Pinpoint cooling jet lubrication

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“However, process design is costlier,” the Grob CEO explains, “because some machining sequences must be observed due to the heat input.” With MQL, it is necessary to consider the heat input by the process and by environmental conditions, and to view the temperature compensation measures at the machines.

High-pressure cooling in demand

In Powertrain applications, Grob identifies a shift toward MQL machining. Due to European energy conservation requirements, MQL technology is increasingly used in Europe. “There are some global companies that have made MQL machining the standard,” says Nahl. “Asian companies produce almost entirely with emulsion, and it's a similar picture in South America.” In Powertrain, he estimates flooding cooling having a 60% share, with MQL at 35%.

The so-called high-pressure cooling is in increasing demand. In this method, the chip area is not simply flooded with coolant. Instead, the cooling lubricant is fed targeted and with high pressure between chip and tool blade. “If cooling lubricants are indispensable, high-pressure cooling, coupled with a precisely aligned supply, is certainly beneficial,” judges Sandvik Manager Christoffel. “Consequently, this is where we see the largest increases.” He also points out that high pressure is not synonymous with high volume. Volume flows in high-pressure cooling may be quite low.

Haas has also registered an increasing trend toward high-pressure internal cooling. “Customers increasingly recognise the higher efficiency of this option,” says Managing Director Thing. For lathing applications, Horn CTO Kannwischer estimates that about 20% of the machines have high-pressure systems with 80 bar. “Manufacturers increasingly provide new machines with 80 bar through the turret, so therefore there is a rising trend here. Higher pressures with 150 bar are so far used only selectively for special applications.”

Cryogenic cooling at the beginning of implementation

An approach for production without any use of cooling lubricants is dry machining, which utilises either restricted cooling air or does without any cooling at all. Haas offers two such solutions: With external automatic compressed air supply, a constant compressed air flow is targeted on the cutter to blow away the chips. Alternatively, air can also be fed in through the spindle. In this case, the airflow is directed with high pressure and high flow volume through the tool onto the cutting edge.

Cryogenic cooling, with either nitrogen or carbon dioxide, has been discussed for several years now. Currently leading is a CO2-concept developed in a technology partnership by Walter AG and the Starrag Group. However, despite the enormous advantages – depending on the application, companies speak of productivity increases of up to 70% and service life increases up to 100% - there is still no end customer using cryogenic cooling in mass production. “We are currently at the beginning of the implementation phase,” says Thomas Schaarschmidt, Segment Manager Energy Business & Application Development at Walter AG.

(ID:43609786)

Cutting tools

Pinpoint cooling jet lubrication

High-pressure cooling in demand

Cryogenic cooling at the beginning of implementation