Brittle material sludge (chips and shavings) remover

Brittle materials are, as the name implies, "brittle materials" and include ceramics, cast iron, concrete and glass.

In recent years, advances in machine tools, tools, and materials have resulted in chips of brittle materials becoming micro-sludge, and the adverse effects of this sludge in the machining fluid have become a problem.

Here, we will introduce such brittle material sludge removal equipment, which we hope you will find useful.

Sun Maintenance Koki

Features of Sun Maintenance Koki's products

SMK RAPTOR

Cited from: https://www.smk-web.co.jp/filtration-smk-raptor.html

The W-coupler type filter employs the advantages of both internal and external pressure type filters. High-performance fiber filter paper is used to collect fine sludge.It can be used for both oil-based and water-based products, and its high filtration speed allows filtration to be completed in a single pass.

The precision filtration filter "FWC" used has an integrated case structure and can be replaced with a single touch. It also helps maintain a clean environment by preventing liquid splashing and reducing cleaning and other maintenance. In case of trouble such as liquid leakage, the sensor detects the abnormality and automatically stops the machine. Safety is also ensured.

SGL

Cited from: https://www.smk-web.co.jp/filtration-sgl.html

This equipment uses high-performance filter paper to achieve ultra-fine filtration. The number of mounted filters is lined up from 1 to 3.You can choose from a compact type with one filter to a large capacity type with three filters to meet your needs.The chassis is compact, takes up little space, and is easy to move around.

Basic Information on Sun Maintenance Koki

filter precision engineering

Features of products handled by Filtration Seiko

Fully automatic high-speed centrifuge ~NKEB-2000S

Cited from: https://www.rokaseiko.com/service/nkeb-2000s

Filtration Seiko's NKEB-2000S is a fully automatic system for separating and discharging sludge.Sludge removal from brittle materials such as ceramics, silicon, quartz glass, and cemented carbide, regardless of whether they are magnetic or non-magnetic.The company is doing so.

As for separation, centrifugal force of up to 2,000 G provides powerful and highly efficient operation. The proper positioning of the bearings suppresses operating noise at high speed rotation. The simple structure of the machine allows for a compact footprint, and the caster wheels make it easy to move the machine between tanks.

Basic Information on Filtration Seiko

Toto Separator Kogyo Co.

Features of products handled by TOTO SEPARATOR KOGYO

Automatic Centrifuge CF Series

Cited from: https://centrifuge-tsk.com/product/automatic/#con_top

The CF series of automatic centrifugal separators use centrifugal force to separate coolant liquid and sludge. The sludge scraping operation is available in manual, semi-automatic, and automatic series, and this product is an automatic type. Safety devices are standard, and there is a choice of 60, 100, and 150 models.

The "Centralized Filtration Circulation System" can be used to manage wastewater and sludge treatment for multiple chemical processing machines in a single location. Since no filters are used, running costs can be reduced.

Semi-automatic Centrifuge TSK series

Cited from: https://centrifuge-tsk.com/product/semi-automatic/#con_top

The TSK series semi-automatic centrifuges are operated by a handle for scraping sludge. The TSK series is available in 60, 100, and 150 models.

Manual Centrifuge TSK Series

Cited from: https://centrifuge-tsk.com/product/product-manual/#con_top

The TSK series of semi-automatic centrifuges are manual centrifuges that use centrifugal force to separate materials with different specific gravity. In addition to the centrifuge, coolant tanks and secondary filtration equipment are manufactured as a system. These products can be installed in a small space and are easy to handle.

Basic Information of Tohto Separator Kogyo Co.

nifco plant

Characteristics of the products handled by Nifco Plant

NKU type magnetic filter

Cited from: http://www.nifcoplant.co.jp/product/nku.html

The NKU type magnetic filter handled by Nifco Plant is a separation method filter that utilizes a special magnetic plate. The plate is installed at the bottom of the conveyor and utilizes magnetic force and sedimentation effect. Coolant liquid is passed over the plate, and even fine sludge is adsorbed. The sludge is automatically discharged out of the machine.

The tank itself is a filter, so there is no need for cleaning.

VP-FILTER

Cited from: http://www.nifcoplant.co.jp/product/vp-filter.html

The VP-FILTER requires a filter in the suction section of the pump. Sludge removal and cellulose supply are fully automated, and operation is simple. Sludge can be re-melted in an electric furnace without separation, allowing reuse of waste.

The special screw conveyor feature also improves the dewatering effect. A wide lineup of models is available and can be selected according to processing capacity. Used for machining, finish grinding of steel, cast iron, aluminum, and carbide ceramics.

DC-FILTER

Cited from: http://www.nifcoplant.co.jp/product/dc-filter.html

DC-FILTER is a pressurized filtration system. It filters by forming a cake layer on the filtering material (blow-off belt) between the upper and lower shakes. The use of special rubber seals maintains a high degree of tightness and enables highly accurate filtration.

Air blow and coolant cleaning at the time of sludge discharge reduces the frequency of filter media replacement, thereby reducing running costs. Space-saving because a large filtration flow rate can be obtained per filtration area.

Basic Information on Nifco Plant

Coolant filtration] Example of brittle sludge removal

Example on a casting machining center

The drum filter conveyor they were using contained a large amount of fine chips and carbon in the coolant liquid, causing many problems due to clogging. In addition, the poor filtration accuracy was also causing many defective products due to scratches.

Results after equipment installation

After installing a certain demo machine and testing it for two months, the coolant life was doubled. Furthermore, the defect rate was reduced by 20%, so they purchased a demo machine and installed it on an existing machining center as needed. The sludge discharged from the machine is now dry, according to the company. Although they do not have statistics, they are enjoying many positive aspects of the machine, such as the fact that not only do they feel that the life of the cutting tools has been extended, but they also no longer have to purchase parts because of the lack of breakdowns.

Example of injector parts machining (steel)

This is an example of a company that wanted to reduce quality defects and tank cleaning.

Results after equipment installation

The defect rate improved from 8% to 2%. Furthermore, the frequency of coolant fluid replacement changed from once a month to once every two months.

• Ceramic sludge (chips and shavings) remover
• Carbide sludge (chips and shavings) remover
• Metal sludge (chips, shavings) remover
• Grinding sludge (chips, shavings) remover
• Cutting sludge (chips and shavings) remover
• Silicon sludge (chips and shavings) remover
• Aluminum sludge (chips and shavings) remover

For grinding process】 【For grinding process】.
Coolant filtration system
Three recommendations

Coolant filtration equipment is used to filter sludge generated from equipment. There are a variety of products available depending on the intended use, so it is important to determine "whether the coolant filtration equipment is suitable for the purpose" and "whether the equipment is suited to the characteristics of sludge.

Filter filtration system capable of filtering all "fine" sludge of 3μm or less Filter filtration system capable of filtering all "fine" sludge of 3 microns or less

Sun Maintenance Koki

Reference: Sun Maintenance Koki official website (https://www.smk-web.co.jp/index.html)

Main materials that can be filtered

• Brittle materials such as cemented carbide, ceramics, and castings

For factories like this

• I want to filter fine sludge less than 3μ.
• I want to use it as a secondary process
• To remove sludge that could not be filtered by other equipment

Check equipment on official website

Capable of filtering "large volumes" of up to 200 l/min Centrifuge

Toto Separator Kogyo Co.

Reference: Toto Separator Industry official website (https://centrifuge-tsk.com/)

Main materials that can be filtered

• Brittle materials such as cemented carbide, ceramics, and castings

For factories like this

• I want to filter more than 100 L
• I want to use it as a primary process
• Want to reduce running costs

Check equipment on official website

High magnetic force filters 5 microns or less High magnetic force enables filtration of 5 microns or less. Magnetic Separator

Sumitomo Heavy Industries Finetech, Ltd.

Reference: Sumitomo Heavy Industries Finetech official website (https://www.shi-ftec.co.jp/)

Main materials that can be filtered

• Metal materials such as aluminum, steel, and iron

For factories like this

• I want to filter metal materials.
• I want to use it as a primary process
• I want to remove metal sludge.

Check equipment on official website