DropsA (formerly Bielomatik Schmiertechnik GmbH) has released the new Multicut Micro SP 51 SE and Micro SP 25 SE from Zeller+Gmelin. The lubricants have been specially developed for use in 1- and 2-channel MQL systems. As a synthetic minimum quantity lubricant with a high additive level, it is particularly suitable for machining high-strength steels and aluminum.
DropsA aims to improve the performance of customers’ production systems and reduce maintenance costs at the same time. Martin Müller, who is responsible for service at Dropsa BM Germany GmbH, highlights the benefits of minimum quantity lubrication: “MQL is not a mass application, but the advantages often outweigh the disadvantages: By using MQL, we can achieve longer tool life and higher machining speeds, which demonstrably leads to an increase in productivity.” However, switching to MQL requires a well-coordinated project in which all parties, from the machine manufacturer to the tool and lubricant suppliers involved, have to work together. According to Martin Müller, many machining processes can be successfully implemented with minimum quantity lubrication.”
Endurance test passed
Almost dry and still runs like clockwork: To ensure that the minimum quantity lubrication works smoothly, DropsA tests every lubricant for system suitability. Bodo Maier, Head of Development and Design at Dropsa BM Germany GmbH in Frickenhausen, emphasizes the outstanding properties of Multicut Micro SP 51 SE: “Cutting oils have quite different properties and it is not always possible to predict exactly how they will interact with certain material combinations. With our tests, however, we can confirm that this oil is compatible with our MQL system.” It is important for the minimum quantity lubrication expert to emphasize that such an approval relates to the DropsA MQL, so it is not necessarily suitable for every machining application in metal cutting. “A wide variety of tools and materials are used in the actual machining process – every alloy reacts slightly differently. There is no universal lubricating oil that is suitable for all processes, and users should pay attention to this,” emphasizes Bodo Maier.
Martin Müller explains: “Every lubricant we approve is thoroughly tested for its properties in advance. We have developed two test procedures for this: an endurance test and an elastomer compatibility test. We therefore operate the entire MQL system in continuous operation for eight weeks and also test critical components for their elastomer compatibility with the lubricant. If the tests are successful, we will release the lubricant.”
Low nebulization and low vaporization
Multicut Micro SP 51 SE was specially developed for use in the field of minimum quantity lubrication. Selected ingredients ensure low fogging and low evaporation. “As DropsA has tested our new lubricant Multicut Micro SP 51 SE, users can always contact our product management team if required,” says Thorsten Wechmann, Strategic Business Unit Manager at the Eislingen-based lubricant manufacturer. For example, the products Multicut Micro SP 25 SE are available in a lower viscosity for 1- and 2-channel systems and Multicut Micro A 20 for 1-channel systems.
5 questions for Bodo Maier, Head of Development and Design at DropsA BM Germany GmbH
Mr. Maier, what are the advantages of minimum quantity lubrication (MQL)?
Maier: By using MQL, we can achieve longer tool life and higher processing speeds, which has been proven to increase productivity. MQL produces fewer impurities and dry chips that are easier to recycle
What goals should be achieved?
Maier: With MQL, three things essentially have to be fulfilled: Lubrication, cooling and the removal of chips from the machining process. Targeted lubrication allows us to get close to the cutting edge during machining, reduce friction and keep process heat to a minimum. The lubricant fulfills its actual task of lubricating the machining process. The compressed air used transports the lubricant to the machining area, serves as cooling and removes the chips from the machining area.
Cutting oils can react quite differently with certain materials. How did DropsA test this?
Maier: We have carried out extensive tests to ensure that the cutting oil from Zeller+Gmelin is compatible with our system components. In the end, we were able to prove that this oil had no negative impact on the components tested.
How does the MQL user find the right cutting oil for his machining?
Maier: The user is ultimately responsible for selecting a suitable lubricant on the basis of our approval list, which was developed in cooperation with various oil manufacturers. With MQL, it is important that the entire system is well coordinated with the machining process. By optimally setting all parameters and tools, new and existing processes can be successfully realized with MMS. In addition, in most cases the cutting values and tool life can be increased.
How is the overarching cooperation in relation to MMS going?
Maier: We do sell the MQL devices, but we want to talk to everyone involved, including machine, tool and lubricant suppliers. It’s about the entire process, which is why we advise our users and customers beyond the use of MMS. We usually come across two types of customers: Users already have experience in using lubricants with MQL, or they have little to no experience and turn to us for recommendations on the right lubricant for their process.