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Filtration@MetalCutting

Case 1: Centralized Coolant filtration and Chip Handling System

System parameters
? Number of machine tools: 26
? Processing methods: turning, milling, drilling, grinding
? Water tank capacity: 50000 liters
? Coolant flow: 5000 l / min
? Coolant pressure: 5.0 bar / 40-80 bar
? Filtration accuracy: 20 microns
? Coolant temperature: 22 ± 1 ° C

System parameters of central chip vacuum suction system
? Number of machine tools: 23
? Processing methods: turning, milling, drilling, grinding
? Chip material: cast iron, steel, aluminum
? Chip suction capacity: 80 kg / h / unit
? Length of chip extraction pipeline: 200 meters
? Suction capacity: 2000 kg / h
? Suction pressure difference: 500 mbar
? Suction speed (pipeline): 30 – 50 m / s
? Chip separation: aluminum chips are separated from cast iron / steel chips automatically

Case 2: Centralized Filtering System for Crankshaft Production

Main System Parameters:

? Coolant flow rate: 6000 l/min

? Workpiece material: Hardened steel

? Chip output: 18 kg/h

System Features:

? Mature and reliable filterless consumable technology

? Filtration accuracy is less than 10 microns

? Temperature control ± 5K / 10 minutes

Case 3: Centralized Coolant Filtration System and Chip Handling System

Solution

KNOLL's MicroPur ultra-precision filtration technology replaces pre-coated filtration technology.

Pre-coating Technology

Cellulose consumption: 192,000 Euro / year

MicroPur Filtration Technology

Filter cartridge consumption: 15,360 Euro / year

Case 4: Crankcase Automatic Coolant Supply and Chip Handling System

Main System Parameters:

? Workpiece materials: Aluminum, cast iron

? Coolant type: Emulsion

? Coolant flow: 10000 l/min

? Chip output: 900 kg/h

System Features:

? Provide coolant filtration cycle and chip disposal for 30 machine tools

Solution:

? Aluminum chip pump

? Multi-stage filtration and recoil filtration

? Dehumidification of centrifuge debris

? Magnetic separation technology

Case 5: Centralized Coolant Filtration System for Grinding Turbine Products

Main System Parameters:

? Workpiece material: Inconel

? Coolant type: Emulsion

? Coolant flow: 4000 l/min

? Chip output: 700 kg/h

System Features:

? Small double-layer structure

Solution:

? Wear-resistant pre-separation equipment

? Modular filtration technology

Case 6: Coolant Centralized Filtration System

18 processing centers with two processing lines

System parameters:

? Two machining lines with a total of 18 machining centers

? Workpiece material: Cast irons

? Coolant flow: 2 x 4500 l/min

? Chip output: 2 x 200 kg/h

System Features:

? Automatic filtering and conveying of cast iron chips

Solution:

? Pump back to the pumping station

? Turbo filtration

? High voltage station

Case 7: Central coolant filtration system and chip handling system

System Parameters:

? Number of machines: 13

? Workpiece materials: Steel, cast iron

? Coolant flow: 1200 l/min

? Chip output: 400 kg/h

System Features:

? Automatic filtering and conveying of cast iron debris

Solution:

? Chipper

? Manual chip delivery

? VRF900-2 vacuum rotary filter

Case 8: Chip Processing and Coolant Filtration System

System Parameters:

? Workpiece material: Inconel

? Coolant flow rate: 10 x 450 l/min

? Chip output: 400 kg/h

System Features:

? 160-meter long chip conveyor

? Extremely harsh external environment

Solution:

? ZK type traction chip conveyor

Case 9: Centralized Chip Handling and Coolant Filtration System

System Parameters:
? Number of machines: 18
? Workpiece material: Steel
? Total coolant flow: 3200 l/min
? Chip output: 200 kg/h
System Features:
? Compact design of the entire system

Case 10: Coolant Centralized Filtration System

System Parameters:

? Number of machines: 19

? Workpiece material: Carbide

? Coolant flow rate: 2400 l/min

? Filtration accuracy: Less than 3 microns

System Features:

? High filtration quality

? Low temperature difference control

? Installed in the foundation

Solution:

? MicroPur ultra-fine filtration system with AK grinding mud concentration.

Case 11: Coolant Centralized Filtration System

System Parameters:

? Number of machine: 2 gantry milling machines

? Workpiece material: Aluminum alloy

? Coolant flow rate: 3000 l/min

? Chip output: 400 kg/h

Solution:

? Multi-stage filtration system

? Backflush filter

? Chip briquetting

Case 12: Coolant Centralized Filtration System

System Parameters:

? Number of machines: 2 grinding machines

? Workpiece material: Hardened steel HRC 65

? Coolant flow rate: 1400 l/min

? Chip output: 25 kg/h

System Features:

? High air content in the coolant

Solution:

? VL vacuum filter

? Coolant degassing holes

Case 13: Coolant Centralized Filtration System

System Parameters:

? Number of machines: 21 grinding machines

? Workpiece material: Hardened steel HRC 65

? Coolant flow rate: 1500 l/min

? Chip output: 250 kg day

System Features:

? After the relocation of the machine tool, it will be incorporated into the central filtering system

? Simple and economical solution

Solution:

? Each machine tool is equipped with a pumping station to draw back the coolant

? Central system filtering

? Adopting turbo filter technology

Case 14: Coolant Centralized Filtration System

System Parameters:

? Number of machines: 4 grinders

? Workpiece material: Carbide

? Coolant type: Pure oil

? Coolant flow rate: 400 l/min

? Filtration accuracy: 3-5 microns

System Features:

? Compact, flexible and highly reliable.

Solution:

? MicroPur filtration system with AK20 grinding mud concentration.

Case 15：Coolant Centralized Filtration System

System Parameters:

? Application: Grinding aircraft engine blades

? Workpiece material: Inconel

? Coolant flow rate: 1800 l/min

System Features:

? 70 bar pressure high pressure pump wear-resistant technology

? According to CSA standards

Solution:

? Multi-stage filtration: Sedimentation, cyclone filtration and bypass centrifuge filtration

Case 16: Centralized Coolant and Chip Handling System

System Parameters:

? Workpiece material: cast iron

? Coolant flow rate: 20,000 l/min

? Chip output: 1100 kg/h

System Features:

? Short installation time

Solution:

? Coolant multi-stage filtration and chip handling system

? Upper and lower floors

Case 17: Coolant Centralized Filtration System

System Configuration:

? 8 sets of compact filters for chip separation

? Sewage tank capacity of 60,000 liters

? Scraper chip conveyor

? Equipped with MicroPur ultra-precision filtration unit

? 4 sets of plate heat exchangers with a total power of 225 kW

? Automatic separation and concentration device for crumbs

? Equipped with safety water tank

Case 18: Coolant Centralized Filtration System

System Parameters:

? Number of machines: 2

? Workpiece material: Steel

? Process: Grinding and grinding wheel dressing

? Coolant flow rate: 600 l/min

? Coolant type: Emulsion

? Operating temperature: 22 ° C

? Chip shape: Granular

? Chip removal: 14 kg/h

System Configuration:

? Static pressure filter

? Magnetic separation device (pre-filtration)

? Bypass centrifuge (fine filtration)

Case 19: Coolant Centralized Filtration System

System Parameters:

? Number of machines: 4

? Workpiece material: Steel

? Process: Grinding

? Coolant flow rate: 400 l/min

? Coolant type: Pure oil

? Working viscosity: 9 mm2 /s

? Residue concentration: ≤ 20 mg/l

? Chip shape: Granular

? Abrasion characteristics: Easy to accumulate

? Chip output: 1 kg/h

? Chip removal: Continuous

Case 20: Coolant Centralized Filtration System

System Parameters:

? Number of machines: 18

? Workpiece material: Steel

? Process: Turning, drilling

? Coolant flow rate: 3240 l/min

? Coolant type: Emulsion

? Coolant concentration: 7%

? Operating temperature: 24 ° C

? Filtration accuracy: 50 μm

? Residue concentration: ≤60 mg/l

? Chip shape: Short

? Chip output: 204 kg/h

? Chip content: 0.7 kg/l

? Chips removal: Continuous

Case 21: Coolant Centralized Filtration System

System Parameters:

? Number of machines: 12 sets (phase I) + 25 sets (phase II)

? Workpiece material: Steel

? Process: Turning, drilling

? Coolant flow rate: 1500 l/min

? Coolant type: Emulsion

? Coolant concentration: 8%

? Operating temperature: 25 ° C

? Chip shape: Short

Case 22: Centralized Chip Handling System

System Parameters:

? Chip output: about 600 kg/h

? Suction length: about 280 meters

? Automatic separation of cast iron and steel chips

System Configuration:

? 11 sets of ZVD chip breakers

? 2 sets of 600K-4 chip removal devices

? 4 sets of chip filter towers

Case 23: Centralized Chip Handling System

System Parameters:

? Workpiece material: High-strength steel

? Process: Drilling, chipping

? Coolant type: Emulsion

? Chip output: 48 dm3/min

? Chip fluid flow: max. 900 l/min/machine

Case 24: Centralized Chip Handling System

System Parameters:

? Number of machines: 19

? Workpiece material: High hardness steel

? Process: Drilling, milling

? Coolant type: Emulsion

? Chip output: 400 l/min

? Chip fluid flow: 450 liters per minute

? High pressure supply: 84 l/100 bar and 40 l/120 bar

? Low pressure supply: 300 l/ 3.5 bar

Case 25: Centralized Chip Handling System

System Parameters:

? Number of machines: 7

? Workpiece material: Steel

? Processing method: Turning

? Coolant type: Pure oil

? Chip fluid flow: 130 l/min

? Working viscosity (40 ° C): 12 mm2 /s

? Chip shape: Short, long, tufted

? Chip transportation: Batch

? Amount of chips per batch: 100 liters (7 machines / 8 hours)

Case 26: Centralized Chip Handling System

System Parameters:

? Number of machines: 10

? Workpiece material: Stainless steel

? Process: Turning, drilling

? Coolant type: Pure oil

? Chip shape: 50% spiral (?15 mm/max. 85 mm), 50% short

? Chip output: 14000kg / 24 hours

? Chip removal: Continuous

Case 27: Centralized Chip Handling System

System Parameters:

? Workpiece material: 50% steel, 50% copper

? Process: Turning, boring, milling

? Coolant type: Emulsion

? Copper chip shape: Short

? Steel chip shape: Long and lumpy

? Chip output: 330 kg / batch

? Chip volume: 250 liters / batch

? Chip feeding frequency: 4 times / 8 hours

Case 28: Centralized Chip Handling System

System Parameters:

? Workpiece material: Steel

? Process: Turning, boring, drilling

? Coolant type: Pure oil

? Working viscosity (40 ° C): 9.7 mm2 /s

? Chip feeding method: Forklift and chip bin

? Chip feeding frequency: ≤2 batches / hour

? Amount of chips per batch: 400 liters

? Chip removal: 0.5 kg/h

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