I received a call from a manufacturer that has a spiral welding operation. They create tubes and pipes from metal strips that are welded together in a continuous operation. The material is placed into the machine and twisted in a way to create a butt seam along the edge for welding. The edge has to be shaved to create a welding seam. Because of the speed of operation, the mechanical trimmer that prepares the edge was getting dull. The operation had to be stop for replacement. Understanding the costs associated with down time, they wanted to improve the length of time before replacement.
He called EXAIR to see if we can offer a solution. With this process, he could not use liquid coolant, as it would affect the welding operation. I suggested that we should use the Cold Gun Aircoolant System. It is designed to improve the life of tools by removing heat that causes premature failure. The Cold Gun produces a cold air stream at 50 deg. F (28 deg. C) below supply air temperature. I recommended the model 5230 High Power Cold Gun for his operation. Because it has the highest cooling capacity and force, it will keep the trimmer cool and clean. The down time was reduced by half, making the manufacturer happy that they called EXAIR.
When liquid coolant cannot be used in an application or the tools are dulling quickly on a dry machining process, you can contact an Application Engineer at EXAIR to get the correct Cold Gun Aircoolant System.
In my blog last week I mentioned an application to dry extruded rubber after quenching in a dip tank. This week I was again contacted for a similar application, only this time the need was to dry a copper wire after quenching. The current setup (above) used rollers to remove water and debris, but failed to solve the problem.
In most applications like this, a Super Air Wipe will be the best solution. An Air Wipe will provide 360° blow off of the part, keep compressed air use low, and keep noise low as well. However, when the diameter of the product is very small, we can also meet the needs of the application by using properly positioned Super Air Nozzles.
In this application, the diameter of the wire could be as small as 2mm, so I was inclined to offer an air nozzle based solution. For example, EXAIR 1109SS Pico Super Air Nozzles mounted around the OD of the wire using Stay Set Hoses, and positioned with 45° angles of attack could provide blow off and cleaning of the small diameter wire. It would also provide a degree of adjustment for the other small diameter wires. Given the variable diameters of the wires in this application, I recommended testing of the nozzle based solution. Speed is another consideration in a wire blow off application, in this application the wire will exceed 1000 feet per minute (fpm). We generally recommend a Super Air Wipe Solution when speeds are below 1000 fpm.
If you have questions about which EXAIR solution will best solve the problem in your application, we are here to help.