. College of Mechanical Engineering and Automation, Liaoning University of Technology, Jinzhou 121001, China . School of Materials Science and Engineering, Xi’an University of Technology, Xi’an 710048, China . School of Mechanical and Automotive Engineering, Qingdao University of Technology, Qingdao 266520, China
Electrostatic atomization minimum quantity lubrication (EMQL) employs the synergistic effect of multiple physical fields to atomize minute quantities of lubricant. This innovative methodology is distinguished by its capacity to ameliorate the atomization attributes of the lubricant substantially, which subsequently augments the migratory and infiltration proficiency of the droplets within the complex and demanding milieu of the cutting zone. Compared with the traditional minimum quantity lubrication (MQL), the EMQL process is further complicated by the multiphysical field influences. The presence of multiple physical fields not only increases the complexity of the forces acting on the liquid film but also induces changes in the physical properties of the lubricant itself, thus making the analysis of atomization characteristics and energy distribution particularly challenging. To address this objective reality, the current study has conducted a meticulous measurement of the volume average diameter, size distribution span, and the percentage concentration of inhalable particles of the charged droplets at various intercept positions of the EMQL nozzle. A predictive model for the volume-averaged droplet size at the far end of the EMQL nozzle was established with the observed statistical value F of 825.2125, which indicates a high regression accuracy of the model. Furthermore, based on the changes in the potential energy of surface tension, the loss of kinetic energy of gas, and the electric field work at different nozzle orifice positions in the EMQL system, an energy distribution ratio model for EMQL was developed. The energy distribution ratio coefficients under operating conditions of 0.1 MPa air pressure and 0 to 40 kV voltage on the 20 mm cross-section ranged from 3.094‰ to 3.458‰, while all other operating conditions and cross-sections had energy distribution ratios below 2.06‰. This research is expected to act as a catalyst for the progression of EMQL by stimulating innovation in the sphere of precision manufacturing, providing theoretical foundations, and offering practical guidance for the further development of EMQL technology.
Just Accepted Date: 11 September 2024Issue Date: 29 October 2024
Cite this article:
Dongzhou JIA,Keke JIANG,Yanbin ZHANG, et al. Model for atomization droplet size and energy distribution ratio at the distal end of an electrostatic nozzle[J]. Front. Mech. Eng.,
2024, 19(5): 35.
Fig.3 Average particle size of droplet under different working conditions.
Fig.4 Droplet size distribution under various conditions. R.S: span values.
Fig.5 Percentage concentration of PM10 at different spray distances.
Fig.6 Percentage concentration of PM2.5 at different spray distances.
Fig.7 Diagram of residual lever.
Fig.8 Fitting degree of particle size formula of broken atomized droplets.
Fig.9 Force analysis of charged droplet. The left diagram shows the hydrostatic pressure. The right diagram shows the electrostatic expansion pressure.
Fig.10 Calculation scheme of equivalent length of liquid film.
Fig.11 Binary turbulent circular free jet.
Fig.12 Turbulent mixing length and time-averaged velocity distribution.
Fig.13 Droplet charge-mass ratio under different pressure and voltage conditions.
Fig.14 Calculation scheme of liquid film velocity at nozzle outlet. Time lag = 0.004 s.
Fig.15 Liquid velocity at nozzle outlet under different voltage and pressure conditions.
Fig.16 Gas quality in one atomization step under different voltage and pressure conditions.
Fig.17 Variation of the potential energy of surface tension in atomization system.
Fig.18 Variation of gas kinetic energy in the atomization system.
Fig.19 Work done by electric field force in atomization process.
Fig.20 Energy distribution ratio of the atomizing system.
Electric field intensity far from the nozzle outlet x
FS
Nozzle diameter jet length ratio
I
Current dimension
?K
Loss of kinetic energy of gas
L
Length dimension
l
Mixing length of any section of jet
l'
Prandtl mixing length
M
Mass dimension
mg
Compressed air quality
ml
Instantaneous mass flow
mmix
Mass of gas liquid mixture
Average mass flow of micro lubricant
R2
Determination coefficient
Rn
Radius of curvature of nozzle
r0
Outlet radius of round nozzle
rg
Radius of gas nucleus
S0
Jet consistency
T
Time dimension
t
Time required for one atomization step
U0
Nozzle initial voltage
Ux
Position potential of the droplet after moving
u
Axial time average velocity of microliquid mass at r point in flow field
u'
Axial fluctuating velocity of microliquid mass at r point in flow field
u0
Initial velocity of gas at nozzle exit
ul
Initial velocity of liquid at nozzle exit
um
Jet velocity on the centerline
ux
Axial velocity of the center of the transverse section away from the exit x
v
Radial time average velocity of microliquid mass at r point in flow field
v'
Radial fluctuating velocity of microliquid mass at r point in flow field
vl
Liquid velocity at nozzle outlet
WS1
Surface potential energy of mother liquid drops before crushing
WS2
Total surface potential energy of subdroplet group
?WE
Work done by electric field force
?WS
Variation of the potential energy of surface tension of droplet system
x
Axial distance from nozzle outlet
α
Free constant
εr
Relative permittivity of air
ζ
Jet turbulence coefficient
ρg
Gas density
ρl
Liquid density
σ
Surface tension coefficient
τ1
Viscous shear stress of jet
Φ
Potential function in needle plate electrode system
Γ0
Initial velocity ratio
1
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