Cutting Fluid Alternatives - Productivity Engineering Applications

 Lesson 107 of Industrial Engineering ONLINE Course.

Refer to Industrial Engineering Case Studies Collection for case studies and productivity engineering applications

Lesson 108. Machining Cutting Temperatures Reduction - Productivity Engineering and Optimization

Increasing productivity of each and every input is to be attempted by industrial engineers.

Process Improvement - Productivity Analysis and Productivity Engineering.

Industrial engineer analyzes each process into its ultimate, simple elements, and compares each of these simplest steps or processes with an ideal or perfect condition and modifies the element appropriately. - F.W. Taylor - Hugo Diemer.

Prof. Hugo Diemer  - Taylor's Industrial Engineering

https://nraoiekc.blogspot.com/2020/05/prof-hugo-diemer-taylors-industrial.html

Sources for Productivity Engineering Information

Product information from engineering firms.

Information from productivity and engineering consultants.

Published Literature.

• Trade magazine.
• Web sites, Blogs, Social Media: LinkedIn, FaceBook, Twitter
• Videos, Podcasts, Webinars

Company visits

Training Programs

Productivity Improvement Using Through-Tool High Pressure Coolant

2020

Burr Oak Tool in Sturgis, MI with 300+ employees and 420,000 ft2 in 3 production facilities,  supplies special machines and tooling to virtually every user of air conditioner evaporator condenser coils in over 70 countries around the world.

Over the years the company sought to continuously refine their processes to reduce cost and increase productivity. In the mid 1980s they began using through tool high pressure coolant delivery on their high speed steel drills.

They purchased first LNS ChipBLASTER in 1994 to use higher pressures. They found that these units performed significantly better, lasted longer and required less maintenance. The LNS ChipBLASTERs allowed the company  to run 1,000 PSI coolant on all  machines with coolant filtration levels of one micron. This combination has cut down machining time  to turn hours into minutes and minutes into seconds when machining steel and aluminum parts. They currently have 60 LNS ChipBLASTER high pressure systems in use.”

They built special flow gauges that mounted on the spindle or mill tool holder to measure precisely how many gallons per minute they needed to deliver to maintain the optimum cutting parameters.

They determined that their CAT 40 machines required 13 GPM and the CAT 50 machines needed 21 GPM to achieve more consistent pressure and cooling, so LNS ChipBLASTER changed the pumps accordingly. By delivering the precise amount of flow and pressure, Burr Oak Tool saw improved tool life and faster throughput.

One example of the benefits of through-tool high pressure coolant at Burr Oak Tool is a stripper plate for a die that requires 3,200 holes drilled into 34 RC 4140 steel The holes are 1mm in diameter and 6 mm deep.  Originally, this process involved a solid drill –  and typically produced a number of broken drills – and lots of pecking. Using the LNS ChipBLASTER to deliver high pressure coolant through a single drill enables  machining  all 3,200 holes with no pecking. This coolant method combined with using a speed head cut production time from 6 – 8 hours down to 40 minutes.

Because applications like this one require drilling very small holes, The LNS ChipBLASTER units are equipped with 1 micron filters that eliminate tiny particles that could clog the small tools.

What is the benefit of  through-tool high pressure coolant delivery?  With the right equipment, like the LNS ChipBLASTER systems, we can cut steel like it’s aluminum and aluminum like it’s wood.” Explains CEO Newell Franks II.

https://lns-northamerica.com/how-one-cnc-shop-embraced-through-tool-high-pressure-coolant-before-it-was-cool/

https://www.mmsonline.com/blog/post/how-one-cnc-machine-shop-embraced-through-tool-high-pressure-coolant-

https://nraoiekc.blogspot.com/2020/06/productivity-improvement-using-through.html

Case Study 40 of  Industrial Engineering ONLINE Course

USE of SECO CAPTOTM JETSTREAM TOOLING® TURNING TOOL

CV-JOINT Machining 

Material: Carbon Steel (SMG 4)

Coolant: Water soluble oil (coolant pressure = 80 bar)

Operation: O.D. turning

Criterion: Chipbreaking control

Fixturing: Hydraulic clamping chuck

Tool: C5-PGLNL-35060-12JET (Seco-Capto™ Jetstream Tooling®)

Insert 1: CNMG120412-MR7, TP2500

Cutting Data:

 
                   vc                       f                       ap
Metric 220 m/min 0.50 mm/rev 3 mm
Inch  720 sf/min  0.020"/rev 0.118"

Results:

Tool life = 40 min.
25% increase to tool life with higher chipbreaking efficiency.

https://www.secotools.com/article/89201?language=en

Job is described in this document
https://www.secotools.com/article/88902

1 - Roughing the outer diameter
Your Challenge:   
Maintaining efficiency through effective chipbreaking when roughing the outer diameter.

Solution:   Jetstream Tooling delivers a high-pressure jet of coolant to the optimum position close to the cutting edge. In addition to eliminating heat build up, this lifts the chip away from the rake face to increase chip control and maximize tool life. Cutting parameters can also be further increased by using ISO/ANSI Duratomic® inserts. Benefits delivered include increased process reliability and productivity

Product:   Seco-CaptoTM Jetstream Tooling Turning Tool

https://www.youtube.com/watch?v=A5GFCyAtK2s

https://nraoiekc.blogspot.com/2020/06/seco-jetstream-tooling-benefit-case.html

Alternative Techniques for Reducing the Use of  Cutting Fluids

International Journal for Research in Engineering Application & Management (IJREAM) 

ISSN : 2494-9150 Vol-02, Issue 03, June 2016.

https://www.ijream.org/papers/IJREAMV02I031512.pdf

Ud 12.9.2022, 4.9.2021

Pub  17.9.2020