Oil to cut
Are you sure your cutting process works well?
Whenever you have to develop a new cutting process you look at many details:
- Kind of tool
- Cutting section
- Material characteristics
- ….Over time, many choices become easier and predictable.
But there is a problem!
The cutting lubrication should always be kept in mind. In fact, if you forget that your machine should have a reliable and precise tool lubrication system…. within a short space of time you will have a lot of trouble. Maybe it seems trivial, but it isn’t.
The lubrication system has to keep the tool cold and has to avoid the aluminium melting among the tool teeth.
It would be easy and obvious if you could use tons of oil.
You need to avoid “to soil” pieces; you have to avoid greasing chips
As you well know, after cutting, the piece undergoes further processing (blasting, hardening or painting) and oil on the surface always gives trouble.
The chip and riser are reclined throwing all in the oven, so the less oil we have the less smoke there will be. So, for the cutting process you have to lubricate “much” and for the rest as little as possible.
That’s why the lubricating system isn’t a trivial thing.
It has to do the best with the minimum amount of oil.
There are several methods of lubricating.
Is someone tells you that one method is as good as the other; it means that he does not know what he is talking about.
Each method is suitable for an application, for a number of revolutions, for a tool and for a material.
Then we must not forget the choice of the lubrication nozzle.
The nozzle must carry air and oil.
Many times it is important to have a nozzle that carries more air rather than more lubricant. At other times it is better to use a nozzle carrying pressure, but with small capacity.
Once you have chosen the system you’ve to chose the oil. If you think choosing the oiling system is complicated, it is 1000 times more complicated to choose the lubricant. There are different types and there are more or less suitable lubricants according to the lubricating system you use.
There are two methods to choose from:
- Trust expert advise
- Do scientific tests
If you trust, you save lots of time and energy (assuming that the expert is really an expert). On the basis of the working parameters, of the material and of the tool, you can choose the lubricant in a scientific way
If you want to do it yourself, you need all your patience and make some scientific tests.
That is, you need to measure the tool yield by always doing the same production and consciously varying cutting parameters and lubricants.
It’s not difficult, you just have to be sure not to make mistakes.
I will tell you a secret:
If you want to get a cut which maintains a close tolerance, lubrication is essential.
If you do not lubricate the tool well, you’ve never cut two pieces in the same way.
So it is useless to have a perfect machine and underestimate this problem. You’ll always have blades that hardly last and pieces looking as if they have been cut by biting.
You do not learn what I’ve written in textbooks at school. I learned it by experience.
Here you can download the video of a cutting operation with a lubricating system and a super-performance lubricant.
I’ve made comparative tests with a system I did at work: With the perfect lubricating system and the correct lubricant, the tool twice as better and cutting tolerance 5 times lower.