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. During the machining process, as 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.
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.
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.
If you are considering an EXAIR product for an application or have additional questions about performance, contact an application engineer for assistance in making the best selection.
I was recently contacted by a plastics manufacturer who was needing some solutions for problem areas in their production processes. The company imports their machines from overseas and they are outfitted with a coolant based, quench system for the tooling. They were wanting to get away from using coolant as the parts were absorbing liquid, causing them to swell, not to mention the mess they were creating, requiring more time and labor to dry and clean the parts manually.
For the first application, replacing the messy misting system, I recommended the customer use our Cold Gun System, Model # 5215. The Cold Gun uses Vortex Tube technology to produce a cold air stream 50°F lower than the incoming compressed air supply temperature. For example, if your supply air was ambient 70°F, you would effectively see 20°F air at the exhaust. This clean, cold air stream can be easily directed to the needed area to prevent any warping or other damage related to heat, while also blowing away the machined fines.
The second part of the process involved the recovery of the plastic scrap and chips created during the machining process. Once again, EXAIR has the ideal solution with our Chip Vac, Industrial Vacuum. The Chip Vac creates a powerful vacuum, with no moving parts or motors to wear out, making them virtually maintenance free. The Chip Vac is designed to vacuum dry or wet chips and collect them in a standard, open-top steel drum. Systems are available in 5, 30, 55 or 110 gallon capacities.
To discuss how EXAIR products might help improve your machining process, give us a call at 800-903-9247.
Now through the end of 2017 if you purchase a Single-Point Cold Gun Kit with Model W5215 for the standard Cold Gun or W5230 for the High Power Cold Gun, we’ll include a free Model 5902 Dual Point Hose Kit, a $35.00 value!!
EXAIR’s Cold Gun was a Product of the Year finalist in 2007. By 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 is pre-set to an 80% Cold Fraction. In other words, 80% of the compressed air supplied to it will exhaust from the cold end of the tube, 20% from the hot end. 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.
The Cold Gun is an invaluable tool for machining a wide range of plastics and other materials that may become contaminated when using traditional coolants or oils. The clean, cold air from the outlet of the Cold Gun keeps the part cool, clean, and dry. Take for example this application where an OEM for the plastics industry uses EXAIR Cold Guns in place of a coolant system.
If you have an application that you believe would be better served by the use of an EXAIR Cold Gun, give us a call. Get one on order today and take advantage of receiving a FREE Dual Point Hose Kit!
During a recent visit with our Hungarian Distributor, I had the opportunity to take a look at an application using some EXAIR Adjustable Spot Coolers and Mini Coolers. The company manufactures cataract lenses and is using the coolers in a dry machining application. The previous process involved using a liquid coolant which caused a washing operation to remove the contaminants before the lenses could move on to the next step of the process. This was not only time consuming, but the solution they needed to use as a coolant was very expensive due to strict regulations that they had to adhere to.
The lenses are set up on a lathe which are precisely cut. The Adjustable Spot Coolers were positioned with the cold airflow just at the point of cutting to keep the temperature at a specific point. If the lenses get too hot, the material becomes less rigid and begins to warp. When this happens, the lens cannot be reworked and must be scrapped. Immediately after coming off of the lathe, an inspector places the lens under a microscope for inspection. At this point, a Mini Cooler is installed to ensure that the temperature of the lens stays cold. If the lens passes inspection, it is immediately placed in a small freezer next to the operator. Temperature probes are in place at several points during the process to ensure that they do not go above the specified temperature.
By implementing a solution with the Adjustable Spot Cooler, this customer was able to boost productivity by removing a cleaning step from the process and also reduce costs by eliminating the need for the costly coolant solution that was required. If you’d like to replace messy coolant systems in your machining operation with a clean compressed air solution, give us a call. An Application Engineer will be happy to look at your process and recommend the most suitable solution.
Machining plastics can be a difficult task as the contact between the part and the tool generates heat, which can result in the plastics beginning to melt and stick to the tooling, causing deformities or even broken tool heads. Often times, companies will introduce a liquid based method of cooling to quench the parts during machining, while this does work, with plastics they tend to absorb some of the liquid, resulting in the finished part being outside the allowable tolerance range. Another area of concern is the mess that liquid cooling creates as now the parts need to be dried and cleaned before they can continue to the next process.
Such was the case last week when I worked with an OEM who was looking for a way to cool the tooling in the machines they build for the plastics industry. The company they were selling the machines to, specifically asked for an alternative method of cooling without using any type of coolant due to the conditions mentioned above. Once again, EXAIR has the perfect solution – the Cold Gun. Incorporating a Vortex Tube, the Cold Gun produces a cold air stream at 50°F below compressed air supply temperature and provides 1,000 Btu/hr. of cooling capacity. Fitted with a magnetic base and flexible hose the unit can be mounted virtually anywhere on the machine and the cold airflow can be easily directed to provide cooling to the critical area. The system also includes a filter separator for the supply line to remove any water or contaminants, ensuring that the exiting airflow is clean and free of debris.
When looking for a reliable method of cooling, whether machining plastics or other material, the cold, clean air from the Cold Gun is the ideal solution in place of messy misting systems. For help with your spot cooling needs or to discuss how using Vortex Tube technology could help in your process, give me a call, I’d be happy to help.
If you’re looking at replacing messy coolant mist systems, look no further than the Adjustable Spot Cooler. EXAIR’s Adjustable Spot Cooler incorporates Vortex Tube technology to produce temperatures ranging from -30°F – +70°F. A Vortex Tube works by imparting a rapid spinning motion to the supplied compressed air. This airflow makes its way to the end of the tube where it is forced to abruptly change directions. It is during this change of direction that energy is given off in the form of heat. The hot air then exits the tube from the hot end, while cold air exits the other end of the tube. As the valve is opened to allow more air to exhaust from the hot end, the temperature at the cold end will decrease. At a sound level of just 73 dBA when operated at 100 psig and stock generator installed, this compact cooler will keep your operation cool, clean and dry without causing unnecessarily high noise levels.
When looking at a Vortex Tube based solution, the variety of options can sometimes be daunting. This is where the versatility of the Adjustable Spot Cooler shines. Through a simple turn of the control knob, you can easily adjust the temperature and cold fraction of the unit. Additionally, the kits come with (2) extra generators (15-H and 30-H) that can be swapped out for the stock generator for more/less cooling power and air consumption. The 15-H generator will deliver up to 1,000 Btu/hr of cooling capacity and the 30-H will provide up to 2,000 Btu/hr of cooling capacity. We have (2) different kits available, the Model 3825 Single Point and the Model 3925 Dual Point Kit. The 3825 is recommended for use in applications where you’re cooling a small surface such as solder joints, hot melts, or drilled plastics. The 3925 system is better served when heat is generated over a larger surface area such as saw blade cooling. The kits use flexible Loc-Line hose to allow you to precisely position the cold airflow onto your target. The Adjustable Spot Cooler provides easy mounting with a swivel magnetic base, allowing you to mount the cooler directly at the most critical point that heat is being generated.
If you’re tired of cleaning up your coolant or have an application that requires dry machining, get one of the Adjustable Spot Cooler systems on order today. They’re in stock ready to ship!
When working with a cooling application, many customers will immediately look to the Vortex Tube and Cold Gun product lines. While this may be the best solution for some applications with smaller areas to cool, cold air from a Vortex tube based solution is not the best method for large parts or larger areas that exceed a footprint of approximately 2″ x 2″. For larger areas, we have other options for many cooling applications. EXAIR’sSuper Air Amplifiers and Super Air Knives are also very effective at reducing the temperature of a part without requiring cold air.
Cooling is a relative concept based on the starting and finishing temperature. What feels “cool” to a human being does not necessarily mean the same thing as “cooling” a part or material. Due to the ability of the Super Air Knives and Super Air Amplifiers to entrain large amounts of ambient temperature air, we can move a lot of air volume across the surface of the target part and quickly lower the temperature.
A simple example I like to use is blowing on a hot cup of coffee just as its been brewed. The temperature of the air coming from your mouth is around 98.6°F, the same as your body temperature. Coffee can be as hot as 185°F when fresh. Due to the temperature differential between your breath and the hot coffee, we’re able to achieve a reasonable amount of cooling just by simply blowing across the surface. Typically, when the target temperature of the part or material needs to be around ambient temperature or higher; the best solution for cooling is going to be either a Super Air Amplifier or Super Air Knife.
To illustrate the above concept even more, recently I was working with a customer that needed to cool a silicon injection mold. The mold had two sides and the customer was looking for a method of cooling it down between cycles. The mold cavity surface was approximately 400°F and they wanted to get it down to around 150°F. They were familiar with the EXAIR Cold Gun as they use them across their facility in various secondary or post-molding drilling operations. They had a spare and decided to hook it up and blow the cold air across the face of the mold to see what happens. The volume of air from the Cold Gun was not enough to sufficiently cool the entire mold, so he reached out to EXAIR for assistance.
Based on the dimensions of the mold and understanding the target temperature to be 150°F, we settled on a system of (2) 120224 4” Super Air Amplifier Kits. One was placed above each side of the mold. As soon as the mold opened, they activated the Super Air Amplifiers and were able to pull the surface temperature of the mold down to an acceptable level. Time is money in any manufacturing operation. Companies that produce injection molded parts will look for any way to improve their process. By implementing a procedure to cool the mold more quickly, they are able to boost their productivity gains and become more profitable.
The Super Air Amplifier Kit comes with an Auto-Drain Filter to keep the air clean and dry, a pressure regulator to allow you to dial in the precise level of airflow, and a shim set that allows you to make gross adjustments to the flow. The Super Air Amplifier is available in (5) different sizes with ¾” up to 8” diameter outlets and flow rates from 219 SCFM to 9,000 SCFM 6″ from the outlet. They are capable of achieving an amplification ratio of up to 25:1 from the compressed air supply. The laminar airflow from the unit minimizes wind shear to produce sound levels that are typically three times quieter than other air movers. If you have an application that requires a similar type of cooling, give us a call. We’ll walk you through the process of selecting the most suitable solution.