The centralized supply and filtration system of grinding fluid has great promotion value. The one-time investment is not large, but the resource conservation effect is obvious and the social effect is significant. Reasonable use of cutting fluid Use and maintenance of cutting fluid 1. Configuration (dilution) Cleaning fluid Concentrated filtration of cutting fluid
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During the grinding process, the coolant plays a very important role in preventing the workpiece from being burned, improving the surface precision and roughness of the workpiece, improving the rust-proof ability of the workpiece and the machine tool, and prolonging the service life of the cutter and the machine tool. Therefore, the rational use and maintenance of grinding fluid is very important in the grinding process. 
The cutting fluid can be divided into two major categories: oil-based cutting fluid and water-based cutting fluid. Oil-based cutting fluids, such as those used in superfinishing bearing factories, are mainly based on kerosene and have a small amount of mechanical oil. After the oil-based cutting fluid passes through the processing site, it generally contains only solid impurities such as abrasive particles and chips. In use, it is only necessary to remove the solid impurities to obtain a clean cutting fluid. Therefore, the treatment is relatively simple. The other type is a water-based cutting fluid represented by an emulsion in which fine oil droplets are highly dispersed in water. The emulsion also contains various surfactants and rust inhibitors. After the emulsion passes through the processing site, it contains solid impurities such as abrasive grains and chips, and it is also easy to breed microorganisms. Microorganisms include bacteria, molds, fungi, etc. These are the main factors affecting the quality of the emulsion. The normal emulsion contains no more than 1000 bacteria/mg. When the bacteria content reaches 10,000 to 100,000 particles/mg, the emulsion will It can turn black and stench, and the cooling and lubrication effect drops rapidly, giving off an unpleasant odor, corroding the equipment, and even the bacteria blocking the filter. At this time, all the emulsion must be replaced and the circulation system thoroughly cleaned.
The configuration of the cutting fluid is diluted with water in a certain proportion. Water-based cutting fluids, especially emulsions, pay attention to the following points when diluting:
(1) Water Quality Water under recommended hardness should not be used under normal circumstances because calcium and magnesium ions contained in high-hardness water will cause anionic surfactants to decompose and the emulsion decomposes, resulting in insoluble metal soaps. Even if the emulsion is made of a non-ionic surfactant, a large amount of metal ions can also cause the micelles to aggregate, thereby affecting the stability of the emulsion. Too soft water should not be used, and emulsions that are configured with too soft water tend to generate large amounts of foam during use.
(2) Dilution The dilution of the cutting fluid is related to the stability of the emulsion. Before using the cutting fluid, it is necessary to determine the dilution ratio and the volume of the required emulsion, and then calculate the amount of the used fluid and the amount of water. When diluting, select a clean container, pour all the required water into the container, and then add the original solution under low-speed stirring. During the configuration, the feed rate of the original solution is based on the non-emulsified stock solution. Note that the procedure for adding stock and water cannot be reversed.
2. Maintenance
Extending the service life of the emulsion In addition to choosing the proper coolant quality and proper use, the maintenance of the cutting fluid is also a very important factor. The maintenance of cutting fluid mainly includes the following items:
(1) Ensure the circulation of liquid circulation. Remove metal chips, metal powder, mold mucus, cutting fluid's decomposition product, and grinding wheel ash in a timely manner to avoid clogging.
(2) Bacteriostasis Cutting fluids (especially emulsions) are essential for bacteriostatic growth. During the use of cutting fluids, bacteria should be checked regularly for appropriate action.
(3) Decontamination Remove chips and floating oil such as metal powder in the cutting fluid in time to eliminate the bacteria breeding environment.
(4) Regularly check the PH value of the cutting fluid, there are major changes, and take corresponding measures in time.
(5) Adding cutting fluid in time, since the cutting fluid will be continuously consumed due to splashing, atomization, evaporation, and the carrying of processing materials and chips during the recycling process, it is necessary to add new fluid in time to meet the total amount of circulating fluid in the system. constant.
The filtering and purifying of the cutting fluid means the process of removing a certain proportion of relatively large solid particles in the cutting fluid from the cutting fluid. The filtered and purified cutting fluid can be reused for mechanical processing to achieve the purpose of recycling. The advantages of filtration and purification of cutting fluid are mainly manifested in the following aspects:
• Extended cutting fluid replacement cycle.
· Improve the service life of tools and grinding wheels. In recent years, studies have shown that if the cutting fluid impurities (such as debris, grinding wheel, etc.) from 40μm reduced to 10μm or less, the tool (or grinding wheel) life can be extended 1 to 3 times.
· Improve the surface roughness of the workpiece and reduce the reject rate.
• Extend the service life of pipelines and pump sets. Solid particles, such as cutting fluids, can accelerate the wear of pipes, pumps and other components.
The filtering and purifying of the cutting fluid can be roughly divided into two major categories of filtration and separation, but they are often combined in practical production. There are two types of cutting fluid: stand-alone filtration and centralized filtration. Single-cycle filtration means that each machine's filtration system is independent. The single-cycle filtration system is generally equipped with the machine tool when it is shipped from the factory. It is generally relatively simple and has relatively low filtration accuracy. It can only meet the requirements of low-precision production and cannot meet the need for high precision. This kind of independent filtration cycle method is generally suitable for working conditions with a small number of machine tools or using different cutting fluids. For large-scale mechanical processing plants that use wet processing, centralized filtration is recommended. The centralized filtration system is a trend of modern wet processing and filtration. Compared with the single-cycle system, the advantages of centralized filtration are as follows:
· Small footprint The large centralized filtration system has a much smaller footprint than single filtration.
·Easy to manage When the cutting fluid is added, the number of points can be reduced, the cutting fluid management personnel can be reduced, the waste cutting fluid can be concentratedly treated, and the environmental pollution is small; the discharged iron scraps are concentrated and the transportation process is convenient; the use condition of the cutting fluid can be detected centrally.
· Filtering accuracy is easy to control.
· Easy to implement automatic control.
The typical centralized filtration system produced by Yantai Xinyang Machinery Co., Ltd. is composed of an automatic dosing system, a liquid supply pipe, a coarse scraper filter, a paper tape negative pressure filter fine filter, an aerobic sterilization, an oil slick cleaning, a liquid supply pump set and Electrical automatic control system. The cutting fluid is sent from the pipeline to the machine tool or automatic line through the supply pipe in the workshop, and the chips are flushed to the liquid return system. Under the action of the pressure nozzle, the chips and emulsion are returned to the filtration system through the overhead pipeline or the underground pipeline system. The emulsion in the filtration system is first coarsely filtered by the screed sedimentation tank, the larger swarf is sent by the squeegee conveyor to the culvert, and the emulsion is then finely filtered by the negative pressure filter. The liquid is sent back to the workshop by the pump set. The system liquid supply pump group adopts variable frequency constant pressure liquid supply technology to ensure the stability of the pressure and flow of the entire filtration system. When the quantity of equipment used in the workshop changes, the pressure in the pipeline also changes, and the pressure sensor will issue The signal, the pump group will automatically adjust the flow, so that the pressure inside the workshop piping system is constant. The dosing system consists of a dosing tank and a dosing pump, as well as corresponding pipes and regulating valves, which can be automatically dosed according to the set values. Oxygen-increasing devices regularly increase oxygen in the tank, inhibit the growth of anaerobic bacteria, and effectively extend the service life of the cutting fluid. The oil removal device automatically clears the liquid float to avoid corrosion of the cutting oil by the oil. The system has a liquid level detection system that automatically detects the liquid level and outputs a signal. With automatic replenishment function, automatic replenishment of the system. The electric control has four modes of manual/automatic/semi-automatic/holiday cycle to meet the use under different working conditions. During the plant holidays and holidays, in order to prevent the cutting fluid from standing and corrupting for a long time, the system adds a recirculating pump. After the system stops operating, the system automatically starts the recirculating pump so that the cutting fluid keeps flowing, which can effectively inhibit the growth of bacteria and greatly prolong the cutting. Liquid life, to achieve the purpose of cost savings.
The concentrated cooling fluid filtration system provides centralized fluid supply and centralized treatment for the grinding fluid in the production workshop. The coolant can be subjected to centralized filtration, degreasing, oxygenation, and sterilization to achieve control over its concentration, pH, and colony count. Ensure that the coolant does not deteriorate and extend the service life of the coolant.
The concentrated filtration and recycling of the cooling fluid can reduce the production cost, reduce the labor intensity of the workers, improve the working environment of the workshop, and reduce the environmental pollution. At the same time, the centralized treatment of the waste coolant can also be realized, thereby further reducing the environmental pollution. The coolant concentration filtration system makes the coolant quality stable over a long period of time, ensuring the need for grinding.
May 12, 2023