Extraction
system for metal
Individuel system solutions from one supplier
1. General
In many machining processes, chip accumulation and handling poses a problem for the process flows. The problem can concern both - the collection and removal of chips during machining and the handling of the chip quantity within the production area.
SPÄNEX offers complete, individual systems for these tasks, e.g. extraction systems, dust extractors and briquetting presses for the collection, separation and disposal of chips.
The extraction systems from SPÄNEX are used especially for dry machining and MQL technology. The chips produced are collected by the air flow from extraction hoods placed close to the tools and fed to the filter system via the piping system. As a rule, these manufacturing processes cannot be operated without effective extraction technology.
2. Extraction systems in comparison
Depending on the individual case, decentralised or central extraction systems are used. In a decentralised system, one dust extractor is assigned to each individual machine or to several small machine groups (Fig. 1). The metal chips and dust produced are usually collected in a container and disposed of.
In central extraction systems, all machines are connected to a large dust extractor (Fig. 2) or a central filter system (Fig. 3) via a piping system. The extracted metal chips and dusts are collected in several bins or a container of the large dust extractor or of the filter system.
Decentralised extraction systems are characterised by the following advantages:
direct adaptation of the extraction power to the connected machine,
high flexibility,
short pipe distances with low pressure losses,
low installation effort,
no disturbing piping system (e.g. during crane operation)
The following points speak in favour of central extraction systems:
lower investment costs for several processing machines,
central separation and buffering of the chips produced,
simple system solution for recirculation/exhaust air operation or simple integration into a central supply air system for hall ventilation,
outdoor installation of the filter unit.
3. Solutions from the practice
Example 1 - Decentralised extraction of aluminium chips
The customer's machines are used to process extruded aluminium profiles (circular saws and milling machines). For the extraction of the individual production lines, 3 large dust extractors (Fig. 7 - Figure 2 units) with pre-separator, filter, integrated fan, container with discharging device and complete control system were supplied.
The powerful dust extractors are arranged on base frames. The metal chips buffered in the containers of the dust extractors are transferred to a conveyor belt via sliding valves. The conveyor belt collects the 3 discharging points of the dust extractors and transports the aluminium chips to a central container. With the metal chip extraction system in the form of dust extractors, not only the productivity but also the working conditions for the service personnel have been decisively improved.
The capacity of the extraction system is 18,000 m³/h.
Example 2 - Central extraction of aluminium chips
At a manufacturer of roller shutters, venetian blinds, insect screens and window shutters, the accumulated sawing, drilling and milling chips are collected via a central extraction system.
The individual machines are connected to the filter system (Fig. 8) outside the building via a pipe system. The filter system is equipped with filter hoses that are cleaned by compressed air (jet pulse system). In this powerful extraction system, the extraction fan is integrated on the clean air side underneath the filter unit, protected from the weather. For energy-efficient operation, the extraction capacity is adjusted to the respective demand via a speed control.
The cleaned extract air is fed through a supply air unit that contains a heat exchanger for heat recovery. The outside air drawn in is thus preheated and brought to the desired blow-in temperature via a reheater.
The metal chips separated in the filter unit are transferred to a container via a mechanical discharging and conveying system.
The capacity of the extraction system is 35,000 m³/h.
Example 3 - Extraction of grey cast iron chips
When machining grey cast iron parts, gra-fit dust is produced in addition to the chips. These particles are collected and separated via an extraction system with a connected large dust extractor.
The powerful SPÄNEX dust extractor and the chip container were not to be placed directly next to the machine, but at a previously defined location in the hall. The piping system was designed accordingly. Below the dust extractor, a chip container is arranged to collect the resulting mixture of casting chips and graphite dust. By using the extraction system, it was not only possible to increase the availability of the machining centre, but also to greatly reduce the otherwise usual cleaning work.
The capacity of the extraction system is 6,000 m³/h.
Example 4 - Extraction of aluminium and grey cast iron chips
During the production of circuit components made of grey cast iron and aluminium using MSS technology, the chips are extracted via 5 large dust extractors.
First, the size and arrangement of the extraction hoods as well as the required extraction air volume of a processing machine were determined with a test system in order to achieve the best conditions for optimum collection and energy-efficient operation. In addition, the extraction efficiency of the dust extractors was adapted to the respective requirements by regulating the fan speed.
Already during the tests, the expectations with regard to chip removal and air pollution control were exceeded, so that the complete chip extraction system, consisting of 5 dust extractors with frequency converters, the piping system with the extraction hoods as well as the complete electrical circuit with control system could be delivered..
Due to the very good chip collection, the amount of cooling lubricant emulsion used could be greatly reduced, resulting in additional savings.
The capacity of the chip extraction system is 30,000 m³/h.
Advantages at a glance
- complete, individual system solutions
- decentralised or cental extraction systems
- extensive range of compact dust extractors and filter systems
- extraction capacity adapted to requirements
- effective filter and cleaning technology
- quiet operation
- several disposal options