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Minimum Quantity Lubrication |
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| Technological Features |
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- Avoid health and environmental hazards
- High cost savings
- Enormous increase in productivity possible
- Cleaner products with higher surface quality
- Longer tool service lives
- Very little consumption of lubricant
- Very user and maintenance friendly
- Produces dry chips, and clean machines
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How it works
The conventional use of coolant lubricants costs a lot of money and is hazardous to health and the environment – and this to greater and greater degrees. You can avoid this if you introduce clean manufacturing technology, and you can increase your productivity at the same time, thus securing yourself the competitive advantages of tomorrow.
The principal feature of dry machining with MQL is the replacement of the coolant with a very small amount of mineral oil free synthetic oil, which is applied directly and in a precisely dosed manner at the cutting point. With the introduction of this residual-free consumption lubricant, your manufacturing costs will decrease considerably, because the high costs for the preparation and removal of emulsion can be avoided altogether. In addition, the costly health and environmental problems associated with the use of coolant lubricants are avoided as well. Cooling the product with emulsion is replaced with a strong reduction in heat from friction due to effective lubrication of the cutting area. Depending on the type of processing, between 5 and 75 ml of the corresponding oil is used per processing hour. The considerably improved lubrication of the machining area creates the possibility to operate the tools at much higher cutting speeds and feed rates. In this way it is not only possible to obtain an enormous increase in productivity, but also longer tool service lives and better surface quality of the products. The dry chips can then be recycled without incurring large cleaning expenses.
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Areas of Use
Principally, every cutting and non-cutting process is convertible from closed circuit cooling with coolant lubricant to dry machining with minimum quantity lubrication. Due to the flexibility of our products, we can offer you suitable individual solutions for a wide variety of manufacturing processes. Following is just a sample of the main manufacturing processes that were successfully made "dry" with our widely used systems.
- Turning
- Milling
- High Speed Milling
- Boring
- Deep Drilling (also alloyed steels)
- Tapping/ Thread moulding
- Grinding
- Drill finishing with single and multiple edge cutting tools
Whether for a processing center, for conventional or for CNC-controlled tool machinery, we offer various MQL systems, that are suitable for use with a wide variety of equipment. We can advise you extensively on the conversion of your manufacturing processes, and also help you with the selection of the ideal lubrication medium and cutting materials, in order to create a competent, individually optimized solution.
Depending on the manufacturing process, it is possible to supply the lubricant as an internal or external lubricant.
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Internal Lubrication
In internal lubrication, the lubricant is transported with a rotary union and through the shaft and the coolant channels of the tool, to be fed directly to the point of cutting. Existing machines can be fitted easily with the system, as long as they already have an internal coolant supply system. For this purpose, GAT offers two different systems.
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ROTOJET A
With the Aerosol-Booster ROTOJET A, the lubrication mixture is produced outside the spindle, and then supplied using a single channel system.
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ROTOJET I
With the ROTOJET I, the production of the oil-air mixture occurs inside the spindle, whereby the oil and air are supplied separately to the mixer jet.
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External Lubrication
In external lubrication, the lubricant is sprayed externally on the processing point using adjustable spray nozzles that are attached to the spindle housing.
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ROTOJET A
With the Aerosol-Booster ROTOJET A, the tool can also be sprayed externally in combination with an aerosol conversion jet. This solution is useful for tools without internal coolant channels. The same booster can be used selectively for internal and external lubrication with the help of a conversion switch.
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Further details can be explained and remaining questions can be answered by personally contacting our technical advisors. For this purpose, use:
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