Machine tool fluids

Machine tool fluids are usually valuable enough to need recycling, and so they must be cleaned before re-use. This is also true of many industrial wastes, that the liquid, once cleaned, or the separated solids, once dewatered (and. perhaps, washed) can be recycled profitably. However, the main bulk of waste slurries have to be dewatered in order that the suspending liquid can be discharged to a river or lake without polluting it, and the solids can be sent for final disposal in as small a bulk and as safe a condition as possible. 

The design of coolant filters and separators for machine tool fluids is an extremely complex and varied subject. Some of the general aspects that have to be considered before a preliminary appraisal can be made are ... 

Most induction ac motors are fixed-speed. However, a large number of motor applications would benefit if the motor speed could be adjusted to match process requirements. Motor speed controls are the devices which, when properly applied, can tap most of the potential energy savings in motor systems. Motor speed controls are particularly attractive in applications where there is variable fluid flow. In many centrifugal pump, fan, and compressor applications mechanical power grows roughly with the cube of the fluid flow. To move 80 percent of the nominal flow only half of the power is required. Centrifugal loads are therefore excellent candidates for motor speed control. Other loads that may benefit from the use of motor speed controls include conveyers, traction drives, winders, machine tools and robotics. 

This chapter examines the need for lubrication and the types of lubricant available. Various applications are considered, including engines gears, hydraulic equipment, machine tools, metal cutting and working fluids, compressors, turbines and electrical oils. The care of lubricants on-site, application of planned lubrication and inclusion within overall maintenance management are examined. 

Some of the recently developed high-performance EP soluble oils have a cutting performance that almost matches that of additive-type neat oils, and they are particularly suitable for demanding operations in machine tools whose design allows the use of water-based fluids. 

Two factors militate against the universal use of water-based fluids. Very severe machining operations call for a lubrication performance that is beyond the capacity of such fluids, and the design of some machine tools means that water cannot be used because of the risk of cross-contamination with machine lubricants. In these instances, neat cutting oil is the only fluid that can provide the required performance. 

Industrial lubrication Machine tools and metal cutting Lubricants for heavy industry Gear lubrication Hydraulic fluids Machine shop lubricants Cutting fluids Compressor lubrication Greases... 

With the implementation of CAD/CAM technology, it is possible to produce prototypes direcily based on a virtual model. The generation of the geometry using RP processes takes place quickly without the requirement of molds and machine tools. The main feature of the process is the formation of the workpiece. Rather than the conventional manufacturing process of a clamped workpiece and material removal techniques, RP processes entaU the layering of a fluid or powder in phases to form a solid shape. 

Process outputs are the effect variables. They can be measured at the workpiece (deviations in dimension, shape and position, microgeometry, physical influence on the surface zone), at the tool (wear), at the machine tool (temperature rise, wear), and in the cutting fluids (temperature rise, contamination, and chemical properties). They can be used to describe the effects of the process. From the process interactions and the... 

Several factors directly or indirectly influence the surface finish of machined parts, such as cutting conditions, tool geometry, work material, machine accuracy, chatter or vibration of the machine tool, cutting fluid, and chip formation. The objective of this research was to investigate the effects of major input parameters on the surface finish of parts produced by dry turning and to optimize the input parameters. From a user s point of view, cutting parameters—cutting speed, feed rate, and depth of cut—are the three major controllable variables as such they were selected as input parameters. 

Particularly, it is expected from (iv) above that panels work effectively to prevent thermal deformation and exciting Aubration on machine tools. In this connection, for example, there have not been any concrete countermeasures developed, although thermal deformation on the whole machine tool structure is produced by the thermal diffusion from motors and the heat generation from machining etc. Temperature distribution control of a part or a whole structure and control to prevent thermal deformation are possible by being able to have a panel fluid flow. 

Metalworking fluids contain mineral oils (refer to p. 80) or synthetic lubricants they are used neat or in admixture with water. They may contain small amounts of biocides, stabilizers, emulsifiers, coiTosion inhibitors, fragrances and extreme pressure additives. The formulations render them suitable for application to metal being worked, generally from a recirculatory system, to provide lubrication, corrosion protection, swarf removal and cooling of the tool and machined surface. 

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