Grinding sludge (chips, shavings) remover

Listed below are coolant filtration systems that can remove grinding sludge generated during the grinding process. We have summarized the features of each.

Sun Maintenance Koki

Features of Sun Maintenance Koki's products

SMK RAPTOR

Cited from: https://www.smk-web.co.jp/filtration-smk-raptor.html

Employing the best parts of both internal and external pressure systems, two ultra-precise filtration filters are mounted in the housing.Prevents problems caused by sludge, maintains machining accuracy and machine quality and performance, and contributes to cost reduction and environmental impact reduction..

SGL

Cited from: https://www.smk-web.co.jp/filtration-sgl.html

This model maintains the filtration technology and performance of the flagship SMK RAPTOR model, while offering three models with different numbers of filters installed. From compact to high-capacity types, you can choose the one that best suits your operating environment and equipment.

Basic Information on Sun Maintenance Koki

Taiho Sangyo

Features of the products handled by Taiho Sangyo

MAGZET

Cited from: http://www.taihosangyo.com/magzet.html

Can be used with wire cutters, grinders, machining centers, etc. that circulate coolant.Compatible with magnetic and non-magnetic sludge, as well as water-soluble and oil-soluble coolant fluids, etc.The system is designed to separate impurities and keep the liquid clean.

Basic Information on Taiho Sangyo

Chubu Clean

Features of Chubu Clean's products

High-precision backwash filtration system

Cited from: http://chubu-cl.com/products/filtration-of-oil/

Filtration equipment that can be used for a variety of machine tools such as machining centers, washers, and grinders. Ceramic filters are used to achieve highly accurate sludge removal.Filter can be backwashed with air.

Sludge collector Sper-Clean-Mate

Cited from: http://chubu-cl.com/products/sludge/

Equipment for removing aluminum chips, iron chips, etc. deposited inside coolant tanks. It is compact in size and equipped with casters, allowing it to be used anywhere you like.

Basic Information on Chubu Clean

Toho Separator

Features of Toho Separator's products

Thickener Back Separator

Cited from: https://tosepa.co.jp/sp/products/thicknerback.htm

Suitable for coolant filtration for grinding and machine tools. By filtering coolant liquid and adsorbing oil, the coolant is kept clean at all times.Sludge in the filter can be taken out in a dehydrated state.The simple structure of the drive unit, consisting only of a pump, makes it difficult to break down.

Basic Information on Toho Separator

skilled artisan

Characteristics of products handled by Junkosho

Taro Jun

Cited from: https://www.junshow.net/product/roka.html

Juntaro, handled by Junkosho, is a bypass circulation filtration system that uses a dedicated bag filter to remove sludge from coolant.Capable of removing sludge from nonferrous materials that cannot be recovered with a magnetic separator.We have a tailor-made system and can make proposals to solve the problem of sludge in grinding processes. Since the only consumable is a filter, this system is also recommended for those who want to reduce running costs.

Basic information about Junko

Western Commerce and Industry

Features of products handled by Seibu Shoko

Pneumatic vacuum filters

Cited from: https://seibushoko.com/products/coolant_filtration_system/

The pneumatic vacuum filter is one of the coolant filtration systems handled by Seibu Shoko and is suitable for processing that requires high filtration accuracy.Nominal filtration accuracy is 10-80µ.Flow rates from 1,000 to 3,000 liters/min are supported.

Basic Information on Seibu Shoko

terral

Teral's product line features

Cyclean

Cited from: https://www.teral.net/classification/coolant_fil_system/

Teral handles CYCLEAN coolant filtration equipment with a lineup of products that can meet various needs, including grinding type, drum filter type, and general-purpose machining type. Various special designs are also available.Tank design for efficient recovery of floating oil by 3D flow analysisThe structure is designed to prevent the accumulation of sludge.

Basic Information on Terral

Nikuni (ini)

Features of the products Nikuni offers

NAX-CSII

Cited from: https://www.nikuni.co.jp/product/94_index_detail.php

The product NAX-CSII handled by Nikuni is a fully automatic coolant filtration system that combines a cyclone filter with a gather-up conveyor.Automatically performs from sludge separation to discharge of coolant liquid, and can remove 20μm sludge with high accuracy.This product can also contribute to reduced maintenance costs since there is no need for periodic filter replacement or tank cleaning due to clogging.

Nikuni Basic Information

What is grinding sludge?

Grinding sludge refers to chips and shavings generated by machine tools during the grinding process. Grinding is one type of mechanical processing, in which the surface of a workpiece is machined using a grinding wheel rotating at high speed. The grinding wheel is composed of small hard particles called abrasive grains, and the abrasive grains gradually chip away at the surface of the workpiece as it is processed. In addition to chips, grinding produces grinding wheel debris at the same time.

Characteristics of Grinding Sludge

Grinding sludge consists mainly of chips and grinding wheel debris, of which grinding wheel debris is mixed in at a rate of 5 to 30%. Since grinding wheel chips are nonmagnetic and spiral-shaped chips have low iron density per unit mass, it is difficult for a magnetic separator, one of the coolant filtration devices, to process grinding sludge. Another factor contributing to the difficulty of processing fine chips is that they are susceptible to liquid resistance, so even if they are attracted to the magnetism, their movement is slow.

Problems with grinding sludge

Many grinding shops suffer from surface roughness deterioration and defects caused by scratches in the grinding process. One of the causes of surface roughness deterioration and defects caused by scratches is fine sludge and abrasive grains mixed in the coolant fluid. If the coolant fluid is not in good condition, the primary performance, lubrication, and cooling properties of the coolant fluid cannot be maintained, and the ability of the blade and grinding wheel may not be demonstrated.

In the grinding process, abrasive grains from the grinding wheel often cause scratches. To control the quality of the grinding process, it is important to remove sludge from the coolant as soon as possible, instead of leaving it as it is.

Coolant filtration] Example of grinding sludge removal

Case studies in response to legal revisions and recycling

One company that runs much of its equipment automatically places a high priority on coolant management because of the long hours of automatic operation, especially in order to minimize the dissolution of sludge.

Because of their commitment to quality, they felt that they had to focus uncompromisingly on coolant management and, by extension, countermeasures against fine sludge. Furthermore, in 2013, "cobalt and its inorganic compounds" were additionally designated in a partial revision of the Regulations for Prevention of Hazards Due to Specified Chemical Substances, and the company also decided to reduce industrial waste treatment by using its own diatomaceous earth filtration.

Therefore, they decided to look forward to installing a filtration filter, and although they had assumed that it would be large and expensive, they decided to use a simple but capable filter for filtering fine sludge.

Results after equipment installation

The company introduced coolant filtration equipment because of its integrated support system, which includes not only filter recovery but also dismantling, firing, and tungsten extraction. The recycling environment has made it possible to save resources and reduce industrial waste.

The company was also able to use the filter in various equipment because it was compatible with coolant. The company was particular about the quality of the coolant used to produce sharpness, and in some cases the coolant is replaced when new equipment is manufactured or introduced in order to preserve the equipment, and the filters have been useful in this process.

These have helped improve their work efficiency and work environment. They also feel that the filtration system is very meaningful from the perspective of focusing on SDG activities.

Example of Scratch Failure in Grinding Machine

Although some of the products were being ground repeatedly every month, approximately 5% of the products were always defective due to scratching. In addition, one of the grinding surfaces had a scratch that looked as if it had been scratched by a fingernail, and although it was difficult to see, it was noticeable when plating was applied. They were having trouble with this situation even though they had enough coolant.

Results after equipment installation

After installing one 750J x 2 filtration unit on the grinder and taking on the challenge, they were not only able to get the dimensions right, but they were also able to reduce the incidence of defects, as there were no flaws and no problems. They also realized cost savings as a result.

• Brittle material sludge (chips and shavings) remover
• Ceramic sludge (chips and shavings) remover
• Carbide sludge (chips and shavings) remover
• Metal sludge (chips, shavings) remover
• Cutting sludge (chips and shavings) remover
• Silicon sludge (chips and shavings) remover
• Aluminum sludge (chips and shavings) remover

For grinding process】 【For grinding process】.
Coolant filtration system
Three recommendations

Coolant filtration equipment is used to filter sludge generated from equipment. There are a variety of products available depending on the intended use, so it is important to determine "whether the coolant filtration equipment is suitable for the purpose" and "whether the equipment is suited to the characteristics of sludge.

Filter filtration system capable of filtering all "fine" sludge of 3μm or less Filter filtration system capable of filtering all "fine" sludge of 3 microns or less

Sun Maintenance Koki

Reference: Sun Maintenance Koki official website (https://www.smk-web.co.jp/index.html)

Main materials that can be filtered

• Brittle materials such as cemented carbide, ceramics, and castings

For factories like this

• I want to filter fine sludge less than 3μ.
• I want to use it as a secondary process
• To remove sludge that could not be filtered by other equipment

Check equipment on official website

Capable of filtering "large volumes" of up to 200 l/min Centrifuge

Toto Separator Kogyo Co.

Reference: Toto Separator Industry official website (https://centrifuge-tsk.com/)

Main materials that can be filtered

• Brittle materials such as cemented carbide, ceramics, and castings

For factories like this

• I want to filter more than 100 L
• I want to use it as a primary process
• Want to reduce running costs

Check equipment on official website

High magnetic force filters 5 microns or less High magnetic force enables filtration of 5 microns or less. Magnetic Separator

Sumitomo Heavy Industries Finetech, Ltd.

Reference: Sumitomo Heavy Industries Finetech official website (https://www.shi-ftec.co.jp/)

Main materials that can be filtered

• Metal materials such as aluminum, steel, and iron

For factories like this

• I want to filter metal materials.
• I want to use it as a primary process
• I want to remove metal sludge.

Check equipment on official website