The use of high-pressure lubricating and cooling fluid allows you to significantly increase the performance of a machine tool and increase the overall productivity of the lathe-bar feeder application. It directly addresses some of the factors that can compromise the efficiency, performance, and quality of machining processes, including bar turning.
The coolant performs two distinct functions: it cools the work area, where friction between the tool and the component generates high temperatures, and properly lubricates the contact point between the cutting edge and the workpiece.
Low-pressure distribution of the coolant often proves ineffective: the heat developed in the contact zone is so high that the fluid evaporates before even reaching the tip of the cutting edge. It is therefore preferable to use cutting tools for high-pressure coolant, such as drills with internal coolant supply and turning tools with targeted jets, combined with a high-pressure unit, for machining with sliding or fixed headstock lathes.
The high-pressure system manages the coolant: it distributes and delivers the fluid at varying pressures, recovers and filters the dirty fluid, contaminated by particles generated during machining, and recirculates it.
The precise and targeted pressurized jet, optimized based on the pressure and flow requirements of each individual tool, effectively cools and lubricates the cutting area. It optimizes chip management and limits heat generation, ensuring an immediate increase in turning center performance and productivity.
Chip control directly impacts the efficiency and performance of the machine tool and the entire production process.
The use of high-pressure coolant during turning operations facilitates chip breakage and evacuation and promotes the formation of smaller chips compared to dry or low-pressure machining. Short chip management significantly reduces machine downtime for maintenance operations, due to the accumulation of long chips on the tool and component or the clogging of the chip conveyor. Thanks to the cooling action and the correct fluid pressure, the work area remains always clean and free of residues.
High pressure requires the use of uncontaminated coolant, free of suspended particles that could clog the fine passages of ducts and nozzles near the cutting tools, causing damage to the workpiece and the tool itself. A highly effective filtration system is therefore required, capable of intercepting microparticles, separating them from the liquid, and ensuring a high level of cleanliness. An advanced and appropriately sized filtration circuit is of fundamental importance for long, uninterrupted operation: it minimizes downtime due to filter cleaning and replacement or other maintenance operations due to blockages caused by poor chip management.
The generation of high temperatures is one of the most impactful factors in turning operations. The use of a high-pressure system for managing the coolant significantly reduces heat generation.
The targeted jet and controlled pressure allow for effective cooling of the cutting area, thus preventing overheating of the tool and the workpiece. The lower temperature brings numerous benefits to the entire process, including proper lubrication, optimized performance and tool life, and increased feed and turning speeds.
Reducing the heat generated also makes it easier to preserve the structure and properties of the material being machined, avoiding deformations and damage due to increased temperatures, such as thermal expansion that changes the size of the workpiece. This achieves better final component quality, a particularly important aspect for applications requiring extremely precise finishing.
The correct choice of high-pressure system for managing the lubricating and cooling fluid is strategic for increasing productivity and reducing overall costs in applications involving chip removal machining such as bar turning.
The IEMCA high pressure system is designed to integrate perfectly with the bar feeder: the compact size and the tidy layout of cables and pipes allow it to be installed under the machine, optimizing the space occupied in the workshop. The operating status is monitored through the same operator panel as the bar loader.
The IEMCA Blue Line high-pressure unit is equipped with a two-stage filtration circuit with cartridge filters: the large filter surface area optimizes system operation and maintenance, minimizing downtime.
Thanks to the use of a vane pump, the coolant can be kept constantly under pressure inside the unit, so it can be quickly recirculated and used, avoiding long waits and energy waste. Output pressures can also be varied based on the needs of each lathe tool to ensure maximum adaptability and flexibility.
The configuration of the IEMCA high-pressure system can be customized to meet the requirements of each individual application, such as the specifics of the production process, type of machining, and material used.
Contact us now to find out how the IEMCA high-pressure unit can improve your production performance.