Automatic cutting tool lubricator reduces operating costs

The financial benefits to be derived by utilising Bielomatik Minimal Quantity Lubrication (MQL) systems mean that the majority of machining centres newly built by Albon for its connecting rod production facilities, worldwide, now incorporate this highly effective automated system for lubricating the machining process.

Using the Bielomatik MQL system not only reduces the capital expenditure required for a new line, but also dramatically cuts lubricant consumption. A typical 'wet' machine may use up to 10,000 litres/hour depending on teh application; while much is recycled, natural wastage means overall losses can amount to 5-15 litres/hour. But, by incorporating MQL, consumption has dropped to less than 150 millilitres/hour.

In addition, cycle times are reduced for each machining operation by an average of 30 per cent.

Another benefit of the MQL system relates to swarf disposal. The use of MQL results in dry swarf, which sells for up to 80 per cent more than 'wet' swarf.

Albon Engineering and Manufacturing is a large independent manufacturing and design company specialising in the machining and assembly of engine components for automotive and diesel manufacturers worldwide. It has been manufacturing steel and cast iron connecting rods for both petrol and diesel engines since the 1970s, producing components for all major OEMs worldwide. The range of connecting rods extends from those for engines below one litre capacity and 50bhp for motorcycles and automotive vehicles, to those for 78-litre engines at 4000bhp for marine and off-highway applications.

Its successful growth is attributed to innovative in-house design and manufacture of special-purpose machines without the usual excessive investment in proprietary machines.

Pressurised ring main

Many of the Albon multi-spindle production machines for roughing and finishing operations incorporate the Bielomatik two-channel MQL system whereby a pressurised small-bore ring main delivers oil from a reservoir and a proportionally controlled air supply separately to the Bielomatik rotary transmission unit fitted to the rear of the spindle. A specially designed 'quick valve' mounted to the rotary transmission controls the exact amount of lubricant required. The oil and air then pass through the integral lance mounted in the centre of the spindle. Separation of the oil and the air is maintained by the two-channel design until the back of the cutting tool, where it mixes in a chamber and produces a fine oil/air mix that is delivered through channels in the tool holder directly to the cutting tool tip.

Since introducing this system, machine designers and production staff have observed an improvement in the machine surface finish, particularly on large deep boring operations. There has also been a very significant reduction in tool wear, with the cutting life extended by as much as 50 per cent, thereby significantly reducing machine downtime and costs.