A few days ago, a netizen left a message to inquire about the purification of cutting fluid: Each processing equipment in our factory is equipped with a cutting fluid filter, why are there still so many problems? I feel that the purification effect is average, which affects the processing quality of the workpiece. If it is not cleaned for a long time, it will emit a rancid smell. We have to clean it regularly, which is time-consuming and laborious. Is there a problem with our choice of purification equipment, or is there a problem with the cutting fluid itself? Is there a better way?

It happened that the editor just visited a large automobile parts group in Anqing City. The group specializes in the production of automobile piston rings, valve guides, seat rings and other automobile engine parts. It is the largest production base of such products in the world. I saw the company's cutting fluid purification system in the workshop, and took this opportunity to consult the person in charge of the company about the experience of cutting fluid purification.

The person in charge of the company introduced that at first they did not have much experience in cutting fluid purification, which was very similar to the above netizen's introduction. Most of the production lines are composed of special grinders. Each machine tool is equipped with an independent cutting fluid sedimentation water tank, or equipped with a rubber roller magnetic separator, and some are equipped with flat mesh paper belt filters, etc.
 

Factory appearance before transformation

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Many problems arise in this situation. During the production process, workpiece grinding chips, grinding wheel dust, guide rail lubricating oil, etc. will enter the coolant tank, and then deposit in the dead corner of the tank, and floating oil will float on the surface of the cutting fluid in the tank. This leads to low filtering accuracy of the cutting fluid, affecting the quality of the workpiece and increasing the scrap rate; deposited impurities will make the cutting fluid easy to deteriorate, and floating oil will cause anaerobic bacteria to breed and accelerate the deterioration of the cutting fluid, emitting a rancid odor.

At the same time, high-temperature grinding will cause a large amount of cutting fluid to evaporate. In the form of flow processing, each workpiece will adhere to a certain amount of cutting fluid, so the concentration in the cutting fluid tank of each machine tool will change and the volume will decrease. This leads to changes in the performance of the cutting fluid, affecting the processing quality of the workpiece and increasing the scrap rate; sometimes there is a sudden lack of fluid, resulting in burns on the workpiece and causing scrap. Because the high temperature in the processing area will gradually be transmitted to the cutting fluid tank, the water tank that cannot be closed will emit a special smell of the cutting fluid, and the steam mixed with oil and water will also condense on the surface of the machine tool and inside the workshop. Pollute the working environment and reduce the grade of the enterprise. Later, the machine tool operators were required to clean the coolant tank regularly, but different operators and different processes had different cleaning levels, which wasted working hours and could not ensure the consistency of various indicators of the cutting fluid.

It was very troublesome at the time, and I was a little crazy!

Later, after research and consultation, the company visited many professional cutting fluid purification companies and finally decided to use a centralized filtration system. The company selected Yantai Keeyun Machinery Co., LTD.! The first centralized filtration system was put into use in 2014.

The appearance of the factory after the transformation

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The independent cutting fluid tank of each grinder is completely removed, and equipped with a dirty liquid lifting tank and an impurity conveying pump. The bottom of the lifting tank is a spherical surface. The impurity pump is very powerful and can convey chips the size of beer bottle caps, so the dirty liquid and deposited grinding chips in the liquid tank can be conveyed out and transported to the centralized filtration system along the closed pipeline.

 Dirty liquid lifting tank

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Closed conveying pipeline

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The centralized filtration system adopts a combination of sedimentation scraper conveyor and negative pressure paper belt filter. The former can remove a large number of large particles of sediment, and the latter can filter a large number of fine mixed impurities 100% through the filter cloth and filter cake formed by the filter layer for repeated filtration, so that the cutting fluid can reach the precision that fully meets the processing requirements.
 

Sedimentation scraper conveyor and negative pressure paper belt filter

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The clean cutting fluid after filtration is supplied to each machine tool at a constant pressure through the variable frequency pump group. The liquid supply pipeline is first the main pipeline and then the branch pipeline according to the layout of the production line. In order to match the opening rate of the machine tool group, variable frequency liquid supply is used to ensure constant pressure liquid supply to prevent water flow fluctuations from affecting processing.

Constant pressure liquid supply system

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In the filtration system, there is an automatic cutting fluid proportioning device, which can replenish the cutting fluid of the concentration required by the process at any time, and the production line will not be short of fluid.
 

Automatic liquid proportioning device

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In the filtration system, there is an oil removal device to collect all the oil spilled on the production line.

Oil removal device

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Oil removal effect diagram

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In the filtration system, a cooling system is also equipped, which can be turned on in high temperatures in summer to control the temperature of the cutting fluid and prevent the workpiece from exceeding the tolerance due to excessive temperature and increasing the scrap rate.

Filtration system equipped with refrigeration unit

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After the first set was put into use, the product quality of this company in Anqing was significantly improved, and the on-site environment was rapidly improved. Therefore, many companies in the group followed their example. Since 2014, the companies of the group have continuously purchased 6 sets of different types of cutting fluid purification equipment systems from Qi Yang Company.

The appearance of the site after the transformation

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Another form of filtration system

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The editor later learned that cutting fluid purification is a relatively systematic work, and different solutions need to be made according to the different situations of their own enterprises. According to the person in charge, the six systems selected by the company are all different, and each time they communicate in detail with Qi Yang Company, and each solution is a new challenge. A new plant of a subsidiary of the group is under construction. Now the technical staff of Qi Yang Company has entered the plant and discussed the next purification system solution with the technical staff of the plant. This is another new challenge!

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