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Machine Tool Coolant Pump Applications

Wanner Hydra-Cell Pro

Electrical Discharge Machining (EDM)

The injection of deionized (DI) water requires precise, consistent control down to very low flow rates at high pressures. DI water is corrosive, non-lubricating, and can cause excessive maintenance with pumps that have dynamic seals and packing.

The seal-free, packing-free design of Hydra-Cell Pro, coupled with a constant accurate flow rate independent of discharge pressure, ensures a controllable and dependable process.

grinding machine graphic

Grinding

In high-speed production grinding, coolant must be pumped to provide cooling and flushing of the contact area between the grinding wheel and the workpiece. The coolant must be pumped at a velocity greater than the speed of the wheel to penetrate the vapor barrier created by superheated steam. Additionally, high-pressure coolant should be applied to the grinding wheel surface to clean the wheel and improve production. Fine filtration for the coolant is a cumbersome and expensive process. Conventional centrifugal, screw, or piston pumps struggle to pump this recycled fluid.

During grinding wheel dressing, fine sub-10 micron particles end up in the coolant. The coolant often contains particles from the workpiece as well as debris from the grinding wheel. These particles are very difficult to filter, but this poses no problem for Hydra-Cell Pro pumps due to their seal-less design.

Boring and Deep Hole Drilling

In deep hole drilling, coolant must be pumped to the end of the drill to cool the bit, flush the chips, reduce tool deflection, and maintain tolerances. The recycled coolant contains many particles from the drilling process. Filtering the coolant sufficiently for most other centrifugal, screw, or piston pumps can be expensive and cumbersome.

Consistent flow rate independent of discharge pressure ensures coolant is delivered to the drill bit even in deep holes.

gears turning

Turning, Threading & Milling

Today, most lathes can greatly increase the metal removal rate with high pressure coolant while reducing thermal shock and the premature tool failure that results from it. The vapor barrier, which forms when coolant boils from the heat generated from the tool and the work piece, can be penetrated with high pressure. The coolant used in these high pressure applications can be recirculated, however, most conventional positive displacement high-pressure coolant pumps require very clean fluids, requiring expensive, high-maintenance filtration.

High pressure coolant in mills and machining centers provides better cooling, increased tool life, reduced friction, and improved surface finishes. High pressure coolant removes chips from the work process and reduces the problems associated with re-cutting of chips. Hydra-Cell Pro coolant pumps can handle 250 micron particles.

No problem machining cast iron with Hydra-Cell Pro

Machining cast iron generates a large amount of dust and fine powder, and when combined with machine tool coolant is difficult to filter out, creating issues for screw pumps. It is the sub-20 microns particles which causes the damage to screw pumps! Hydra-Cell Pro’s seal-less design can handle these solid-loaded coolants reliably.

Long life and minimal maintenance costs

Any servicing is simple. With no dynamic seals wearing or tight internal tolerances to set or maintain, servicing can be carried out in any basic workshop. Depending on the duty, an annual oil change, and typically once every 2-3 years, a low cost liquid end replacement kit is all that is required. A true “fit and forget” solution.

Energy efficient and reduced energy costs

Being a true positive displacement pump, the seal-less design of the Hydra-Cell Pro pump eliminates internal flow losses giving overall efficiencies of 78% - 90%.

Cleaning and Degreasing

Hydra-Cell Pro’s seal-less design, with many choices of materials of construction, enables many different chemical cleaning liquids to be used. Recycling the liquids and having suspended fine particles is not a problem for a Hydra-Cell Pro pump.

High pressure capability ensures short cycle times and high productivity.

Deburring

Even at pressures at 350 bar, the Hydra-Cell Pro seal-less design can handle recirculated deburring liquid without expensive seal flushing and regular maintenance.

Technological Advantages Hydra-Cell® Pro Seal-less High-pressure Coolant Pumps

From neat oils, very low viscosity water-based and synthetic coolants, Hydra-Cell Pro high pressure coolant pumps deliver a consistent predictable performance; year after year.

Reduce Costs and Improve Productivity with Hydra-Cell Pro Coolant Pumps

  • Handles fines that can destroy pumps with dynamic seals
  • Requires no fine filtration
  • Minimal maintenance
  • Outstanding energy efficiency
  • Provides peace of mind with over 40 years of partnership with world-class HPC manufacturers and the largest CNC machine tool manufacturers

Reliably handle coolant with suspended metal particles

Typically, coolant filtration systems filter down to 10 microns, but damage to coolant pumps with dynamic seals is often caused by higher ppm of sub-10 micron particles. Hydra-Cell Pro’s seal-less design eliminates this issue, reducing operating and lifetime costs while increasing productivity.

Hydra-Cell Pro’s seal-less design allows the pump to handle liquids with suspended solids from 0.1 microns up to 500 microns, reliably and consistently over many years. The wide choice of valve materials, such as ceramic and tungsten carbide, enables processing of materials ranked 10 on the Mohs hardness scale, such as diamond.

Energy efficient and reduced energy costs

As a true positive displacement pump, the seal-less design of the Hydra-Cell Pro pump eliminates internal flow losses, giving overall efficiencies of 78% to 90% (from pump shaft to hydraulic power). This results in significant energy savings, and with no dynamic seals, this efficiency remains consistent year after year.

Long life and minimal maintenance costs

Any servicing is simple. With no dynamic seals to wear out or tight internal tolerances to set, servicing can be carried out in any basic workshop. Depending on the duty, an annual oil change and typically replacing a low-cost liquid end kit once every 2-3 years is all that’s required. A true “fit and forget” solution.

Lifetime costs comparison (5 years)*

Lifetime costs comparison chart

Pump-shaft to hydraulic power efficiency comparison**

Pump shaft to hydraulic power efficiency comparison chart

Hydra-Cell seal-less pump technology

Reliably handling different cutting coolant technologies

Different cutting tool liquids can vary in viscosity, from thick oils at 20 mm²/s to emulsions and synthetic water-based coolants at 1 mm²/s. Hydra-Cell Pro’s seal-less design ensures there is no reduction in flow rate with increasing pressure, especially with low-viscosity coolants.

Flow rate comparison

Flow rate comparison chart

Get our brochure

Learn more. Download the Hydra-Cell Pro Machine Tool Coolant Pumps brochure

* Lifetime costs comparison is based on a machine tool performing milling, drilling, or turning at 103 lpm and 70 bar. Energy costs are calculated based on 103 lpm at 70 bar running for 4,000 hours per annum at 12 Euro cents per kWh. Figures represent the average user who wants to maintain process discharge pressure within +/- 10% and has adopted a simple filtration management system and specification. Calculations do not take motor efficiencies into account. A traditional screw pump typically requires replacement after 24 months due to seal wear. As parts are not available for repair, a complete replacement pump purchase is necessary. In contrast, the Hydra-Cell Pro seal-less pump requires only minimal servicing, and depending on duty, may only require a complete fluid end kit replacement once every two years.

** Efficiencies are calculated assuming water-based coolants. Four-pole motors were used due to their highest efficiency.

Wanner Hydra-Cell® Pro

Wanner Hydra-Cell® Pro Seal-less Coolant Pump Selection

Consult our pump selection graph to find the right pump for your application.

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