Tag: air coolant

Cold Gun Aircoolant Systems Eliminate Mist & Breathing Problems In Machine Shops

Published on by Russ BowmanLeave a comment

Some machine tool operations require flood coolant. Not only does the liquid remove heat of friction from the tool and the work piece, it also provides lubrication that the cutting of some materials require. For other machining operations, mist coolant removes heat, provides a measure of lubricity, and minimizes (to a degree) the volume of liquid used in a flood coolant application.

This high speed photograph illustrates how flood coolant gets atomized by a machine cutting tool.

Whether you flood or mist liquid right onto a tool cutting metal, some of it’s going airborne. CNC machines are oftentimes equipped with collection systems for coolant mist, and it’s not unusual to see ambient mist collectors installed in machine shops to take care of the mist that escapes individual machines.

These mist collectors play an essential role in these facilities, as there are considerable health risks associated with exposure to these fluids, both oil- and water-based. In the U.S., the National Institutes of Health (NIH) compiles & analyzes risks associated with skin contact & inhalation of metalworking fluids. The National Institute for Occupational Safety and Health (NIOSH) has comprehensive recommendations of limitations on exposure to them. In England, the Health & Safety Executive agency likewise published a document geared toward helping machine shops and their employees work safely with them.

Speaking of NIOSH, they strategize a Hierarchy of Controls that can be applied to most any industrial process:

Elimination of the hazard isn’t always possible, but when it is, it’s the most effective option.

While mist collectors (Engineering Controls) are reasonably effective (and essential in the large number of applications where metalworking fluids are necessary), there are still a fair amount of applications where liquid coolant CAN be eliminated. For those applications, consider the EXAIR Cold Gun Aircoolant Systems.

Cold Guns not only eliminate messy and potentially hazardous liquid coolants, but also have been proven to improve cutting tool life.

Using Vortex Tube technology, EXAIR Cold Guns generate cold air flow from a supply of compressed air, instantly & on demand, with no moving parts to wear or electrical components to burn out. They’re safe, quiet, effective, and install in minutes, using a built-in bar magnet and 1/4 NPT compressed air connection.

Both Standard & High Power Systems come with Filter Separators, and are available with Single or Dual Point Hose Kits.

We know we can’t replace liquid coolant in every machining application, but if you’d like to explore elimination of it in your processes, give me a call.

Russ Bowman, CCASS

Application Engineer
EXAIR Corporation
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Cold Guns for Spot Cooling or Replacing Mist Systems

Published on by Jordan T ShouseLeave a comment

By using only a source of compressed air, the Cold Gun and High Power Cold Gun produces a stream of clean, cold air 50°F (28°C) below your compressed air supply temperature. The Cold Gun is very quiet at only 70 dBA and has no moving parts to wear out. Just supply it with clean compressed air and it’s maintenance free.

How does it work, and what are the benefits?

  • The Cold Gun uses compressed air to produce a stream of clean, cold air at 50°F (28°C) below supply air temperature. Generally this will be 20°F-30°F outlet temperature.
  • They use Vortex Tube technology…no moving parts to wear out.

How A Vortex Tube WorksInstant cold air flow with no moving parts!

  • Cold flow and temperature are preset to optimize cooling capability, and are non-adjustable to prevent freeze-up during use.
  • Eliminates the expense of both the purchase & disposal of cutting fluids when replacing expensive mist systems.
  • Removes the potential for health problems associated with breathing mist & vapors, and the safety issue of slipping on a wet floor.

Cold Gun Aircoolant System selection is easy & straightforward…we offer a standard, and a High Power version to meet your specific needs.

CG
Four systems to choose from, to meet most any need.

We also offer Single & Dual Point Hose Kits, to further meet the needs of your application.

One of the best applications I have seen with our cold gun came from a customer in Peru. They are a gold mining operation and they were having trouble with the liquid they were using to cool a saw. Read all about it here!

IMG_20180613_094120_HDR

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

Jordan Shouse
Application Engineer
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The Case for the Cold Gun

Published on by Russ BowmanLeave a comment

Heat is an unavoidable by-product of any cutting or machining operation. Think about it: you’re creating friction on a piece of material with a fast-moving piece of harder material in order to forcibly separate pieces of the original material from its existing shape & size. No matter what, something’s going to get hot: the work piece, the tooling, or (almost always) both. If you don’t do something about it, your parts can become damaged, your tooling can become dull and brittle, and productivity will suffer.

There are ways to alleviate the problem…you can slow the speed of your tooling, but that’s hardly practical, and only marginally effective.  You can use liquid cooling…in fact, you may have to if the particulars of the operation require the lubrication you can only get from a cutting oil or liquid coolant.  But those can be messy, expensive, and the time you spend maintaining the coolant could certainly be spent better elsewhere…like, on machining your products!

The EXAIR Cold Gun Aircoolant System is a novel solution to these problems…heat related and otherwise:

  • The Cold Gun uses compressed air to produce a stream of clean, cold air at 50°F (28°C) below supply air temperature.
  • They use Vortex Tube technology…no moving parts to wear out.

Instant cold air flow with no moving parts!

  • Cold flow and temperature are preset to optimize cooling capability, and are non-adjustable to prevent freeze-up during use.
  • Eliminates the expense of both the purchase & disposal of cutting fluids.
  • Removes the potential for health problems associated with breathing mist & vapors, and the safety issue of slipping on a wet floor.

Cold Gun Aircoolant System selection is easy & straightforward…we offer a standard, and a High Power version to meet your specific needs.

Four systems to choose from, to meet most any need.

We also offer Single & Dual Point Hose Kits, to further meet the needs of your application.  Right now, you don’t have to decide up front…order a Cold Gun Aircoolant System with a Single Point Hose Kit before December 31, 2018, and we’ll throw in the Dual Point Hose Kit for free.

If you’d like to find out more about how Cold Gun Aircoolant Systems can improve your machining or cutting operations, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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Beat the Heat: Cold Gun Air Coolant Systems Extend Tool Life with No Messy Coolant

Published on by Dave WoernerLeave a comment

In most drilling, machining, and cutting operations a flood of coolant is used to remove heat from the work piece and the tool. This coolant is sprayed, and after it impacts the tool or part it sprays everywhere. In some case there is no way around using coolant due to required cutting speed, specific heat of the part, or the need for lubrication. In other applications coolant is prohibited from touching the work piece due to application requirement. This means that the tool and the work piece operate at a higher temperature and could damage the tool or work piece.

Cold Gun
Cold Gun, Model Number 5315, In Use

EXAIR Cold Gun Air Coolant System drop the temperature of compressed air by 50 degrees Fahrenheit. This air is then blown on a tool and work piece to take way most of the heat generated during machining. Used in combination with a tool that can handle a higher temperature like a high performance carbide the Cold Gun can deliver reliable machining without the mess of coolant.

Normally in dry machining you also loss coolant’s ability to clear chips from the work area. These chips can trap heat and further increase the temperature of the work area. The chips will also work harden with repeated cutting causing more wear on the tool and a bad surface finish on the part. With a flood of coolant the chips are washed away, but with dry machining air must be used to clear the work area. EXAIR 5315 Standard Cold Gun features (2) 1″ wide nozzle that can be used to cool and the produce enough air flow to prevent chip build up. If you are looking for more information on dry machining, Brian Boswell wrote a thesis on the topic.

Dry machining doesn’t just replicate the machining with a flood coolant it can improve the process. Extended exposure to airborne lubrication mists present potential health risks to machinists. Coolant is becoming more expensive to dispose of after it has been used this is only going to increase over time as environmental regulation become greater. Removing the coolant from your process can ease your environmental impact while still maintaining the quality machining your customers require.

Dave Woerner
Application Engineer
@EXAIR_DW
DaveWoerner@EXAIR.com