High Technology Lubrication for Sawing Aluminum
Precision lubricants, sometimes called micro-applied lubricants, have revolutionized the sawing of aluminum -- billets,
extrusions, ingots, sheet and plate -- in recent years. This new technology, which is believed to have its origins in
the aerospace industry, is now the standard in plants around the world.
Users know these products by various trade names - CanMist and others. All offer advanced chemical properties
and require special applicators for precise application of minimal quantities of coolant/lubricant to the saw blade surfaces.
The function of saw coolants/lubricants is to cool the blade and prevent the accumulation
of metal build-up of hot metal in the "gullet" of the blade. Precision lubricants typically offer significant
advantages over the water emulsions, solvent carried oils, and wax sticks which were previously used:
- better quality cut ends
- drier cut ends
- less cleaning of parts and machinery
- reduced lubricant costs
- lower smoke generation
- minimal staining of parts
- drier saw chips - easier to sell or reclaim
- increased tool life
- improved safety (not OSHA regulated)
- no coolant maintenance, reclamation, or disposal
- reduced storage, freight, and handling costs
Chemical
technology has continued to improve the performance of sawing fluids, resulting in improved quality, with no odor, elimination
of smoke, non staining, non freezing, ease of removal in anodizing and painting, and improved pricing. Most of these
products are biodegradable, non-toxic, and environmentally sound. Depending on the application, additives may be included
for increased heat extraction, to be non-staining in heat treating, and to provide extreme pressure and wear properties.
The quality and performance of these products are expected to continue to be improved in the future.
Precision Applicators
Special applicator systems are needed to precisely meter and dispense the tiny amounts of these micro-applied sawing
fluids in exactly the right location. In the most common designs, fluid is metered by air-driven positive-displacement
injector pumps, which dispense a variable fluid volume per stroke. The driving air is likewise adjustable through a
pneumatic timer, and the spray pattern may be fine tuned by adjusting the atomizing air, which is delivered separately to
the applicator nozzle through a coaxial tube.
Many commercially
available micro-applicators have not been compatible with high-tech sawing fluids, so it is important to insure compatibility
of seals and other components. Some designs have been difficult to repair. Recent improvements to applicator systems
include:
- larger reservoirs (up to ½ gallon)
- self-priming fluid injectors
- manifolds and mounting brackets for yhe spray tips
- improved
component materials - seals, metals, fittings
- more easily
repaired
Amcol Corporation has recently introduced the
unique "T-60 Posi-Pump," which incorporates multiple injector pumps in a single extruded aluminum body - normally
1 to 5 injectors per unit, but even 8 or 10 are possible. Brass components and Viton seals insure fluid compatibility
and long life; there is no stacking of pumps and no O-rings. The injectors are inherently self-priming, and vapor lock
and cavitation are eliminated.
Tooling Lubrication for
Non-Ferrous Extrusion
Specialty lubricants and release
agents for high temperature non-ferrous extrusion press tooling from Amcol may be used to prevent metal build-up on tooling
and to prevent sticking. Typical applications:
- fixed
dummy blocks
- butt shear blades
- hot log shear tooling and entry lubrication
Lubricants
of this family increase productivity by reducing metal build-up on dummy blocks, butts stuck to the ram or butt shear blade,
and logs hanging up at the entry to the hot shear. Fluids may be applied by hand-held wand or sprayed automatically.
Automatic Lubrication of Press Tooling
Automatic spray applicators relieve the operator from the job of periodically hand spraying the dummy block and butt
shear and save downtime by spraying automatically during the press dead cycle. Automatic applicator systems available
from Amcol are custom tailored to the individual press. They may be purchased complete with control timers or may be
actuated from the press PLC control system. They are typically configures to apply fluids periodically, for example,
after every 5 or 10 billets are extruded.
Similar applicators
may be added to hot log shears to eliminate problems of hang-up at the point where the log enters the shear tools.
For more information contact:
Amcol Corporation
21435 Dequindre - Hazel Park MI 48030 USA
Tel:
248-414-5700 Fax: 248-414-7489
Or contact:
Al
Kennedy - Agent for portions of the southeastern
USA
Kennedy Eurotech, Inc. -
4 Oak Point - Newnan GA 30263 USA
Tel: 770-304-1000 or 800-364-7995
- e-mail: alkennedy@numail.org
