Case Study: An Alternative to Dry Machining
Occasionally a milling operation comes along that cannot be done using coolants to dissipate the heat. Such is an operation at a machine shop in New Miami, Ohio. They have a job using 4140 steel with a 35 Rc rating. The inserts are so hard that coolants are not recommended because they can cause cracking. The operation is set up at a speed of 1350 rpm with a 5 inch per minute feed rate. The 2 inch cutter has three inserts.
The customer requires the end product to be mirror finished. Any discoloration from the heat results in a scrap product. For this reason, the inserts must be replaced after every eight pieces. At $8.00 per insert plus the operators time to replace the spent units, another method of machining had to be found.
Qualiturn contacted AiRTX Ltd., The Air research Technology Company. They recommended the Stainless Steel Model 60040 that converts normal shop air into a sub-zero air stream and provides instant spot cooling. AiRTX manufactures the only Stainless Steel cooler on the market which is very practical over aluminum units in hot areas with high speed chips involved.
Using the Model 60040, Qualiturn, was able to increase production by 400% before changing the inserts. According to Mike Barber, owner of Qualiturn Machining Center, "the AiRTX Model 60040 at $275.00 was paid for during the first hour's run of products".
Compact, reliable, and maintenance free, the Stainless Steel Model 60040 provides a simple, clean, and coolant free solution to many machining operations. Just plug into a standard compressed air line (80-90 psi), aim the flexible 12" nozzle, and let it go to work. The magnetic base holds the Model 60040 in place on the machine. The same sub-zero air is available regardless of the position of the Model 60040.
In addition to dry machining, the Stainless Steel Model 60040 can improve drilling, grinding, or tapping operations. Also cooling motors, parts, processors, and mold are easily achieved to increase production. You can even use the cold air to shrink shafts and the hot air for expanding a bearing's trace for easy fits in pressing bearings onto shafts.