"Aiming" Flood Coolant

[HimyKabibble]

I recently finished enclosing my knee mill, so I could use flood coolant, instead of the FogBuster-type coolant I've been using. I'm really happy with the result, But, I'm having a few issues:

1) The flood is, of course, wonderful in terms of keeping things cool, but it does not do nearly as good a job of clearing chips, unless I set the flow rate high enough that coolant splashed EVERYWHERE, even over the 24" high walls of the enclosure.

2) One of the things I did not like about the Fogbuster was that it had to be carefully aimed, and often re-aimed mid-cut, to be effective. I'm finding flood to be not terribly different in this respect. I have tools varying in length by up to about 8", and it still seems like the nozzles have to be re-aimed with each toolchange. How is this handled in a production machine with a toolchanger? Is there simply so much coolant flowing that it doesn't matter?

3) I've always thought it odd that some people complained about mist systems putting too much mist into the air. I never had that problem at all, but with the flood system, the humidity in my shop is increased very dramatically when the machine is running. This is going to be a real problem in a few months when the weather turns cold. I'm currently using KoolMist 77. Would some other coolant minimize this problem?

Regards,
Ray L.

[keebler303]

Production machines have motorized nozzles which can move or follow a tool so it will have a programmed position for each tool in the tool changer. The ones that don't just use multiple nozzles, maybe each one directed at a different depth along the spindle centerline. Then of course there is through tool coolant, which is probably best in terms of chip removal.

Matt

[txcncman]

Most production machines DO NOT have motorized nozzles. On most production machines, we have several nozzles, with at least one aimed for each tool length. We also try to install tools as close to the same length as possible, when possible. If it is known a coolant nozzle will need to be re-aimed for a certain tool, programming an M00 machine stop just prior to that tool with a note to the operator to change the coolant nozzle works.

[Geof]

With a copious flow of coolant and a rapidly spinning tool you are always going to get a lot of coolant aerosol created and spread into the air. On production machines the standard fix for this is a mist extraction system that collects the air out of the machine and passes it through a coalescing filter before returning it to the shop.

Depending on how much time you spend in your shop it may be a good idea to put a top on your enclosure and rig some sort of extraction system. The coolant aerosol is okay to tolerate for brief exposure but prolonged breathing of it can generate health problems. If you have noticed that you are coughing a bit more since starting to use flood coolant you should as least wear a particulat filter mask.

[txcncman]

Adding, most people that are serious about machining as a business will invest in what is needed to keep things working smoothly. Air conditioning (not necessarily cooling) is one of these investments.