‘Near dry’ machining cools things down, including costs

Related Vendors

HASCO Hasenclever GmbH + Co KG

Renishaw plc

ACT Limited Advanced Carbide Tooling Ltd.

Saving costs by lowering coolant volume

Standard consumption for a milling operation is approximately 10ml (two teaspoons) per nozzle per hour. Four teaspoons of liquid is said to be used for each hour of cutting time.

With such low volumes of oil being needed, thus reducing costs, the unit also improves tool life and surface finish quality, increasing health and safety issues, benefitting manufacturers that machine high-value materials and generate considerable amounts of swarf, the supplier explained. It also said swarf remains dry, which improves chip evacuation with compressed air lines. The rapid removal of swarf from the work envelope enhances tool life and prevents chip re-cutting. Additionally, end users get better prices for their swarf scrap that is not contaminated by cutting oil.

This system is popular in the aerospace industry, where material value and swarf generation is high. BAE Systems first used it at its ship and submarine pipe shops, where the guttering effect of using flood coolant during the sawing of pipes resulted in messy operations. The unit’s use in other applications followed this successful implementation. In the machining of wing ribs, where 80% of the material is turned into swarf, Micro Lube eradicated chips being trapped in the pockets, the company explained.

To meet industry demands, ACT said the unit comes with options tailored to customer requirements. Among them are actuators, offered in air-actuated form or with a choice of three solenoid voltages or, alternately, with manual or remote toggle switches or even with a foot pedal. Moreover, oil reservoirs are available in 1/3, 1, 2 or 3-litre sizes, with the option of a float level indicator and delivery hoses being reinforced or braided for tougher applications.

The supplier noted that for oil to reach its target, hoses come in standard 3m lengths with options up to 15m, while end nozzles are offered from 150 to 750mm in copper or steel or as a horseshoe form for bandsaw applications. Nozzles and applicators are available with magnetic or fixed clamping options, so users can rapidly adjust spray as required, it added.

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