Effectively and Efficiently Remove Chips and Debris from Blind Holes

I was recently contacted by an automotive parts manufacturer that was looking for a solution for cleaning out blind holes in a variety of machined parts. After discussing the application, we settled on a 1697SS-6-CS VariBlast Compact Safety Air Gun with Pico Nozzle, 6” Extension, and a Chip Shield. The small M5 nozzle at the tip of the gun allowed them to insert it inside of the hole and dislodge the hard-to-reach chips inside of the holes.

1697SS VariBlast Compact Safety Air Gun

This worked very well for removing the chips, but they were encountering an unexpected issue as these chips were now getting lodged in other areas of the part as they were ejected. They then had to visually inspect the entire part after each blowoff to ensure that everything was completely removed.

What they thought to be an ideal solution, ended up not being the best fit. They gave us a call back to inquire about an alternative solution. We offer another product, the Deep-Hole Vac-U-Gun, that is capable of both removing chips and debris from blind holes and also vacuuming it away simultaneously.

This addresses the problem of dislodged chips being caught elsewhere on the parts. Fortunately, EXAIR offers an unconditional 30-day guarantee for all stock products. They were able to return the previously purchased gun and apply the credit towards the purchase of the Deep Hole Vac-u-Gun system.

The Deep Hole Vac-u-Gun is a low-cost solution to quickly remove chips and contaminants from grooves, containers, and drilled holes. In applications where simply blowing the debris out of the hole isn’t suitable, simply position the Deep Hole Vac-u-Gun over the hole and press the trigger. A small blow tube (3) dislodges and lifts the chips while the large suction tube (5) vacuums them away. The operator is then protected from flying debris since the contaminants are then contained within the suction tube and directed into a filter bag or other container with the included vacuum hose.

Sometimes we don’t always get it right on the first try. But, with the ability to take advantage of the 30-day guarantee we’ll make sure to get the best product to you for your application. With same day shipments with orders received by 3:00 ET for stock products, EXAIR can get a solution out to you quickly!

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD

EXAIR Has a New Product: The Soft Grip Super Air Scraper

Scrape off, and blow away, stubborn debris with the Model 1244-48 Soft Grip Super Air Scraper.

EXAIR has designed a new nozzle called the Super Air Scraper.  This nozzle combines a scraping blade with our 2” Flat Super Air Nozzle.  It creates a mechanical force with a compressed air force to remove stubborn sticky material.  This patent-pending nozzle can be added to the EXAIR Soft Grip Air Gun to create a powerful scraping tool.

Let’s breakdown the nozzle.  The 2″ Super Air Scraper nozzle is a model 1144 which has a ¼” NPT female connection.  The model 1144-A includes a ¾ – 32 UN adaptor for connecting to the Soft Grip Safety Air Gun extensions.  The scraper can be changed when worn with a replacement blade; model 902007.  To add flexibility to the Super Air Scraper, a shim set, model 1132SS, can be used to modify the blowing force.  With these combinations, the nozzle complements the scraper as an effective way to clean with compressed air.

Soft Grip Super Air Scraper

To get pressurized air to the nozzle, EXAIR attached the 1144-A Super Air Scraper nozzle to the Soft Grip Safety Air Gun.  This gives a comfortable and ergonomic way to use and operate this product.  We offer different extensions for hard-to-reach applications ranging from 6” (152mm) to 72” (1,829mm) in length.  With the extensions that are 36” (914mm) and longer, EXAIR installed an additional foam grip sleeve.  This gives additional leverage for scraping material at a distance like floor level.  Chip Shields are also offered to prevent blow-back onto the operator.  You can view the details of the new product at this link on our website: Soft Grip Super Air Scraper.

To give some ideas for applications, the Soft Grip Super Air Scraper can be used for removing tape, gasket material, caulk, adhesive, paint, labels, and more.  With the addition of air, the detached material is blown away during scraping, keeping the area clean to target the remaining “stuck” material.  If gummy or flaky substances are a nuisance for workers, the Soft Grip Super Air Scraper can keep the machine or work station clean and operational.

Just like all cataloged items for EXAIR, we stock these parts for same day shipment with orders placed before 3 p.m. EST.  We offer a 30-day unconditional guarantee to allow you to see how great this product can work in your application.  If you have a sticky, flakey, or greasy substance that needs to be removed, the Soft Grip Safety Air Scraper is up to the challenge.  If you have any questions about the product or your “gummy” situation, you can contact an Application Engineer for help.

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

Product Overview: Back Blow Safety Air Guns

BackBlowNozzle

EXAIR’s highly engineered and efficient Back Blow Nozzle’s provide a powerful 360° airflow through an array of holes to remove coolant, chips or debris.  Back Blow Nozzle’s are the perfect solution for cleaning out the inside of any pipe, tube, hose or channels.

They are available in three different sizes:

M4 X .5 BB Nozzle

.25 NPT BB

1 NPT BB

The Back Blow Nozzle’s are also offered on the VariBlast, Soft GripHeavy Duty, and Super Blast Safety Air Guns.  They can be configured with different length extensions (up to 72″) to make nearly any cleaning job within reach!   We recommend the optional Chip Shield since the air stream is carrying the debris back towards the operator.

1604SS-6-CS-lftangle
Variblast Safety Air Gun 1604SS-6-CS, Includes 1004SS Back Blow Nozzle With 6″ Extension and Chip Shield. The 1604SS Is Offered In 6″, 12″, 24″ and 36″ Lengths.

1204SS-6-CS
Soft Grip Safety Air Gun 1204SS-6-CS, Includes 1004SS Back Blow Nozzle With 6″ Extension and Chip Shield.  The 1204SS Is Offered In 6″, 12″, 24″ and 36″ Lengths.

1206SS-6-CS559
Soft Grip Safety Air Gun 1206SS-6-CS, Includes 1006SS Back Blow Nozzle With 6″ Extension and Chip Shield.  The 1206SS Is Offered In 12″, 18″, 24″, 36″, 48″, 60″ & 72″ Lengths.

1306SS-6-CS
Heavy Duty Safety Air Gun 1306SS-6-CS, Includes 1006SS Back Blow Nozzle With 6″ Extension and Chip Shield.  The 1306SS Is Offered In 12″, 18″, 24″, 36″, 48″, 60″ & 72″ Lengths.

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Super Blast Safety Air Gun 1219SS, Includes 1008SS Back Blow Nozzle With 1′ Extension.  The 1219SS Is Offered In 1′, 3′ & 6′ Lengths.

Take it from me EXAIR’s Safety Air Guns fitted with a  Back Blow Nozzles are a must have for any operation that needs to remove debris from pipes, tubes or hose!

If you would like to discuss Safety Air Guns with Back Blow Nozzles or any of our quiet and efficient compressed air devices, I would enjoy hearing from you…give me a call.

Steve Harrison
Application Engineer
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Video blog : VariBlast Compact Safety Air Gun

The following short video is a brief overview of our VariBlast Compact Safety Air Gun. The VariBlast Compact Safety Air Gun’s unique design features a variable flow trigger allowing you to achieve varying levels of force from the same nozzle.

If you have any questions, please  contact an application engineer at 800-903-9247.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

Back Blow Air Nozzles Clean Inside Diameters

They say time flies when you’re having fun. Maybe that’s why I found it a little hard to believe it’s been almost two years since we introduced the Back Blow Air Nozzles. They’ve become yet another “textbook” solution to a great many applications:

*Model 1004SS M4 Back Blow Air Nozzles are used to dry the inside of a closed cylinder after a zinc bonding process.  They’re also fitted to Model 1204SS-12-CS M4 Back Blow Safety Air Gun to remove chips & cutting fluid from freshly cut pipe ends.

*Our Model 1006SS 1/4 NPT Back Blow Air Nozzle won Plant Engineering Magazine’s “Product Of The Year” Bronze Award in 2015, and are successfully employed in a wide range of uses:

  • Blowing out splined bores by a gear manufacturer
  • Quickly cleaning out spindles between tool changes by a CNC machinery operator
  • Removing the last bits of powder from spent toner cartridges by a printing equipment recycler

*The Model 1008SS 1 NPT Back Blow Air Nozzle is becoming famous in hydraulic cylinder repair shops…after a cylinder bore is honed, one quick pass of the powerful blast it produces cleans bores from 2″ to 16″.  We can even put it on the Model 1219SS Super Blast Back Blow Safety Air Gun, with a 1ft, 3ft, or 6ft extension.

EXAIR Back Blow Air Nozzles come in three sizes, for bores from 1/4″ to 16″ in diameter!

If you want to see how they work, check out this video:

I could have sworn Lee Evans just made that video, but apparently, it’s over a year old now.  Time does indeed fly, and I promise we’re having fun!  If you’d like to find out more about how a Back Blow Air Nozzle – or any of our engineered compressed air products (old or new) – can make your operations quieter, more efficient (and hence, probably, more fun,) give me a call.

Russ Bowman
Application Engineer
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Proper Supply Line Size And Fittings Provide Peak Performance

Many times when we provide the air consumption of an EXAIR product, we get a response like…. “I’ve got plenty of pressure, we run at around 100 PSIG”. While having the correct pressure available is important, it doesn’t make up for the volume requirement or SCFM (Standard Cubic Feet per Minute) needed to maintain that pressure. We commonly reference trying to supply water to a fire hose with a garden hose, it is the same principle, in regards to compressed air.

When looking to maintain an efficient compressed air system, it’s important that you use properly sized supply lines and fittings to  support the air demand (SCFM) of the point-of-use device. The smaller the ID and the longer the length of run, it becomes more difficult for the air to travel through the system. Undersized supply lines or piping can sometimes be the biggest culprit in a compressed air system as they can lead to severe pressure drops or the loss of pressure from the compressor to the end use product.

Take for example our 18″ Super Air Knife. A 18″ Super Air Knife will consume 52.2 SCFM at 80 PSIG. We recommend using 1/2″ Schedule 40 pipe up to 10′ or 3/4″ pipe up to 50′. The reason you need to increase the pipe size after 10′ of run is that 1/2″ pipe can flow close to 100 SCFM up to 10′ but for a 50′ length it can only flow 42 SCFM. On the other hand, 3/4″ pipe is able to flow 100 SCFM up to 50′ so this will allow you to carry the volume needed to the inlet of the knife, without losing pressure through the line.

Pipe size chart for the Super Air Knife

We also explain how performance can be negatively affected by improper plumbing in the following short video:

 

Another problem area is using restrictive fittings, like quick disconnects. While this may be useful with common everyday pneumatic tools, like an impact wrench or nail gun, they can severely limit the volumetric flow to a device requiring more air , like a longer length air knife.

1/4″ Quick Connect

For example, looking at the above 1/4″ quick disconnect, the ID of the fitting is much smaller than the NPT connection size. In this case, it is measuring close to .192″. If you were using a device like our Super Air Knife that features 1/4″ FNPT inlets, even though you are providing the correct thread size, the small inside diameter of the quick disconnect causes too much of a restriction for the volume (SCFM) required to properly support the knife, resulting in a pressure drop through the line, reducing the overall performance.

If you have any questions about compressed air applications or supply lines, please contact one of our application engineers for assistance.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

EXAIR Heavy Duty Safety Air Gun Reduces Noise Level and Saves Air!

IMG-20170719-WA0014
Inside of the customer’s fin press

Just this week I’ve been working with an aerospace manufacturer that had some concerns about a cleaning operation on one of their fin press machines used for a stamping process. After each operation, they need to blow out the dies to remove any residual oil and debris. They were currently using a ¼” open copper tubing operating at 90 psi. Their reason for contacting EXAIR was due to a recent OSHA compliance training that their production manager had attended. He learned about OSHA 1910.242(b), a directive that we’ve written about many times in the past, that states compressed air devices used for blowoff must maintain a dead-end pressure less than 30 psi. Additionally, the sound levels were far too high to adhere to OSHA directive 29 CFR 1910.95(a). This was a major concern for them and a common theme that we hear from many of our customers. As this manufacturer is clearly aware, fines associated with failing to comply to OSHA directives can be quite costly. Their failure to adhere to this and a few other directives led to a total penalty of $33,800.00.

1360_csbox
EXAIR’s Heavy Duty Safety Air Gun with Chip Shield

After some discussion about the different types of solutions that EXAIR has to offer, we settled on the Model 1310-18-CS. At a sound level of just 74 dBA when operated at 80 psi, we were able to drastically improve upon the sound levels that he was previously experiencing. This was a very welcomed solution by his operators, as they were now able to clean out the dies without having to wear any hearing protection. The Chip Shield also added some additional protection so that no debris could come back towards the operator. In addition to addressing his sound level concerns, we were also able to save a substantial amount of compressed air. The 1310-18-CS will consume just 14 SCFM of compressed air at 80 psi. A ¼” pipe operated at this pressure will consume approximately 69 SCFM. This is an 80% reduction in compressed air usage for just one operation!!

If you have an application where sound level needs to be reduced or you’re looking to improve upon employee safety, EXAIR has the solution. Give us a call today to find out how we can implement a solution to keep OSHA inspectors at bay.

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@exair.com
Twitter: @EXAIR_TD