Optimize processes with precise fluid control for machine tools
In metalworking, precision and efficiency are key factors in achieving high-quality products and optimising production costs. An often underestimated but highly important aspect concerns the correct management of lubricating and cooling fluids, also known as coolants or cutting oils, which play an essential role: they reduce friction between the tool and the workpiece, dissipate the heat generated by the cutting process, remove chips and protect the machinery from corrosion. Inaccurate or insufficient application can lead to premature tool wear, reduced surface quality of the machined workpiece, increased operating costs and a reduction in the useful life of machine tools.
To maximise the effectiveness of these fluids and ensure the stability and productivity of metalworking processes, it is essential to adopt advanced dosing and regulation systems. But what are the most suitable technologies for accurately managing lubricants and coolants, ensuring optimal application and contributing to the success of mechanical operations? Let's take a closer look at the solutions available for efficient and reliable control.
Dosing pumps for lubricating fluids: precision at the service of the tool
Dosing pumps for lubricating fluids are at the heart of every efficient lubrication and cooling system in metalworking. Their function is to deliver the desired quantity of lubricant or coolant with extreme precision, directly to the point of contact between the tool and the workpiece or to the mechanical surfaces to be protected. Unlike traditional systems based on continuous flow or manual application, dosing pumps guarantee millimetric control, avoiding waste and ensuring that the fluid arrives exactly where and when it is needed.
There are several types of pumps suitable for this purpose: proportional volumetric pumps, for example, are ideal for mixing lubricant-coolant concentrates with water in exact proportions, creating stable and homogeneous emulsions, while other pumps can be used for dosing pure oils or high-viscosity fluids, common in specific processes such as shearing or deep drilling.
The accuracy of these pumps is crucial for several reasons: insufficient dosing would not ensure adequate lubrication, resulting in overheating and premature tool wear; excessive dosing, on the other hand, would lead to unnecessary fluid waste, high disposal costs and potential contamination of the working environment. The implementation of reliable dosing pumps not only extends tool life and improves the surface finish of parts, but also reduces overall operating costs through lower fluid consumption. These pumps are often integrated into automated systems, allowing for real-time control and adjustment based on machining parameters.
Lubrication and cooling systems: an integrated approach to performance
A modern lubrication and cooling system is much more than just a pump: it is an integrated system that manages the entire life cycle of the fluid within the machining process. These systems are designed to optimise the application, recovery, filtration and stabilisation of lubricating and cooling fluids, with the primary function of ensuring a constant and controlled supply of fluid to the cutting point, maintaining its chemical and physical properties unchanged over time.
A complete system typically includes storage tanks, mixing systems for concentrates, dosing pumps (such as those described above), filtration systems to remove chips and contaminants, and heat exchangers to maintain the fluid temperature within an optimal range. Some advanced systems also incorporate modules for continuous monitoring of fluid parameters (such as pH, concentration, presence of bacteria) and reconditioning systems to extend its life.
The adoption of a well-designed and properly managed lubrication and cooling system translates into numerous advantages: it reduces fluid consumption, minimises machine downtime for cleaning or fluid replacement, improves the quality of the final product and creates a healthier working environment by limiting operators' exposure to oil mists and bacteria. It is an investment that pays off in terms of productivity, costs and sustainability.
Dosing systems for technical oils: specific solutions for complex requirements
In addition to coolants, numerous technical oils are used in metalworking for specific applications, such as the lubrication of gears, guides, bearings or hydraulic systems. Dosing systems for technical oils are designed to handle these fluids with the same precision and reliability as coolants. Dosing requirements can vary considerably depending on the viscosity of the oil, the frequency of application and the environmental conditions.
These systems often use gear or screw pumps for high-viscosity oils, or peristaltic pumps for applications requiring extreme precision and no contamination. Dosing can be continuous or pulsed, depending on the application: for example, the lubrication of a linear guide system requires periodic application of precise quantities of oil, while a hydraulic system requires constant fluid replenishment.
The implementation of dedicated dosing systems for technical oils ensures that every component of the machine tool receives the lubrication necessary to function properly, preventing friction and wear and contributing to the longevity and reliability of the entire equipment. Precise control in this area is essential not only for machine performance, but also for reducing maintenance costs and unplanned downtime.
Rely on Mixtron for flawless dosing in metalworking
Mixtron is the ideal partner for all your lubrication and cooling needs. Our proportional volumetric dosing pumps and dedicated solutions for managing lubricants, coolants and technical oils are specially designed to offer excellence in terms of accuracy, efficiency and durability.
With Mixtron, you can choose systems that allow you to optimise fluid consumption, extend the life of tools and machine tools, improve machining quality and reduce maintenance and disposal costs. Our products guarantee precise and controlled application, contributing to a cleaner and safer working environment, as well as more sustainable and cost-effective production processes. Contact us now for more information!
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