Machining technology Efficiency by Optimising Coolant Supply
Coolants, used in production for such tasks as boring, turning or grinding, can reduce friction by lubricating. Likewise, their cooling effect aims to dissipate heat. In addition, they remove cuttings by a rinsing action and thus raise tool service lifetimes. Regardless of whether the need is for a high machining rate, where the rinsing and cooling effects are especially important, or for light machining, high powers, long service lifetimes or excellent surfaces, the manufacturers of coolants offer different products for the most varied applications.
New cutting and grinding oils, based on the latest generation of oil products, have been developed by such firms as the Oemeta Chemische Werke GmbH in Uetersen. In the gas-to-liquid (GTL) process, very pure synthetic basic oils are derived from natural gas; they are free of organic nitrogen, heavy metals, and compounds of zinc and chlorine.
Process security of GTL oils proved
These so-called oemetols display a very high flashpoint and very low volatility. “This provides good worker protection with minimal product consumption. The better lubrication and improved foaming behaviour of GTL compared to conventional mineral or hydro-cracking oils reduce wear and enhance process security,” we hear.
The process security of GTL oils is apparently further underlined by diverse approvals by firms in the automobile and components industry and by machine builders. “Our GTL oils are non-cytotoxic to EN ISO 10993-5:2009. An essential precondition for use in implants in the medical sector is good biocompatibility. Ideally, both the working materials and the processing media here should be biocompatible.”
High lubricating performance reduces wear
The firm’s formaldehyde-free coolants are entirely free of formaldehyde-emitting depot substances, which are often used in conventional water-soluble coolants as biocides. In the meantime, free formaldehyde has been officially categorised as a health hazard. “Formaldehyde-free products have been shown to have better human compatibility. With these, high product stability leads to long service lifetimes. The use of these practice-tested products is therefore recommended for future- secure machining,” explains the manufacturer.
Cutting and grinding oils of the Hycut family are based on synthetic ester oils. These provide extremely good lubrication and result therefore, according to Oemeta, in significantly reduced tool wear. The use of synthetic saturated ester oils, according to the firm, leads to high ageing-resistance and therefore long running times. At the same time, the good cleaning performance of these synthetic oils means clean machines and components and, in the case of grinding, an exceptionally good material removal rate.
One coolant system for the whole production
“These multifunctional products can be used as processing oils, coolants or cleaners. They are mutually compatible and therefore enable, for example, intermediate cleaning to be omitted,” says the firm in describing the advantages. Because of the broad range of applications and flexibility of Hycut, whole production areas can be supplied by only one coolant system. An advantage: after processing with one Hycut oil, the next stage can continue using a Hycut emulsion without any intermediate washing. Oil infiltrations, such as those from the machine bed ways, improve the lubrication performance rather than contaminating the emulsion.
The special point about Hycut as an emulsion is said to be the possibility of separate management of oil and additives to enable perfect adaptation to different requirements in process, material and lubrication. Targeted re-dosaging of individual components is possible throughout the entire service lifetime of the emulsion. Such customers as Audi, BMW and Volkswagen, according to Oemeta, rely on the Hycut system.
These and other products, as well as various services, will be presented by Oemeta at the EMO in Hannover.
All-round service for coolants
To ensure that modern coolants work as efficiently and cost-effectively as possible, regular checks and adequate maintenance work are recommended.
This provides numerous advantages:
- avoidance of machine downtimes;
- raised process security;
- longer coolant lifetimes and therefore reduced purchasing and disposal costs;
- improved tools service lifetimes and component quality;
- optimisation of human and environmental compatibility, as well as
- the documentation and analysis of consumption data.
For all of these, Oemeta offers service concepts tailored to the individual firm. A building-set system provides the most varied adaptation options, enabling everything from simple monitoring or laboratory measurement to complete coolant management.
Collaboration between manufacturers of coolants and machines
An optimised coolant supply works best where there is close collaboration between the manufacturers of coolant and machine, as in the following example: Since 2018, Oemeta has been providing technical support for applications in the four Mazak technology centres in Göppingen, Düsseldorf, Munich and Leipzig, and also at fairs. Oemeta’s careful control and monitoring of the products involved enables cooling and lubrication in machining processes to be optimised for Mazak customers even before the machines leave the works. The aim is an optimum interplay of machine, tool and cooling technology. In addition, customers can receive comprehensive support and advice regarding problems or coolants for special requirements. Possible topics include filtration and recycling of coolants, or achieving stable processes and long service lifetimes for these fluids.