Fine filtration for grinding applications

Rollomatic grinding machine with Comat filter system
Rollomatic grinding machine with Comat filter system

Coventry-based Advanced Grinding Solutions (AGS) has made a significant number of sales on behalf of Comat, a premier Italian manufacturer of filtration systems for grinding applications.

Comat manufactures super-filtration systems that deliver ≤ 2-3μm filtration quality (making oil cleaner than unused oil as supplied new) and importantly do so throughout the entire working cycle whilst minimising lifetime running costs and maintaining maximum coolant consistency.

Importantly for end users, Comat filter systems, via their Intelligent Performance Technology allows them to be remotely monitored in real-time during the manufacturing processes with customers’ filter systems fine-tuned by Comat to ensure optimum filtration performance. Furthermore depending upon the model, Comat units can be monitored, controlled, and optimised by integrated controls or externally via PCs, tablets or smartphones.

AGS sold an additional five Comat filtration systems to customers in the tool grinding and medical engineering sectors in the latter half of 2020, mainly for connection to the Rollomatic multi-axis grinding machines also represented in the UK and in Eire by AGS. Existing UK Comat end-users include Samwell Tools in Poole and Rugby-based AW Precision amongst others.

Today, more than 20,000 machine tools use Comat Filtration Systems, with more than 120,000,000 litres of metalworking oil being super-filtered every day.

Comat's Superfiltration technology uses continuously regenerating filtering media (diatomaceous earth, cellulose or other vegetable media), to ensure that particles larger than ≤ 2-3μm are removed from cutting fluids and the fluid itself is maintained at a stable desired fixed temperature of ±0.2°.

Oil cleanliness is measured according to internationally set and agreed standards such as the National Aerospace Standard 1638. Brand new, neat cutting oil is typically classified in category 9. However with Comat Superfiltration systems brand new clean oil is brought down, and then held, to a finer filtration category of just 7 or 8.

Oil that is filtered by Comat systems does not need to be replaced and many clients report that they have never changed the oil for up to 20 years (save top-ups due to oil loss). Main applications for these filter systems include tool grinding on Rollomatic and similar grinding machines and also on turning machines and automatic lathes. Comat systems can operate with any oil having a viscosity ranging between 5 and 30 Cst at 40°C (104°F).

The filter’s media needs to be regenerated once per day for full production/heavy stock removal applications and this takes around 15 minutes. Machines do not need to be stopped whilst this is carried out. If the system is fitted to a grinding machine used for regrinding cutting tools then regeneration of the media would only be required every one to two weeks.

Superfiltered oil on a Comat system

In terms of running costs, according to the manufacturer, Comat systems are usually only around 25% of the cost of running competitor filter systems which often rely on expensive candles or filters. Most end users supported by AGS are only spending around £250 a year on the Comat filter media compared with users of other systems facing large bills when sets of filter candles or discs, that are a wear item, need replacing.

Impressively, the filtration levels from Comat systems are so high that new virgin oil has to go through several regeneration cycles in order for it to meet the finer filtered quality of older/used oil that is filtered with Comat filters. The low cost media used in Comat equipment is very cost-effective and there are no cartridges, paper rolls or expensive candles to replace.

Today 80% of sales are for Comat EVO systems that offer 24/7 monitoring and are equipped with a facility whereby the system when registering any issue will send an email/alarm warning to both the end user and the Comat HQ to inform them of a problem.

That said, Comat units are reliable and a check-up maintenance visit is only recommended every two years. During such a visit the history of all parameters since installation or the last service check can be recalled and the system optimised when necessary to suit grinding or turning processes that may have changed slightly over that time.

Comat ECO systems are the basic version of Comat filter units and are offered to cost-conscious customers that want highly economic solutions and don’t need automatic remote diagnostic support. However, these systems still offer the same high level of filtration and ongoing reliability.

Comat filtration systems ensure a high and consistent quality of machined components, increased lifetime of cutting fluids, reduced machine wear and importantly bring about an increased lifetime of grinding wheels and cutting tools.

From small standalone systems to support a single grinding machine or lathe with a capacity of 60l/minute up to centralised units that can cater for up to 12 grinding machines or 25 lathes with a capacity of over 1,000 l/minute, Comat has all bases covered.

Furthermore the systems can handle any type of contaminant including brass, carbide, ceramics, glass, HSS, special aerospace and medical alloys, and PCD.

Advanced Grinding Solutions www.advancedgrindingsolutions.co.uk

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