Cutting sludge recovery case 1 / Cutting fluid lifespan doubled, defect rate reduced by 20%
The magnetic separator method creates a difference in "sludge recovery capability" / The lifespan of cutting fluid in machining centers for castings is doubled!
Installed 90 units in 5 years! It has become an invaluable presence that is now indispensable. It greatly contributes to reducing product defect rates and extending the lifespan of cutting fluids. ◇ Introduction Background 〇 Traditionally, a drum filter conveyor was used for machining castings. 〇 Since the chips generated during casting machining are fine and contain a large amount of carbon, troubles due to high-pressure pump and nozzle clogging occurred frequently. 〇 Additionally, using coolant with poor filtration accuracy on the workpieces led to defects due to scratches, among other issues. ◆ Implementation Effects ● As a result of a two-month test, the lifespan of the cutting fluid was doubled, and the defect rate was reduced by 20%, yielding astonishing results. ● The units were quickly installed in existing machining centers, and now 90 machining centers are equipped with them. ● The discharged sludge is mostly dry, and even after six years of use, its condition has not changed.
basic information
◆ Standard (Fine Particle) Type (K/F) ◆ Cutting Secondary Filtration and Shaving Processing Compatible Type (KS/FS) ◆ High Filtration Precision Type (KD/FD) ◆ High Filtration Precision / Cutting Secondary Filtration and Shaving Processing Compatible Type (KSD/FSD) ◆ High Flow Rate Processing Type (K/F) (Details) ◇ Secondary Filtration Type (KS/KSD) - Recovers over 90% (by weight) of the mud-like sludge generated in large quantities during cast machining, which is below 100μ. ◇ Shaving Processing Compatible Type (KS/KSD) - Reduces chip entrapment in the squeezing roller through P rollers and specially arranged magnetic drums. - Significantly reduces the amount of cutting oil used by decreasing oil carryover.
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Applications/Examples of results
◆ Coolant Treatment for "Grinding Processing" 1. Significant improvement in the recovery of grinding sludge from accumulated deposits in the grinding tank. 2. The in-house coolant purification system combined with fine magnets reduces machine burden and improves yield rates. 3. The burden of troublesome maintenance tasks is greatly reduced, contributing to ECO. 4. The lifespan of the magnetic drum in grinding processing is increased, and operational costs are drastically reduced. 5. Maintenance such as coolant liquid replacement and cleaning in grinding processing is significantly reduced. ◆ Coolant Treatment for "Cutting Processing" 1. The lifespan of cutting fluid in casting machining centers is doubled. 2. Sludge accumulation in the coolant tank of machining centers is drastically reduced. 3. Secondary filtration in cutting processing contributes to the recovery of particulate sludge. ◆ Coolant Treatment for "Shaving Processing" 1. Zero degreasing in shaving processing contributes to extending pump lifespan.
