Cutting fluid problem solved

By developing a completely new generation of bactericide-free cutting fluids, Henkel has succeeded in banishing the drawback of emulsions splitting in use and the related bad odor nuisance, thus providing a long-awaited answer to a major problem associated with water-miscible metalworking fluids. The new emulsions of the Multan brand have proved themselves in industrial practice.

In demanding metalworking applications, nothing goes without coolant fluids. These "liquid tools" are essential when it comes to exploiting the full potential of modern high-performance machine tools. At the same time, users everywhere are increasingly clamoring for advanced coolant fluid concepts with enhanced manufacturing shop performance. Bacterial contamination with its well-known, unpleasant side-effects leading to emulsion splitting, is one factor that has been singled out repeatedly as a major cost driver.

Unwanted microorganisms
Even in advanced technology machining centers a strong build-up of odor may be experienced when the machines had been idle for a long time. The reason for these unpleasant odors can be bacterial contamination of the metal cutting emulsion. This is a natural biological process. However, once the bacteria have multiplied to a certain level, the emulsion can split and become unusable. There have been two ways of avoiding such problems in the past. The first option is to use conventional, bactericide-free metalworking fluids where bacterial growth is initially tolerated up to a certain concentration, then combated by adding bactericides. The disadvantage here is that the dead microorganisms act as excellent nutrients for the next generation of bacteria, so the process has to be repeated at ever shorter intervals. The second option is to use fluids that contain bactericides, which permanently suppress bacterial growth.

Pictures: The switch to the new emulsifier technology of Multan 71-2 eliminates the problem of bacterial growth in metal-cutting fluids, without any need for later addition of bactericides.

Focus on safety, health and environment
In both cases, the use of bactericides has to be viewed critically. Exposure to bacteria or bactericides represents a potential health hazard for employees, who may develop skin irritations or increased sensitization after contact with them. Frequent changing of emulsions that have split is not only very costly but also puts an additional burden on the environment. Henkel offers a sustainable solution to this cutting fluid problem with the patented emulsifier technology of its Multan 71-2 products. After intensive development work, a microbiologically robust cutting fluid was formulated that not only contains no bactericides (such as formaldehyde splitters), but does not need any later addition of bactericides to keep it stable either. The new product is suitable for many different kinds of machining from roughing to grinding. 

Henkel operates worldwide with leading brands and technologies in three business areas: Laundry & Home Care, Cosmetics/Toiletries and Adhesive Technologies. Founded in 1876, Henkel holds globally leading market positions both in the consumer and industrial businesses with well-known brands such as Persil, Schwarzkopf and Loctite. Henkel employs about 48,000 people and reported sales of 15,092 million euros and adjusted operating profit of 1,862 million euros in fiscal 2010. Henkel's preferred shares are listed in the German stock index DAX and the company ranks among the Fortune Global 500.

For further information, e-mail: evelyn.necker@henkel.com or view website: www.henkel.com  Refer to page 180 

Customised Carbolite raises the roof on an
advanced ceramic materials production process

Facing the introduction of a new manufacturing process to its Gloucester production facility the abrasives division of a major multinational manufacturer of advanced ceramic materials needed to rapidly replace some large raised hearth furnaces that had reached the end of their useful lifespan.

Carbolite was called in to meet the challenge and the UK's largest manufacturer of laboratory and industrial furnaces and quickly realised that a rapid implementation of a well trusted design was crucial for the abrasives manufacturer to ensure the new manufacturing operation had the best chance of starting on schedule. 

The application requirement called for a rapid cycling batch furnace capable of de-binding and sintering 100kg of graphite matrix with a ceramic powder inclusion at up to 1000°C, under a reducing atmosphere of nitrogen and hydrogen. 

Carbolite's solution features a design that has been built for export customers several times before at the company's factory in the UK's Peak District.

Unlike previous occasions the application did not require an afterburner but it was vital that a 600 x 1200mm Inconel 601 retort was used to contain the nitrogen/hydrogen atmosphere.  Inconel-coated catch trays were also added to the retort to capture any process material that might fall from the load. Because the nitrogen/hydrogen reducing gas was pre-mixed and below the explosive limits for hydrogen it was not necessary to provide the gas safety system that Carbolite would normally provide when working with higher concentrations of hydrogen.       

Uniform heating of the load was critical so a 3-zone control system compatible with the aerospace standard NADCAP 2750 D, Class 2 was installed that offered   optimum control uniformity. Each of the three zones was equipped with its own independent over-temperature protection device and at the heart of the control system a sophisticated multiple segment programmer system was fitted that was able to recall multiple separate, process specific, temperature profiles.

To enable fast turn-around times between process batches, a wheeled load handling device featuring a jacking lift mechanism was included in the specification.  Faster cooling of the retort at the end of the process was achieved using an electrical lifting device which progressively raises the highly efficient, low thermal mass, insulated roof of the furnace to allow heat to escape more quickly.

Carbolite, which is highly experienced in the design and manufacture of a wide range of de-binding furnaces, with or without after-burners and catalytic converters, is also experienced in offering custom designed modified atmosphere control solutions.

Carbolite in profile
Established in 1938, Carbolite has over 60 years of experience in the design & manufacture of electric laboratory & industrial furnaces, laboratory & industrial ovens & incubators.

During this time, Carbolite has established an enviable reputation for its ability to design and manufacture quality products for standard & special applications for laboratory, pilot scale & industrial applications. Today, Carbolite equipment has become the standard against which other heat processing equipment is measured.

For further information, e-mail: info@carbolite.com or view website: www.carbolite.com  Refer to page 337

Simplified software integration for laser profile scanners

Micro-Epsilon has developed a wide range of freely downloadable software modules and instrument drivers for its scanCONTROL series of laser profile scanners. These software plug-ins simplify integration of laser profile sensors with the user's own software environment.

In order to process recorded profile information from any laser scanner (profile sensor), the scanner must be integrated with a suitable software application such as LabVIEW^Ò or Geomagic Qualify^Ò. Conventional laser scanners often leave this task to the user, who will have to carry out labour-intensive software programming to ensure that the measured data is correctly integrated and processed.

Simplified software integration available for laser profile scanners from Micro-Epsilon.

When working with Micro-Epsilon's scanCONTROL series of laser scanners, the user is aided by freely available, ready-to-use software tools. A software development kit is available for C/C++. This library for scanCONTROL supports both static and dynamic loading.

If the user works with LabVIEW, help is provided in the form of a ready-to-use, downloadable device driver, which can be integrated directly with the user's own virtual instruments (VIs) via the use of software modules.

In addition, a software plug-in is available for users of Geomagic Qualify inspection software. This enables the user to compare actual measured profiles directly with the target model. Geomagic Qualify allows rapid, precise graphical comparisons between digital reference models and manufactured parts, prior to volume production. Micro-Epsilon's plug-in supports both online operation with all scanCONTROL sensors, as well as the importing of offline data. Therefore, the plug-in can also be tested quickly and easily without a sensor.

The scanCONTROL range of laser scanners record, measure and evaluate profiles on a variety of different target surfaces. Often referred to as profile sensors, laser scanners use the triangulation principle for two-dimensional profile detection on target surfaces. Using special lenses, a laser beam is enlarged to form a static laser line and projected onto the target surface. A high quality optical receiver system projects the diffusely reflected light from this laser line onto a highly sensitive sensor matrix. In addition to distance information (z-axis) the controller also uses this camera image to calculate the position along the laser line (x-axis). These measured values are then output in a two-dimensional coordinate system that is fixed with respect to the sensor. Both with moving objects and a traversing sensor, it is possible to obtain 3D measurement data.

For further information, email: info@micro-epsilon.co.uk  Refer to page 109