In metal cutting and metalworking companies, the use of coolant is a very common thing. However, it also brings certain problems to industrial enterprises. For example, the cost of machine tool cooling and lubrication equipment can reach a few percent of the investment in machine tool procurement; it increases the environmental protection tax, industrial pollutants and sewage charges that enterprises have to pay. These all increase the additional cost of machine tools. If the coolant is not handled properly, it will increase environmental pollution and damage personal health. Therefore, in recent years, the voice and desire to use dry cooling lubrication has become stronger and stronger. But so far, a variety of dry cooling lubrication techniques can not improve the quality of the cutting surface while improving the life of the tool. The best alternative to dry cooling lubrication is the minimum amount of cooling lubrication, referred to as MMKS.
Air/oil fusion cooling
This process of spraying air and lubricating oil to the cooling point of action is very reliable and convincing in numerous cooling lubrication methods. This technology has been successfully applied in the milling and turning of aluminum alloys, non-ferrous alloys, low-alloy carburized steels and tool steels. Oelheld, a coolant manufacturer, is involved in a number of research and project developments to tap into the larger applications of MMKS's minimum cooling and lubrication.
One of the R&D projects they participated in was the replacement of a large number of cooled stainless steel drilling technology projects with minimal cooling technology, which is a very difficult to cut metal material. For this high-alloy X90CrMoV18 stainless steel material (18% chromium, 1.3% molybdenum, 0.12% vanadium), the use of minimal cooling technology is indeed a demanding project. This high-alloy steel has excellent corrosion resistance and is suitable for making highly wear-resistant parts such as rolling bearings or materials for surgical instruments. When processing such a metal material, the heat generated by the drilling process and conducted to the acute angle of the orifice is a problem that must be solved. Insufficient cooling can cause the drilling tool to wear quickly, and the plastic deformation of the cutting edge of the bit will eventually cause it to lose its cutting ability. Typically, the minimum amount of cooling lubrication system's cooling lubricant is made from mineral oil, lubricating esters and synthetic oils. The minimum amount of cooling lubricant produced by this base material has little effect in the minimum amount of cooling lubrication, and even with different additives, the durability of the tool at high flow cooling lubrication is not achieved.
In the processing of this material, the shape of the swarf is aggravated due to the insufficient cooling lubrication, and the chip breaking performance is deteriorated due to the high temperature and large deformation of the swarf. Therefore, it is necessary to optimize and optimize the drill bit used in terms of its geometry, size, substrate and surface coating material. The best result of the durability of the drill tool is achieved by using a TiAlN/MoS2 coating material in combination with a microcrystalline carbide drill bit with improved micro-geometry.
Optimized building block lubrication system
To find the most suitable minimum amount of cooling lubricant, Oelheld's researchers used a reliable building block product development system. That is, it is first optimized by the active additive. To this end, R&D engineers have worked on five basic active additive groups:
Abrasion protection additive (AW): Avoids tool wear by reacting with a deformable metal surface coating material.
High Pressure Resistant Additive (EP): Reduces micro-wear between the tool and the surface of the metal being cut at high pressures and temperatures.
Additives (FM) that reduce the coefficient of friction: reduce the coefficient of friction of the metal-contacting surfaces and reduce the heat load.
Oxidation inhibitor: prevents the cooling lubricant from solidifying due to oxidation and deoxygenation to form an acidic substance.
Preservative: Prevents the ingress of acid and oxygen by a protective film formed on the surface of the metal to form a water repellent layer or to constitute a basic pH value in a water-soluble cooling lubrication system.
Finally, R&D engineers chose a water-soluble organic salt as the basis. Its high water content is very important, and a series of experiments have been carried out to prove that the less the amount of additives used in water, the better the wear resistance of the tool. At this point, it can be said that there is really a minimum amount of cooling lubrication for stainless steel materials. After the water in the coolant evaporates, what remains on the surface of the tool is a highly adherent salt film that is beneficial for friction reduction.
Oelheld's developers have further refined the performance of this organic salt solution. The first is to add AW anti-wear protection agent, and then add EP high pressure additives. At this point, the tool life of the minimum amount of cooling lubrication is increased by 60% compared to the durability of the stainless steel drill bit at high flow cooling lubrication.
The best cooling lubrication for improved tool life can also be cooled with minimal cooling when machining high alloy steels.
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