受限空间小型急冷塔内喷雾蒸发的数值模拟

针对受限空间内小型急冷塔冷却水蒸发过程,运用计算流体力学(CFD)进行数值模拟,基于涡壳进气型急冷塔研究了喷嘴雾化粒径、喷射速度、喷射角度等喷嘴运行参数对急冷塔内蒸发过程的影响机制。结果表明:随着液滴粒径的增大,液滴蒸发时间、轴向以及径向蒸发距离均随之显著上升,粒径由40 μm增大至80 μm时蒸发时间增加了293%;当液滴喷射速度增加时,液滴的蒸发时间、轴向以及径向蒸发距离均有所下降,但增大至一定程度后其影响作用减弱;随着液滴喷射角度的增大,液滴蒸发时间及轴向蒸发距离减小,而径向蒸发距离无显著变化。因此,在急冷塔尺寸受限时选用70 μm以下的小雾化粒径喷嘴能够直接有效提升急冷塔的运行安全性。同时,与均匀进气型急冷塔相比,采用涡壳进气型急冷塔以及喷嘴成切圆布置方式能够在急冷塔上部形成湍流强化区域,喷嘴雾化粒径为80 μm时,轴向安全裕度可提升7%。该模拟结果可为小型化急冷塔的工程应用提供优化设计方案与运行指导参考。     

Machining evaluation of a hybrid MQL-CO2 grinding technology

Although there are already successful industrial experiences in other machining industries with the elimination of coolants, this is not so in the grinding industry due to the large amounts of generated heat that must be evacuated from the contact zone. In this work, a new approach to the elimination of fluids in grinding is presented. The technology is based on the use of a hybrid Minimum Quantity of Lubricant (MQL)-low temperature CO₂ system that reduces lubrication consumption. Abrasive grits are protected by the layer of frozen oil, resulting in a significant improvement in grinding wheel life and surface quality of the machined component. Although the cooling action is reduced with respect to the conventional coolant, no thermal damage was observed on the workpiece.     

Design and evaluation of an atomization-based cutting fluid spray system in turning of titanium alloy

Tool life has been a vital issue in machining titanium alloys. Recently, an atomization-based cutting fluid (ACF) application has been found to be an effective approach for cooling and lubrication in micromachining operations. In this study, an ACF spray system is developed for macro-scale turning of Ti–6Al–4V. The spray system is designed to minimize interaction between the fluid droplets, and the gas nozzle to control the divergence of the fluid droplets. Experiments are conducted to study the effect of five specific ACF spray parameters including fluid flow rate, spray distance, impingement angle, and type and pressure level of the droplet carrier gas on cutting forces, tool life, and chip characteristics. It has been observed that the combination of lower pressure (150 psi) air-mixed CO₂ with a higher flow rate (20 ml/min) and a larger spray distance (35 mm) produces a significantly longer tool life and broken chips. The results also reveal that the ACF spray system can extend tool life up to 40–50% over flood cooling.     

雾化合金液滴的凝固动力学分析与计算

雾化凝固过程对雾化制粉和喷射沉积材料的组织有重要影响。雾化凝固过程主要由液态冷却、再辉、偏析凝固、共晶凝固与固态凝固阶段组成。分析了雾化过程中的液滴的速度与粒度分布及凝固各阶段液滴凝固潜热的释放与环境导热之间的热平衡。     

Study of specific energy and friction coefficient in minimum quantity lubrication grinding using oil-based nanolubricants

An investigation on minimum quantity lubrication (MQL) grinding was carried out with the scope of documenting the process efficiency of oil-based nanolubricants. The nanolubricants were composed of MoS₂ nanoparticles (<100 nm) over coated with organic agents, dispersed in two different base oils—mineral oil (paraffin) and vegetable oil (soybean). Surface grinding tests were carried out on cast iron and EN 24 steel under different lubrication conditions—MQL using nanolubricants (varying compositional chemistry and concentration of nanoparticles), pure base oils (without nanoparticles) and base oils containing MoS₂ microparticles (3–5 μm), and flood grinding using water-based coolant. Specific energy, friction coefficient in grinding and G-ratio were used as measurands for determining the process efficiency. Results show that MQL grinding with nanolubricants increases the process efficiency by reducing energy consumption, frictional losses at the wheel–workpiece interface and tool wear. The process efficiency is also found to increase with increasing nanoparticle concentration. Soybean and paraffin based-nanolubricant performed best for steel and cast iron, respectively, showing a possible functional relationship between the compositional chemistry of nanolubricant and the workpiece material, which will be the goal of future work.     

Analytical model of metalworking fluid penetration into the flank contact zone in orthogonal cutting

Metalworking fluids (MWFs) are used widely in machining process to dissipate heat, lubricate moving surfaces, and clear chips. They have also been linked to a number of environmental and worker health problems. To reduce these impacts, minimum quantity lubrication (MQL) sprays of MWF delivered in air or CO₂ have been proposed. MQL sprays can achieve performance comparable with conventional water-based or straight oil MWFs while only delivering a small fraction of the fluid. This performance advantage could be explained by the enhanced penetration into the cutting zone that results from delivering MWF in high pressure and precise sprays. To explore this hypothesis, an analytical model of MWF penetration into the flank face of the cutting zone is developed and validated using experimental data. The model is based on a derivation of the Navier–Stokes equation and the Reynolds equation for lubrication and applied to an orthogonal cutting geometry under steady-state conditions. A solution to the model is obtained using a numerical strategy of discretizing the analytical scheme with two-dimensional centered finite difference method. Penetration into the cutting zone is estimated for MQL sprays delivered in air, CO₂ and N₂ as well as two conventional MWFs, straight oil and semi-synthetic emulsion. The model suggests that conventional MWFs, do not penetrate the cutting zone fully and fail to provide direct cooling to the flank zone where wear is most likely to occur. MQL sprays do penetrate the cutting zone completely. Using convective heat transfer coefficients from a previous study, a finite element heat balance is carried out on the tool to understand how each fluid impacts temperature near the flank tip of the tool. The results of the modeling effort are consistent with experimental measurements of tool temperature during turning of titanium (6AL4V) using a K313 carbide tool. The prediction of temperature near the flank indicates that MQL sprays do suppress temperatures near the flank effectively. These results help explain the low levels of tool wear observed for some MQL sprays, particularly those based on high pressure CO₂. This modeling framework provides valuable insight into how lubricant delivery characteristics such as speed, viscosity, and cutting zone geometry can impact lubricant penetration.     

Minimum quantity lubrication in grinding: effects of abrasive and coolant–lubricant types

This research has been conducted to study the influence of the abrasive and coolant–lubricant types on the minimum quantity lubrication (MQL) grinding performance. One type of CBN and three types of conventional wheels (corundum) have been tested. The tests have been performed in presence of fluid, air jet and eleven types of coolant–lubricants, as well as, in dry condition. The results indicate that the finest surface quality and lower grinding forces could be obtained while grinding with CBN wheel. In case of conventional wheels, the coarser and high porosity wheels induce much proper grinding results. Furthermore, grinding when utilizing MQL with oil results in higher grinding performance.     

新型旋切式气液两相喷嘴及内部流场数值模拟

本文在对各种气动性喷嘴及其雾化机理分析的基础上提出一种新型雾化喷嘴--旋切式气液两相喷嘴。该喷嘴具有结构简单、喷雾量无限可调、喷雾锥角调整灵活、防堵塞、雾化效果好的优点。通过CFD数值模拟研究发现,在旋切式喷嘴内部液流已经被气流剪切雾化成细小颗粒,其均匀的分散在气流中,在混合室内部形成气液混合流,形成一次雾化。当气液混合流脉冲喷出孔喷时,体积进一步膨胀,同时,高速液滴外部空气相互作用,产生二次雾化,促进了雾化效果。     

液幕式湿法脱硫中喷嘴型线对竖直射流特性的影响研究

液幕湿法脱硫就是利用竖直向上喷射的石灰石浆液冲洗烟气,吸收效果好坏主要取决于喷嘴的竖直射流情况,试验研究了7种用于该塔中的喷嘴竖直射流特性。发现各喷嘴竖直射流都存在临界雾化速度。整理出无量纲平均半径与射流速度之间的关系,分析发现喷口直径和喷嘴高度对回落液体覆盖面积影响不大。试验结果表明所有喷嘴的回落液幕分布均匀性相同。导出了射流高度与喷射压力关系式,发现试验范围内喷嘴阻力损失情况相当。     

Three-dimensional laser machining of structural ceramics

Three- dimensional laser machining of structural ceramics such as alumina (Al₂O₃), silicon nitride (Si₃N₄), silicon carbide (SiC) and magnesia (MgO) was carried out using a 1.06 μm wavelength pulsed Nd:YAG laser. The rate of machining predicted in terms of material removed per unit time (mg/s) increased with an increase in heating rate (K/s). A thermal model based on temperature dependent absorptivity and thermophysical properties, in addition to conduction, convection and radiation based heat transfer, was developed to predict material removal rate. Predicted values were compared with actual measurements made from machined cavities. Such a study would enable advance predictions of the laser processing conditions required to machine cavities of desired dimensions.     

恒定横流底部多孔排放近区污水稀释扩散效果因素研究

借助于人工模型试验，分析了恒定横流底部多孔排放时扩散器设计参数（射流角度、射流速度、喷口个数）、上升管间距）及环境参数（环境水深、环境流速）对污水近区稀释扩散效果的影响，实验结果表明，除了环境条件对污水稀释扩散效果影响明显之外，扩散器设计参数对污水的近区稀释扩散也有显著的影响，针对白龙港排放口水域，喷口射流角度宜控制在１０°左右，喷口个数取１６个     

Water jet guided laser as an alternative to EDM for micro-drilling of fuel injector nozzles: A comparison of machined surfaces

To characterize the inner surface of the fuel injector nozzle holes drilled by EDM and water jet guided laser drilling (Laser Micro-Jet) a specifically conceived scanning probe microscopy technique with true non-contact operating mode was used. A difference in morphology of the drilled surfaces is evident from the acquired surface topography along the hole axis for the two compared drilling techniques. Results showed that the surface texture can be characterized by (i) maximum peak-to-valley distance and (ii) periodicity. Acquired maps confirm that electro-eroded surfaces are an envelope of craters randomly distributed with total excursion up to 1.7 μm with a crater size of 15 μm. While, the efficient melt expulsion and immediate cooling of water jet guided laser generates a peak to valley distance of 800 nm with a periodicity of 18 μm. Average R_q derived from the measured cylindrical surfaces was 450 nm and 150 nm for EDM and Laser Micro-Jet, respectively. Water jet guided laser drilling has proved to be a reliable alternative to EDM from the point of view of repeatability of the results and surface quality to facilitate the atomization of the fuel jet.     

高压喷雾及其在煤矿井下粉尘防治中的应用

系统分析了高压喷雾的喷雾参数，雾粒粒度分布，雾粒在雾流中运动的平均速度，雾粒带电及喷咀结构，并将此技术用于煤矿井下采煤机和炮掘工作面，取得了很好的降尘效果。     

Preparation and characterization of Pd/Fe bimetallic nanoparticles immobilized on Al2O3/PVDF membrane: Parameter optimization and dechlorination of dichloroacetic acid

Using a liquid–solid phase inversion method, a hybrid matrix poly(vinylidene fluoride)(PVDF) membrane was prepared with alumina(Al2O3) nanoparticle addition. Pd/Fe nanoparticles(NPs) were successfully immobilized on the Al2O3/PVDF membrane, which was characterized by Scanning Electron Microscopy(SEM) and Transmission Electron Microscopy(TEM). The micrographs showed that the Pd/Fe NPs were dispersed homogeneously. Several important experimental parameters were optimized, including the mechanical properties, contact angle and surface area of Al2O3/PVDF composite membranes with different Al2O3 contents. At the same time, the ferrous ion concentration and the effect of hydrophilization were studied. The results showed that the modified Al2O3/PVDF membrane functioned well as a support. The Al2O3/PVDF membrane with immobilized Pd/Fe NPs exhibited high efficiency in terms of dichloroacetic acid(DCAA) dechlorination. Additionally, a reaction pathway for DCAA dechlorination by Pd/Fe NPs immobilized on the Al2O3/PVDF membrane system was proposed.     

Evaluation of near-dry machining effects on gear milling process efficiency

One of the main environmental pollution sources related to machine building industry is the huge amount of cutting fluids which are supplied during the machining processes. In order to avoid the problems induced by cutting fluids' usage, considerable progress has been recently made in the field of near-dry machining (NDM). Converting conventional processes to minimal quantity lubrication (MQL) methods imposes new tasks' classification within the tribiological system in order to guarantee the process safety and product quality. This paper gives an overview on some requirements to be considered for a successful MQL application into industrial practice. Its last part is focused on the evaluation of NDM effects on the gear milling process efficiency, with respect to hob wear, surface quality, cooling effect, and environment protection.     

空气助力雾化喷嘴雾化特性实验研究

冻云中液态水滴的中值直径是影响飞机结冰的一个重要参数,选择合适的喷嘴用于模拟冻云显得尤为重要。采用马尔文Spraytec喷雾粒度分析仪对两种不同孔径的喷嘴进行了详细的实验研究,在最小中值直径工况点进行了粒度分布分析。研究发现中值直径随气压的增加而减小,在气压和水流量变化时喷雾锥角稍有波动,但变化范围不大。     

空气助力雾化喷嘴雾化特性实验研究

冻云中液态水滴的中值直径是影响飞机结冰的一个重要参数,选择合适的喷嘴用于模拟冻云显得尤为重要。采用马尔文Spraytec喷雾粒度分析仪对两种不同孔径的喷嘴进行了详细的实验研究,在最小中值直径工况点进行了粒度分布分析。研究发现中值直径随气压的增加而减小,在气压和水流量变化时喷雾锥角稍有波动,但变化范围不大。     

风送式抑尘喷雾机喷嘴的优化选型

为了更好地指导风送式抑尘喷雾机喷嘴的选型,收集了5种内部结构的喷雾机喷嘴,对比其雾化特性,并检验选定的喷嘴应用于工程现场的降尘效果。结果表明:1)斯普瑞和泰格两种喷嘴具有较大的雾化角,能满足大面积降尘的需求,适用于大多数抑尘喷雾机;2)同一供水压力下,喷孔直径为0.5 mm的斯普瑞喷嘴雾滴粒径远小于其他结构的喷嘴,将其安装在抑尘喷雾机,能有利于细小颗粒粉尘的捕集;3)将喷孔直径为0.5 mm的斯普瑞喷嘴安装于工程现场抑尘喷雾机,实测全尘降尘效率和呼尘降尘效率分别高于90%和80%,降尘效果良好。     

离心旋流式喷嘴雾化特性实验研究

目的进一步优化低温多效蒸馏技术中的喷淋布液方式,提高海水淡化换热效率。方法采用马尔文激光粒度分析仪、高速摄像机和翻转水量仪对不同口径的CJ-9型离心旋流式喷嘴进行研究。结果同一口径的喷嘴,随着水流压力的增加,液滴粒径分布的均匀性显著提高。随着水压的增加,同一个喷嘴液体破碎的纹路变密,同时液膜破碎的长度变短,破碎效果越好,雾化性能越好。同一口径的喷嘴,入口压力越大,其边缘流峰值越高,空心化率现象越明显。同一压力下不同口径的喷嘴,口径越大,其形成双波峰的跨度越短;同一口径的喷嘴,入口压力越大,其形成双波峰的跨度越长,其边缘流峰值越高。结论液滴粒径分布的均匀性随着水压的增加或孔径的减小而显著提高,喷淋密度在直径方向上存在两个峰值,运用"峰谷叠加"原理,来满足低温多效蒸发器布液均匀的整体要求。