The technology available to create near dry CNC machining operations can drive down manufacturing costs and is better for the environment.

It is estimated that on large scale production sites cooling lubricant can make up nearly 20% of the total manufacturing cost. Indeed, the cost of purchasing, maintaining and disposing of cutting fluids is a significant factor when evaluating a machine’s operating costs.

A typical ‘wet’ machine may use 10 to 10,000 litres/hour of lubricant depending on application and whilst much is recycled, losses due to natural wastage as aerosol spray into the atmosphere and adherence to swarf, can amount to between three and 15 litres/hour.

With Bielomatik’s Minimal Quantity Lubrication (MQL) system oil consumption can be reduced significantly to between 100 and 150 ml/hour, the company claims. Apart from reducing the amount of lubricant used, any machine shop that switches to MQL can benefit from easier disposal of metal cuttings since they are virtually oil-free. Additional benefits include improved machine performance and productivity.

Another important feature that allows near dry machining is the elimination of coolant carryover in component pockets aiding faster processing times between operations.

Traditional beliefs indicate that totally dry cutting, as compared to flood cutting, lowers the required cutting force and power on the part of the machine tool as a result of increased cutting temperature. Unfortunately achievable tool life and part finish often suffer under completely dry conditions and also the permissible feed and depth of cut have to be restricted.

According to Bielomatik, use of its MQL system delivers precise measured quantities of lubricant to the cutting tip – offering significant beneficial financial gains. Also, in hard turning applications, use of an MQL system can lead to reduced tool wear even at reasonable power/feed levels providing the MQL parameters can be strategically tuned. With MQL manufacturing costs can be reduced by up to 15% without detriment to the quality of the finished component.

Recognition of the financial and environmental benefits of MQL systems means that nowadays new machine builds often come complete with MQL technology. Although retrofitting an MQL system to an older machine has traditionally been problematic and costly, the latest single channel MQL system from Bielomatik is said to overcome most of the difficulties, enabling existing machining operations to be converted to MQL and thus enjoy all the inherent benefits.

For companies interested in switching to MQL technology Bielomatik is able to provide a test rig allowing users to judge for themselves the environmental and cost savings to be made.

Bielomatik
www.bielomatik.co.uk