Targeted cooling lubricant – Targeted internal supply of cooling lubricant under high pressure during milling

In industrial milling, the cooling lubricant is fed internally and continuously applied to all cutting edges, even though only a few of them come into contact with the workpiece and the chip, depending on the angle of engagement. A large part of the volume flow misses the chip formation zone, creates spray mist, and is discharged unused. This results in high energy costs for companies due to high-pressure pumps and expenses for the treatment and disposal of the cooling lubricant. The limited visibility reduces process reliability and makes setup more difficult. In addition, the thermal management of the tools is suboptimal, which can have a negative impact on service life and component quality. In view of rising energy prices and ESG requirements, the pressure to act is growing. Companies need a practical, rotation angle-dependent dosing system for internal cooling in order to guide cooling lubricants (KSS) precisely and efficiently to active cutting edges only, thereby reducing costs and emissions.

Objectives

The project aims to develop and validate selective internal cooling for milling tools. Non-engaging cutting edges are disconnected from the cooling lubricant supply via integrated microvalves depending on the angle of rotation. Plans include flow modeling, channel geometry design, actuators, sensors, and control technology, as well as integration into CNC. The effectiveness will be verified in industrial reference applications with a focus on energy efficiency, process stability, and component quality.

Benefits

• Low energy consumption of the cooling lubricant pump and fewer emissions
• Lower cooling lubricant consumption and reduced treatment and disposal
• Less spray mist, better visibility, and increased occupational safety
• More stable temperature control, longer service life, and greater process reliability
• Consistent component quality and shorter non-productive times

Approach

In cooperation with Pokolm Frästechnik GmbH, a prototype tool for selective cooling lubricant supply is being developed. The development is accompanied by fluid simulations, with a focus on pressure peaks, leakage risks, and flow optimization. The design is iteratively adjusted, then the tool is manufactured and compared to a typical reference tool in milling tests. Finally, a positioning kinematic system is implemented, which allows the number and direction of the nozzles to be specifically controlled via CNC.

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Contact Alexander Schulze via email at schulze@ifw.uni.hannover.de or by phone at +49 511 762 18179.