Tag: tool cooling

Mini Cooler Overview

Published on by jasonkirbyLeave a comment

The basic vortex tube has been utilized in numerous industrial cooling applications over the years. Some of these applications have gained such popularity that they have led to the creation of specialized “applied products” tailored to meet specific needs. These products encompass the Adjustable Spot Cooler, Mini Cooler, Cold Gun, and Cabinet Coolers, all of which are available in our catalog and on our website.

The Mini Cooler utilizes a vortex tube to transform a limited quantity of compressed air into two low-pressure streams that flow in opposite directions, one within the other. This interaction allows the two air streams to exchange heat, resulting in the generation of cold air at one end of the tube and hot air at the other. A flexible hose channels the cold airstream towards the surface intended for cooling.

Heat produced by processes like machining, welding, soldering, brazing, electrical losses, and the functioning of rotating or reciprocating machinery poses considerable challenges that extend beyond simple comfort. Efficient heat removal from these activities is crucial for uninterrupted operation, as significant amounts of heat often require dissipation. For example, power plants generating electricity employ large pumps to circulate thousands of gallons of water each minute through extensive heat exchangers, which condense steam from turbines, enabling reheating and sustaining turbine functionality.

The Mini Cooler operates on the Vortex Tube principle to produce cold air from compressed air without any moving components, providing immediate cooling on demand. This method relies on a physical phenomenon rather than direct heat transfer, allowing the Mini Cooler to deliver cold air at specified flow rates and temperatures as soon as compressed air is supplied. It can be activated or deactivated as frequently as required, and its design eliminates the risk of wear from moving parts or failure of electrical components. With a compressed air requirement of just 8 SCFM at 100 psig, even relatively small compressors, some as low as 3HP, can sustain continuous operation of the Mini Cooler.

If you would like to discuss the Mini Cooler, please do not hesitate to contact an Application Engineer. We are always happy to help!

Jason Kirby
Application Engineer
Email: jasonkirby@exair.com
Twitter: @EXAIR_jk

Cold Gun Aircoolant Systems™ Versus Messy Coolant

Published on by John BallLeave a comment

In any machining operation, tool wear is unavoidable.  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. 

Coolants are used to reduce friction and help mitigate some of the wear by reducing heat, but then you’re left with a mess on the part and in the machine itself.   The fine mist will create a fog which will stick to the wall and personnel.  Also, with the dirty parts, cleaning will take additional manpower and time.  What if I were to tell you that there’s a way to safely, effectively, and easily perform machining, grinding, and cutting operations without coolant?  I would like to introduce you to EXAIR’s Cold Gun Aircoolant System™. 

The Cold Gun utilizes the vortex principle to produce a cold air stream that will provide chip evacuation and cooling at the cutting tool and material. The vortex phenomenon will drop the incoming compressed air temperature by 50°F (28oC).  So, if you supply compressed air at 70oF (21oC), it will blow cold air at a temperature of 20oF (-7oC).  This means that the removal of chips by using cold air will help reduce the heat buildup within both the cutting tool and the material, which can help prevent thermal creep. Keeping the cutting tool and the material cooler reduces the amount of wear on the tooling and or coating of the tool and has been found to reduce tool wear by over 21%.

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 a great system for machining a wide range of materials like plastics and MDF, or for grinding 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.  

If you have an application that you believe would be well-served from the cold airflow generated by an EXAIR Cold Gun, an Application Engineer will be happy to assist you.  We offer a Cold Gun and a High Power Cold Gun which reduces heat even faster.  Get one on order today and take advantage of our limited time promotion and receive a FREE Dual Point Hose Kit upgrade for qualified online purchases. 

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

Achieve the Perfect Temperature with EXAIR’s Adjustable Spot Cooler

Published on by Tyler DanielLeave a comment

EXAIR’s Adjustable Spot Cooler is an ideal fit for those who need the ability to adjust the temperature of their spot cooling solution. This user-friendly tool is available right out of the box with the necessary accessories to allow you to quickly install and implement the solution. It can be great for dry-machining processes or applications where you’re looking to replace a standard coolant-based method of cooling.

If that sounds like something you’re looking for, then the Adjustable Spot Cooler could be an excellent product for optimizing your processes. 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 direction. 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 a stock generator installed, this compact cooler will keep your operation 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 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 a 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 position the cold air flow directly at the most critical point where 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 the same day with an order received by 2:00 ET!

Tyler Daniel, CCASS

Application Engineer

E-mail: TylerDaniel@exair.com

X: @EXAIR_TD

Coolant Mess Vs. “Dry” Machining

Published on by Brian FarnoLeave a comment

It seems like a lifetime ago now that I have been with EXAIR for almost 14 years. However, I come from the metal cutting industry and still have numerous contacts and interests in what kind of technological advancements the industry sees. In the industry and even today, there seems to be a constant battle between using coolant to provide chip evacuation, lubrication, and cooling during a cut versus trying to tune the programs and feeds to perform dry machining. During dry machining, the operator may stand there and keep a handheld Safety air gun blowing chips away from the cutter and out of the tool path. The machine may even be plumbed up with compressed air to run through the traditional coolant lines rather than pumping liquid. This comes with its own issues. What if I were to tell you there is a third option?

You already know a third option exists if you read our blog regularly. It is the EXAIR Cold Gun Aircoolant System. These utilize the vortex principle to produce a cold air stream that will provide chip evacuation and cooling of the cutting tool and material. It will drop the incoming compressed air temperature by 50°F and easily point that cold stream of air at the cutting point just like a coolant line. This means the evacuation of the chip and, by using the cooler air, you can help reduce the heat buildup within both the cutting tool and the material, which can prevent thermal growth creep as well. Keeping the cutting tool and the material cooler reduces the amount of wear on the tooling and or coating of the tool. This has been found to reduce tool wear by over 21%.

This can not only reduce tool wear and improve the finish, but it also reduces the amount of cleanup by not introducing the liquid aspect. No more mopping up around the open guard machines or having to wipe down or blow off parts to remove moisture. The parts will come off the machine dry and the chips will go into the chip hoppers dry as well.

If you would like some help determining which of the four Cold Gun options is the best fit for your machining operation, please contact an Application Engineer today.

Brian Farno, MBA – CCASS Application Engineer

BrianFarno@EXAIR.com
@EXAIR_BF