Fogless cooling for surface and belt grinders

Kosa_PL

Kosa_PL

Joined
Aug 25, 2013
Messages
1,220
Hello everyone!

As from some time I got surface grinder, there will be awesome to get some coolant.
But as all we know a flood type and classic mister make a big mess around and in some time all stuff in workshop have thin layer of dry coolant residue on them.

I asked myself " why to not make a good fogless mister by myself? "

Small search on Practical Machinist forum resulted in design of fogless mister like Fogbuster.
After that we need a coolant right ? ;)
Here in Poland I got a Silvergrind 3001 designed specifically for grinding and precision grinding. ( 5% emulsion)
But in US you have Cimtech M26 etc. good coolants.

When using this type of mister on lathe or milling maschine, we use a very small amount of coolant.
But for grinding we need this more like 100-300ml per hour, to get good cooling of hardened blank, keep belt/wheel clean, and also less friction result in less heat. Belts also should last for longer.

In 2 days I start to make first fogless misters and will report progress of work on 2 systems, 1 for SG and 2nd for belt grinder.
View attachment Fogless mister v1.pdf

Cheers,
Konrad
 
I'll be curious to see this build Konrad. I've built flood coolant systems for a couple of my machines, but my larger SG came with a big flood setup that I use. Personally I don't find it very messy, and it's nice because it has a hose diverted with a sprayer for spraying off the chuck also. However, a good mist system can be nice and clean, and has advantages, but the commercial options are expensive.
 
I will publish here whole process of building, then people who want will be able to look how to make this :)
 
Some photos :)

Now I need to wait for a 11,8mm drill and 1/4"-19 tapp, to finish this.
And also other drill chuck to mount 1mm drill :P

Also I make 2 M5 tapped holes for mounting.

1TXWMN.jpg

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I just use a $0.25 irrigation sprayer like this http://amzn.com/B00B8QWT8G with a submersible water pump. I have a foot switch to turn the pump on/off, and a valve to control the output of the sprayer.

These spray nozzles have 10-32 male threads, so they can be threaded into any plastic or metal pipe, tubing, or fitting. I have mine mounted on the end-cap of lock-line tubing.
 
Why not just purchase a cold gun? Shoots a stream of 20F air out at your work piece...

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Cold gun is not used for surface grinding alone.
It's used in hybrid method.

More important role of coolant in surface grinding is to lubricate and clean cutting area. When that area is properly lubricated then less heat is generated and also wheel last longer.
And surface finish is better.

The main role of cold gun -15 / -20*C is to generate microstresses on grinding wheel that cause inactive grains to be pulled off by inertial force, and because of this wheel is clean.
And surface finish is even better.

When we combine MQL at level 80-250ml/h with -15*C air from cold gun we can achieve a finish like with flood cooling or even better.

Some stuff to read for you guys ;)

http://www.ijitee.org/attachments/File/v4i1/A1694064114.pdf
https://keio.pure.elsevier.com/en/p...ooling-technology-and-minimum-quantity-lubric
http://www.isaet.org/images/extraimages/P513561.pdf
And a lot more ;P
https://www.google.pl/search?q=Surf...zIgdgB#q=Surface+grinding+MQL+cooling&start=0
 
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You seem like a very knowledgeable guy kosa! Thanks for posting the info and links! Learn something new every day 😊👍
 
When it's done you gotta make a video so we can see it in action!!
 
Yeah I know those cold air guns seem awesome, and they are great for certain applications, but they're highly particular. They consume a lot of air, and even though they can make things cold, they don't have a high capacity for heat removal, and add no lubricity, both of which are massive factors, especially when grinding. Flood of course is king of those factors, but as mentioned, has it's own detractors.

Mist will be a good compromise, and I've seen some pretty impressive grinding rates with mist cooled surface grinders, or I'd be skeptical.


Excited to see how this works out.
 
I've been thinking about doing something like this for my CNC machine. I'll be following this with interest! Thanks for doing this.
 
Grinding coolant ordered.

Waiting now for Silver Lubricants SILVERGRIND 3001 - 8 liters canister :P

For now I have small stop on drilling... Old vise tried to break my ribs by acting Black Hawk Down on bench drill...
Need new drilling vise :D
 
Almost done :)

1/4-19 taps , 2 needle valves ( 3,5$ one :P )

Just need to buy Mig 1mm jet, make small modyfication of that and all done :D.

Next version of MQL fogless mister will be even better and slighter.




 
Whole unit :)





Working on 30PSI ( to have kinetic energy neede to break airflow around grinding wheel)

Now making mounting and then I wil make a video of this ;)
 
Kosa, so this will shoot out a stream of refrigerated coolant onto the work piece?
 
Nope.

For now it's a just Fogless MQL mister.

https://www.youtube.com/watch?v=fOENAKiceOw

https://www.youtube.com/watch?v=D4aFy3tRpI4

Probably Vortex tube will be not used for now ( I need there probably 0,6 MPa to get effect with 250l/min that means new Air supply unit. )

Walther using KoolMist and this is a mister wit ha loot of fog.
As he using mostly water, his lungs are safe.

But A Fogless mister is a more better solution.
When grinding is good to get grinding lubricating coolant.
Lubrication = Less friction = less force = less heat = belt last for longer! And knife finish is better.

But with classic mister this can go into you lungs, with fogless NOPE.
Also less coolant is lose as spray around grinder, sticking to grinder , you and walls.
 
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