As part of the Global Manufacturing Festival FMS were invited to present at the Advances in Machining Conference hosted at the AMRC Training Centre by the Manufacturing Technologies Association.
Steve Thompson, Technical Director at FMS, focussed his presentation on "Filtration in High Performance Machining Applications" and the impact of typical fluid delivery systems supplied with machine tools, which are based on settlement tank principles, relying on the fine particles produced during the cutting process and tramp oils to be retained within the sump tank.
The aim of the presentation was to raise awareness of what is happening at the rear of the machine tool by highlighting the risk contaminants remaining in the fluid have on what is trying to be achieved at the front of the machine and the impact these traditional filtration systems have on increasing the overall cost per part.
As part of the presentation a video was shown of AMRC apprentices 'dumping a sump', not only were metal particles distributed throughout the sump and around the external coolant flood and wash pumps, which we all see as 'sump sludge', but the 70 bar filter bag showed how the particles and tramp oil were not retained but rather passed through to delivery through the spindle. This is a prime cause of tool failure, wear and component surface quality defects.
The presentation highlighted that as machine tool performance demands increase the traditional sump side methods of checking concentration, pH and bug growth only really focus on health and safety aspects of fluid use and not performance. Whilst these are important they do not provide process control measures to maximize cutting tool performance. FMS are developing technology to bridge this process control and management gap.
There are already examples where the machining of emerging materials in aerospace applications require production be stopped and sumps dumped after only a few weeks of use due to component surface quality defects.
FMS questioned if value for money was obtained by installing ancillary equipment such as tramp oil separators. Is the problem of tramp oil resolved by installing a tramp oil separator? A separator only removes the free oil already floating in its immediate vicinity, whilst tramp oil in the transition phase will return to the cutting zone. FMS warned that if the inside of the machine tool is oily or blue smoke comes from the cut then tramp oil is circulating within the fluid stream.
The issues highlighted in the presentation are typical in all traditional OEM supplied machine tool filtration systems and are common occurrences across all mill/turn and grinding platforms, however, they are generally accepted as normal consequences of production. FMS explained the root cause of typical failure modes can be attributed to contamination retained within the fluid stream and presented a solution to mitigate these risks and impacts.
IFDR precision filtration solutions and A-I Conveyor systems are a proven step change in technical capability and operational reliability to efficiently remove particles and tramp oil out and away from the cutting fluid before it returns to the cutting zone.
The A-I conveyor will recover swarf and chips to 150 micron as standard and with the addition of a drum filter down to 50 micron. This maximizes the metal recycled through traditional routes.
IFDR Precision Filtration Solutions recover the finer particles to below 10 micron, removing tramp oil and mitigating the risks and impacts from traditional filtration systems. IFDR Solutions are supplied either as a retrofit to existing machine tools or as part of a new turnkey installation and have proven their worth in many applications on equipment from leading machine tool manufacturers including Mazak, Mori Seiki and Hermle.
With increasing demands on machining performance the important message of the presentation was to: "Consider the fluid delivery and swarf recovery systems equally as important as the machine tool". If you settle for the traditional systems supplied with the machine tools the same recurring cost impacts will continue.
The full presentation with Improved Productivity Studies and Turn-key installation examples can be viewed at https://www.youtube.com/watch?v=OzmrD6VUtQ4&feature=em-upload_owner
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