Mist Cooling

What is the nozzle configuration? If it ls like a tube, it won't work well. If it a thin disk with a small orifice, it will work better, expecially if there is are swirling guides inside.

It is a tube like nozzle specially designed to produce mist.

Do a goggle search for misting nozzles and you find a couple of companies that make what your looking for. I had put together a system sometime ago using just normal hose hold water pressure and it worked as designed.

He needs to wear his google goggles while searching. Possibly even while misting the work. Also needs to pay attention to water quality to a certain extent.

Misting nozzles are used extensively. (manufacturers - just do a search) for such as making snow for ski slopes, etc. There is a huge range of nozzles for many different circumstances, fluids and pressures. One firm did send me a few free samples for testing.

Such as: http://www.bete.com/products/spraynozzles.html - More than you use?

Hope this helps,

jt.

My beautiful ski slope.... Lost in the mists of time.

I forgot to mention an important part.Mist type of cooling is to reduce internal stress induction during machining with conventional cooling method. Mist cooling has higher higher heat transfer coefficient leading to proper cooling rate, which is sufficiently than cooling rate that causes annealing.

I think your trying to keep the friction induced heat temperature below tempering temperatures. So you must be machining something very hard, and want to keep it's properties, and do real fast machining.

It's pretty tough to beat a fully wetted (flooding), heat transfer, unless your using some super cooled, magic specific heat spray lubricant, in large volumes, that exceeds immersion flooding. This is heat transfer, and I don't see how atomized material can do magic unless it evaporates, and absorbs massive latent heat of fission, in the process.

What is the working fluid that you can afford to do this? And vaporizes, and lubricates, and is non toxic.

Are you developing this for a product, or just playing.

Dear Friend,

In the machining, it is NOT the COOLING the HEAT ALONE and the coolant serves as LUBRICANT as well.

While machining, heat is generated more in the job and partly in the cutting tool.- mainly work done on the job. The Heat is generated on account of friction, between the job to be machined and the tool. If you study the chip formation theory while machining, the energy balance will indicate FRICTION plays a VITAL ROLE. If lubrication is not proper, the FINISH of the job will suffer.

Hence Lubrication is REQUIRED and the Mist which you are thinking, may NOT give the desired Lubrication effect.

DHAYANANDHAN.S

Mist cooling is only advantageous when extremely high cutter speeds (25 -50K rpms) are used. At those speeds full flood cooling is simply repelled by centrifigul forces and expelled metal chips, leaving the lubrication and cooling at the point of cut reduced. Vapor has lower mass and can get into the point of cut better and also uses evaporation for additional cooling. But you must provide proper ventillation since the vapor is an extreme health hazard, expecially when using the exotic formulas that work well in a vaporized state. I advise against it. Flood coolant, properly mixed, with cutter speeds below 20,000 rpm can yield satisfactory metal removal rates in virtually all instances. As usual, proper tooling at proper speeds and feeds are the root issues to good quality work, reasonably fast, and cost effective.

The current systems on the market all use air to atomize, and force this onto the cutter. If your particle size is too small, you will not overcome the "relative wind" of a spinning cutter. Unless your doing a lathe operation, where material is spinning against a "stationary" cutter. Even that has moving air from the spinning of the spindle chuck.