EMO Hannover 2019, 16 - 21 September

    EMO Hannover 2019, 16 - 21 September
    EMO news

    Dry machining and MQL conquering more and more applications

    Wet or dry – EMO Hannover 2019 showcasing wide range of technologies (Part 1)

    08 Apr. 2019
    10-01_Bielomatik_Teil_1
    The shavings which are produced when machining using minimum quantity lubrication (MQL) are virtually residue-free and can be recycled directly.

    Frankfurt am Main, 10 April 2019. – Production managers in manufacturing often have to ask themselves: should we continue with conventional machining and coolant lubricants, or do dry machining or minimum quantity lubrication (MQL) represent viable alternatives? Several factors influence this decision. In Part 1 of this two-part series of technical articles being published in the run-up to EMO Hannover 2019, lubrication system experts and scientists give their assessment. Tool and machine manufacturers shed light on the subject in the second part.

    Very high temperatures are generated in the cutting zone during machining. Coolant lubricants reduce friction, provide cooling (but may also cause destructive thermal shocks) and support the removal of chips. Back at the turn of the millennium, some experts predicted dry machining would make a breakthrough as a substituting process. It is now time to assess the current position. In which areas have this process, or minimum quantity lubrication (as quasi-dry machining) become established, and to what extent? In this two-part technical report, lubrication system manufacturers, machine and tool suppliers and scientists provide a comprehensive assessment from various perspectives and identify the advantages and disadvantages of the respective technologies.

    Particular relevance for series machining

    "The main area of application for minimum quantity lubrication lies in the machining of prototype parts as found in large-scale series production in the automotive industry - especially of powertrains. The parts range from the cylinder head and engine block to the crankshaft or camshaft, connecting rod, gearbox and wheel carrier, etc.," says Jürgen Keppler in Technical Sales at bielomatik Leuze GmbH + Co. KG in Neuffen. The BadenWürttemberg-based engineering company is a recognised specialist in the development and manufacture of high-quality MQL systems. "Further industrial applications include the machining of cubic components and mechanical engineering castings such as fittings, pump housings or valves. It is a great advantage in the aviation industry, too, if complex components are not flooded with emulsion."

    The expert estimates that MQL is used for machining about 15 per cent of new large-series components, rising to 70 per cent for deep hole drilling in crankshafts, for example. "MQL will continue to grow in the other application areas I just mentioned," says Keppler, convinced. "The upswing in MQL machining predicted some 20 years ago has mainly occurred in the automotive sector. Here, the advantages of MQL could be fully exploited in the machining of cast and forged parts. The high quantities involved also allowed the related R&D work to be carried out. New application are-as will also arise from the forthcoming changes in e-mobility and additive manufacturing. The great advantage of MQL lies in the cost savings to be made in resources such as oil, water and energy." Further advantages are dry workpieces, no carry-over of emulsion and contamination in the production bays, and the prevention of associated health risks. "The con-stant further development of materials and applications is placing new demands on machining processes and thus on MQL systems. This will certainly result in interesting solutions," says Keppler.

    What do the scientists say?

    "Thanks to modern cutting materials, dry machining has been introduced in almost all areas of machining production. Increasing cost pressure, but also energy consumption and ecological aspects are leading to a renaissance of these technologies," says Dr. Ivan Iovkov Head of Cutting Technology at the Institute of Machining Technology ISF of the Technical University of Dortmund. "Dry machining is not only used in conventional milling or turning. There are also efforts to minimise or completely avoid the use of coolant lubricants in complex processes such as deep drilling and gear hobbing.

    However, the cutting processes and the technology still need to be adapted in certain ways." Dry machining tends to be more common in big companies which process larger quantities than in smaller companies which specialise in varying types of high-precision and complex components.

    "I think there will be both dry and wet machining in the future," he predicts. "We need to take a holistic view of production when deciding whether dry machining makes sense or whether it will involve disproportionately high process adaptation costs. The continuous further development of MQL device technology and coatings, the increasing accuracy of the machine park, but also digitalisation – for example through in-process sensor monitoring of relevant variables – will make it possible in the future to carry out more and more dry or MQL machining under robust practical conditions."

    Summary

    It is too soon to speak of conventional machining processes being com-prehensively replaced by dry machining or minimum quantity lubrication, as wet machining (involving larger quantities of coolant lubricant) still accounts for an estimated 85 per cent of machining. Nevertheless, dry processes are conquering more and more areas, both in the general machining sector and above all in special areas. In the second part of the article, tool and machine manufacturers take a practical view of the different production technologies and recommend adopting a holistic approach. Trade visitors to EMO Hannover 2019 will find extensive information and support which can help them find the right technology for their own individual applications.

    Author: Dag Heidecker, daxTR – Technik + Redaktion, Wermelskirchen

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    Contact persons

    VDW Verein Deutscher Werkzeugmaschinenfabriken e.V.
    Gerda Kneifel
    Presse- und Öffentlichkeitsarbeit
    Corneliusstraße 4
    60325 Frankfurt am Main
    Deutschland
    Tel.: +49 69 756081-32
    g.kneifel@vdw.de
    www.vdw.de

    bielomatik Leuze GmbH + Co. KG
    Carolin Nuffer
    Marketing Schmiersysteme
    Daimlerstr. 6–8
    72639 Neuffen
    Tel. +49 7025 12-478
    Fax +49 7025 12-556
    E-Mail: Carolin.Nuffer@bielomatik.de
    Internet: www.bielomatik.com

    Technische Universität Dortmund
    Institut für Spanende Fertigung ISF
    Maschinenbau III, Raum 2.029
    Dr.-Ing. Ivan Iovkov
    Abteilungsleiter Zerspanung
    Baroper Str. 303
    44227 Dortmund
    Tel. +49 231 755-4860
    Mobil +49 160 97 999 337
    Fax +49 231 755-5141
    E-Mail: ivan.iovkov@tu-dortmund.de
    Internet: www.isf.de

    EMO Hannover 2019 – the world’s premier trade fair for the metalworking sector

    From 16 to 21 September 2019, international manufacturers of production technology will be spotlighting smart engineering at the EMO Hannover 2019. Under the motto of "Smart technologies driving tomorrow’s production", the world’s premier trade fair for the metalworking industry will be showcasing the entire band-width of modern-day metalworking technology, which is the heart of every industrial production process. The fair will be presenting the latest machines, plus efficient technical solutions, product-supportive services, sustainability in the production process, and much, much more. The principal focus of the EMO Hannover is on metal-cutting and forming machine tools, production systems, high-precision tools, automated material flows, computer technology, industrial electronics and accessories. The trade visitors to the EMO come from all major sectors of industry, such as machinery and plant manufacturers, the automotive industry and its component suppliers, the aerospace sector, precision mechanics and optics, shipbuilding, medical technology, tool and die manufacture, steel and lightweight construction. The EMO Hannover is the world’s most important international meeting point for production technology specialists from all over the planet. The EMO Hannover 2017 attracted almost 2,230 exhibitors from 44 different countries, and around 130,000 trade visitors from 160 nations. EMO is a registered trademark of the European Association of the Machine Tool Industries CECIMO.

    You will find images relating to this article on the internet at: www.emo-hannover.de/imagedatabase?keyword=dry machining . You can also follow the EMO Hannover using our social media channels

    http://twitter.com/EMO_HANNOVER
    https://de.industryarena.com/emo-hannover
    http://www.linkedin.com/company/emo-hannover
    http://www.youtube.com/metaltradefair
    http://facebook.com/EMOHannover

    10-01_Bielomatik_Teil_1

    Photo: bielomatik Leuze The shavings which are produced when machining using minimum quantity lubrication (MQL) are virtually residue-free and can be recycled directly.

    10-02_Trockenbearbeitung_ISF_Teil_1

    Photo: ISF There are many successful examples of dry machining in individual industries or companies.

    10-03_ganzer Prozess_Teil_1

    Photo: Dag Heidecker Users are recommended to take a holistic view when deciding whether to deploy dry or MQL machining or whether a classic process should be used.

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