Cold Gun Replaces Inefficient and Ineffective Open Pipe

In any machining operation, tool wear is an inevitability. Cutting tools heat up due to friction and this heat contributes to premature tool wear. As tooling wears, poor tolerances and dimensional inaccuracy are common. Additionally, as the cutting edge dulls increased cutting force is required which further increases the amount of heat generated and exacerbates the problem.

Coolants can be used to reduce friction and help mitigate some of the wear, but then you’re left with the mess that coolant brings along with it both on the part and in the machine itself. What if I were to tell you that there’s a way to mimic the effects of coolant, but without all of the mess? All of this can be achieved with a supply of compressed air and one of EXAIR’s Cold Gun Systems.

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I recently worked with a metalworking company on replacing several open-pipe blowoffs on their CNC machines with EXAIR Cold Guns. The open pipes were not effective at keeping the tooling cool, but did a decent job of blowing away chips. Premature tool wear was leading to increased downtime and slowing production as they were frequently having to replace the tooling. Not to mention, these blowoffs were extremely loud and forced anyone on the shop floor to be wearing in-ear and over-the-ear hearing protection.

Each of their CNC machines had one open-line coolant hose or similarly sized open tube blowing compressed air onto the tool. Temperatures in the facility get fairly warm in the summer and this was having little to no impact. They didn’t want to deal with the mess that comes along with coolant, so they looked to EXAIR for a solution. They ended up installing (1) 5215 Single Point Cold Gun System for trial on one of their machines.

Immediately they noticed the reduction in sound as the Cold Gun operates at just 70 dBA, but they also noticed a 20% reduction in tool wear compared to the open-air lines after a short time in operation. It didn’t entirely eliminate the need for hearing protection as there are other processes occurring, but it did lower it to a point that they weren’t forced to use both in-ear and over-the-ear protection.

EXAIR’s Cold Gun was a Product of the Year finalist in 2007. Using only a source of compressed air, the Cold Gun and High Power Cold Gun produces a stream of clean, cold air 50° (28°C) below your compressed air supply temperature. The Cold Gun is very quiet at only 70dBA and has no moving parts to wear out. Just supply it with clean, dry compressed air and its maintenance free!

The Cold Gun has been preset to achieve maximum refrigeration. This prevents the Cold Gun from freezing up during use and optimizes the gun’s cooling capacity. The Cold Gun is an ideal alternative to messy and expensive coolant mist systems. It eliminates the cost of purchase and disposal of cutting fluids as well as worker related health problems from breathing airborne coolant or slipping on wet floors. Replacing a coolant-based system also eliminates the need for secondary cleaning operations after milling or drilling.

If you have an application that you believe would be better served by the use of an EXAIR Cold Gun, give us a call.

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

 

EXAIR Mini Cooler Overview

I recently had a chat conversation with a customer who was looking to cool the tooling on his CNC router, mill and lathe in his small machine shop. As the day went on the tooling would begin to heat up, it would warp the bit, causing irregularities in the finished product. In some cases the tooling was getting so hot, it would actually break, creating a safety concern.

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Model 3925 Adjustable Spot Cooler System has a Dual Outlet Hose Kit for distribution of cold air flow to two points.

He had reviewed some of our cooling products and was thinking of using our Cold Gun in the application but was concerned with the air demand. The Cold Gun consumes 15 SCFM @ 100 PSIG and provides a 50°F temperature drop (from supply temperature) with 1,000 Btu/hr. of cooling capacity. The problem was that his compressor only produces a little over 9 SCFM. I explained that the existing compressor would in fact be undersized as it doesn’t produce enough volume to keep up with the demand of the Cold Gun.

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EXAIR Mini cooler with dual and single outlets

Due to the limited amount of compressed air available, our Mini Cooler System, Model #3808, would be the better solution. The Mini Cooler also provides a 50°F temperature drop with a little less cooling power, 550 Btu/hr., but this system only requires 8 SCFM @ 100 PSIG, falling within the existing compressor’s output capacity. The Mini Cooler also includes a magnetic base as well as flexible tubing to direct the cold air to the desired location, making it easy to move from machine to machine.

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EXAIR Mini Cooler with dual Points

For U.S. and Canadian customers, EXAIR offers a 30-day unconditional guarantee to try.

If you want to learn more about the EXAIR Mini Cooler or any cooling product, you can contact an Application Engineer.  We will be happy to help you.

Jordan Shouse
Application Engineer

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A Cold Winter’s Chill and Vortex Tubes

Two weekends ago I had the pleasure of flying out to meet my friend in Colorado Springs and ski the weekend at Breckenridge. As an avid skier Breckenridge has been one of the resorts I have been wanting to ski since I started skiing out west. The weather was amazing and I couldn’t ask for better; the Saturday blue skies and cool breeze followed up by a Sunday of snow fall. The Trip was a dream come true. Breckenridge is specifically known for having high winds that howl across the peaks that stand at a max of 12,998 ft. above sea level. These chilling winds would freeze just about anyone if you aren’t dressed prepared for them as they blow right in your face on the lift. As I was sitting on the lift with these cold winds blowing in my face it brought to mind EXAIR’s Vortex Tubes, Cold Guns, and Cabinet Coolers.

EXAIR’s Vortex Tubes and similar products provide everything from a cool blast of air to a frigid breeze to cool off various parts and products. In a lot of smaller milling and grinding applications the Cold Gun has been used as a replacement to costly coolant-based alternatives. Vortex tubes have been used in cooling applications since 1945 and assist in everything from stress testing electronics to cooling down plastic parts during ultrasonic welding.

 Vortex tubes use a source of compressed air to create a hot and cold stream of air coming out on opposite ends of the device. This means that not only can the vortex tube be used for cooling but also heating applications. In one case a vortex tube was used to heat up an adhesive before it was sealed to get a better adhesion. Although the vortex tube can be used for heating purposes those applications are few and far between as usually a heating element or other heating source is more applicable.
Vortex tubes are quickly adjustable, just as the winds of Breckenridge can change from being a breeze to almost blowing you off of the mountain. Weather in the mountains is always varying and so are EXAIR’s Vortex Tubes.

If you have any questions or want more information on how we use our vortex tubes to improve processes all over industry. Give us a call, we have a team of application engineers ready to answer your questions and recommend a solution for your applications.

Cody Biehle
Application Engineer
EXAIR Corporation
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Georges J Ranque: Father of the Vortex Tube

Georges J. Ranque is known as the inventor and father of the Ranque-Hilsch Vortex tube. The vortex tube is device that takes a compressed gas and generates hot and cold streams from a source of compressed gas. George accidentally discovered the phenomenon on accident while studying physics at Ecole Polytechnique in Paris France. Ranque was looking was performing an experiment on a vortex-based pump to vacuum up iron fittings; during the experiment he noticed that warm air was being expelled out of one side and cold air out of the other when he inserted a cone into one end of the vortex. In 1931 Ranque filed for a patent for the vortex tube and two years later presented a paper on it.

Georges vortex tube was all but lost and forgot about until 1945 when the German physicist Rudolph Hilsch published a paper on the device. This paper became widely read and exposed the vortex tube to the industrial manufacturing environment. This paper revived what was thought to be lost and led the vortex tube into what we see today.

How an EXAIR Vortex Tube operates

During World War 2 Georges Ranque started to develop different steels that would be used in military aviation efforts. He later went on to work at Aubert et Duval Steelworks as the Director of Metallurgical Laboratory. While at Duval he would continue to developing alloys for the aviation industry.

Interestingly, in 1972 he went on to publish a book on the search for the Philosophers Stone, a mythological chemical substance that Alchemist’s thought could be used to turn base metals into Gold. The following year in 1973 he passed away in his home just outside of Paris.

Here at EXAIR we have expanded the uses of Ranque’s original vortex tubes for various different cooling uses. The vortex tube can be found in our Cold Guns, Spot Coolers, and Cabinet Coolers. In many cases EXAIR’s spot coolers and cold guns have been used to replace coolant in simple milling and grinding applications. Also, EXAIR’s Cabinet Coolers have been keeping control cabinets from overheating for many decades. 

If you have any questions or want more information on how we use our vortex tubes to improve processes all over industry. Give us a call, we have a team of application engineers ready to answer your questions and recommend a solution for your applications.

Cody Biehle
Application Engineer
EXAIR Corporation
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