Time also lapses when ordering metalworking consumables and evaluating the coolant and lubricant remaining around the rag. Many companies have come to realize that producing high-quality products in different ways is the foundation of a company's survival.
Choosing the right coolant is not the only consideration for achieving good cooling. If the coolant is not effectively delivered at the appropriate temperature and pressure, the coolant used does not use properly positioned and properly shaped nozzles, and the filtration system used does not match the job being processed, then provided in these cases The coolant may not work at all, or it will produce even worse results.
Technology is not the only challenge faced by coolant and lubricant suppliers. US lubricant giant ITW RocolNorth America and most other suppliers are under pressure to keep up with basic inventory costs. This is a dual challenge, namely the lack of oil and rising prices. To ensure that customers are provided with the best solutions to meet their needs, ITW Rocol North America continues to strengthen its close cooperation with its customers. They have developed a dual route that provides both traditional splash coolant and coolant with a micro-lubrication (MQL) system.
ITW Rocol North America has developed an Accu-Lube series of organic coolant/vegetable oils for the MQL market for quasi-dry cutting. Because this vegetable oil has many advantages, it can solve the inherent problems of water tank-based water tank maintenance and coolant treatment, so the MQL market prospect is very promising. For traditional splash cooling, the company has recently tended to use biostable semi-synthetic coolants such as Rustlick Ultracut 370R coolant.
Whether to use the splash cooling method or the MQL method depends on the specific machined parts. The key question is whether it is possible to deliver liquid to the part processing area and to limit the rigor of oil mist generated in the work environment. If the oil mist is very polluted, many changes will be required for customers and suppliers who use metalworking coolants.
Basic research on coolant
Basic research has always been a research focus of Mercedes-Benz Oil Company, especially the surface chemical properties of lubricants under high pressure conditions. For example, what happens when the tool comes into contact with the workpiece? How to effectively use the chlorine, phosphorus and sulfur in the coolant to control the surface finish of the workpiece. It is also necessary to quantify how the films are formed and what makes them. Next, and perhaps the most important question, is to understand how these chemical elements break the atomic bonding between the surface of the workpiece material in a complex process, such as the bonding between iron atoms, and take control of the splitting method to open the surface and advance The purpose of the material falling off the workpiece. These chemicals act as a high-speed hydrogen embrittlement agent to control friction through a film formed on the surface of the sliding contact zone.
Basic research is closely related to the production process of the coolant, in which the contact pressure reaches above GigaPascal (GPa) or is related to a point at which any level of plastic deformation can occur.
The use of vegetable oils <br> The rising price of oil has become a problem that cannot be ignored in grinding operations. One of the reasons for the tendency to use solvent refined oil is that it is less sensitive to thermal shock. Thermal stability is very important for any precision grinding operation. The researchers found that water-based coolants can cause damage to the workpiece due to thermal stability problems under severe grinding conditions. Moisture boils on the cutting surface, causing the entire system to dry out. However, customers who prefer to use oil-based coolants must also understand the cause of the oil mist and a higher pressure flow system to remove the oil mist.
Blaser believes that vegetable oil is a huge market. Vegetable oils are not only environmentally safe, but they also increase productivity. In one application case, Basso's engineers saved 30% of the production cycle after switching to vegetable oil. They found that applying vegetable oils in more difficult processing environments yielded the highest productivity. For example, the use of plant lubricants in titanium alloy processing can achieve higher benefits than processing aluminum. Vegetable oils are polar, a property that allows vegetable oil additives to effectively form a fine, evenly distributed surface layer.
After starting to use vegetable oil-based products, Basso customers have repeatedly praised their ability and benefits in improving production efficiency, and they are used more frequently and processed faster.
In addition, vegetable oil can be discharged from the machine together with the chips, and the quality of the parts produced is better, and the use can be 20% to 30%. This also compensates to some extent the cost gap between the use of mineral oil and vegetable oil. Because if only from the price point of view, the initial use of vegetable oil-based cutting coolant, the price per gallon can jump 5 to 9 dollars, which is a small expense for the production company. Another advantage of vegetable oils is that most vegetable oils have a higher flash point than mineral oil, which is clearly safer for those customers who have been using oil products.
Basso has also achieved remarkable results in the research of high pressure coolants and cutting oil units. They have developed coolants that control foaming and gasification, which allows customers to fully enjoy the productivity benefits of high pressure. Water quality, tank size, cycle time, pump configuration, pressure, and delivery of coolant through the tool are all important considerations when selecting the right metalworking coolant for high pressure applications.
Coolant filter selection
The coolant filter plays an important role in the performance of the coolant. Andy Nelson, product application manager at Masdar Chemicals, believes that the filter should be such that the circulating particles in the filtered coolant are no more than 10% of the tolerance range. For example, with a tolerance range of ±0.13 mm, a filter that reliably removes particles larger than 0.0025 mm is selected to ensure that the scratches or cumulative errors left by the chips do not affect the tolerance requirements. If a high surface finish is required, even a small scratch will affect the surface quality and measurement. And over time, particle accumulation can also occur on the filter. Therefore, it is necessary to periodically remove the particles accumulated in the coolant because they cause unnecessary chemical reactions in the coolant, which in turn affects the surface finish.
In the grinding process, the coolant quickly wets the wheel, and the wheel becomes a rapidly moving sponge that brings the coolant to the contact surface for cooling and lubrication. The more coolant the wheel can absorb, the stronger the coolant's ability to reduce parasitic drag. The residue deposited on the grinding wheel has a great influence on the grinding wheel. Therefore, it is necessary to pay attention to maintaining the standard size of the grinding wheel, normal dressing and cleaning the grinding wheel, and removing tiny particles deposited on the grinding wheel. Some of these residues are minerals contained in the mixed hard water, and the other part is derived from the residual oil.
The cations in the residue, especially magnesium and calcium ions, react chemically with the wetting agent in the coolant to produce a soft oily residue that adheres to the surface of the wheel, reducing the ability of the wheel to adsorb coolant. In addition, this chemical reaction also reduces the amount of humectant in the coolant, which affects its ability to effectively wet the wheel. If in the cooling liquid, an "excess" ordinary "subject" antifoaming agent is added, wherein the main active ingredient is a water-insoluble "oily" substance (generally one or more silicone composite emulsions), then A similar situation will occur. These problems can often occur at any time when "hard-closed grinding wheels of very small size are used".
Oil mist control
The amount of mineral oil allowed in the oil mist of metal processing plants may be variable. The American Government Industrial Hygienists Committee (ACGIH) recommends an oil mist limit of 0.2 mg/m3. Although ACGIH is not a regulatory agency, the Occupational Safety and Health Administration (OSHA) accepted their advice.
Once this new restriction comes into effect, it will affect the equipment manufacturer and end users, and will require significant improvements to the equipment. This means that the synthetic liquid can be used more, requiring the system to have better control of the oil mist. In theory, vegetable oils will not be included, so their use may increase.
The reason for the tendency to use vegetable oil processing is because of the rising price of oil and the greater use of high-pressure lubricants and lubricants that pass through the tool. Vegetable oils have stronger anti-foaming properties, stronger anti-microbial properties and greater biostability.
The use of high-magnesium alloys and low-magnesium alloys is increasing, especially in the automotive industry, because of the excellent strength-to-weight ratio of this material.
Due to this trend, other related metalworking coolants have been introduced. Magnesium is an active metal that releases hydrogen when it comes into contact with water, which can cause fire or explosion. Therefore, the coolant used in the processing of magnesium alloys is prohibited from occurring in such a reaction, which should be given sufficient attention.
Coolant and grinding
Automakers are willing to spend millions of dollars on grinding machines, but they are reluctant to invest in ducts and cutting fluids, which is not uncommon in the current grinding industry.
In the grinding process, the coolant plays a special role, which not only plays a decisive role in the quality of the product, but also has a great influence on the processing cost. The power consumed by the grinding wheel spindle motor is mainly distributed in the aspects of grinding wheel drive, grinding and coolant transfer. The heat generated by the workpiece during grinding must be cooled immediately to prevent local temperature overshoot and material phase transitions due to further heating. Phase transitions tend to cause residual stress and white layer formation, reducing the fatigue life of the material, causing cracks on the surface and subsurface of the material.
The use of cooling and lubricating fluids, as well as the selection of appropriate process parameters, minimizes the heat generated by the grinding surface and removes most of the heat generated by the grinding wheel, chips and coolant to achieve the cooling of the production process.
The delivery pressure, flow rate, temperature and flow direction of the coolant have a great influence on the quality and economy of the production process. The pressure control fluid flow rate, flow rate and temperature control the heat transfer rate of the liquid, and the flow direction can cause the liquid to clear the air barrier moving around the grinding wheel. The injected liquid must be aligned with the grinding zone in front of the grinding wheel to open a passage for the circulation of air.
The amount of coolant flow depends on the grinding wheel used, and the heat generated by the spindle power consumed during the grinding process needs to be cooled. In many cases, the time spent on the coolant nozzle and the liquid pump/filter design tends to be close to the machine's run time. In other cases, machine tool builders offer flexible nozzle systems based on flexible plastic nozzles or small diameter curved metal tubes, especially for tool grinders and aerospace products. The injection pressure of the coolant should match the rotation speed of the grinding wheel, generally between 0.4 and 0.2 kPa. While plastic nozzles can only be moved or shunted at much lower pressures, open small diameter tubes can even be retracted back due to the reaction force of the jet force and are therefore unsuitable for application. Other problems associated with the nozzle include high-pressure jet cracking problems, high-pressure surge flow in the front of the outlet, extreme proximity to the grinding wheel, and proximity to the target by trial and error.
A wide range of tests have been conducted for the combination of a circular nozzle with a coherent jet and a high degree of configurability. In a recent case study, the customer used mineral oil as a coolant to grind the blade root shape of the turbine blade and found the following advantages:
Strategic measures should be taken for the application of the coolant, that is to say, only the coolant can be used where it is needed, which should be energy efficient and economical. An excellent engineering product should have various degrees of adjustability to reduce setup time.
And the coolant selected should meet the processing needs and cost and production benefits. Direct oil products, such as mineral oils, synthetic oils, etc. generally have high lubricating properties, while water-soluble emulsion type coolants such as synthetic water-soluble emulsions, semi-synthetic water-soluble emulsions and oil/water mixed emulsions are the best. Coolant.
Choosing the right coolant is not the only consideration for achieving good cooling. If the coolant is not effectively delivered at the appropriate temperature and pressure, the coolant used does not use properly positioned and properly shaped nozzles, and the filtration system used does not match the job being processed, then provided in these cases The coolant may not work at all, or it will produce even worse results.
Technology is not the only challenge faced by coolant and lubricant suppliers. US lubricant giant ITW RocolNorth America and most other suppliers are under pressure to keep up with basic inventory costs. This is a dual challenge, namely the lack of oil and rising prices. To ensure that customers are provided with the best solutions to meet their needs, ITW Rocol North America continues to strengthen its close cooperation with its customers. They have developed a dual route that provides both traditional splash coolant and coolant with a micro-lubrication (MQL) system.
ITW Rocol North America has developed an Accu-Lube series of organic coolant/vegetable oils for the MQL market for quasi-dry cutting. Because this vegetable oil has many advantages, it can solve the inherent problems of water tank-based water tank maintenance and coolant treatment, so the MQL market prospect is very promising. For traditional splash cooling, the company has recently tended to use biostable semi-synthetic coolants such as Rustlick Ultracut 370R coolant.
Whether to use the splash cooling method or the MQL method depends on the specific machined parts. The key question is whether it is possible to deliver liquid to the part processing area and to limit the rigor of oil mist generated in the work environment. If the oil mist is very polluted, many changes will be required for customers and suppliers who use metalworking coolants.
Basic research on coolant
Basic research has always been a research focus of Mercedes-Benz Oil Company, especially the surface chemical properties of lubricants under high pressure conditions. For example, what happens when the tool comes into contact with the workpiece? How to effectively use the chlorine, phosphorus and sulfur in the coolant to control the surface finish of the workpiece. It is also necessary to quantify how the films are formed and what makes them. Next, and perhaps the most important question, is to understand how these chemical elements break the atomic bonding between the surface of the workpiece material in a complex process, such as the bonding between iron atoms, and take control of the splitting method to open the surface and advance The purpose of the material falling off the workpiece. These chemicals act as a high-speed hydrogen embrittlement agent to control friction through a film formed on the surface of the sliding contact zone.
Basic research is closely related to the production process of the coolant, in which the contact pressure reaches above GigaPascal (GPa) or is related to a point at which any level of plastic deformation can occur.
The use of vegetable oils <br> The rising price of oil has become a problem that cannot be ignored in grinding operations. One of the reasons for the tendency to use solvent refined oil is that it is less sensitive to thermal shock. Thermal stability is very important for any precision grinding operation. The researchers found that water-based coolants can cause damage to the workpiece due to thermal stability problems under severe grinding conditions. Moisture boils on the cutting surface, causing the entire system to dry out. However, customers who prefer to use oil-based coolants must also understand the cause of the oil mist and a higher pressure flow system to remove the oil mist.
Blaser believes that vegetable oil is a huge market. Vegetable oils are not only environmentally safe, but they also increase productivity. In one application case, Basso's engineers saved 30% of the production cycle after switching to vegetable oil. They found that applying vegetable oils in more difficult processing environments yielded the highest productivity. For example, the use of plant lubricants in titanium alloy processing can achieve higher benefits than processing aluminum. Vegetable oils are polar, a property that allows vegetable oil additives to effectively form a fine, evenly distributed surface layer.
After starting to use vegetable oil-based products, Basso customers have repeatedly praised their ability and benefits in improving production efficiency, and they are used more frequently and processed faster.
In addition, vegetable oil can be discharged from the machine together with the chips, and the quality of the parts produced is better, and the use can be 20% to 30%. This also compensates to some extent the cost gap between the use of mineral oil and vegetable oil. Because if only from the price point of view, the initial use of vegetable oil-based cutting coolant, the price per gallon can jump 5 to 9 dollars, which is a small expense for the production company. Another advantage of vegetable oils is that most vegetable oils have a higher flash point than mineral oil, which is clearly safer for those customers who have been using oil products.
Basso has also achieved remarkable results in the research of high pressure coolants and cutting oil units. They have developed coolants that control foaming and gasification, which allows customers to fully enjoy the productivity benefits of high pressure. Water quality, tank size, cycle time, pump configuration, pressure, and delivery of coolant through the tool are all important considerations when selecting the right metalworking coolant for high pressure applications.
Coolant filter selection
The coolant filter plays an important role in the performance of the coolant. Andy Nelson, product application manager at Masdar Chemicals, believes that the filter should be such that the circulating particles in the filtered coolant are no more than 10% of the tolerance range. For example, with a tolerance range of ±0.13 mm, a filter that reliably removes particles larger than 0.0025 mm is selected to ensure that the scratches or cumulative errors left by the chips do not affect the tolerance requirements. If a high surface finish is required, even a small scratch will affect the surface quality and measurement. And over time, particle accumulation can also occur on the filter. Therefore, it is necessary to periodically remove the particles accumulated in the coolant because they cause unnecessary chemical reactions in the coolant, which in turn affects the surface finish.
In the grinding process, the coolant quickly wets the wheel, and the wheel becomes a rapidly moving sponge that brings the coolant to the contact surface for cooling and lubrication. The more coolant the wheel can absorb, the stronger the coolant's ability to reduce parasitic drag. The residue deposited on the grinding wheel has a great influence on the grinding wheel. Therefore, it is necessary to pay attention to maintaining the standard size of the grinding wheel, normal dressing and cleaning the grinding wheel, and removing tiny particles deposited on the grinding wheel. Some of these residues are minerals contained in the mixed hard water, and the other part is derived from the residual oil.
The cations in the residue, especially magnesium and calcium ions, react chemically with the wetting agent in the coolant to produce a soft oily residue that adheres to the surface of the wheel, reducing the ability of the wheel to adsorb coolant. In addition, this chemical reaction also reduces the amount of humectant in the coolant, which affects its ability to effectively wet the wheel. If in the cooling liquid, an "excess" ordinary "subject" antifoaming agent is added, wherein the main active ingredient is a water-insoluble "oily" substance (generally one or more silicone composite emulsions), then A similar situation will occur. These problems can often occur at any time when "hard-closed grinding wheels of very small size are used".
Oil mist control
The amount of mineral oil allowed in the oil mist of metal processing plants may be variable. The American Government Industrial Hygienists Committee (ACGIH) recommends an oil mist limit of 0.2 mg/m3. Although ACGIH is not a regulatory agency, the Occupational Safety and Health Administration (OSHA) accepted their advice.
Once this new restriction comes into effect, it will affect the equipment manufacturer and end users, and will require significant improvements to the equipment. This means that the synthetic liquid can be used more, requiring the system to have better control of the oil mist. In theory, vegetable oils will not be included, so their use may increase.
The reason for the tendency to use vegetable oil processing is because of the rising price of oil and the greater use of high-pressure lubricants and lubricants that pass through the tool. Vegetable oils have stronger anti-foaming properties, stronger anti-microbial properties and greater biostability.
The use of high-magnesium alloys and low-magnesium alloys is increasing, especially in the automotive industry, because of the excellent strength-to-weight ratio of this material.
Due to this trend, other related metalworking coolants have been introduced. Magnesium is an active metal that releases hydrogen when it comes into contact with water, which can cause fire or explosion. Therefore, the coolant used in the processing of magnesium alloys is prohibited from occurring in such a reaction, which should be given sufficient attention.
Coolant and grinding
Automakers are willing to spend millions of dollars on grinding machines, but they are reluctant to invest in ducts and cutting fluids, which is not uncommon in the current grinding industry.
In the grinding process, the coolant plays a special role, which not only plays a decisive role in the quality of the product, but also has a great influence on the processing cost. The power consumed by the grinding wheel spindle motor is mainly distributed in the aspects of grinding wheel drive, grinding and coolant transfer. The heat generated by the workpiece during grinding must be cooled immediately to prevent local temperature overshoot and material phase transitions due to further heating. Phase transitions tend to cause residual stress and white layer formation, reducing the fatigue life of the material, causing cracks on the surface and subsurface of the material.
The use of cooling and lubricating fluids, as well as the selection of appropriate process parameters, minimizes the heat generated by the grinding surface and removes most of the heat generated by the grinding wheel, chips and coolant to achieve the cooling of the production process.
The delivery pressure, flow rate, temperature and flow direction of the coolant have a great influence on the quality and economy of the production process. The pressure control fluid flow rate, flow rate and temperature control the heat transfer rate of the liquid, and the flow direction can cause the liquid to clear the air barrier moving around the grinding wheel. The injected liquid must be aligned with the grinding zone in front of the grinding wheel to open a passage for the circulation of air.
The amount of coolant flow depends on the grinding wheel used, and the heat generated by the spindle power consumed during the grinding process needs to be cooled. In many cases, the time spent on the coolant nozzle and the liquid pump/filter design tends to be close to the machine's run time. In other cases, machine tool builders offer flexible nozzle systems based on flexible plastic nozzles or small diameter curved metal tubes, especially for tool grinders and aerospace products. The injection pressure of the coolant should match the rotation speed of the grinding wheel, generally between 0.4 and 0.2 kPa. While plastic nozzles can only be moved or shunted at much lower pressures, open small diameter tubes can even be retracted back due to the reaction force of the jet force and are therefore unsuitable for application. Other problems associated with the nozzle include high-pressure jet cracking problems, high-pressure surge flow in the front of the outlet, extreme proximity to the grinding wheel, and proximity to the target by trial and error.
A wide range of tests have been conducted for the combination of a circular nozzle with a coherent jet and a high degree of configurability. In a recent case study, the customer used mineral oil as a coolant to grind the blade root shape of the turbine blade and found the following advantages:
- The service life of the grinding wheel is doubled, and the glassy CBN content is increased by 25% after each dressing;
- Reduce the inference power and further improve the machining accuracy;
- Eliminates abrasive burns and grinding cracks;
- After laser aiming, the setting speed is increased;
- Reduced energy consumption of the liquid pump and cooling unit;
- The degree of adjustability of the nozzle to different machined parts is increased.
Strategic measures should be taken for the application of the coolant, that is to say, only the coolant can be used where it is needed, which should be energy efficient and economical. An excellent engineering product should have various degrees of adjustability to reduce setup time.
And the coolant selected should meet the processing needs and cost and production benefits. Direct oil products, such as mineral oils, synthetic oils, etc. generally have high lubricating properties, while water-soluble emulsion type coolants such as synthetic water-soluble emulsions, semi-synthetic water-soluble emulsions and oil/water mixed emulsions are the best. Coolant.
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