CN110096777B - Electrostatic atomization milling droplet transportation modeling and transportation effect evaluation method - Google Patents
Electrostatic atomization milling droplet transportation modeling and transportation effect evaluation method Download PDFInfo
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- 238000003801 milling Methods 0.000 title claims abstract description 60
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Abstract
The invention discloses a method for modeling transport and evaluating transport effect of electrostatic atomization milling droplets, which comprises the following steps: establishing a three-dimensional milling model, introducing the model into simulation software, meshing, calculating an airflow field caused by high-speed rotation of a milling cutter, calculating an electrostatic field, measuring physical parameters of lubricating oil, measuring atomization current, calculating necessary initial parameters for droplet trajectory simulation, calculating a droplet trajectory, and performing post-processing and evaluation on a simulation result. The method fully considers the influence of milling cutter rotation on droplet transportation during electrostatic atomization milling, can effectively predict the transportation track of charged droplet groups during electrostatic atomization milling, evaluates the droplet transportation effect, and provides a basis for optimization and selection of electrostatic atomization parameters.
Description
Technical Field
The invention belongs to a milling technology, and particularly relates to a method for modeling transport and evaluating transport effect of electrostatic atomization milling droplets.
Background
With the improvement of awareness of environmental protection and sustainable development, green cutting technology attracts more and more attention. micro-Quantity Lubrication (MQL) is a method in which a very small amount of lubricating oil is mixed with compressed air having a certain pressure, atomized, and sprayed to a processing area to perform cooling Lubrication. Compared with the traditional wet cutting, the advantages of the minimal quantity lubrication are mainly represented as follows: 1. the lubricating oil is supplied in a high-speed atomized particle form, so that the permeability of the lubricating oil in processing is enhanced, the cooling and lubricating effects are improved, and the cutting temperature, the cutting force and the cutter abrasion are reduced; 2. the consumption of the lubricating oil is only one ten thousandth of that of wet cutting, so that the use cost of the cutting fluid can be obviously reduced, and the harm of using a large amount of cutting fluid to the environment and human bodies is also reduced. However, the micro-lubrication uses compressed air as atomization power and oil mist particle transmission carrier, the oil mist particles are not restrained after being sprayed out, and part of the oil mist particles are likely to be scattered, so that higher oil mist concentration is generated in the working environment. This not only causes great pollution to the environment, but also causes great harm to human health through two ways of skin contact and respiratory system. It is desirable to find a new droplet formation and delivery method that reduces or avoids the above-mentioned disadvantages of minimal lubrication.
The electrostatic atomization milling principle is that a high-voltage electrostatic field is established between a charging nozzle and a cutter and a workpiece, a small amount of lubricating oil is sent to the charging nozzle with negative electricity for charging, when the charged quantity reaches a critical value, the electrostatic repulsion force between the surface charges of the charged lubricating oil is larger than the surface tension and the viscous force of the charged lubricating oil, so that the lubricating oil is broken into charged droplets, and the droplets fly to a cutting area under the action of the electric field force.
Research shows that compared with micro-lubrication, electrostatic atomization can further improve milling performance, greatly reduce the concentration of working environment oil mist, effectively reduce environmental pollution and human health hazards, and is expected to become a new generation of green cooling and lubricating technology for cutting processing. And the improvement of the electrostatic atomization milling performance and the environmental protection performance is greatly dependent on the effective transportation of the fog drops to a processing area. Therefore, the method for evaluating the droplet transportation effect has very important significance for optimizing the electrostatic atomization parameters to fully exert the electrostatic atomization milling efficiency by obtaining and analyzing the droplet transportation tracks under different atomization parameters.
The current high-speed cameras and particle image velocimeters can detect flow fields in different atomization modes. However, because the milling cutter rotates at a high speed and the milling area is narrow during the electrostatic atomization milling, it is difficult to obtain the transportation track of the charged droplet group to the milling area by using the detection means, and further optimize the electrostatic atomization parameters.
And modeling is carried out on the transport of the electrostatic atomization milling droplets through a numerical method, and the prediction of the transport trajectory of the droplets is a feasible scheme. Although there are currently studies on modeling electrostatically atomized droplet transport between a nozzle and a stationary flat electrode, the following problems exist: (1) The bidirectional coupling method is adopted for modeling, the calculation speed is low, and the three-dimensional expansion is difficult; (2) The used fog drop packing technology (each package is a certain amount of fog drop sets) represents the motion of all fog drops in the whole package by the motion of the fog drop package, and the motion of the huge amount of fog drops is difficult to truly reflect; (3) The need to make difficult to implement droplet diameter measurements makes the modeling process inconvenient and limits applicability. And when the electrostatic atomization is milled, a high-voltage electrostatic field exists among the nozzle, the milling cutter and the workpiece, and the electric field force is the power for conveying the fog drops. The milling cutter rotates at a high speed, so that the electrostatic field intensity and distribution are influenced, and the transport of fog drops to a milling area is hindered by the brought airflow resistance, so that the transport track of the fog drops is influenced. These all make the method of modeling electrostatically atomized droplet transport between the nozzle and the stationary flat electrode unsuitable for modeling electrostatically atomized milled droplet transport. Therefore, no public report of the electrostatic atomization milling droplet transportation modeling and transportation effect evaluation method is found so far.
Disclosure of Invention
The purpose of the invention is as follows: the invention aims to solve the defects in the prior art and provides a method for modeling transport and evaluating transport effect of electrostatic atomization milling droplets.
The technical scheme is as follows: the invention discloses a method for modeling transport and evaluating transport effect of electrostatic atomization milling droplets, which comprises the following steps:
firstly, a three-dimensional milling model is established, wherein the model comprises a milling cutter, a nozzle, an air area and a surface to be milled.
And step two, importing the model established in the step one into simulation software, and carrying out mesh generation based on a physical field to be used. Due to the use of turbulent flow fields, boundary layer treatment needs to be carried out on the near-wall surface of the milling cutter, and the area possibly passed by the fog drops and grids near the nozzle are appropriately refined.
And thirdly, defining an air material, and calculating an airflow field caused by high-speed rotation of the milling cutter by using a steady-state method based on a freezing rotor method. The freezing rotor method, namely the geometric rotation is not performed, the coordinate system rotates reversely relative to the rotation direction of the milling cutter, and high-fidelity speed field distribution can be obtained in a short time.
And fourthly, inheriting the solution of the third step, calculating an electrostatic field, wherein the nozzle is connected with negative high voltage, and the milling cutter and the surface to be milled are grounded.
And fifthly, measuring physical parameters of the lubricating oil such as density, viscosity, surface tension and the like.
And sixthly, measuring the atomization current according to actual conditions.
And seventhly, calculating necessary initial parameters for simulating the fog drop track according to an electrostatic atomization theory by using the surface tension and the atomization current of the lubricating oil measured in the fifth step and the sixth step, wherein the necessary initial parameters comprise the number of the generated fog drops, the diameter of the fog drops and the charge number of single fog drops in unit time.
And step eight, inputting the parameters of the step five and the step seven, inheriting the solution of the step four, and calculating the fog drop track by a transient method. The turbulent flow field and the electrostatic field do not interfere with each other, and the fog drops have very little influence on the turbulent flow field and the electrostatic field, so the stepwise solution inheriting the previous solution is particularly suitable.
And ninthly, carrying out post-processing on the simulation result to obtain a time-varying graph of the ratio of the flow rate of the lubricating oil which can reach the target area to the total flow rate of the lubricating oil, and evaluating the fog drop transportation effect according to the steady-state result of the ratio, wherein the larger the steady-state result of the ratio is, the better the fog drop transportation effect is.
Further, in the fifth step, a balance measuring cylinder method is adopted to measure the density rho of the lubricating oil p (ii) a Measurement of lubricating oil viscosity mu by rotation method p (ii) a Measuring the surface tension sigma of the lubricating oil by adopting a platinum plate method; and in the sixth step, a picoampere meter is used for measuring the atomization current under the conditions of actual lubricating oil flow and voltage.
Further, in the seventh step, the number n of mist droplets generated per unit time and the diameter d of mist droplets are set to be equal to or smaller than the predetermined value p And the charge number Z of a single droplet is calculated as follows:
wherein I = nq, Q = nV p 、
q＝Ze、q＝2π(16σε 0 R 3 ) 1/2
I is the atomization current, Q is the single droplet charge, Q is the lubricant flow, V p Is the volume of a single droplet, R is the radius of the droplet, e is the charge of a single electron, sigma is the surface tension of the lubricating oil, epsilon 0 Is the dielectric constant in vacuum.
Further, in the eighth step, the fog drop trajectory calculation equation is as follows:
wherein m is p Is the droplet mass, v is the droplet velocity vector, F D For drag forces (i.e. resistance to air flow caused by high-speed rotation of the milling cutter to which the droplets are subjected), F e Is the force of an electric field, F c Is the coulomb force between the droplets.
Furthermore, in the ninth step, the fog drop conveying effect is evaluated through the ratio P of the flow rate of the lubricating oil reaching the target area to the total flow rate of the lubricating oil,
wherein, N p The number of fog drops reaching the target area at the current time, V p Is the volume of a single droplet, Q is the flow rate of the lubricating oil, and t is the corresponding droplet transport time.
Has the advantages that: compared with the prior art, the invention has the following advantages:
(1) The influence of milling cutter rotation on droplet transportation during electrostatic atomization milling is fully considered, the transportation track of charged droplet groups during electrostatic atomization milling can be effectively predicted, the droplet transportation effect is evaluated, and a basis is provided for optimization and selection of electrostatic atomization parameters;
(2) Efficient convergence can be obtained by modeling the electrostatic atomization milling droplet transportation by adopting a step-by-step one-way coupling method, tens of thousands of droplet tracks can be tracked simultaneously, and the characteristics of charged droplet groups are revealed more easily;
(3) The method avoids the diameter measurement of the fog drops which is difficult to implement, and the modeling process is simple, convenient and easy to implement.
Drawings
FIG. 1 is a schematic diagram of a three-dimensional milling model constructed in the present invention;
FIG. 2 is a schematic diagram of model splitting in the present invention;
FIG. 3 is a schematic diagram of meshing in the present invention;
FIG. 4 is a schematic diagram of boundary conditions in the present invention;
FIG. 5 is a diagram of a droplet transport simulation in an example;
fig. 6 is a diagram for evaluating the droplet transport effect in the example.
In the figure: 1-a nozzle; 2-milling cutter; 3-air domain; 4-milling a surface to be milled; 5-symmetric conditions; 6-negative potential conditions; 7-grounding; 8-continuity conditions; 9-outlet.
Detailed Description
The technical solution of the present invention is described in detail below, but the scope of the present invention is not limited to the embodiments.
The invention discloses a method for modeling transport and evaluating transport effect of electrostatic atomization milling droplets, which comprises the following steps:
firstly, establishing a three-dimensional milling model, wherein the model comprises a milling cutter, a nozzle, an air area and a surface to be milled;
step two, importing the model established in the step one into simulation software, and performing mesh generation;
thirdly, defining an air material, and calculating an airflow field caused by high-speed rotation of the milling cutter by using a steady-state method;
fourthly, inheriting the solution of the third step, and calculating an electrostatic field, wherein a nozzle is connected with negative high voltage, and a milling cutter and a surface to be milled are grounded;
fifthly, measuring physical parameters of the lubricating oil, wherein the physical parameters comprise density, viscosity and surface tension;
sixthly, measuring atomization current according to actual conditions;
seventhly, calculating necessary initial parameters for simulating the droplet track according to an electrostatic atomization theory by using the surface tension and the atomization current of the lubricating oil measured in the fifth step and the sixth step, wherein the necessary initial parameters comprise the number of generated droplets in unit time, the diameter of the droplets and the charge number of single droplets;
eighthly, inputting the parameters of the fifth step and the seventh step, inheriting the solution of the fourth step, and calculating the fog drop track by a transient method;
and ninthly, carrying out post-processing on the simulation result to obtain a time-varying graph of the ratio of the flow rate of the lubricating oil reaching the target area to the total flow rate of the lubricating oil, and evaluating the fog drop conveying effect according to the steady-state result of the ratio.
The embodiment is as follows:
an uncoated cemented carbide milling cutter manufactured by SANDVIK corporation was used for example for electrostatic atomization milling.
Firstly, a three-dimensional milling model as shown in fig. 1 is established, and a solution domain is a quasi-torus region between a milling cutter and a nozzle. As shown in fig. 2, for the convenience of analysis and calculation, the model is split into A, B, C, the area a is a small circular ring near the wall of the milling cutter, and the area a is a rotation domain; the area B is a large circular ring body far away from the wall surface of the milling cutter, and the part is a static area; the region C is the target region (defined as the region to be cooled and lubricated depending on the processing conditions) and can be used to count the number of droplets entering this region. A and B form an assembly, and C forms a union with A. The modeling parameters for the electrostatic atomization milling of the droplet transport in this embodiment are shown in table 1.
TABLE 1 Electrostatic atomization milling droplet transport modeling parameters
And secondly, based on a multiple-grid technology, the geometric subdivision grids are subjected to selection between solving precision and memory consumption. A dynamic grid is used in the area A, a static grid is used in the area B, and the interface of A and B is refined, as shown in figure 3.
And thirdly, using a turbulent flow k-epsilon model as a control equation, setting the clockwise rotating speed of the area A to be 1200r/min, and introducing an air material in the area A, B. Pressure outlets were set, top symmetric conditions, interface a and B continuity conditions, and the rest wall conditions, as shown in figure 4. And calculating the airflow field caused by the high-speed rotation of the milling cutter by a steady-state method based on a frozen rotor method.
And fourthly, taking the solution obtained in the third step as an initial value, taking the Gauss law as a control equation, setting the wall surface voltage of the nozzle to be-7 kV, grounding the milling cutter and the surface to be milled, setting the interface of the A and the B as a continuity condition, and calculating the electric field intensity, as shown in figure 4.
Fifthly, measuring the density rho of the lubricating oil by using a balance measuring cylinder method p Measurement of lubricating oil viscosity mu by rotation method p The surface tension σ of the lubricating oil was measured by the platinum plate method, and the results are shown in Table 2.
Sixthly, the flow rate of the lubricating oil was measured by using a picoampere meter, and the atomization current was measured under a voltage of-7 kV, and the results are shown in Table 2.
TABLE 2 measurement results
Seventhly, calculating necessary initial parameters for simulating the fog drop track according to the electrostatic atomization theory by using the surface tension and the atomization current of the lubricating oil measured in the fifth step and the sixth step, wherein the necessary initial parameters comprise the number n of the generated fog drops and the diameter d of the fog drops in unit time p And the number of individual droplet charges Z. The calculation formula is as follows:
I＝nq (1)
Q＝nV p (2)
q＝Ze (4)
q＝2π(16σε 0 R 3 ) 1/2 (5)
wherein I is atomization current, Q is single droplet charge amount, Q is lubricating oil flow, and V p Is the volume of a single droplet, R is the radius of the droplet, e is the charge of a single electron, sigma is the surface tension of the lubricating oil, epsilon 0 Is the dielectric constant in vacuum.
According to the formulae (1) to (5)
And eighthly, inputting parameters of the fifth step and the seventh step, taking the solution of the fourth step as an initial value, taking the density, viscosity, surface tension, droplet diameter, the number of droplets generated in unit time and the charge number of a single droplet as initial conditions, and taking the inlet, the outlet, the adhered wall and the particle continuity as boundary conditions, and calculating the droplet trajectory by adopting a transient method. The fogdrop locus calculation equation is as follows:
wherein m is p Is the droplet mass, v is the droplet velocity vector, F D As drag force (resistance to air flow caused by high-speed rotation of milling cutter to mist droplets), F e Is the force of an electric field, F c Is the coulomb force between the droplets.
F D Obtained from stokes' law:
u′＝u+u f (13)
where μ is the air viscosity, k is the turbulent kinetic energy, ε is the turbulent dissipation, C L Is Lagrange time scale coefficient, u is air turbulence field velocity, u f For turbulent velocity pulsation, u f,rms For turbulent velocity pulsation root mean square, τ L For lagrange time scales, τ p As particle velocity response time, S t Is the stokes number and xi is a normally distributed random number.
F e Obtained from the following equation:
F e ＝eZE (14)
where E is the electric field vector.
F c Obtained by the following formula:
where the subscript j represents the jth droplet and r represents the position vector.
And ninthly, carrying out post-processing on the simulation result to obtain a fog droplet transportation simulation diagram as shown in fig. 5.
To evaluate the effect of droplet transport, the ratio of the flow of lubricant to the total flow of lubricant that reaches the target area, i.e. the ratio
Wherein N is p Is as followsThe number of fog drops that reached the target area at the previous time. The time dependence of P is obtained by suitable time steps, as shown in fig. 6, and P finally reaches a relatively stable value.
The larger the steady state result of the P value is, the better the fog droplet transportation effect is. And (3) detecting a fog drop flow field at the outlet of the nozzle and in the open space by using a high-speed camera and a particle image velocimeter as a judgment standard of the feasibility of the transport model, and using the fog drop flow field as a basis for adjusting parameters of the transport model.
Claims (3)
1. A method for modeling transport and evaluating transport effect of electrostatic atomization milling droplets is characterized by comprising the following steps:
firstly, establishing a three-dimensional milling model, wherein the model comprises a milling cutter, a nozzle, an air area and a surface to be milled;
step two, importing the model established in the step one into simulation software, and performing mesh generation through a multiple mesh method;
thirdly, defining an air material, and calculating an airflow field caused by high-speed rotation of the milling cutter by using a steady-state method;
fourthly, inheriting the solution of the third step, and calculating an electrostatic field, wherein a nozzle is connected with negative high voltage, and a milling cutter and a surface to be milled are grounded;
fifthly, measuring physical parameters of the lubricating oil, wherein the physical parameters comprise density rho p Viscosity [ mu ] of p And surface tension σ;
sixthly, measuring atomization current according to actual conditions;
seventhly, calculating necessary initial parameters for simulating the droplet track according to the electrostatic atomization theory by using the surface tension and the atomization current of the lubricating oil measured in the fifth step and the sixth step, wherein the necessary initial parameters comprise the number n of the generated droplets in unit time and the diameter d of the generated droplets p And the charge number Z of the single fog drop, the calculation formula is as follows:
wherein I = nq, Q = nV p 、
q＝Ze、q＝2π(16σε 0 R 3 ) 1/2
I is the atomization current, Q is the single droplet charge, Q is the lubricant flow, V p Is the volume of a single droplet, R is the radius of the droplet, e is the charge of a single electron, sigma is the surface tension of the lubricating oil, epsilon 0 Is a vacuum dielectric constant;
and eighthly, inputting parameters of the fifth step and the seventh step, inheriting the solution of the fourth step, and calculating the droplet trajectory by a transient method, wherein the calculation equation is as follows:
wherein m is p Is the droplet mass, v is the droplet velocity vector, F D As drag force, F e Is the force of an electric field, F c Is the coulomb force between the droplets;
and ninthly, carrying out post-processing on the simulation result to obtain a time-varying graph of the ratio of the flow rate of the lubricating oil reaching the target area to the total flow rate of the lubricating oil, and evaluating the fog drop conveying effect according to the steady-state result of the ratio.
2. The method for modeling transport and evaluation of transport effect of electrostatically atomized milled droplets as claimed in claim 1, wherein: in the fifth step, the density rho of the lubricating oil is measured by adopting a balance measuring cylinder method p (ii) a Measurement of lubricating oil viscosity mu by rotation method p (ii) a Measuring the surface tension sigma of the lubricating oil by adopting a platinum plate method; what is needed isAnd in the sixth step, a picoampere meter is used for measuring the atomization current under the conditions of actual lubricating oil flow and voltage.
3. The method for modeling transport and evaluation of transport effects of electrostatically atomized milled droplets according to claim 1, wherein: in the ninth step, the fog drop conveying effect is evaluated by the ratio P of the flow rate of the lubricating oil reaching the target area to the total flow rate of the lubricating oil,
wherein, N p The number of fog drops reaching the target area at the current time, V p Is the volume of a single droplet, Q is the flow rate of the lubricating oil, and t is the corresponding droplet transport time.
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