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Machine tool cutting fluid filtration purification

时间:2012-04-19 10:38

Grinding bearing machining processes have a direct impact on the accuracy of the finished bearing performance and service life, and processing of cooling liquid to prevent the workpiece burns, improve accuracy and roughness of the surface to improve the workpiece and the machine's antirust ability to extend the service life of cutting tools and machine tool has a very important role. Therefore, rational use and maintenance of grinding fluid in the bearing process is essential.

The role of a cutting fluid

In the process of bearing processing, wet processing, and can greatly improve the capacity and service life of cutting tool, to improve product accuracy, and reduce scrap. The main advantage of the wet machining with cutting fluid

1) lubrication: cutting fluid to lubricate the tool, improve tool cutting capacity;

2) The cooling effect: a certain flow of cutting fluid, cutting tropical walk, thereby reducing the temperature of the tool;

3) red crumbs role: chip solution can chip will be washed away, fall into the chip removal ditch to drain away the groove of BTA cutting fluid to hydraulic chip removal;

4) to improve the surface roughness: cutting fluid washed away by the processing surface of the iron filings, iron filings will not scratch the machined surface, thereby increasing the roughness;

5) reduction of corrosion: the appropriate choice of the cutting fluid can prevent the corrosion of the workpiece, Machine Tool;

2 cutting fluids reasonable use

Cutting fluid composition can be roughly divided into two major categories of oil-based cutting fluids and water based cutting fluid。 The oil-based cutting fluid such as superfinishing bearing plant used to add a small amount of machine oil to kerosene-based cutting fluid。 Oil-based cutting fluids generally contain solid impurities such as abrasive, chip processing site, the utility only need to separate out solid impurities can have access to clean cutting fluid, so the processing is relatively simple。 The other is water-based cutting fluid, subtle emulsion droplets highly fragmented distribution in the water emulsion, the emulsion also contains a variety of surface active agents and anti-rust agents additives。 Emulsion after processing site in addition to containing abrasive grains, chips and other solid impurities, but also easy to breed microorganisms。 Micro-organisms including bacteria, mold, fungi, etc。, these are the main factors affecting the quality of the emulsion, the normal bacterial content of the emulsion is not more than 1000 / mg, 10000 100 000 / mg when the bacterial content of the emulsion smelly black, the rapid decline of cooling and lubricating effect, issued by the unpleasant odor, corrosion of equipment, and even bacteria will filter blockage, then you must replace all emulsion and thoroughly clean the circulatory system。

3 the mechanism of bacteria breeding in the cutting fluid

Bacteria in the emulsion can be divided into pro-oxygen and anaerobic two categories. Where anaerobic bacteria is the culprit for the black-odor of the emulsion. Always contain a certain amount of dissolved oxygen in the emulsion, so there are always pro-oxygen bacteria growth and reproduction in this environment, consume dissolved oxygen in the emulsion, resulting in hypoxic water, then anaerobic bacteria will take the opportunity to multiply hyperplasia, anaerobic bacteria to organic components and salts in the emulsion as a nutrient, decomposition of ammonia, hydrogen sulfide and other unpleasant pungent gas, anaerobic decomposition of organic acid emulsion pH value decreased with iron reaction, the emulsion showing the gray and black, this process is quite fast in a certain temperature and certain miscellaneous quality of "dead water" environment, the purpose of the emulsion system is to try to delay this process.

Use and maintenance of the cutting fluid

4.1 configuration (dilution) the configuration of the cutting fluid is diluted with water by a certain percentage. Water-based cutting fluid emulsion when diluted to note the following:

1) water quality under normal circumstances should not use more than recommended hardness of the water, because of the high hardness of the water contains calcium and magnesium ions make the anionic surfactant failure, emulsion decomposition, the water-insoluble metal soap。 Even if the emulsion is made of non-ionic surfactants, metal ions can also be the micellar aggregation, thus affecting the stability of the emulsion。 Too soft water unfit for use, easy to produce large amounts of foam too soft emulsion of the water configuration during use。

2) diluted cutting fluid dilution related to the stability of the emulsion. Cutting fluid prior to use, should determine the dilution ratio and the required volume of the emulsion, and then calculate the liquid volume and quantity of cutting fluid. Dilution to select a clean container, all the necessary water into the container by adding the liquid and then mixing at low speed, configuration, the stock solution by adding speed does not appear not emulsified liquid prevail. Note the accession process of the liquid and water can not be reversed.

4.2 to maintain

To extend the life of the emulsion in addition to select the proper coolant quality and rational use of cutting fluid maintenance is also very important factors. The cutting fluid maintenance include the following:

⑴ to ensure the smooth flow of the liquid circulation line immediately removed the loop line of metal shavings, metal powder, mold mucus, cutting fluid decomposition, wheel gray, to avoid congestion。

⑵ antibacterial cutting fluid (emulsion) antibacterial growth is essential, the use of cutting fluid to regularly check the bacteria content in a timely manner to take corresponding measures。

⑶ purification in a timely manner to get rid of the metal powder such as chips and cutting fluid floating oil, eliminate bacteria environment.

⑷ inspected regularly cutting fluid pH values, there are significant changes in a timely manner to take corresponding measures.

⑸ timely additional cutting fluid, cutting fluid splash, atomization, evaporation, and processing materials and chip carrying the recycling process, will continue to consume, and therefore timely addition of new fluid to meet the total circulating fluid in the system unchanged.

(5) cutting fluid purification

The cutting fluid filtration and purification of the upcoming cutting fluid in a certain proportion of relatively large solid particles, the process of removal from the cutting fluid. After filtration and purification of the cutting fluid for machining to achieve the purpose of recycling. The main advantages of the cutting fluid filtration and purification in the following areas:

1) to extend the replacement cycle of the cutting fluid: According to the practice of my plants that can greatly lengthen the replacement cycle of the cutting fluid filtration and purification.

2) to improve the service life of cutting tools and grinding wheels: In recent years, studies have shown that in the cutting fluid impurities (such as debris, grinding wheels, powder, etc。) reduced from 40μm to 10μm, the tool (or wheel) can prolong life for 1 - three times。

3) improvement of the surface roughness, reduce scrap rates。

4) to extend the pipeline and pump service life, cutting fluid and solid particles chip will accelerate the wear of the pipes and pumps and other components。

6 cutting fluid filtration and purification of type

The filter can be roughly divided into the cutting fluid filtration and purification and separation of the two major categories, but the actual production often used in combination.

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