The work performed on tool room machines is prototype or short run jobs and there is rarely the opportunity to optimize tooling, feeds or speeds. The machine and cutting tools must be able to absorb punishment from processes that are much less refined than can be achieved on longer runs using automated machines. Over the years there has been a continuous evolution in metalworking tool room equipment capabilities, with the exception being coolant-lubricant options.
Equipping manual or CNC-enabled open machining platforms such as knee-mills, bed-mills, drills, tool grinders and lathes with flooded coolant systems leaves the tool room equipment, operators and floors awash. When flooding is not possible or desired, this leaves air-oil or air-only lubricating and cooling options. However these near-dry and dry machining fluid options are very limiting, in particular for hard machining applications and work requiring only dry machining and producing lots of tool heat.
Portable and adaptable dry and near-dry CO2 composite spray machining fluid technology offers the tool room machinist with productivity and machining quality improvements as good as or better than those achieved with high pressure flooded coolants, but without the mess. CO2 composite sprays offer a unique set of cooling and lubricating capabilities to enable machining of harder, more abrasive materials and using more capable and expensive cutting tools. Cutting tools last longer and parts are machined cooler, quicker and cleaner with improved surface finishes. Tool room machines, floors and air stay clean.
David Jackson serves as the Chief Technology Officer for Cool Clean Technologies, Inc, based in Eagan, MN.
Tuesday, January 6, 2009
Dimensional grinding using composite CO2 machining fluids
During dimensional machining of a polymer-coated precision valve spool, a Norton 80 grit grinding wheel generates temperatures of up to 450 degrees F. A traditional coolant-lubricant approach requires interrupted processing to provide substrate dimensional control due to thermal expansion, in particular the polymer-metal interface.
A composite CO2 machining fluid spray (Air, MQL-Soy oil and carbon dioxide particles) directed into the grinding zone is able to maintain substrate temperatures to under 90 degrees F. Efficient removal of excess heat with minimal oil lubrication during precision grinding allows the machining operation to proceed to completion in a single and continuous step with reduced cycle time and improved dimensional stability.
An additional benefit of using this unique machining fluid technology with precision grinding includes a potential for significantly reducing wheel dressing intervals. In this particular application a 50% increase in parts production was realized between wheel dressing intervals.
David Jackson serves as the Chief Technology Officer for Cool Clean Technologies, Inc, based in Eagan, MN. He may be reached via e-mail at david.jackson@coolclean.com.
A composite CO2 machining fluid spray (Air, MQL-Soy oil and carbon dioxide particles) directed into the grinding zone is able to maintain substrate temperatures to under 90 degrees F. Efficient removal of excess heat with minimal oil lubrication during precision grinding allows the machining operation to proceed to completion in a single and continuous step with reduced cycle time and improved dimensional stability.
An additional benefit of using this unique machining fluid technology with precision grinding includes a potential for significantly reducing wheel dressing intervals. In this particular application a 50% increase in parts production was realized between wheel dressing intervals.
David Jackson serves as the Chief Technology Officer for Cool Clean Technologies, Inc, based in Eagan, MN. He may be reached via e-mail at david.jackson@coolclean.com.
CO2 Composite Spray Machining: An Introduction (Part 2)
In the previous blog, CO2 composite spray technology was introduced with a focus on basic components and operational characteristics of a spray system. This blog completes the introduction with a description of various performance aspects of a CO2 composite spray and includes initial laboratory test results for this new machining fluid technology.
Managing Heat
A CO2 composite spray manages machining heat through both physical (thermal transfer) and chemical (i.e., Rehbinder) effects. Frictional heat generated at the cutting edge is eliminated indirectly using chip-tool-workpiece temperature control and directly through juvenile surface reactions using a suitable lubricant chemistry, including carbon dioxide itself. Efficient heat removal is achieved through adjustable heat capacity, phase change phenomenon and reactive chemistry within the spray.
Penetration and Sticking Power
For CO2 composite sprays of the second kind, the combination of sublimating solid coolant and subcooled lubricants (mass) with near-sonic air flow (velocity) creates significant surface penetration power (Force = mass x velocity), which allows the coolant and lubricant particles to penetrate deeply into cracks and crevices and intimately contact machining surfaces. Particle velocities of between 50 m/s and 300 m/s are easily obtained with CO2 composite sprays. Upon entering the cutting zone, the cooling lubricant spray provides chip cooling and chip evacuation during sublimation or evaporation of the CO2. During expansion, electrostatically-charged CO2 gas and lubricant uniformly coat and penetrate cutting interfaces. Compared to conventional high pressure flooding techniques, CO2 composite sprays operating at 120 psi can exert particle-fluid impact stresses of over 8,000 psi.
Cutting Performance
In standardized cutting tests (see Table 1 below) performed by an independent testing laboratory (TechSolve, Inc., Cincinnati, Ohio), it was demonstrated that CO2 composite sprays using a bio-based oil additive outperformed conventional flood processes using standards: synthetic oil, soluble oil, and semi-synthetic fluids with extreme pressure agents, in terms of both uniform tool wear and cutting force (see CO2 Composite Spray data line 1 in the cutting force figure below).
Hard Machining Advantages
CO2 composite sprays offer several technical advantages and opportunities for challenging machining applications involving superhard tools and hard or abrasive substrates. These include:
• Supercharge existing cutting fluid chemistries in minimum and bulk amounts with increased coolant power and cutting zone penetration
• Increase machining efficiency for harder and more abrasive materials
• Improve surface finish
• Test new advanced coolant-lubricant additives in minimum quantities on-the-fly without having to change-out coolant sumps
• Optimize challenging machining processes with customized combinations of coolant, lubricant and advanced cutting tool coatings such as PCD, CBN and coated HSS
Another advantage provided by CO2 composite sprays is that they are a very clean and lean technology. Implementing CO2 composite spray technology can reduce or eliminate the use of flood coolants. This conserves fossil fuels, water and energy, and eliminates (or reduces) the generation of nonproductive outputs, hazardous wastes, air emissions, wastewater, or other pollutants.
Wrap-Up
CO2 composite spray technology improves machining productivity while reducing operating costs and environmental pollution. CO2 composite spray technology can be implemented along side many older and newer machining and metalworking processes, including machinery, materials, methods, processes, cutting tools and fluids, augmenting a successful conversion to a clean and lean metalworking operation.
Future blog articles will focus on specific commercial machining applications and challenges which have been addressed with CO2 composite technology.
David Jackson serves as the Chief Technology Officer for Cool Clean Technologies, Inc, based in Eagan, MN. He may be reached via e-mail at david.jackson@coolclean.com.
In the previous blog, CO2 composite spray technology was introduced with a focus on basic components and operational characteristics of a spray system. This blog completes the introduction with a description of various performance aspects of a CO2 composite spray and includes initial laboratory test results for this new machining fluid technology.
Managing Heat
A CO2 composite spray manages machining heat through both physical (thermal transfer) and chemical (i.e., Rehbinder) effects. Frictional heat generated at the cutting edge is eliminated indirectly using chip-tool-workpiece temperature control and directly through juvenile surface reactions using a suitable lubricant chemistry, including carbon dioxide itself. Efficient heat removal is achieved through adjustable heat capacity, phase change phenomenon and reactive chemistry within the spray.
Penetration and Sticking Power
For CO2 composite sprays of the second kind, the combination of sublimating solid coolant and subcooled lubricants (mass) with near-sonic air flow (velocity) creates significant surface penetration power (Force = mass x velocity), which allows the coolant and lubricant particles to penetrate deeply into cracks and crevices and intimately contact machining surfaces. Particle velocities of between 50 m/s and 300 m/s are easily obtained with CO2 composite sprays. Upon entering the cutting zone, the cooling lubricant spray provides chip cooling and chip evacuation during sublimation or evaporation of the CO2. During expansion, electrostatically-charged CO2 gas and lubricant uniformly coat and penetrate cutting interfaces. Compared to conventional high pressure flooding techniques, CO2 composite sprays operating at 120 psi can exert particle-fluid impact stresses of over 8,000 psi.
Cutting Performance
In standardized cutting tests (see Table 1 below) performed by an independent testing laboratory (TechSolve, Inc., Cincinnati, Ohio), it was demonstrated that CO2 composite sprays using a bio-based oil additive outperformed conventional flood processes using standards: synthetic oil, soluble oil, and semi-synthetic fluids with extreme pressure agents, in terms of both uniform tool wear and cutting force (see CO2 Composite Spray data line 1 in the cutting force figure below).
Hard Machining Advantages
CO2 composite sprays offer several technical advantages and opportunities for challenging machining applications involving superhard tools and hard or abrasive substrates. These include:
· Supercharge existing cutting fluid chemistries in minimum and bulk amounts with increased coolant power and cutting zone penetration
· Increase machining efficiency for harder and more abrasive materials
· Improve surface finish
· Test new advanced coolant-lubricant additives in minimum quantities on-the-fly without having to change-out coolant sumps
· Optimize challenging machining processes with customized combinations of coolant, lubricant and advanced cutting tool coatings such as PCD, CBN and coated HSS
Another advantage provided by CO2 composite sprays is that they are a very clean and lean technology. Implementing CO2 composite spray technology can reduce or eliminate the use of flood coolants. This conserves fossil fuels, water and energy, and eliminates (or reduces) the generation of nonproductive outputs, hazardous wastes, air emissions, wastewater, or other pollutants.
Wrap-Up
CO2 composite spray technology improves machining productivity while reducing operating costs and environmental pollution. CO2 composite spray technology can be implemented along side many older and newer machining and metalworking processes, including machinery, materials, methods, processes, cutting tools and fluids, augmenting a successful conversion to a clean and lean metalworking operation.
David Jackson serves as the Chief Technology Officer for Cool Clean Technologies, Inc, based in Eagan, MN. He may be reached via e-mail at david.jackson@coolclean.com.
Managing Heat
A CO2 composite spray manages machining heat through both physical (thermal transfer) and chemical (i.e., Rehbinder) effects. Frictional heat generated at the cutting edge is eliminated indirectly using chip-tool-workpiece temperature control and directly through juvenile surface reactions using a suitable lubricant chemistry, including carbon dioxide itself. Efficient heat removal is achieved through adjustable heat capacity, phase change phenomenon and reactive chemistry within the spray.
Penetration and Sticking Power
For CO2 composite sprays of the second kind, the combination of sublimating solid coolant and subcooled lubricants (mass) with near-sonic air flow (velocity) creates significant surface penetration power (Force = mass x velocity), which allows the coolant and lubricant particles to penetrate deeply into cracks and crevices and intimately contact machining surfaces. Particle velocities of between 50 m/s and 300 m/s are easily obtained with CO2 composite sprays. Upon entering the cutting zone, the cooling lubricant spray provides chip cooling and chip evacuation during sublimation or evaporation of the CO2. During expansion, electrostatically-charged CO2 gas and lubricant uniformly coat and penetrate cutting interfaces. Compared to conventional high pressure flooding techniques, CO2 composite sprays operating at 120 psi can exert particle-fluid impact stresses of over 8,000 psi.
Cutting Performance
In standardized cutting tests (see Table 1 below) performed by an independent testing laboratory (TechSolve, Inc., Cincinnati, Ohio), it was demonstrated that CO2 composite sprays using a bio-based oil additive outperformed conventional flood processes using standards: synthetic oil, soluble oil, and semi-synthetic fluids with extreme pressure agents, in terms of both uniform tool wear and cutting force (see CO2 Composite Spray data line 1 in the cutting force figure below).
Hard Machining Advantages
CO2 composite sprays offer several technical advantages and opportunities for challenging machining applications involving superhard tools and hard or abrasive substrates. These include:
• Supercharge existing cutting fluid chemistries in minimum and bulk amounts with increased coolant power and cutting zone penetration
• Increase machining efficiency for harder and more abrasive materials
• Improve surface finish
• Test new advanced coolant-lubricant additives in minimum quantities on-the-fly without having to change-out coolant sumps
• Optimize challenging machining processes with customized combinations of coolant, lubricant and advanced cutting tool coatings such as PCD, CBN and coated HSS
Another advantage provided by CO2 composite sprays is that they are a very clean and lean technology. Implementing CO2 composite spray technology can reduce or eliminate the use of flood coolants. This conserves fossil fuels, water and energy, and eliminates (or reduces) the generation of nonproductive outputs, hazardous wastes, air emissions, wastewater, or other pollutants.
Wrap-Up
CO2 composite spray technology improves machining productivity while reducing operating costs and environmental pollution. CO2 composite spray technology can be implemented along side many older and newer machining and metalworking processes, including machinery, materials, methods, processes, cutting tools and fluids, augmenting a successful conversion to a clean and lean metalworking operation.
Future blog articles will focus on specific commercial machining applications and challenges which have been addressed with CO2 composite technology.
David Jackson serves as the Chief Technology Officer for Cool Clean Technologies, Inc, based in Eagan, MN. He may be reached via e-mail at david.jackson@coolclean.com.
In the previous blog, CO2 composite spray technology was introduced with a focus on basic components and operational characteristics of a spray system. This blog completes the introduction with a description of various performance aspects of a CO2 composite spray and includes initial laboratory test results for this new machining fluid technology.
Managing Heat
A CO2 composite spray manages machining heat through both physical (thermal transfer) and chemical (i.e., Rehbinder) effects. Frictional heat generated at the cutting edge is eliminated indirectly using chip-tool-workpiece temperature control and directly through juvenile surface reactions using a suitable lubricant chemistry, including carbon dioxide itself. Efficient heat removal is achieved through adjustable heat capacity, phase change phenomenon and reactive chemistry within the spray.
Penetration and Sticking Power
For CO2 composite sprays of the second kind, the combination of sublimating solid coolant and subcooled lubricants (mass) with near-sonic air flow (velocity) creates significant surface penetration power (Force = mass x velocity), which allows the coolant and lubricant particles to penetrate deeply into cracks and crevices and intimately contact machining surfaces. Particle velocities of between 50 m/s and 300 m/s are easily obtained with CO2 composite sprays. Upon entering the cutting zone, the cooling lubricant spray provides chip cooling and chip evacuation during sublimation or evaporation of the CO2. During expansion, electrostatically-charged CO2 gas and lubricant uniformly coat and penetrate cutting interfaces. Compared to conventional high pressure flooding techniques, CO2 composite sprays operating at 120 psi can exert particle-fluid impact stresses of over 8,000 psi.
Cutting Performance
In standardized cutting tests (see Table 1 below) performed by an independent testing laboratory (TechSolve, Inc., Cincinnati, Ohio), it was demonstrated that CO2 composite sprays using a bio-based oil additive outperformed conventional flood processes using standards: synthetic oil, soluble oil, and semi-synthetic fluids with extreme pressure agents, in terms of both uniform tool wear and cutting force (see CO2 Composite Spray data line 1 in the cutting force figure below).
Hard Machining Advantages
CO2 composite sprays offer several technical advantages and opportunities for challenging machining applications involving superhard tools and hard or abrasive substrates. These include:
· Supercharge existing cutting fluid chemistries in minimum and bulk amounts with increased coolant power and cutting zone penetration
· Increase machining efficiency for harder and more abrasive materials
· Improve surface finish
· Test new advanced coolant-lubricant additives in minimum quantities on-the-fly without having to change-out coolant sumps
· Optimize challenging machining processes with customized combinations of coolant, lubricant and advanced cutting tool coatings such as PCD, CBN and coated HSS
Another advantage provided by CO2 composite sprays is that they are a very clean and lean technology. Implementing CO2 composite spray technology can reduce or eliminate the use of flood coolants. This conserves fossil fuels, water and energy, and eliminates (or reduces) the generation of nonproductive outputs, hazardous wastes, air emissions, wastewater, or other pollutants.
Wrap-Up
CO2 composite spray technology improves machining productivity while reducing operating costs and environmental pollution. CO2 composite spray technology can be implemented along side many older and newer machining and metalworking processes, including machinery, materials, methods, processes, cutting tools and fluids, augmenting a successful conversion to a clean and lean metalworking operation.
David Jackson serves as the Chief Technology Officer for Cool Clean Technologies, Inc, based in Eagan, MN. He may be reached via e-mail at david.jackson@coolclean.com.
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