Spot Cooling

A new solution to an old problem. Heat build up on dry machining operations reduces tool life and machining rates. The Cold Gun Aircoolant System produces a stream of clean, cold air at 50°F (28°C) below supply air temperature. Operation is quiet and there are no moving parts to wear out. It will remove heat to prolong tool life and increase productivity on machining operations when liquid coolants cannot be used.

The Cold Gun is also an alternative to expensive mist systems. It eliminates the costs associated with the purchase and disposal of cutting fluids and worker related health problems from breathing airborne coolants or slipping on wet shop floors.

The standard Cold Gun and High Power Cold Gun incorporate a vortex tube to convert an ordinary supply of compressed air (1) into two low pressure streams, one hot and one cold. The Cold Gun’s hot airstream is muffled and discharged through the hot air exhaust (2). The cold air (3) is muffled and discharged through the flexible hose (4), which directs it to the point of use. Easy mounting and portability are provided through the use of an attached magnetic base (5).

Applications include tool sharpening, drill and cutter grinding, drilling, band saw cooling, plastic machining and setting adhesives. 

EXAIR offers two types, the Cold Gun and the High Power Cold Gun.  The High Power Cold Gun blows twice the amount of cold air as the Cold Gun which doubles the cooling capacity.  They come standard with either a Single Point or a Dual Point Hose Kit with a cone and flat nozzle.  All systems come with a magnetic base and a filter separator.  The magnetic base makes this device simple to attach to your machine and start using. 

Jordan Shouse
Application Engineer

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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.

HP_coldgun_2007finalist

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.

minicoolerWFAM_500
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.

MiniCoolerLVpr2019_350
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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No Drip Atomizing Spray Nozzles: Overview

Are you tired of your dripping nozzle leaving puddles on your equipment and making a mess? Do the liquids you use to treat or coat your materials cost you a great deal of money? EXAIR’s No Drip Atomizing Spray Nozzles have been engineered eliminate drips; these patented nozzles contain a spring mechanism that when the air pressure reaches above 30 psig the valve will open allowing the liquid to escape out.

EXAIR No Drip Air Atomizing Spray Nozzles come in three styles. Internal mix, External mix and Siphon fed. 

One of the most commonly used types of No Drip Atomizing Spray Nozzles is the Internal Mix. The Internal Mix nozzle mixes the liquid and the air inside the cap and produces the finest droplet size out of the three. Due to the fact that the liquid and air are mixed in the cap, Internal Mix nozzles are used on liquids that have a lower viscosity (less than 300 cP). This means that they are usually used on liquids such as water, water soluble/diluted lubricants, lightweight oils, or rust inhibitors.

External Mix No Drip Atomizing nozzles have the highest flow rates and allow the air and liquid flows to be adjusted independently. These are best when precise liquid flow is needed. External mix nozzles can be used when the liquid viscosity is above 300 cP. 

Siphon Fed No Drip Atomizing nozzles require no liquid pressure and can be use dwith gravity fed liquids or siphon liquid from a height as much as 36 in. (91cm). These can be used with liquids up to 200 cP. 

No Drip Atomizing Nozzle
The No Drip Atomizing Spray Nozzles share the same spray patterns as our line of standard atomizing spray nozzles. This means that they are available in Narrow Angle Round Pattern, Wide Angle Round Pattern, Flat Fan Pattern, Deflected Flat Fan Pattern and 360° Hollow Cone Pattern. Along with the five different spray patterns they also come in three different inlet sizes of 1/8″, 1/4″ and 1/2″ NPT.
No Drip Flat Fan Spray Nozzle
Each NPT size also comes in a variety of different sizes in the corresponding spray volume. For example, the 1/8” No Drip Internal Mix Flat Fan Nozzles have for different Nozzles with a flow rate ranging from 3.47 GPH to 28 GPH (13.2 LPH to 105.99 LPH). This gives the No Drip Internal Mix Atomizing Nozzle 36 different variations to fit your application.
No Drip Siphon Fed Round Pattern Atomizing Nozzle
The normal applications for No Drip Atomizing Spray Nozzles Include but not limited to the following:
  • Painting
  • Coating
  • Rinsing
  • Cooling
  • Quenching
  • Wetting,
  • Humidification
  • Dust Control
  • Snow Making

Or any application where drips can harm a products finish or waste valuable liquids. 

For more information on EXAIR’s No Drip Atomizing Spray Nozzles or any EXAIR‘s Intelligent Compressed Air® Product lines, feel free to contact EXAIR and myself or any of our Application Engineers can help you determine the best solution.

Cody Biehle
Application Engineer
EXAIR Corporation
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