Greetings,

 ChipBLASTER is the world leader in coolant systems and technology in the field of High-Pressure-Coolant. We are internationally recognized for the most reliable, most economical, and most successful units in the market. This offers you, our valuable customer, productivity increases, reduced energy costs, increases in tool life, reduced cycle times, and a higher cutting quality with better surface finishing.

 The ChipBLASTER key to success is the total temperature and chip control in the cutting process, which eliminates a number of problems that traditional coolant application can only solve by reducing the cutting speeds.

 The difference that makes ChipBLASTER the technological leader is that ChipBLASTER addresses the cooling subject from a new, purely scientific point of view.  Everything ChipBLASTER does is based on scientific understanding rather than trial and error or reverse engineering.

 In the machining example on the following pages we show the benefit on high pressure coolant.  In a similar test you could easily see much longer overall tool life if cutting at conventional machining speed by using high pressure coolant.  In some cases, such as the solid carbide drills, you can get up to 10 times the tool life when you are cutting with high pressure coolant at conventional speeds.

 Or if you prefer the same tool life in your process, you can cut much faster with high pressure coolant.  In this machining example the parts could be completed in just over 4 hrs (versus 9 hrs at conventional speed) running maximum speed with high pressure coolant.

 However, running an optimized process between tool life and cutting speed gives you the most profitable result.  By doing so, we can show a metal removal rate increase of 80% and an overall productivity increase of 59% over conventional machining with 4-5 times longer tool life.

 The productivity increases shown in this real production scenario is available on over 90% of the applications in the metal cutting industry.  The ROI is reached after 35 days and you will be able to realize approximately € 77,880.00 in savings per year, per single shift!

 We are looking forward to hearing from you and to answering all your questions regarding High-Pressure-Coolant and ChipBLASTER.

Sincerely 

Part: Hydraulic Manifold Block

Material: 1018 Steel

Machine Tool: Vertical Machining Center (40 Taper)

Coolant Unit: ChipBLASTER JV10 (Max Volume 38 lpm)

Coolant Type: Master Chemical C350 10% Concentration Level

Pressures: Low Pressure (4 Bar) and High Pressure (70 Bar)

Tool

Tool Type

Manufacturer

T-1

45 Degree Face Mill

Kennametal

T-2

25 mm Chamfer Tool

K-Tool

T-3

30 mm Indexible Magic Drill

Kyocera

T-4

27 mm Indexible Drill

Kennametal

T-5

13 mm by 90 degree Spot Drill

Kennametal

T-6

17 mm QPV Spade Drill

Kennametal

T-7

19 mm Solid Carbide End Mill

ChipBLASTER Modified

T-8

#16 Indexible Port Tool

Metcut

T-9

#8 Indexible Port Tool

Metcut

T-10

19 mm Solid Carbide Ball Nose

ChipBLASTER Modified

T-11

12 Pitch Indexible Thread Mill

Xact Form

T-12

16 Pitch Indexible Thread Mill

Xact Form

T-13

6.7 mm Solid Carbide Drill

CJT Coolcarb

T-14

32 mm Bottom Tap

OSG

T-15

8.7 mm Solid Carbide Drill

CJT Coolcarb

Operation

SMM

RPM

FPR/mm

mm/min.

Cut Time per Part

T-1

KENNAMETAL 45 DEG FACE MILL

212

977

.846

826

1:16

T-2

25 MM (K-TOOL) CHAMFER TOOL

396

5730

.203

1164

:52

T-3

30 MM KYOCERA MAGIC DRILL

92.5

1132

.114

129.4

1:01

T-4

27 MM KENNAMETAL CORE DRILL

132

1797

.102

182.6

:26

T-5

1/2 BY 90 DEG. CARBIDE SPOT

163

4737

.051

240

:20

T-6

17 MM SPADE DRILL (peck drill every 13mm)

39.6

853

.203

173

4:32

T-7

19 MM STRAIGHT CEM, 1.95 OUT

92

1783

.279

498

2:43

T-8

#16 INDEXABLE PORT TOOL

199

2200

.102

223

:30

T-9

#8 INDEXABLE PORT TOOL

144

2791

.076

212

:53

T-10

19 MM BALL NOSE CEM, 1.85 OUT

92

1783

.279

498

1:05

T-11

12 PITCH INDEXABLE THD MILL

132

3056

.015

46.6

2:58

T-12

16 PITCH INDEXABLE THD MILL

132

2547

.025

64.7

3:13

T-13

6.7 MM CJT DRILL

92

5026

.152

766

:15

T-14

32 OSG BOTTOM TAP

13

606

1.25

757.9

:20

T-15

8.7 MM CJT DRILL 66 MM LOC

79

3333

.178

592

:23

*Total Time to Complete 20 Parts

9 hours 1  minute

Operation

SMM

RPM

FPR/mm

mm/min.

¹PMR

Cut Time per Part

T-1

KENNAMETAL 45 DEG FACE MILL

325

1500

.847

1270

154%

:52

T-2

25 MM (K-TOOL) CHAMFER TOOL

691

10000

.203

2032

175%

:35

T-3

30 MM KYOCERA MAGIC DRILL

188

2300

.144

330

255%

:28

T-4

27 MM KENNAMETAL CORE DRILL

132

1800

.254

457

250%

:15

T-5

1/2 BY 90 DEG. CARBIDE SPOT

173

5000

.051

254

106%

:15

T-6

17 MM SPADE DRILL (peck drill every 13mm)

93

2000

.229

457

264%

1:37

T-7

19 MM STRAIGHT CEM, 1.95 OUT

116

2250

.452

1016

204%

1:23

T-8

#16 INDEXABLE PORT TOOL

272

3000

.093

279

125%

:26

T-9

#8 INDEXABLE PORT TOOL

233

4500

.073

330

164%

:38

T-10

19 MM BALL NOSE CEM, 1.85 OUT

103

2000

.762

1524

306%

:27

T-11

12 PITCH INDEXABLE THD MILL

134.5

2800

.032

88.9

191%

2:15

T-12

16 PITCH INDEXABLE THD MILL

145

3800

.023

88.9

137%

1:48

T-13

6.7 MM CJT DRILL

103

5600

.204

1143

149%

:13

T-14

32 OSG BOTTOM TAP

16.3

750

1.25

937.3

124%

:19

T-15

8.7 MM CJT DRILL 66 MM LOC

95

4000

.235

939

159%

:18

*Total Time to Complete 20 Parts

5 hours 39 minutes

Cost Savings Per 20 Parts

Assuming € 75/hr shop rate for the machine

€ 75.00 x 3.3 hours = € 247.00

QPV Spade Drill Insert

Picture taken after completion of the 20 parts

4 bar coolant pressure

QPV Spade Drill Insert

Picture taken after completion of the 20 parts

70 bar coolant pressure

Porting Tool Inside Edge

Picture taken after completion of the 20 parts

4 bar coolant pressure

Porting Tool Inside Edge

Picture taken after completion of the 20 parts

70 bar coolant pressure

4 bar coolant pressure

Coolant is applied through “fish eyes”. Most of the coolant force is not effectively because it is not directed at the cut point.

70 bar coolant pressure

Coolant is applied at the chip/tool interface or through the tool and all of the coolant force is used directly at the cut point.