CASE STUDY: CUSTOMER SPECIFICATION/CHALLENGE
When the owner of a flashlight manufacturing company called us, he was looking for a solution to cool aluminum during cutting without using liquid coolant. The company uses an Avid CNC PRO60120 milling machine with a 5' x 10' table, a 3 HP spindle, and VFD to machine many of the parts they produce. They use two ¾-inch thick MDF cutting boards, which are milled flat to better support the workpieces being machined. Liquid coolant cannot be used with MDF boards because it contaminates them. When the company tried machining aluminum, the product's soft, malleable nature caused it to bind with the cutting tools, resulting in rough surfaces and damaged tools. After machining, the aluminum parts are powder-coated and laser-engraved, so a smooth surface is essential.
THE SOLUTION
After considering all parameters, it was agreed that the Cold air gun 611 Frost Free the best result for the application. The company's 3-horsepower air compressor with a 60-gallon tank would power the cold air gun. The 611's frost-free capabilities were crucial for the manufacturer, as they did not want condensation dripping from the cold air gun's flexible nozzle onto the workpieces or the MDF scrap board. The 611's air consumption was well-suited to their compressed air source, and its 900 BTUh cooling capacity and temperature adjustability met their requirements for working with 3.1 mm (1/8 inch) thick aluminum sheets.
THE RESULT
The company fabricated a steel bracket that attached to the aluminum plate on the Avid spindle, allowing the 611's magnetic support base to be used to quickly mount the Frost Free cold air gun close to the cutting tool. The Avid machine is equipped with a vacuum chip removal system. The 611's flexible nozzle extends through the brush surrounding the vacuum intake head, directing the cold air close to the cutting tool. The manufacturer reports that the 611 performs exceptionally well when cutting aluminum, preventing the aluminum from sticking to the cutting tools and resulting in improved surface finish.
HOW THE FROST-FREE COLD AIR GUN WORKS
Frost-free cold air guns utilize vortex tube technology and filtered compressed air to produce sub-zero temperatures as low as -10°F for numerous industrial spot cooling applications. Because there are no moving parts that can wear out, frost-free cold air guns require no electricity at the point of use, only a source of clean, dry compressed air. The frost-free cold air gun features a double-insulated, flexible cold air outlet that prevents condensation and frost buildup on the nozzle.
Frost-free cold air guns are most commonly used for cooling metal parts during the machining and repair of metals, plastics, wood, ceramics, and other materials. Cold air machining outperforms mist coolants and significantly increases tool life and feed rate in dry machining operations. The active cooling provided by a frost-free cold air gun prevents heat-induced part growth and simultaneously improves part tolerances and surface finish. 611 Frost-Free cold air gun It consumes only 15 scfm of compressed air while simultaneously generating up to 900 BTU of cooling and temperatures as low as -10 °F.
Learn more here More about Vortec cold air guns.
Source: SUREFIRE SOLUTIONS WITH VORTEC AIR COOLING (vortec.com)