Extraction of Emulsion Mist from various CNC machine tools using central Extraction - 2 Pages

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Extraction of Emulsion Mist from various CNC machine tools using central Extraction

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EXTRACTION OF EMULSION MIST FROM VARIOUS CNC MACHINE TOOLS USING CENTRAL EXTRACTION Mauersberger und Fritzsche is an SME with a long tradition in gear manufacturing for drive technology and in the production of high-quality structural steel cupped shears. The company has CNC machining and milling centres from renowned manufacturers, such as Monforts, Doosan, Yang and Mori Seiki, in which workpieces are cooled, purged and lubricated with water-soluble cooling lubricants (emulsions). The task, which the corporate management adressed to UAS, was to improve the air climate in the hall using a filter system. Solution CNC machining and milling centres and CNC lathes are cutting machine tools, i.e. a workpiece is shaped by means of material removal using tools such as borers, cutters, lathes. The term “lathe” was originally derived from the workpiece being rotated on a spindle (of an axis). Today’s “centres” have several axes, in which tools and workpieces move. Workpiece and tool changers supplement the systems so that complex geometries can be produced on one machine tool. The “CNC” in the name is derived from Computer Numeric Control, which means that production processes can be programmed and the programmes stored in the memory of the machine. Ergo, repetitive production procedures only need to be called up. There is the tendency to automate heavily and to minimise interventions by the operator. Today’s high-speed processing requires the introduction of cooling lubricants. These are used to cool the cutting edges on the direct contact surface to the workpiece during the cutting procedure, to lubricate the contact surface and remove any arising chippings through “purging”. Through the rotation and energy input, the cooling lubricant forms an aerosol mist at this moment, which is extremely hazardous to health if inhaled. The company’s machinery comprises approx. 10 machine tools. For this reason, the advantages and disadvantages of single-station extraction units were weighed up against a central extraction system. The advantages of a central extraction system prevailed in this project. On balance, the investment costs are lower despite higher costs for piping and assembly, while maintenance is concentrated on a central point. In addition, a summer/winter set-up as hall ventilation can be realised easily with this concept, which permits exhaust air operation in the summer and a recirculated air operation in the winter to save heating costs. In general, it is not possible to give one blanket answer to the question about single-station extraction units or central extraction systems. This must be decided on the facts of the relevant plant. However, as a general rule, the overall or life cycle costs of a central system with a ventilation system performance from 6,000m³/h tend to be lower. In this case, a two-staged electrostatic filter is used as filter, which reliably filters out harmful substances and emulsion mist, such as aerosols, and offers the client an approx. 15% reserve for production expansions. The client was initially sceptical towards the electrostatic filter solutions as the rumour is still spreading through the market that “emul- Client: Mauersberger und Fritsche E X T R AC T ION OF EMULSION MIS T F ROM VARIOUS CNC MACHINE T OOLS USING CEN T R AL E X T R AC T ION

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EXTRACTION OF EMULSION MIST FROM VARIOUS CNC MACHINE TOOLS USING CENTRAL EXTRACTION However, thousands (!) of installed UAS electrostatic filter systems have proven the opposite over the last decades: even oil and emulsion mists can be filtered with outstanding results if you have 35 years of knowledge like UAS. Knowledge, which can also be seen, for example, in the piping used for raw (polluted) gas, as this should be made of longitudinally welded steel and be oil-tight on the flange connections. “Cheaper” folded spiral-seam pipes are reputed to save costs but, according to UAS experience,...

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