CNC Machining Centers (Lathes, Drills, Mills, Turning & Horizontal/Vertical Machines)
CNC Machining is a process used in the manufacturing sector that involves the use of computers to control machine tools. Tools that can be controlled in this manner include lathes, mills, routers and grinders. The CNC in CNC Machining stands for Computer Numerical Control.
There are many advantages to using CNC Machining. The process is more precise than manual machining, and can be repeated in exactly the same manner over and over again. Because of the precision possible with CNC Machining, this process can produce complex shapes that would be almost impossible to achieve with manual machining. CNC Machining is used in the production of many complex three-dimensional shapes. It is because of these qualities that CNC Machining is used in jobs that need a high level of precision or very repetitive tasks. Often water based coolants, semi-synthetic coolant, or an oil based coolant is applied by nozzles or flood emulsion to protect the tool and the workpiece. This process produces a coolant mist, oily mist, and or oil smoke which is ideal for our Clean Air ZeroMist™ OM Series, Clean Air ZeroSmoke™ OS Series, or Clean Air ZeroSmoke™ HS Series.
Rotary Transfer Machines
Multiple stations with drilling processes that eliminate additional machines that may be required. Process produces highly complex parts that eliminate costly secondary machines/processes. Typical rotary transfer machines include: Hyrdomat, Tornos, and BTB. This process produces high concentrations of smoke and mist which is well suited for the Clean Air ZeroSmoke™ OS and HS Series.
Forging is a manufacturing process involving the shaping of metal using localized compressive forces. Forging is often classified according to the temperature at which it is performed: “cold”, “warm”, or “hot” forging. Forged parts can range in weight from less than a kilogram to 580 metric tons. Forged parts usually require further processing to achieve a finished part. This process produces an oily smoke and often “solids” which is well suited for our Clean Air ZeroSmoke™ HS-Series with a specially designed pre-filter section.
Heat Treating Process
Heat treating is a manufacturing process involving the shaping of metal using localized compressive forces. Heat treating is often classified according to the temperature at which it is performed: “cold”, “warm”, or “hot” forging. Heat treated parts can range in weight from less than a kilogram to 580 metric tons. These parts usually require further processing to achieve a finished part. This process produces intense heat and an oily smoke which is well suited for the Clean Air ZeroSmoke™ HS-Series.
High Speed CNC Grinding
CNC Grinding Systems are widely used to produce parts for aerospace, medical, automotive, and other industries. Extremely hard and exotic materials are generally no problem for today’s grinding systems and the multi-axis machines are capable of generating quite complex geometries. Grinder types include; centerless, ID, OD, and surface grinders. High spindle speeds and high-pressure coolant delivery produce high concentrations of smoke/mist which is ideal for our Clean Air ZeroMist™ OM series, the ZeroSmoke™ OS series on certain applications, and on extreme cases, the Clean Air ZeroSmoke™ HS series for multiple machines.
Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mold cavity. The mold cavity is created using two hardened tool steel dies which have been machined into shape and work similarly to an injection mold during the process. Most die castings are made from non-ferrous metals, specifically zinc, copper, aluminum, magnesium, lead, pewter and tin based alloys. Depending on the type of metal being cast, a hot- or cold-chamber machine is used. This process produces an oily mist, oil smoke and sticky die lube that is well suited for the Clean Air ZeroSmoke™ HS-2400 series, with specially designed spray system on the inlet plenum.
Electrical discharge machining (EDM), sometimes colloquially also referred to as spark machining, spark eroding, burning, die sinking, wire burning or wire erosion, is a manufacturing process whereby a desired shape is obtained using electrical discharges (sparks). Material is removed from the work piece by a series of rapidly recurring current discharges between two electrodes, separated by a dielectric liquid and subject to an electric voltage. One of the electrodes is called the tool-electrode, or simply the “tool” or “electrode”, while the other is called the work piece-electrode, or “work piece”. The process depends upon the tool and work piece not making actual contact. This process produces a semi-dry oily smoke that is well suited for our Clean Air ZeroSmoke™ OS Series.
Fastener Mfg. Cold Forming/Warm Forming
Heading is a metalworking process which incorporates the forging, extruding and upsetting process. It is often performed in the cold state, resulting in cold working. This process produces a near net shape work piece, which means the final product is almost finished. An important consideration in heading is the tendency for the bar to buckle if its unsupported length to diameter ratio is too high. This ratio usually is limited to less than 3:1 but with appropriate dies, it can be higher. Older machines are known as single-stroke headers, while newer machines are known as double-stroke headers, because they have two strokes; one stroke moves the work piece into the machine and the second heads the work piece. Typical parts include bolts, nuts, fasteners and related components formed from coils of rod. This process produces an oily mist and heavy concentrations of oil smoke that is well suited for our Clean Air ZeroSmoke™ HS-2400 series.
Gear Cutting & Hobbing
Hobbing is a machining process for gear cutting, cutting splines, and cutting sprockets on a hobbing machine, which is a special type of milling machine. The teeth or splines are progressively cut into the work piece by a series of cuts made by a cutting tool called a hob. Compared to other gear forming processes, it is relatively inexpensive but still quite accurate, thus it is used for a broad range of parts and quantities. It is the most widely used gear cutting process for creating spur and helical gears; more gears are cut by hobbing than any other process, as it is relatively quick and inexpensive. Typically, these machines run on a lower intensity, and mist/smoke levels are light to moderate. These processes are ideal for our Clean Air ZeroMist™ OM series.
A parts washer is a piece of equipment used to remove contaminants or debris, such as dirt, grime, carbon, oil, grease, metal chips, cutting fluids, mold release agents, ink, paint, and corrosion from work pieces. Parts washers are used in new manufacturing and re-manufacturing processes; they are designed to clean, de-grease, and dry bulk loads of small or large parts in preparation for assembly, inspection, surface treatment, packaging and distribution. Parts washers may be as simple as the manual “sink-on-a-drum” common to many auto repair shops, or they may be very complex, multi-stage units with pass-through parts handling systems. Parts washers are essential in maintenance, repair and re-manufacturing operations as well, from cleaning fasteners, nuts, bolts and screws to diesel engine blocks and related parts, rail bearings, wind turbine gears boxes and automotive assemblies. Typically, these machines produce steam, mist, and often light smoke as well as detergent contamination. These machines are ideal for the Clean Air ZeroMist™ OM Series as well as the Clean Air ZeroSmoke™ OS Series.