In the production of metal parts for the automotive industry, various problems are caused by metal chips.
Hoerbiger Synchron Technik GmbH manufactures engine components and other metal parts on a large scale for the automotive and energy industries, as well as a wide range of other components for different industrial sectors.
Problem
During machining, coolant is applied through fine nozzles on the machine tools. These nozzles are regularly clogged by metal chips generated in the machining process. When the nozzles become blocked, the cooling fails, which can lead to the breaking of cutting inserts. Cleaning or repairing the clogged nozzles is time-consuming and costly.
Clogged nozzle in the coolant lubrication system.
Clogged nozzle in the coolant lubrication system
Solution
As a test, a magnetic filter type FMF 310/1 was installed in the pump circuit of the first machine tool to remove metal chips and other steel-based contaminants. Since the installation, no nozzles have been clogged.
FMF Magnetic Filter in a Bypass Line
Result
The FMF magnetic filter, made of robust stainless steel and equipped with a powerful permanent magnet, filters all steel particles from the coolant before it is sprayed through the coolant nozzles again and onto the workpieces. Since the installation, the nozzles have operated without clogging or being damaged by particles. Additionally, the service life of the coolant has increased, leading to reduced operating costs.
Due to the excellent results with this machine tool, 19 additional machines—each with the same issue—were also equipped with magnetic filters.
Additional Issue
Following the successful use of the magnetic filters in machining, Hoerbiger turned their attention to another problem in the parts washing process.
After machining, engine components are blasted and then washed. The metallic dust from the blasting unit heavily contaminates the washing medium in the MTM washing system (an industrial high-pressure cleaning and washing unit), which resulted in short service lives of both the washing water and the connected filters.
Wash system with FMF (on black hose)
Solution
Due to the high performance of the pump used, a larger magnetic filter than those used in the machine tools was required. Because of the high flow rate, the FMF 420/6 magnetic filter was selected and installed directly after the pump. Shortly after installation, it was clear that the magnetic filter was removing significant amounts of contamination from the washing water.
Result
The use of the magnetic filter not only improved the cleanliness and therefore the effectiveness of the washing water, but also extended the service life of the existing filters four times over. Based on these positive results, the same magnetic filters were installed in two additional washing systems.
Metallpartikel an den Magnetstäben durch verunreinigtem Kühlschmierstoff
Summary of Advantages:
- The filter service life in the MTM washing system has increased fourfold.
- The nozzles no longer clog with metal particles, preventing machine downtime.
- Significantly fewer nozzles need to be replaced.
- No surface damage occurs due to contaminated coolant.
- Fewer particle-related failures reduce maintenance needs.
- Lower particle contamination results in higher surface quality of metal parts.
- The lifespan of costly coolant has increased.