PROJECT
TESTING IN PRACTICE AND PERSPECTIVES
Abbildung 1: Source: Profactor Produktionsforschungs GmbH
Two enterprises – Protan Produktionstechnik and Josef Haidlmair Werkzeugtechnik – used the minimum cooling lubricant system developed in project 2 in practical applications. They tried particularly delicate applications in order to identify the limitations and problems of the technology. They worked in deep cavities to investigate chip removal and cooling lubricant delivery in hard to access spots. Weak points were associated, amongst others, with an increased susceptibility to corrosion of whetted surfaces and with shorter tool life.
As far as emissions are concerned, the trials yielded some rather promising results. At Protan for instance, the use of an emulsion-based cooling lubricant system (in long-hole drilling on a gear ring) reduced the overall aerosol concentration from initially 16.22 mg/m3 (flood lubrication) to 1.88 mg/m3. This corresponds to a reduction of emissions by approx. 90%.
Experience from practice has shown that the chemical, physical, and technological properties of the cooling lubricants have to be adapted to the individual processes through careful selection of additives. There is still need for further development in the field of nozzle systems because suitable solutions are technologically relatively complex and expensive. Solutions are also required for inherent weak points of minimum lubrication systems such as poor chip removal.
Overall, the research projects have demonstrated the great potential for development of emulsion-based minimum cooling lubricant systems using renewable raw materials. The research results constitute an important basis for further diffusion of the new technologies. The project partners Agatex Feinchemie GmbH and TPS Technische Produkte are now in a position to further optimize “Bio-Minimum-Lubrication” on the basis of experience gained so far.
Abbildung 2: Source: Profactor Produktionsforschungs GmbH
