The biggest benefit of the minimum amount of lubrication for the internal cooling tool is “green†because it is very environmentally friendly and helps to create more profit for the business.
Minimum Quantity Lubrication (MQL) cutting (ie near dry cutting) is a win-win processing mode that significantly reduces coolant usage, associated equipment and energy costs, coolant droplets that are emitted into the air, and irritates the skin of operators. Possibility, at the same time, it can potentially increase productivity and workpiece processing quality. This is a common feature of the external liquid supply MQL and the internal cooling tool MQL that will be discussed in this paper.
Unlike conventional cooling methods, where a large amount of coolant is poured at the tool/workpiece interface, the internal cooling tool MQL is an aerosol formed by compressed air and lubricant (usually vegetable oil, lubricating ester or alcohol, etc.) through the machine tool spindle and the inside of the tool. The coolant passage is accurately injected from the cooling orifice outlet onto the cutting edge of the tool. Kevin Howes, North American sales manager for Bielomatik, which produces the MQL liquid supply system, said that about 90% of these optimized dosing lubricants are consumed during cutting, and the remaining 10% are mostly taken away by the chips. There is very little (or no) residue on the workpiece. He added that the amount of lubricant used in the MQL system is about 10-150 ml/h (0.003-0.04 gph), compared to 132 gph or higher for wet cutting with 5% emulsion.
It is generally accepted that the conversion from wet cutting to near dry machining can reduce the processing costs associated with coolant by 10%-17%. Howes said, "Some people say they don't spend that much on the coolant, but they don't consider all the other costs. They only consider the cost of the coolant itself."
Other costs include filtration systems and media, sumps, recirculating chillers, high pressure infusion sets, centrifugal or chip briquetting machines for removing coolant from chips, and bactericides. In addition, Howes said that when building a "green factory" using MQL technology, there is no longer a need to specifically reinforce the foundation for supporting a heavy coolant filtration system. "They only need to pour a flat floor of a certain thickness for the MQL machine. ."
Some parts manufacturers may say that their cast coolant will be reused after filtration, but this does not mean that all coolant in the system will not be lost. Howes said, “Customers told me that the amount of coolant lost is incredibly large, especially on older machines.†This loss is caused by evaporation and leakage, as well as being sucked out by the oil mist collector during cutting. According to end-user estimates, in a production environment, the amount of coolant lost per part is 1/2 to 1 gallon. “If you process 250,000 parts per year, you can lose 250,000 gallons of coolant.â€
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