The film tells about the development of new promising coolants by Soviet research institutes, shows their efficiency, use at advanced metalworking enterprises. The issues of cleaning coolants and their utilization are considered. Soviet exposition at the METALWORKING'84 exhibition.
Manufacturing of parts for hydraulic, steam turbines and nuclear reactors.
Checking the accuracy and quality of metal processing.
CNC machines.
Machining centers.
Automatic lines.
Cooling fluids (CFL).
Table of processed materials and corresponding CFLs.
VNIPKI of the oil refining and petrochemical industry.
Cooling fluid creation laboratory.
Parameters taken into account when creating CFLs.
A scientist is solving the issue of coolant biostability.
Creating a bactericidal additive Vazin, which allows to extend the service life of the coolant Ukrinol-1. The ET-2 liquid went bad a week after production.
The new additive Kontsid-1 significantly extended the shelf life.
Equipment for checking new CFLs.
Liquids intended for rolling are examined on a rolling mill model.
The metal obtained after processing is checked using X-ray diffraction analysis.
Cooling fluid studies are carried out under conditions as close as possible to production conditions.
The effect of coolant on the metal surface is studied using electron microscopy.
A picture of the metal surface under a microscope.
Friction apparatus for testing the scuffing properties of lubricants.
Testing the surface quality.
Surface image.
List of lubricants developed by the research institute.
Assembling a Rubik's cube against the background of the coolant table.
The NPO Central Research Institute of Mechanical Engineering Technology studies the effect of the cooling and lubricating action of liquids on the process of tool wear and the formation of microroughnesses.
At low cutting speeds, work without coolant leads to intensive wear of the carbide tool.
Tool after work without and with coolant.
Graph of the dependence of tool life on the processing speed without coolant and with its use.
The use of active coolants reduces the size of the build-up, reduces the roughness of the machined surface.
However, weakening the protective role of the build-up can lead to a decrease in the tool life of the high-speed tool.
Graph.
With continuous cutting at high speeds, the use of coolant increases the tool life.
Comparison of cutters after work with and without coolant.
With intermittent processing at high cutting speeds, the use of aqueous coolants can lead to a decrease in tool life and even to its destruction.
Sample cutter.
The use of consistent lubricants allows to increase the tool service life several times.
In the production of turbine blades at the Leningrad Metal Plant PO, the emulsion Akvol-2, oil coolant MP-1, MP-99 are successfully used.
At the Nevsky Plant named after Lenin PO, oil liquids are used, which allowed to increase the tool service life by 1.5 times.
Footage of parts processing using special coolants.
Abundant supply of liquid when grinding a part.
Supply of coolant under pressure.
Use of coolant by spraying, for example, when processing turbines.
When drilling deep holes, a tool with internal channels is used, through which coolant is supplied directly to the cutting zone.
At the Podolsk Machine-Building Plant, coolant MP-3 was used for such an operation.
Ultra-deep drilling operation at the Nevsky Plant Association.
In this turbine rotor, the hole depth reaches 16 meters.
Exclusively thanks to the coolant, by selecting a rational value for its pressure and viscosity, the removal of chips from the cutting zone is achieved at such a depth.
Creation of coolant, Coolant Research, Tool wear, Extra deep drilling
Leningrad Podolsk
VNIPKI of the oil refining and petrochemical industry. NPO Central Research Institute of Mechanical Engineering Technology. PO Leningrad Metal Plant. PO Nevsky Plant named after Lenin. Podolsk Machine-Building Plant.
Metalworking shop.
Collection of used cutting fluids at the Volga Automobile Plant.
The plant has a centralized system for storing concentrates, preparing, transporting and storing liquids.
In the preparatory shop, the components are mixed in sealed containers in the required proportions.
Laboratory control of liquids at the plant.
Through an extensive pipeline system, cutting fluids from the warehouse are delivered to the shops to each machine, each head and then through nozzles to each tool.
Multiple use of liquid in a closed cycle.
For the simplest cleaning, cutting fluids are sent to an underground settling tank.
On automatic lines that use water emulsions, belt filters with a cleaning fineness of up to 20 microns are used.
Magnetic separators provide a high degree of cleaning.
Some machines use separators in combination with belt filters.
Cleaning of liquids using special centrifugal devices, hydrocyclones and centrifuges.
A pneumatic system that sucks out the resulting aerosols after ionization.
Completely used cutting fluids are sent for disposal.
International exhibition METALWORKING'84. The exhibition presents a cutting fluid cleaning system using paper and fabric belts, centrifuges, and hydrocyclones.
A unit for cleaning liquids contaminated with ferromagnetic particles using a magnetic chain filter is demonstrated.
The use of magnetic rods allows separating particles smaller than a micron.
A unit for electrostatic cleaning of cutting fluids using reusable filters.
When passing through an electrostatic field, the particles are charged and deposited on the electrodes.
A model of the unit.
The element used for filtration, flextubes woven from stainless steel threads.
Powder is deposited on them, through which the liquid is filtered.
A pneumatic jack periodically cleans the system.
Parts made using cutting fluids.
Tool.
Mosaic in the laboratory for creating cutting fluids.
Research Institute building.
Cleaning of coolant
Moscow Leningrad Tolyatti
Volzhsky Automobile Plant. Exhibition METALWORKING'84.