Mist Coolant System

What is Mist Coolant System?

Mist coolant system is a system that is used in various CNC metal machining operations to cool down the overall operating temperature during the working process. During a CNC machining operation, the cutting tools rotate at a high speed to cut the work pieces and heat is generated during the process. Since the excessive heat may affect the properties of both the cutting tools and the work pieces, a mist coolant system is necessary in order to lower the operating temperature and maintain the quality of the machining operation.

Generally speaking, the mist coolant system permits the atomization of water into micro droplets around six to eight microns in size. The water droplets generated by the mist coolant system is light in weight and can be easily evaporated. Due to its light weight, the micro water droplets are able to stay in the air for a longer period of time. When the water droplets contact with hot air around the machining site, they flash evaporate and reduce the heat in the air.

The mist coolant system is widely involved in modern CNC manufacturing and engineering since it is an efficient, durable and economy approach to dissipate heat during heavy duty, high speed machining operations. What the mist coolant system does is not just lowering the working temperature but also blowing away the tiny chips that are generated during the cutting process. By cooling down the cutting tool and the work pieces and evacuating the metal shreds, the quality and productively of the operation can be immensely improved.

Anatomy of mist coolant system

In a mist coolant system, there are the coolant reservoir, the air valve, the flexible tube and the nozzle tip. The general style mist coolant system applies the Venturi principle (Venturi effect) to generate the air stream for cooling. The Venturi effect refers to the constriction within a pipe system that varies the flow of the fluid that passes through the pipe. The fluid velocity is increased as the fluid passes through the pipe and the pressure of the fluid drops on the other hand.

How the mist coolant system works?

When the air valve is open, the air passes through the system and is released hence on through the nozzle tip. The Venturi effect takes place when the air passes through the air valve and the coolant is drawn from the coolant reservoir and joins the air flow to form a mist spray. The force of the mist spray is regulated by the air valve. The air valve serves as the key component in a mist coolant system to control both the volume and velocity of the air stream.

The nozzle tip is comprised of a coolant port and the nozzle housing. The coolant mist is released from the system through the coolant port. The nozzle housing is a movable component which is made to adjust the coolant volume. The coolant volume can be adjusted by turning the nozzle housing. A general style mist coolant system is simple in design while versatile in application. It can be modified for automatic operations or semi-automatic operations by incorporated with a computerized control system.

The mist spray that exits the system is the flash evaporation process that repeats millions of times in a single second. The flash evaporation consumes a great amount of heat energy and removes the heat from the air. In this process the evacuation of the mist is important. If the mist is not removed properly, it results in the building up of humidity around the working site which can sometimes be harmful to the machining operation.

Advantages of mist coolant system

The first advantage of a mist coolant system is that, it is a more versatile approach comparing to other types of cooling system. Due to the simplicity of the design, a mist coolant system can be manually operated, semi-automatically operated, or it can go fully automatic. This characteristic enables the system to be applied in light duty operations as well as heavy duty operations. For the light duty operation process, a typical mist coolant system with smaller coolant capacity and a single nozzle tip is fine for the job. For the heavy duty manufacturing process, a mist coolant system with multiple nozzles and greater coolant capacity can run continuously and efficiently to achieve the task.

A mist coolant system can offer an excellent efficiency to the operation and extend the lifespan of the cutting tools too. Sometimes the excessive operating heat can be destructive to the machining system. The metal fatigue may take place when the heat is not reduced properly. Furthermore, failures may occur when the excessive heat accumulates to a certain extent. Therefore, an efficient mist coolant system is required to avoid the heat damage. Reducing heat in a CNC machining process can potentially double or even triple the tool life. With a mist coolant system, heavier cuts, faster speeds and better finishes can be carried out.

In addition to the efficiency and versatility that a mist coolant system can offer, the safety of the personnel that is involved in the machining process is also guaranteed. A mist coolant system generates significantly less hazardous chemicals to human beings. On top of that, the mist evacuation system in an automatic process further assures that the chances the operators inhale the mist fog fumes are minimized. A system as such does not cause corrosion and odors which bring about a positive effect in maintaining the condition of the machinery and the personnel at the same time.

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