微量润滑切削液雾滴在线混合装置优化与试验  

Optimization and Experiment of Multi-component Inline Mixer for Mixing Cutting Fluid Droplets in Minimal Quantity Lubrication

作　　者：代祥 宋海潮 DAI Xiang;SONG Haichao(College of Mechanical Engineering,Nanjing Vocational University of Industry Technology,Nanjing 210023,China;Jiangsu Province Precision Manufacturing Engineering and Technology Research Center,Nanjing 210023,China)

机构地区：[1]南京工业职业技术大学机械工程学院,南京210023 [2]江苏省精密制造技术工程研发中心,南京210023

出　　处：《机械科学与技术》2025年第3期465-476,共12页Mechanical Science and Technology for Aerospace Engineering

基　　金：江苏省工业感知及智能制造装备工程研究中心开放基金项目(ZK21-05-16);2021江苏省高校优秀科技创新团队(智能装备及其精密制造技术)项目(21CXTD-01);江苏省精密制造技术工程研发中心项目(JSPMET2024)。

摘　　要：切削液在线混合式微量润滑喷雾通过获得油水融合型雾滴,可有效改善加工区的润滑和冷却特性。为促进异相切削液在线混合及融合,构建了预雾化切削液精准在线混合微量润滑系统,采用数值方法优化了射流式切削液雾滴在线混合装置,并进行了试验验证。数值仿真表明:采用DPM模型对预雾化雾滴在装置内迁移运动进行数值模拟,并采用面积加权均匀性指数γα描述其截面分布,可有效衡量在线混合效果;喷嘴直径d_n和注入口个数n对水雾分布均匀性影响显著,而面积比m和分流器长度L_(nt)则不显著,且仅有L_(nt)对检测面上油雾分布均匀性无显著影响;混合装置最优参数为油雾注入口n_(o)=2,水雾注入口n_(w)=3、d_(n)=2 mm、L_(nt)=7 mm、m=1∶2。验证试验表明:优选装置对应油基和水基切削液喷雾沉积CV值(变异系数CV,记为CV)分别低至0.2050和0.3183,对应γim值(沉积均匀性指数)则分别高达0.9165和0.8888,均优于其他结构参数混合装置;主射流气流量和预雾化气流量的增加均有助于实现更高的喷雾沉积均匀性以及更小的沉积雾滴直径。优选装置能够实现良好的异相雾滴混合融合效果,避免单相雾滴存在。The application of minimal quantity lubrication(MQL)with inline-mixed multi-component cutting fluids enables effective lubrication and cooling in machining processes through oil-on-water(OoW)droplet generation,which necessitates an optimized mixing system.This study developed a precision inline mixing MQL system with optimized structural configurations to enhance heterogeneous cutting fluid droplet fusion.The research methodology comprised numerical simulations assessing droplet distribution uniformity across various mixer designs,complemented by experimental validation through spray pattern analysis and deposition characterization.Results indicate that the DPM(Discrete phase model)model can be applied to numerically simulate the migration movement of the heterogeneous pre-atomized cutting fluid droplets in the mixer,and the area-weighted uniformity index(γ_(α))can be applied to extract and analyze the distribution characteristics of the droplets at the outlet section of the mixer,which can effectively measure the inline mixing efficacy of the mixer.The nozzle diameter d_(n)and the number of injection ports n have significant effects on the distribution uniformity of water droplets in the end section of the mixer,while the area ratio m and the diverter length L_(nt)have no clear effects.Moreover,only the L_(nt)has no significant effects on the uniformity of the oil droplet distribution in the detection section.The optimal parameters of the mixer determined by numerical simulation are no(Number of oil jet inlets)=2,n_(w)(Number of water jet inlets)=3,d_(n)=2 mm,L_(nt)=7 mm,m=1∶2.The physical spraying tests indicate that the spray deposition CV(Coefficient of variation)value of oil-based and water-based cutting fluid is as low as 0.2050 and 0.3183,and the correspondingγ_(im)(Deposition uniformity index)is as high as 0.9165 and 0.8888,respectively.The spraying deposition uniformity for the mixer with optimal structural parameters is better than that for other mixers.The optimized mixer configuration achieves su

关 键 词：切削液 微量润滑 在线混合效果 沉积均匀性 数值仿真 喷雾试验 

分 类 号：TG501[金属学及工艺—金属切削加工及机床]