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Thread: Mist Coolant systems
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31st May 2018, 11:44 AM #1Member: Blue and white apron brigade
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Mist Coolant systems
Gents, following on from Krisfarms post in The "Latest projects" thread, I thought I would start a new thread on this topic.
Look on ebay I see a basic fluid/air mixer like this one starts at around $10
https://www.ebay.com.au/itm/Cutting-...AAAOSwytJaN5F7
Screen Shot 2018-05-31 at 8.36.09 am.png
Those that look like Kris's mixer look like have needle valve controls at the mixed and look like this cost a bit more
https://www.ebay.com.au/p/Mist-Coola....c100005.m1851
Screen Shot 2018-05-31 at 8.35.46 am.png
Does anyone know of any others?
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31st May 2018, 04:38 PM #2Golden Member
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BobL
I just posted a reply back on the other post. I would definitely pay the bit extra and go for the twin needle valve mixer.I did look at some that had adjustable nozzles as well but after using mine for a while now I do not think that would be needed.
Bob
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31st May 2018, 06:57 PM #3Golden Member
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Noga mist unit, Fogbuster.
If you can afford them
Ken
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31st May 2018, 08:33 PM #4Member
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Are the misting systems supposed to be better? You would assume that a solid stream of fluid would have more cooling capacity?
Cheers,
Steve
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31st May 2018, 09:42 PM #5Member: Blue and white apron brigade
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Have a read of this, //metalworkforums.com/f65/t1210...40#post1935481
Last edited by BobL; 24th Nov 2018 at 12:26 PM.
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1st Jun 2018, 05:36 PM #6Golden Member
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BobL
I will be interested in your coolant system build and what you think of the results using it.For my mister system I only use very clean ATF oil mixed with a bit of kerosine just to dilute it a bit. 250 mls kero in 1500 mls ATF. I found this allows me to achieve a very fine mist. By using clean mix I have not had any problems with nozzle clogging.Reusing sump oil may create a problem.I have built a couple of chip/oil guards for my mill that can be removed easily ie no tools required.One guard is just a piece of heavy vinyl sheet 400*300mm that is held in place at the back of the vise with two magnets and can be height adjusted or removed as required, the other guard is a piece of polycarbonate sheeting that I folded up to suit my mills vice and it just drops in place behind the two washers in the end of the vise. I use these mostly when fly cutting to contain the oil and chips.
If any oil gets spilt on the floor a few sheets of newspaper soak it up.
Bob
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1st Jun 2018, 08:27 PM #7Member: Blue and white apron brigade
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Sure your system makes a lot of sense. I will try both new and used ATF but I will clean up the used ATF first. I'm not sure if I will try ATF in my sump - I might just leave regular coolant in that for a while. If ATF was to be used in the sump an in line filter will probably be needed. Then it comes down to how often any filter will need cleaning or replacing and at what point does this become more of a PITA than cleaning out a WSO sump.
I have built a couple of chip/oil guards for my mill that can be removed easily ie no tools required.One guard is just a piece of heavy vinyl sheet 400*300mm that is held in place at the back of the vise with two magnets and can be height adjusted or removed as required, the other guard is a piece of polycarbonate sheeting that I folded up to suit my mills vice and it just drops in place behind the two washers in the end of the vise. I use these mostly when fly cutting to contain the oil and chips.
If any oil gets spilt on the floor a few sheets of newspaper soak it up.
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2nd Jun 2018, 10:02 AM #8Senior Member
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Hi Bob
From what l can see ATF costs about the same as some threading and cutting oils ($30-$40 for 4 litres)
Unless you are getting your ATF for free, why would you use it rather than threading or cutting oil?
Maybe l missed the bit about cheap ATF?
l like the idea of not using soluble oil, it certainly doesn't smell good when it gets old.
By the sound of it, 4 litres would last a long time using your method.
Anyway l have ordered a mister to give it a try.
Pete
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2nd Jun 2018, 03:17 PM #9Member: Blue and white apron brigade
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2nd Jun 2018, 03:32 PM #10Golden Member
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Hi Pete
After using water based coolants for a couple of years and finding rust developing under my mills vise, plus the mixture going rancid in my lathe and mills tank, I had to find an alternate. A good friend of mine who was an industrial chemist suggested trying the ATF oil as it is one of the best grades of oils made. I use second hand ATF oil in both my mill and lathe when using a flood supply. I asked my local automatic transmission service shop if they could save me some of the cleanest oil.I offered to pay him but he said no payment needed as he had to pay to have it removed.I originally ran this through a filter system that I rigged up and then cut the filter open to see how it looked inside, there was hardly anything visible inside it. So now all I do is store a 20 litre drum of used oil for a couple of months and only draw off the top.This is probably a bit of an overkill as well as I am sure there are plenty of small metal particles in any coolant that has been used in any metal cutting operation.
On my misting systems I originally used virgin ATF oil mixed with a bit of kerosine I did this as the needle valves in the control unit can be adjusted down very finely and I did not want any blockage. This worked perfectly. Last week I tried a mix of used ATF/kerosine in my misters and so far it has worked just fine as well.I am sure other oils could used in these misters as long as they are of a low viscosity.
Bob
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7th Jun 2018, 01:44 AM #11Member: Blue and white apron brigade
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My Mechanic promised me 20L of used ATF last week but he forgot to tell his assistant that I needed it and all his waste oil got bundled off to the waste oil disposal centre. When I asked the mechanic about it he directed me to an Auto transmission specialist about 10km away and they had hundreds of litre of waste ATF but
- it was all stored in oily (on the outside) 50L oily drums (ie not easy to handle)
- it contained quite a bit of other oils as well ie regular gearbox oil.
- all of the oil in the drums was surprisingly dirty - it looked like over used engine oil to me. Each drum was probably contaminated by just one or two vehicles worth of ATF that had gone waaaay past their change by date.
They did allow me to collect about 10L of reasonably clean ATF direct out of a pickup auto tranny they were emptying which is better than nothing. So it looks as though its not quite as easy as I thought. I have gone back to my mechanic and will ask him to collect any cleaner used ATF into a container I will supply to him.
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5th Sep 2018, 06:21 PM #12Member: Blue and white apron brigade
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After much mucking about I have finally set up my mist cooling system.
The messy photo below shows the air supply starting top right corner with a with a brass tap plumbed into the retic comp air line (1)
I will turn this tap off when I finish the milling job.
R is a small regulator to drop the air pressure a bit.
T is a small tap that I will use to turn turn the air pressure off at the job
IMG_3275.jpg
Closer up view of regulator and Mixer M
IMG_3276.jpg
Above you can also see the black 3/8" air line and the small (5mm) transparent ATF line heading to the mixer (M)
Sorry the mixer is hard to see but it's one of these from ebay
One input is for the compressed air and the other for the fluid
This shows the air/ATF mixer and the brass delivery nozzle. The other darker blue flexible coolant line is for ATF flood cooling.
The white beaker was just collecting the coolant to measure the flow.
I ran it for five minutes and it collected 2mL of fluid.
IMG_3278.jpg
This shows the 1L ATF reservoir I'm currently using - at the rate of 0.4mL/min it will last 42 hours but on some small jobs I should be able to get double that.
I decided to use new ATF in the first instance and diluted it with kero the same was as krisfarm.
IMG_3279.jpg
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5th Sep 2018, 07:50 PM #13Pink 10EE owner
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Does the mist cause respiratory problems from breathing in fine vapour?
Gold, the colour of choice for the discerning person.
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5th Sep 2018, 11:05 PM #14Member: Blue and white apron brigade
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7th Sep 2018, 12:39 PM #15Most Valued Member
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Very interesting, I can see how mist cooling would work really well on my shaper, which like most shapers is not really suitable for flood cooling systems.
Another project to add to the list that I already don't have time for.
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