It is not abnormal practice for engineers to completely shun any lubrication system when operating under high speeds and pressures to fine tolerances. While some persist with flood coolants, some such systems can result in unpleasant odours, a wet workplace and an increased maintenance requirement. 

In spite of these problems, flood coolant systems are often deemed to be better than completely ruling out lubrication altogether. Companies who dismiss coolant units to avoid these inconveniences will instead run the risk of quickly worn tools, spoilt finishes and substantial associated costs. 

New MQL systems provide a solution, offering an alternative that strikes a suitable lubrication balance. Machining with minimum quantity lubricant is fast replacing wet machining processes as a cost saving and environmentally-friendly option. MQL systems cut coolant costs compared to flood coolant systems, using a spray mist rather than flooding and consequently resulting in a reduction in the volume of coolant used during the process. Financial gains are realised through the hike in system efficiency, as tool life lengthens and maintenance requirements reduce following the implementation of proper care and protection afforded by the correct lubrication quantity. 

The cost of cleaning is slashed, as flooding systems may drown tools and the tangible workspace with substance after only a few hours of up time, improving both the company’s bottom dollar and the health and safety credentials of the physical environment. 

Andy Roberts, technical manager at cutting equipment manufacturer, Keencut, recently implemented an MQL unit to replace an existing flood coolant system. He said: “Using a flooding systems was becoming increasingly impractical as a way of working. Since introducing the MQL process, we have been amazed by the results. Using the Lubrilean unit is the closest thing to dry machining, without the drawbacks. If ever there’s an overspray, it’s such a small amount that we can easily wipe it away with a cloth.

 

“Health and safety has been hugely improved, removing the slip risk which was often prevalent. With Lubrilean, there’s not a single drip. The whole process is markedly easier, more manageable and more efficient. Our estimation is that we have saved between 5 and 10% of the overall process time by incorporating an MQL unit, dramatically improving what was previously a messy, unpleasant job.”

Avoiding excess oil and white water usage, the eco-friendly solution is used entirely at the rate in which it is dispensed, thereby requiring no thorny negotiations to execute the appropriate disposal of excess used solutions.

Brian Smith, division manager at Lubemec, says: “The technology really does transform engineering processes, delivering ease, accuracy and efficiency in place of awkward handling and health and safety worries for flood systems. Engineers benefit from tremendous improvements in tool life and maintenance requirements, particularly in a high-pressure environment. Introducing a system often saves days of labour for cleaning and maintenance which, once the system is installed and operational, becomes completely redundant.

“It’s important that manufacturers and suppliers understand their customers and appreciate what the industry requirements are at ground level. It’s not difficult to sell an MLQ system; The market needs it, the gap was there and we are now able to satisfy our customers with a whole range of real benefits that make a difference to their day to day operations.”

HES Lubemec is a specialist lubrication division within Group HES and is a major stockist and distributor for SKF/Vogel.