Carbide sludge (chips and shavings) remover
The following is a summary of the features of coolant filtration systems that are compatible with carbide sludge and the manufacturers that handle them.
Sun Maintenance Koki
Features of Sun Maintenance Koki's products
SMK RAPTOR
Cited from: https://www.smk-web.co.jp/filtration-smk-raptor.html
The device is equipped with two ultra-fine filtration filters in a stylish housing.Combines the advantages of internal and external pressure type filters and uses high performance fiber filter paper for filtration of fine sludgeThe company is doing so.
SGL
Cited from: https://www.smk-web.co.jp/filtration-sgl.html
Three variations are available with different numbers of filters installed, from 1 to 3 filters. From the compact 1-filter type to the 3-filter type capable of handling large capacities, you can select the appropriate device for your machine tool and operating environment.
Basic Information on Sun Maintenance Koki
| Head office location |
2-103 Torisumi, Midori-ku, Nagoya, Aichi, Japan |
| Phone number |
052-624-8481 |
| Official HP |
https://www.smk-web.co.jp/index.html |
Keiji Kosan
Features of products handled by Keiji Kosan
Lycraean N Series
Cited from: https://www.keg-keijikousan.com/works/metal/series-n.php
This device uses an internal pressure filter and is equipped with a compact filter that fits in a pail. It is relatively easy to install, even in limited space.Sludge in the filter can be easily discharged, reducing the need for maintenance.
Lycraean R Series
Cited from: https://www.keg-keijikousan.com/works/metal/series-r.php
Tank-mounted filtration system for various machine tools. The size is suitable for small to medium capacity tanks. Equipped with casters for easy mobility.
Basic Information on Keiji Kosan
| Head office location |
7-7 Nishiura-cho, Fukakusa, Fushimi-ku, Kyoto-shi, Kyoto |
| Phone number |
075-643-3201 |
| Official HP |
https://www.keg-keijikousan.com/ |
Nikuni (ini)
Features of the products Nikuni offers
Coolant Filtration System NAX-CP
Cited from: https://premium.ipros.jp/nikuni/product/detail/200773009/
Fully automatic filtration system combining spring filter, dewatering machine, powder feeder, and cycle pre-coating system.Sludge from hard-to-settle ceramic cemented carbide and other materials can be recovered efficiently.This helps to improve machining accuracy and extend the service life of tools and equipment.
Ultrafiltration system BAX
Cited from: https://premium.ipros.jp/nikuni/product/detail/2000198100/
NC backwash filter is used for filtration of 1μm tungsten carbide, HSS steel, ceramics, etc. No filtration aids are used, allowing easy recovery of reusable valuable materials.
Nikuni Basic Information
| Head office location |
843-5 Kuchi-Kuji, Takatsu-ku, Kawasaki-shi, Kanagawa |
| Phone number |
044-833-1121 |
| Official HP |
https://premium.ipros.jp/nikuni/ |
filter precision engineering
Features of products handled by Filtration Seiko
Fully automatic high-speed centrifuge ~NKEB-2000S
Cited from: https://www.rokaseiko.com/service/nkeb-2000s
Fully automatic centrifuge for separating and discharging sludge such as cemented carbide, ceramic, silicon, and quartz glass.The centrifugal force is up to 2,000 G for efficient separation.
Basic Information on Filtration Seiko
| Head office location |
5F, 1-10-1 Nihonbashi-Kakigaracho, Chuo-ku, Tokyo Goethe House Co. |
| Phone number |
03-6264-8575 |
| Official HP |
https://www.rokaseiko.com/ |
Toho Separator
Features of Toho Separator's products
Thickener Back Separator
Cited from: https://tosepa.co.jp/products/thicknerback.htm
Filters made of Tetoron or rayon pulp for filtration of carbide, ceramics, etc.Adsorbs oil as well as filtrationThis helps to maintain the coolant fluid in a clean condition.
PSS type filtration system
Cited from: https://tosepa.co.jp/sp/products/pss_m.htm
Suitable for filtration of coolant liquid for carbide, ceramics, and grinding, this device has a simple mechanism. It is designed to be hard to break down. A wide variety of filter types are available for filtration of various liquids.
Basic Information on Toho Separator
| Head office location |
3-2-40 Nishikiori-Kita, Tondabayashi-shi, Osaka, Japan |
| Phone number |
0721-25-1330 |
| Official HP |
https://tosepa.co.jp/index.htm |
Sankyo Giken Kogyo Co.
Features of Sankyo Giken Kogyo's products
Coolant filtration system for machine industry
Cited from: https://www.sankyogiken.co.jp/product/03.html#structure
A precoat type microfiltration system in which a filter aid is precoated on the filter cloth and pressure filtration is performed.Capture and separate micron-sized sludgeThe instantaneous back-pressure cleaning system provides efficient filtration cleaning.
Basic Information on Sankyo Giken Kogyo Co.
| Head office location |
1485, Kamimaruko-Hachiman-cho, Nakahara-ku, Kawasaki-shi, Kanagawa, Japan |
| Phone number |
044-433-4451 |
| Official HP |
http://www.sankyogiken.co.jp/ |
Kamogawa
Features of Kamogawa's products
Carbide is completely filtrated.
Cited from: https://suwa.monozukuri.or.jp/hitowaza_pdf/5-2004.pdf
Ultra-precision filtration system capable of single-pass filtration of cemented carbide and ceramic sludge, employing a 1μ filter to achieve filtration equivalent to NAS 5 grade.Lineup includes not only water-soluble but also oil-soluble filtration systemsThe company is doing so.
Perfect Filtration-kun Evolution
引用元：https://www.kamog.co.jp/news/%E3%80%90%E8%A3%BD%E5%93%81%E7%B4%B9%E4%BB%8B%E3%80%91%E5%AE%8C%E5%85%A8%E6%BF%BE%E9%81%8E%E3%81%8F%E3%82%93%E3%82%A8%E3%83%9C%E3%83%AA%E3%83%A5%E3%83%BC%E3%82%B7%E3%83%A7%E3%83%B3/
The KAMOG bacteria inhibitor keeps the inside of the tank clean and prevents the formation of odors.
Basic Information on Kamogawa
| Head office location |
78 Nakamiya-cho, Takeda, Fushimi-ku, Kyoto-shi, Kyoto |
| Phone number |
075-605-3123 |
| Official HP |
http://www.kamog.co.jp/ |
Sumitomo Heavy Industries Finetech, Ltd.
Features of the products handled by Sumitomo Heavy Industries Finetech
FINEMAG series UK type
Cited from: https://www.shi-ftec.co.jp/products/finemag
Equipped with a magnetic drum that can generate a high magnetic field, with a surface magnetic force of 9000 gauss.Effective in collecting sludge that is difficult to magnetize, such as in grinding cemented carbide tools, as well as fine sludge from lapping and honing processes..
Basic Information on Sumitomo Heavy Industries Finetech, Ltd.
| Head office location |
8230 Otsushima, Tamashima, Kurashiki City, Okayama Prefecture |
| Phone number |
03-6737-2556 |
| Official HP |
https://www.shi-ftec.co.jp/ |
Mitaka Kogyosho
Features of Mitaka Kogyosho's products
RRF (precoated microfiltration system)
Cited from: http://mitaka-ind.co.jp/products/product01/
Compatible with non-magnetic processing fluids such as cemented carbide, aluminum, and ceramics. Our unique spring filter material ensures stable filtration.It is also characterized by the ability to perform backwashing using the liquid in the filtration cylinder, extending the life of the filter media.
Simplified filter pressure filtration MCF type series (with precoat circuit)
Cited from: http://mitaka-ind.co.jp/products/filter/
This filtration system is useful for removing non-magnetic materials such as carbide, carbon, and aluminum. The filter is pre-coated with a filter aid, which improves filtration accuracy and reduces clogging due to sludge.
Basic Information on Mitaka Kogyosho
| Head office location |
1857-1 Gandoshima, Kamisue, Komaki City, Aichi Prefecture |
| Phone number |
0568-72-5031 |
| Official HP |
http://mitaka-ind.co.jp/ |
Unimagtec
Characteristics of Unimagtec's products
Candle Filters
Cited from: https://unimagtech.jp/about
(*As of February 2024, the official is not available for viewing.)
Unimagtec handles candle filters, which are filtration equipment specializing in cemented carbide.Long-term filtration accuracy of 1 µm and no maintenance requiredThe feature of the system is that it is Sludge can be removed in high purity and reused as an expensive resource.
Basic Information on Unimagtec
| Head office location |
1-613-1, Kamisuge, Meito-ku, Nagoya-shi, Aichi, Japan |
| Phone number |
052-777-8247 |
Official HP
(*As of February 2024, the official is not available for viewing.) |
https://unimagtech.jp/ |
skilled artisan
Characteristics of products handled by Junkosho
Taro Jun
Cited from: https://www.junshow.net/product/roka.html
Sludge generated by carbide polishing is removed with a special bag filter,Increases the life of cutting oils and cleaning fluids and reduces problems caused by sludgeThe coolant filtration system is a coolant filtration system that filters the coolant. The only consumable is the filter, which helps to keep costs down. Demo units are also available, so you can consider introducing the system after confirming its usability.
Basic information about Junko
| Head office location |
2249 Saedo-cho, Tsuzuki-ku, Yokohama City, Kanagawa Prefecture |
| Phone number |
045-942-4100 |
| Official HP |
https://www.junshow.net/index.html |
Bunri era (1260.4.13-1261.2.20)
Features of the products that Bunri handles
Cyclone Filter Apollo S
Cited from: https://www.bunri.com/product/aps/
The cyclone filter Apollo S is,Cyclone type secondary filtration system for a wide range of magnetic and non-magnetic materialsIt is It is also capable of removing fine chips and sludge. The drain part replacement system is standardized as an anti-wear measure, so even if the drain discharge part is worn out over time due to hard material sludge, it can be used for a long time by replacing the part.
The filtration accuracy and defoaming mechanism of the previous model have been retained while the main unit has been downsized, realizing a reduction in the motor capacity of the supply pump. In addition, the use of consumables such as cartridge filters and paper filters is not necessary, thus reducing the cost and labor of filter disposal.
Basic Information on Bunri
| Head office location |
1-34-8 Oi, Shinagawa-ku, Tokyo |
| Phone number |
03-3778-2061 |
| Official HP |
https://www.bunri.com/ |
What is carbide sludge?
Cemented carbide sludge is chips and shavings generated when machining cemented carbide. Incidentally, cemented carbide is an alloy made by sintering highly hard metal carbide powders. Sintering refers to the technique of heating and baking hardened metal or ceramic powders at a temperature at which they do not melt.
Since cemented carbide has the second highest hardness after diamond, it is difficult to process by cutting, and grinding or electrical discharge machining is basically used.
Major carbide sludge
Cemented carbide is manufactured using tungsten carbide powder. Tungsten is also mainly contained in cemented carbide sludge generated in the processing of cemented carbide, and its small grain size makes it difficult to recover by general filtration methods, so diatomaceous earth (silicon) and pulp are used for filtration. On the other hand, carbide sludge containing large amounts of silicon is difficult to recycle and must be disposed of as industrial waste, for example.
Tungsten can be recycled by filtration
Tungsten contained in cemented carbide sludge is one of the rare metals called rare metals. While tungsten is used in a wide range of industrial fields, including cutting tools, machine parts, electrode materials, and heat dissipation materials, its supply is unstable due to regional unevenness in reserves.
Since securing rare metals is also essential to maintaining and strengthening the international competitiveness of Japan's manufacturing industry, the Ministry of Economy, Trade and Industry (METI) has mentioned strengthening the promotion of recycling related to metal mineral resources. Recycling of rare metals, including tungsten, has become a national project.
One of the problems in recycling tungsten contained in cemented carbide sludge is the filtration aids required to recover the small particle size sludge. Because it is time-consuming to recover tungsten from sludge containing large amounts of filter aids such as silicon and pulp, in many cases tungsten is disposed of as industrial waste.
In an attempt to solve this problem, Sun Maintenance Koki Co., Ltd. developed a microfiltration device that can efficiently collect sludge without the use of filtration aids. The device incorporates a specially shaped non-woven fabric inside the device, which can collect most of the sludge contained in the processing fluid. The collected sludge does not contain any filtration aids, enabling recycling of tungsten.
Coolant filtration] Example of carbide sludge removal
Concerns before introduction: Difficulty in maintaining cutting performance
Filtration of cutting fluid, which affects cutting performance, is an indispensable process in the manufacture and polishing of cemented carbide tools. On the other hand, the filtration equipment that had already been installed was not able to filter the fluid as expected, and the oil was turning increasingly black during processing.
In this state, it is difficult to maintain cutting performance, and even finer carbide sludge can enter the machine, causing breakdowns. In addition, the machine becomes dirty from the cutting fluid, which turns increasingly black, making cleaning and maintenance difficult.... With this background in mind, we decided to install equipment with higher filtration performance than before.
Results after equipment installation
I was dissatisfied that the filter I had been using did not filter cleanly when the filter was not clogged immediately after replacement. The filter in the newly installed equipment has much improved filtration efficiency, and I like that it filters cleanly from the beginning. After about six months, the filter becomes so clogged with sludge that it weighs 20 or 30 kg, which is too heavy to carry when replacing it, so we feel it is cost-effective to think that we have removed so much sludge.
Frequently Read Related Pages
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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
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
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.
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