Abstract
In this article, the electrostatic atomization experimental setup was designed and fabricated, and high-speed camera was used to observe and analyze the atomization modes of graphite water-based and oil-based nanofluid using cutting tool as electrode under different electrode voltages and distances, flow rates, and nozzle angles. Three-dimensional finite element simulations of the electrostatic field between nozzle and cutting tool were conducted using the software Ansoft Maxwell to investigate the effect of electrode voltage and nozzle angle on the electrostatic atomization mode. The results indicate that spindle mode is a suitable electrostatic atomization mode for cooling and lubricating the cutting edge. The nozzle angle with the largest electrostatic field intensity is presented so as to generate good break-up effect of jet in spindle mode. Furthermore, the operating range of spindle mode in terms of the electrode voltage and flow rate for graphite water-based and graphite oil-based nanofluid under the nozzle angle with the largest electrostatic field intensity is achieved. The outcome of this study is helpful for further development of electrostatic atomization cutting technique.
Highlights
Cutting fluids are generally used in metal cutting process to improve the tribological characteristics of cutting zone and to remove the heat generated, improving the tool life and surface finish
Many efforts have been undertaken to develop some alternatives to cutting fluids which are cryogenic cooling, minimum quantity lubrication (MQL), refrigerated gas cutting, and cryogenic minimum quantity lubrication (CMQL).[1,2]
In order to analyze the effect of electrostatic field on the electrostatic atomization mode, the values of nozzle angle u1 and u2, electrode voltage U, and electrode distance h defined in the simulations are the same as those defined in the experiments
Summary
Cutting fluids are generally used in metal cutting process to improve the tribological characteristics of cutting zone and to remove the heat generated, improving the tool life and surface finish. In this research, the aim is to investigate the electrostatic atomization modes of nanofluids using cutting tool as ground electrode, and the effect of electrostatic field between cutting tool and nozzle on them. High-voltage electrostatic field forms between the nozzle and the cutting tool. The stable graphite water-based and oilbased nanofluids prepared are used as the atomization fluids in the experiments. The properties of fluid such as dynamic viscosity, conductivity, relative permittivity, and surface tension influence the electrostatic atomization of fluid. According to the concept of electrostatic atomization cutting, negative high voltage and 0 kV are assigned to nozzle and tool, respectively. Distance h defined in the simulations are the same as those defined in the experiments
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