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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 |
The following study was done under controlled conditions in a machine shop. | |
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) |
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Tools Used:
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 |
|
T-15 |
8.7 mm Solid Carbide Drill |
CJT Coolcarb |
Cutting Conditions and Times:
Low Pressure Coolant
Operation |
SMM |
|
FPR/mm |
mm/min. |
|
Cut Time per Part |
|
T-1 |
KENNAMETAL 45 DEG FACE |
212 |
977 |
.846 |
826 |
|
|
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 |
|
|
T-4 |
27 MM KENNAMETAL |
132 |
1797 |
.102 |
182.6 |
|
:26 |
T-5 |
1/2 BY 90 DEG. CARBIDE |
163 |
4737 |
.051 |
240 |
|
:20 |
T-6 |
17 MM SPADE DRILL (peck drill every 13mm) |
39.6 |
853 |
.203 |
173 |
|
|
T-7 |
19 MM STRAIGHT |
92 |
1783 |
.279 |
498 |
|
|
T-8 |
#16 INDEXABLE |
199 |
2200 |
.102 |
223 |
|
:30 |
T-9 |
#8 INDEXABLE |
144 |
2791 |
.076 |
212 |
|
:53 |
T-10 |
19 MM BALL NOSE |
92 |
1783 |
.279 |
498 |
|
|
T-11 |
12 PITCH INDEXABLE |
132 |
3056 |
.015 |
46.6 |
|
|
T-12 |
16 PITCH INDEXABLE |
132 |
2547 |
.025 |
64.7 |
|
|
T-13 |
6.7 MM CJT DRILL |
92 |
5026 |
.152 |
766 |
|
:15 |
T-14 |
32 |
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 |
High Pressure Coolant
Operation |
SMM |
|
FPR/mm |
mm/min. |
1PMR |
Cut Time per Part |
|
T-1 |
KENNAMETAL 45 DEG FACE |
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 |
132 |
1800 |
.254 |
457 |
250% |
:15 |
T-5 |
1/2 BY 90 DEG. CARBIDE |
173 |
5000 |
.051 |
254 |
106% |
:15 |
T-6 |
17 MM SPADE DRILL (peck drill every 13mm) |
93 |
2000 |
.229 |
457 |
264% |
|
T-7 |
19 MM STRAIGHT |
116 |
2250 |
.452 |
1016 |
204% |
|
T-8 |
#16 INDEXABLE |
272 |
3000 |
.093 |
279 |
125% |
:26 |
T-9 |
#8 INDEXABLE |
233 |
4500 |
.073 |
330 |
164% |
:38 |
T-10 |
19 MM BALL NOSE |
103 |
2000 |
.762 |
1524 |
306% |
:27 |
T-11 |
12 PITCH INDEXABLE |
134.5 |
2800 |
.032 |
88.9 |
191% |
|
T-12 |
16 PITCH INDEXABLE |
145 |
3800 |
.023 |
88.9 |
137% |
|
T-13 |
6.7 MM CJT DRILL |
103 |
5600 |
.204 |
1143 |
149% |
:13 |
T-14 |
32 |
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 |
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Cost Savings Per 20 Parts |
Assuming € 75/hr shop rate for the machine |
€ 75.00 x 3.3 hours = € 247.00 |
*Tool changes, manual operations, and part re-clamping are added to the cut times for this total
1(PMR) Percentage Metal Removal compared to Low Pressure
Total saving per 20 parts with high pressure coolant = €247.00
ROI of ChipBLASTER JV10 CE certified unit
€ 12,368.00 (Cost for JV10 CE) / € 354.00 per day = 35 Days*
Savings per Year (220 work days per anno): 220 days x € 354.00 per day = € 77,880.00*
*(Based on productivity increase in parts of 59% daily, per one 8 hour shift.)
Call us today at +1-814-724-6278 to discuss your specific application with us.
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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 |
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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 |
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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. |