Oh No! Another Mister

I made this over 2 years ago and it is still in use today.
I do not use any chemicals just plain water at about 20 psi with the water flow turned down so I can just see the mist.
The air pressure tends to keep the cut clear of chips too.
I have learned that for me smaller cuts and slower feeds work better and fewer broken bits.
Most of my work on this CNC mill is with 0.125 and smaller end mills.
I have done several jobs with a 0.0315 tool making branding irons for woodworkers.

Thanks for looking

Ray

Don't you get any rusting from only using water? I use flood coolant with Kool Mist that has rust inhibitors, and it does make a mess. I would like to change over to a mist type system but was always concerned about breathing in the mist. As you are using smaller bits on a CNC unit, I tend to use my very old manual mill in the horizontal mode where it makes a lot of (big) chips. What do you think?

Mike
 
Hot tools/parts are cooled by removing heat. This can be done by transfer through absorption of heat to a cooler material as is done with flood coolant or by evaporative cooling as is done with mist coolant.

The ability of a material to remove heat by absorption depends upon the specific heat of the material (calories/ºC/gram) x the mass of the material. Flood cooling works because the coolant has a fairly high specific heat and we flood the work area with fresh coolant. It also has a high thermal conductivity which facilitates heat transfer.

Mist coolant has a fairly high specific heat but there isn't much mass. However, the mist coming in contact with the tooling and/or work evaporates. While the mist has a specific heat of around 1 cal/ºC/gram, it has a heat of vaporization of around 550 cal/gram and is therefore capable of efficient cooling. The compressed air in the stream aids in chip removal.

Using oil serves primarily as a lubricant. Its specific heat is much lower than water based coolants and its thermal conductivity is lower as well. Its lubricity does assist, though,by reducing friction and resultant heat generation.

Using compressed air does not provide much in the way cooling by virtue of its low specific heat and low mass but it does serve another important function which is chip removal. We use either water or oil to quench steel to harden it because of their ability to quickly pull heat away from the steel. Subjecting the steel to a blast of cold air simply will not do the job.
 
I try to do most of my metal parts in batches making 2 to 6 identical items in a run. I will use about a quart of water for a 2 hour run. I have a valve that controls the amount of water used so you can up the air pressure to blow the chips and still only use a small amount of water.
When I am done I dry the machine with towels and then go over with an oily rag.
I live in Florida and rust is a constant battle.
Thanks

Ray
 
I set up a cold air gun on my mill, and I I have to agree with RJ. It does work as chip removal, but at cooling it is marginal. I have a flood coolant system on my big lathe which I can see the advantages of in a commercial operation, but haven't had a chance to use it. I'm thinking a mister, as mentioned above would be a good compromise. Wondering out loud whether some materials cut better under higher temps than others? perhaps they provide a certain amount of lubricity via there molecular makeup? Mike
 
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