With standard turning tools the coolant doesn't even hit the part

The operator aims the coolant by hand at the tool using snap together plastic beads or copper tubing. Every operator does it differently, and during operation the coolant lines are frequently pushed out of alignment so that the operator has to manually readjust the aim of the coolant, often every time they change a part. One coolant manufacturer estimates that 40% of the time the coolant doesn’t hit the tool or the part. Even when the coolant hits the tool there is no directional control; it can typically come from any direction within a 180-degree arc in one axis and a 90-degree arc in the other axis. Real process control from setup to setup and throughout a production run is virtually nonexistent.

Coolant alignment machined into the Tool Holder.

Tools designed for coolant. ChipBLASTER has introduced a unique nozzle design as part of the holder, insuring that the coolant always hits the insert at exactly the right spot, putting the force where you need it. This new turning system includes carbide inserts optimized specifically for high-pressure coolant. The process is repeatable from setup to setup and throughout a production run. Coolant application with this new technology is over a million times more accurate.

The coolant that is aimed at the tool doesn’t get to the tip of the tool.

The essence of the problem with standard low pressure coolant systems is that so much heat is produced that the coolant boils away before it can reach the chip tool interface where metal is actually cut. The super heated steam forms a barrier that low pressure coolant can’t penetrate. Some of the most toxic elements in the coolant are there to provide a slippery residue when all of the water has boiled away. Effective cooling does not occur and there is little real lubrication provided. Unfortunately, the vapor barrier that forms is not powerful enough to keep chips from falling back into the chip/tool interface and causing damage.

High force coolant (pressure and volume) prevents Vapor Barrier.

Properly applied high pressure and high volume coolant prevents this vapor barrier from forming by causing a localized pressure increase. So much liquid is forced into the cutting zone that heat is removed and no vapor can form because of the pressurization. A great deal of FORCE is required to achieve this pressurization, and this mass of liquid provides lubrication and flushes chips away from the cut There is a great deal of discussion about pressure, pressure is meaningless without volume. Force requires both mass and velocity, and the coolant must, of course, be focused at the chip tool interface, it doesn’t matter how big a gun you have if you miss the target. With all of the elements you have real control of your process, damage from heat and chips is eliminated, tools can cut until they wear out. High-pressure coolant keeps the temperature low; changing the way metal is cut. Tools last a long time, chips can’t weld, metal can be cut at much higher surface speeds, damaging chemical reactions do not occur at low temperatures. With a properly designed high pressure and high volume coolant and the appropriate tooling system, surface speed can be increased a minimum of 30%, with some operations improving by 300%. High-pressure coolant also provides lubricity by blasting lubricating fluid between the chip and the insert at hundreds of miles per hour. Combined with much lower temperature, this increased lubricity often causes surface finishes to be twice as good.