excessive air compression and backpressure when used with the air-oil mist in minimum quantity lubrication (MQL) machining, leading to wasted lubricant and excess wear.
Innovation Solution
The thread tap features helically extending passages with apertures at the threading end that release lubricant in opposite directions, a manifold chamber at the base end, and a cap that directs fluid radially outward, optimizing lubrication flow and reducing air compression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional thread taps with internal passages are used for MQL machining, then lubrication is supplied to cutting edges, but excessive air compression and backpressure occur
Solution Approach 1:
The internal passage is segmented into multiple smaller passages (at least two) that extend helically along the shaft. Each passage delivers lubricant to a different cutting edge, distributing the air-oil mist flow and reducing compression in each individual passage while maintaining effective lubrication delivery to all cutting edges.
Solution Approach 2:
The passages are configured to extend helically along the shaft in addition to radially outward to the cutting edges. This helical arrangement in a third dimension allows the passages to follow the spiral path of the cutting edges, optimizing lubricant delivery while reducing air compression through the extended passage length and orientation.
2Reliability
If high volume liquid lubricant flow is used, then cutting edges are well-lubricated, but lubricant waste increases
Solution Approach 1:
The system transitions from liquid-based emulsion lubrication to pneumatic delivery of air-oil mist. The lubricant is atomized and delivered as a compressible gas-phase mixture, allowing precise control of lubricant quantity and reducing waste while maintaining effective lubrication at the cutting edges.
Solution Approach 2:
The lubricant delivery system changes the physical state and concentration parameters by delivering a lean air-oil mist rather than high-volume liquid. The air-to-oil ratio is optimized to provide sufficient lubrication while minimizing lubricant consumption and waste.
3Stability of the object's composition
If internal passages deliver lubricant based on supplied pressure, then flow is consistent, but air compression causes excess wear
Solution Approach 1:
By dividing the single internal passage into multiple smaller passages, the air compression and backpressure in each passage is reduced while maintaining consistent lubricant delivery to each cutting edge. The segmented configuration distributes the compressive load across multiple flow paths.
Solution Approach 2:
The helical passage configuration acts as an intermediary that gradually directs the air-oil mist from the shaft interior to the cutting edges. This intermediate helical path reduces sudden pressure changes and air compression effects while ensuring steady lubricant delivery.
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 design provides a balanced lubrication flow, reducing waste and wear, and enhancing the efficiency of MQL thread tapping by ensuring consistent and effective lubrication delivery.
Implementation Method 1
The ratio of air to oil in the air-oil mist is typically very high and the lubricant mist acts as a compressible fluid (unlike the incompressible liquid lubricant of conventional thread tapping)
Implementation Method 2
The shaft includes a plurality of passages that extend helically from the threading end to a base end of the shaft
Implementation Method 3
The deflecting body narrows in an axial direction toward the passage to direct fluid from the passage radially outward
Data Source
AI summary
A thread tap includes a shaft and teeth. The shaft includes helical passages from the threading end to the base end of the shaft. Each passage opens through an aperture in the threading end. A second tap includes a cap and the shaft includes an axially extending passage. The cap is coupled to the threading end and at least partially defines apertures in fluid communication with the passage and the exterior of the tap. A third tap includes teeth spaced apart by a plurality of linear flutes. The shaft includes a central passage and a plurality of flute passages. Each flute passage extends radially outward from a common location in the central passage to a corresponding one of the flutes. The central passage is closed to a terminal end of the threading end.