Atomizing-based cutting fluid delivery system and method

1. An atomizing cutting fluid system, comprising:

a common chamber terminating in a shaped droplet nozzle and including a nozzle section immediately behind the shaped droplet nozzle;

an atomizer that creates spray directly within the common chamber behind the nozzle section;

a cutting fluid supply line to provide cutting fluid to the atomizer; and

a high velocity gas nozzle within the nozzle section and behind the droplet nozzle configured to provide a high velocity gas to entrain the flow of droplets, wherein the nozzle section and droplet nozzle are configured to produce a fully developed droplets-gas flow at a predetermined distance from the droplet nozzle.

2. The system of claim 1 , further comprising a high velocity gas mixing section that mixes air and CO 2 in a ratio that produces a temperature slightly higher than the freezing point of water to the high velocity gas nozzle.

3. The system of claim 1 , further comprising a gravity fed, pumpless cutting fluid supply tank supplying cutting fluid to the cutting fluid supply line.

4. The system of claim 1 , wherein the high velocity gas nozzle and the droplet nozzle are co-axially disposed.

5. The system of claim 1 , wherein the droplet nozzle and the nozzle section provide a ˜4° convergence with ˜18.8 mm exit at the droplet nozzle, there is a ˜0.75° convergence with ˜1.6 mm exit at the high velocity gas nozzle and the high velocity gas nozzle exit is ˜5 mm behind the droplet nozzle.

6. The system of claim 1 , used in a method to machine titanium alloy and disposed at the predetermined distance to create a thin film on a tool substrate and effectively penetrate that film into the tool-chip interface.

7. The system of claim 6 , further comprising a system controller, wherein droplet flow velocity and gas velocity are controlled by said system controller to set a droplet entrainment angle that produces a focused droplet and entrained flow at the predetermined distance.

8. The system of claim 7 , wherein the droplet flow velocity, droplet size, and gas velocity are controlled to allow droplets to be entrained and mixed gradually until achieving a fully-developed flow region.

9. The system of claim 1 , further comprising a high velocity gas delivery supply that delivers high molecular weight inert gas to the high velocity gas nozzle.

10. The system of claim 1 , further comprising air inlets disposed behind the atomizer to disperse and create a flow of droplets created by the atomizer.

11. The system of claim 1 , wherein said cutting fluid supply line provides cutting fluid in close proximity and in front of a tip of the atomizer.

12. The system of claim 11 , further comprising a valve to control delivery of cutting fluid from said cutting fluid supply line.

13. The system of claim 12 , wherein said valve comprises a plurality of valves including a shut-off valve upstream of a flow control valve.

14. The system of claim 1 , wherein said cutting fluid supply line provides cutting fluid through a body center of the atomizer.

15. The system of claim 1 , wherein said cutting fluid is supplied via gravity flow without any pump.

16. A cutting system including a cutting fluid system of claim 1 , the cutting system including a tool, the cutting fluid system being arranged to deliver a thin film at an interface between the tool and a workpiece.

17. The system of claim 1 , wherein the high velocity gas comprises a mixture of air and CO 2 in a ratio that produces a droplets-gas flow having a temperature in the range of ˜1-4° C.