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Development of particulate imaging systems and their application in the study of cutting fluid mist formation and minimum quantity lubrication.

机译：颗粒成像系统的发展及其在切削液雾形成和最小量润滑研究中的应用。

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摘要

Cutting fluids are widely used to cool and lubricate, flush away chips, and inhibit corrosion during machining operations such as drilling, turning, and grinding. However, significant negative effects, in terms of environmental, health, and safety consequences, are associated with the use of cutting fluids. Health problems are mainly related to the suspended particles near the work place. One of the primary sources of these particles is mist produced through the application of cutting fluids in machining operations. To resolve the health problems related to cutting fluid mist inhalation, several recent research efforts have focused on investigating the mechanisms associated with cutting fluid mist formation. These researches predicted that one of the principal mechanisms associated with cutting fluid mist formation is the atomization mechanism. A series of theoretical models have been developed to predict the droplet size in various process conditions.; To validate these atomization models associated with the application of a cutting fluid stream to a rotating workpiece, an imaging system is developed to measure droplets size which is not achievable with typical aerosol sampling devices. The imaging system utilizes backlight illumination and two cameras to extend the size measurement range. Efforts are also taken to reduce the errors caused by the depth-of-field effect by experimentally modeling the relationship between true and measured diameters. This method extends the depth-of-field of an imaging system using halo width to compensate the size error for out-of-focus droplet, and it also eliminates the effects of droplet size on depth-of-field by setting a critical halo width.; Based on the imaging system, a series of experiments have been conducted to explore the effect of workpiece rotation speed and fluid flow rate on droplet count and mass distributions as well as mean diameters. Also investigated is the impact of angular and radial positions relative to the workpiece on droplet characteristics. Experiments related to fluid film width and maximum fluid flux a rotating workpiece could sustain are performed to justify model predictions.; To eliminate the time-consuming calibration procedure an imaging formation model has been developed to predict the droplet intensity distribution based on geometrical optics and diffraction theory. The model allows to predict the profile of a droplet given the position of the droplet and the optical system parameters. The behavior of the relationship between measured diameter and halo width has been simulated, which could be used to predict the actual droplet size.; Minimum quantity lubrication (MQL) technology as an intermediate alternative between flood and dry machining applications is also studied. The effects of the lubricant flow rate and droplet characteristics on the cutting performance in terms of cutting force, workpiece temperature, surface finish, and air quality is investigated. Comparisons are made among dry, MQL, and fluid flood applications.
机译：切削液被广泛用于冷却和润滑，冲走切屑，并在诸如钻孔，车削和磨削之类的机械加工过程中抑制腐蚀。但是，就切削液的使用而言，就环境，健康和安全后果而言，存在明显的负面影响。健康问题主要与工作场所附近的悬浮颗粒有关。这些颗粒的主要来源之一是通过在加工操作中施加切削液而产生的薄雾。为了解决与吸入切削液雾有关的健康问题，最近的一些研究工作集中在调查与切削液雾形成相关的机理上。这些研究预测，与切削液雾形成有关的主要机理之一是雾化机理。已经开发了一系列理论模型来预测各种工艺条件下的液滴尺寸。为了验证与将切削液流施加到旋转的工件上相关的这些雾化模型，开发了一种成像系统来测量液滴尺寸，这是典型气溶胶采样设备无法实现的。该成像系统利用背光照明和两个摄像头来扩展尺寸测量范围。通过对真实直径和测量直径之间的关系进行实验建模，还努力减少由景深效应引起的误差。该方法扩展了使用光晕宽度的成像系统的景深，以补偿散焦液滴的尺寸误差，并且通过设置临界光晕宽度，还消除了液滴尺寸对景深的影响。;基于成像系统，已进行了一系列实验，以探索工件转速和流体流速对液滴数和质量分布以及平均直径的影响。还研究了相对于工件的角度和径向位置对液滴特性的影响。进行了与流体膜宽度和旋转工件可以承受的最大流体通量有关的实验，以证明模型预测的正确性。为了消除耗时的校准程序，已经开发了成像形成模型，以基于几何光学和衍射理论来预测液滴强度分布。该模型允许在给定液滴的位置和光学系统参数的情况下预测液滴的轮廓。模拟了测量的直径和光晕宽度之间关系的行为，可以用来预测实际的液滴尺寸。还研究了最小量润滑（MQL）技术作为泛洪和干式加工应用之间的中间替代方案。在切削力，工件温度，表面光洁度和空气质量方面，研究了润滑剂流速和液滴特性对切削性能的影响。在干式，MQL和液驱应用中进行了比较。

著录项

  • 作者

    Ju, Chuanxi.;

  • 作者单位

    Michigan Technological University.;

  • 授予单位 Michigan Technological University.;
  • 学科 Engineering Mechanical.; Engineering Industrial.
  • 学位 Ph.D.
  • 年度 2005
  • 页码 205 p.
  • 总页数 205
  • 原文格式 PDF
  • 正文语种 eng
  • 中图分类 机械、仪表工业;一般工业技术;
  • 关键词

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