Unlocking the Secrets: The Science Behind Filtration for Cutting Tool Grinding Machines

In today’s fast-paced manufacturing industry, efficiency and precision are critical. Investing in cutting tool grinding machines has become essential to keep up with the ever-growing demand for quality products. These machines offer a range of benefits that can significantly enhance your production process.

From sharpening dull blades to reducing cycle times, cutting tool grinding machines are designed to make your operations sharper, faster, and more robust. These machines can transform your cutting tools by utilizing advanced technology and innovative features, ensuring optimal performance and longevity.

Whether in the automotive, aerospace, or machining industry, investing in cutting tool grinding machines is a strategic move that can give you a competitive edge.

Get ready to revolutionize your production process and experience the power of cutting tool grinding machines.

Estimated reading time: 8 minutes

Using no filtration at all with your cutting tool grinding machine

The basic idea for a tool grinding machine is to use high-pressure oil. The oil keeps the cutting elements, like the grinding wheel and blanks, cool so they do not overheat, fail, or deform. If you do not use grinding oil, there is excessive heat generation, and the cutting tool will never meet the quality parameters.

The oil inside the grinding zone must be filtered before it goes back into the machine tank. You need to filter your oil because it will contain tiny particles of carbide or HSS (high-speed steel). When mixed with oil, these particles cause significant damage to your tool and cutter grinding machine. When this happens, your grinders and wheels will wear out much faster than expected, which means costly replacement and maintenance costs down the road!

Most tool and cutter manufacturers supply machines with just an oil collection tank. The carbide/HSS-laden oil comes from the grinding zone, and the same black oil circulates back. Hence, cutting tool manufacturers need to be vigilant and aware of this and plan to install an effective filtration system immediately.

Every cutting tool manufacturer planning to invest in an expensive tool and cutter grinding machine needs to read this- 4 reasons to invest in a high-quality grinding oil filtration system.

Another threat of not using any filtration system is cobalt leaching in the grinding oil you use.

Using a paper band filtration system

A paper band filtration system is an inferior way of filtering grinding oil. It is the worst and most ineffective method of filtration that you can use. Some might argue that it is better not to have any filtration system than to use a paper band filtration system, especially for tool and cutter grinding applications. But why is that?

Let me explain:

The carbide/HSS particles in grinding oil are minute. 80% are less than 10 microns. The paper band filter design does not allow pressure build-up. Hence, there is no squeezing action while filtering.

Now, the tiniest opening on the filter paper might be less than 10 microns. However, that does not mean each pore on the paper is less than 10 microns. Hence, the filtration efficiency depends on the porosity of the paper.

The filtration efficiency one can expect from a paper band system is 50 microns. Hence, the carbide/HSS particles pass through the filter paper and settle in the tank, or the pump picks them up with the oil and re-circulates them in the machine.

It’s not just about keeping the oil clean; it’s also about safety! Suppose you’re not using a high-quality filtration system. In that case, you risk having your machine fail at an inconvenient time—like when you grind special carbide tools for demanding applications like medical, aerospace, and defence.

Effects of using paper band system-

• Oil remains black with carbide/HSS particles.
• The grinding wheel life deteriorates despite having a filtration
• Carbide is abrasive; hence if it remains in circulation, it settles on the machine bed and ball screws and damages them. Thus increasing maintenance costs of the machines and affecting accuracy.

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Why is a bag filter system wrong for tool and grinding machines?

The bag filter is a better choice than the paper band filter, but still a wrong choice overall. However, for this article’s purpose, let’s understand that the filter media used in these systems cannot generate enough resistance to trap the carbide / HSS dust.

Cutting tool manufacturers use the bag filter system because they are cheap to operate and cause many issues. Bags cannot generate enough resistance to trap the carbide / HSS dust; therefore, they need regular cleaning (which can become very time-consuming).

Hence, it is twice the punishment for manufacturers who use bag filters for filtering carbide or HSS particles. Firstly, the bag does not filter oil down to the desired level. Secondly, the bags are consumable. Importantly, carbide starts to choke the bag pores, reducing the rated oil flow through the bags. At this point, there is no option but to replace them.

Do you know how carbide leaching affects the life of your cutting tools?

Are cartridge filters better compared to bag filters?

1-micron filter cartridges are indeed good at removing carbide particles from grinding oil, but there are a few things you need to know about them.

First, the dirt load in tool and cutter grinding machines is high, leading to higher cartridge consumption. Moreover, it would be best to discard these oil-soaked paper cartridges appropriately.

Frequent cartridge changes are expensive for your business because you must replace them frequently. Moreover, spend money to discard them properly.

For example: If you use a 1-micron cartridge on a machine that runs 24 hours per day, seven days a week, and only changes the filter once every eight days (typical), your costs will be much higher than with a 5-micron cartridge.

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Filtration system for carbide recovery from your cutting tool grinding machine

Carbide recovery is another important consideration when choosing an oil filtration system for your tool and cutter grinding machine. Because carbide scrap is so valuable, getting all the carbide out of your used oil makes sense.

But many conventional filter systems can’t do that. Paper band filters, for example, don’t separate the carbide from the rest of the oil—so it gets discarded along with the media. The same goes for cartridge filters, which consist of multiple layers of different materials that can trap fine particles inside them.

The only way to get every bit of carbide out of your used oil is with a Transor India filtration system. Transor India filters capture even fractions of microns—less than one-millionth of a meter!

If you want to invest in a high-quality, long-lasting filtration system that will recover carbide and help you grind the best cutting tools, speak with our experts. Please click here to contact us.

Using a centrifuge to filter out carbide/HSS

Centrifuges are not a good option if you’re trying to filter out carbide and HSS from your grinding oil.

You see, centrifuges are not filters. They don’t use filter media to remove the solid particles from a fluid—they use centrifugal force to separate the particles.

So if you’re trying to filter out 1-micron particles from the grinding oil using a centrifuge system, it won’t work. You’ll end up with clear oil still full of carbide and HSS!

But if you want to recover carbide? A centrifuge is your best bet. They work like a kidney: dirty and clarified oil returns to the same tank. That way, you can check how clean your tank’s oil is—and if it’s black or blackish (which means there’s carbide or HSS), you know what needs to change.

Finally, we must mention another thing: a centrifuge adds heat as it spins. So if your application is temperature-sensitive, which most carbide-cutting tool grinding is, be careful when using this method!

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How can cutting tool manufacturers plan their investment?

We understand that the cutting tool business is very competitive. Manufacturers follow the above-mentioned wrong practices to save on initial investments.

However, each manufacturer has to think about the trade-off between saving money by cutting corners initially and paying a higher price for maintenance and low quality later. If anybody you know and care about uses one of the above systems with their tool and cutter grinding machines, please share this article with them to make them aware!

In conclusion, we would like to say that there are many other ways to improve the performance of your grinding machine without breaking your bank account. We hope this article has provided valuable information for those looking to optimize their grinding processes without spending too much money on equipment or upgrades! The key is to invest in high-quality accessories from reputable manufacturers.