Magnetic filter extracts metal cutting fines

UK toolmaker was seeking a highly effective magnetic filtering system that also offered environmental benefits, which it found through using an Eclipse Magnetics Filtramag system.

At last week's UK MACH 2008 machine tool exhibition, Eclipse Magnetics, said it had supplied its innovative Filtramag magnetic filter to Elite Tooling in Rotherham, to provide a cleaner and more environmentally friendly method of operating.

Elite Tooling makes standard and bespoke solid carbide slotting, end mill and form tools.

The company wanted a highly effective magnetic filtration system to meet environmental standards.

Eclipse Magnetics' Filtramag system enables manufacturers to meet their environmental commitments, said the company.

The reason is, said Eclipse Magnetics to manufacturingtalk, there are no filter cartridges to dispose of, which otherwise could cause an environmental protection issue.

Eclipse added that Filtramag also helps the environment because there is no loss of fluid associated with replacing the sodden cartridge and it can extend the useful life of the fluid, making it a sound environmental choice.

Elite Tooling said that it had been working with the UK's Environmental Agency to find a better way of disposing of the sodden filter cartridges, before it had become acquainted with Filtramag.

Managing director at Elite Tooling, Bob Hill, explained: "Grinding fluid is now classed as bio-waste which meant that we had to dispose of our filters in the past through a specialist company, which proved very expensive.

Installing Filtramag therefore allowed us to eliminate two of our biggest problems - how to increase filtration levels and how to improve our environment credentials".

* Extra benefit - Elite Tooling was surprised by an additional Filtramag benefit in that the system produces saleable reclaimed material, so that that payback began immediately after installation.

Once the filter 'cake' is removed from the Filtramag unit, it is allowed to drain and then sold to a company that recycles it.

Filtramag is used on Elite Tooling's Walter 5-axis tool and cutter grinding machine that makes high performance drilling, tapping and milling carbide tools.

One of the main difficulties when grinding carbide is ensuring that the cutting oil is suitably filtered before it is reintroduced into the grinding operation at the cutting face.

Eclipse Magnetics told manufacturingtalk that re-circulating contaminated oil can cause the following problems.

* Compromise surface finish quality.

* Produce inconsistent parts.

* Result in oil degradation.

* Reduce, within a few months, a critical, expensive machine tool into a tired looking and worn piece of equipment.

Hill said: "Our Walter Helitronic Power Grinder enables various carbide cutting tools to be machined from stock bar including the flute shaping operation, which generates the most contamination.

Producing the final cutting edge is an extremely accurate operation, the last thing you need to be thinking about at this stage is whether or not the suspended particles in the cutting oil is going to affect the finished tool".

* Unreliable paper filter - the paper filter medium used before by Elite Tooling proved to be unreliable for removing the micron sized carbide particles in order to maintain the high standards.

The first indication of this became apparent when the particles began to lie down on the top of horizontal surfaces, making the machine look as if it had been working 'flat out' for the last few years.

Hill explained: "It was at this stage that we realised we needed to protect our machines, which were our biggest investment, and, knowing that the particles were magnetic, decided to ask Eclipse Magnetics to come up with the solution".

After a brief discussion and a visit by the Eclipse Magnetics engineers it was decided to install a Filtramag unit.

The filter was installed by Walter GB and as Hill said: "It exceeded our expectation in terms of filtration efficiency and I would recommend the Filtramag to any company who grinds or hones component parts".

* High intensity rod magnets - the Filtramag uses six high intensity rare earth rod magnets.

The rods have pole concentrators and a proven magnetic circuit geometry that generate controlled, deep reaching magnetic flux fields, which produces 11,000 Gauss.

These flux fields attract and retain any magnetic particles that are suspended in the fluid down to the individual micron level.

Eclipse Magnetics said that the Filtramag offers unrivalled levels of magnetic performance and contamination removal efficiency, when compared to more conventional filter units.

Elite Tooling said it had also found that the improved filtration levels significantly reduced wear on their machines.

Other benefits of using Filtramag compared to cartridge type filters include the following.

* Zero running costs.

* No maintenance costs.

* Elimination of downtime associated with changing filter media.

* Back pressure is also avoided, even when the magnetic cores are totally saturated with contamination and no mess.

Filtramag units are available with various port connection sizes.

The Filtramag will hold up to 6kg of debris before cleaning is required.

The units can be used with grinding, honing, lapping, boring and fine-detail machining, said Eclipse Magnetics.

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