The tool manufacturer HAM Präzision demonstrates in its Performance Center that perfect machining results can be achieved with the KNOLL Minimal Quantity Lubrication System AerosolMaster 4000 ATS, not only in aluminum and steel, but even in titanium. The key is the aerosol produced, which settles on the tool edge, avoids strong heat development, and then virtually evaporates. Users thereby unlock significant long-term savings potential.
Minimal Quantity Lubrication (MQL) is still anchored in many minds as a dirty and sticky process. A prejudice that Raffael Eberle, who runs the tool manufacturer HAM Präzision together with his parents Petra and Günter Eberle, strongly contradicts: 'You can't say that. It depends on the right MQL system. In the aerosol dry lubrication process (ATS) offered by KNOLL, for example, an ultra-fine air-oil mixture is generated, which provides the necessary lubrication and cooling during the machining process. The consumption is minimal, a shot glass of lubricant per hour is sufficient. This way, no sticking and no dirt can occur.'
The trained production engineer knows exactly what he is talking about: 'After all, we are intensively involved with machining as an application field for our products.' HAM Präzision - the carbide tool factory Andreas Maier GmbH in the Upper Swabian municipality of Schwendi - has been producing tools made of solid carbide and polycrystalline diamonds (PCD) since 1969. 'We have a standard range that covers many applications. But we primarily see ourselves as a solution provider for particularly demanding machining tasks. We support our customers in optimizing their processes, minimizing cycle times, and saving tool changes. For this, we develop special and combination tools that account for about 70 percent of our sales volume.'
Raffael Eberle's enthusiasm is for process analysis and optimization, which not only makes their own production more efficient. 'Our experiences in this regard are valuable for many customers, and they can be expanded in joint projects,' believes the HAM managing director. However, this requires a suitable testing field and partner companies willing to collaborate on an optimized process chain. Against this background, HAM decided in 2019 to search for partners and establish a Performance Center that represents such a process chain - from the digital component through simulation to actual machining on the machine.
HAM Performance Center represents the complete process chain
'We searched for and found suitable partners for the Performance Center,' reports Raffael Eberle. 'Today, renowned global players are represented here, such as Hermle, KNOLL, Zoller, SolidCAM, Lang Technik, Blum, Diebold, and many more, with whom we represent the complete process chain.'
Together with these companies, HAM works on various projects and organizes practical technology workshops several times a year to optimize production. Managing director Günter Eberle, who mainly deals with technical issues, adds: 'Of course, we also use the HPC to demonstrate our solid carbide and PCD tools under chip removal as well as to showcase cutting behavior and process stability. The HPC is also available to our partners for their own trials or for demonstrations in the presence of customers.'
Various cooling and lubrication options
Central elements of the Performance Center include a 5-axis machining center Hermle C 12 U and its coolant supply. This is provided by KNOLL Maschinenbau with a coolant emulsion filtration system and the modern MQL system AerosolMaster 4000 ATS. HAM application technician Marc Schäfer, who has been involved in the establishment of the Performance Center from the beginning, clarifies: 'To meet current and future production challenges, it is important that we can represent and compare the machining process with various cooling-lubrication options. On our Hermle C 12 U, we are able to operate with emulsion, but also to machine completely dry with air, or with the aerosol dry lubrication ATS from KNOLL.'
KNOLL products have been present in HAM's own production for many years. Almost all machining centers are equipped with filtration systems and chip conveyors from the Bad Saulgau company. 'When it comes to perfect coolant supply and filtration, KNOLL is our first point of contact,' emphasizes Raffael Eberle. Accordingly, the HPC managers were happy to respond to the recommendation of Ralf Spöcker, the responsible KNOLL area sales manager, to additionally install the AerosolMaster at the Hermle machining center in the Performance Center. 'It was not a big effort,' confirms Marc Schäfer. 'The AerosolMaster is just a relatively small box to be added. Hermle provided the necessary interface, and the rest was basically plug & play.'
The crucial difference
The experiences that HAM has had with aerosol dry lubrication are overwhelmingly positive. 'This is an extremely innovative technology,' judges Marc Schäfer. 'It differs from other MQL systems in the particularly fine atomization of the lubricant.'
Benjamin Hailfinger, KNOLL product manager for the AerosolMaster, specifies: 'Our patented process ensures that a very fine, stable aerosol is created from a synthetic oil and air, which we also deliver directly to the tool edge at high speeds. If the oil droplets were larger - as is the case with some other MQL systems - they would be flung outward by the rotation, resulting in them landing not on the cutting edge but on the machine wall. Our fine aerosol lubricates at the right spot and evaporates in the process.'
Sustainable and energy-efficient
Marc Schaefer considers the use of the KNOLL AerosolMaster to be valuable in many ways: "On the one hand, we achieve the desired lubrication at the tool cutting edge, which increases the tool life. With an oil consumption of only 3 to 25 ml/h, the process is resource-saving, sustainable, and energy-efficient. I also save myself the cleaning of the cooling lubricant system, do not need pH value measurement, and no additives to prevent fungal infestation." Additionally, the machine remains clean, and the workpieces can often be further processed without prior cleaning.
Schaefer's colleague in HPC, application technician Michael Schließer, adds an example: "We had a component from medical technology that had to go through ten different cleaning tanks and testing stations after conventional processing. After ATS machining, there were only four stations left."
Günter Eberle points out that "we are able to represent almost any machining with the KNOLL MMS system, from aluminum to steel to titanium – which most machinists can hardly believe. But we are demonstrating live here that what seems impossible is indeed possible."
And KNOLL supports HAM in process optimization all the way to the selection of the oil. ATS expert Hailfinger explains: "We have broad-spectrum oils in our portfolio that are ideal for contract manufacturers because they cover a wide range of applications.
For users who desire the highest performance, generate fine surfaces, and achieve high tool life, we can provide a tailor-made oil for the material with appropriate additives." This has been done for titanium machining.
ATS also for difficult-to-machine materials
When HAM developed a new tool product line for these challenging titanium alloys, they also wanted to test aerosol dry lubrication and compare the results with cooling lubricant emulsion. For this purpose, the application technicians designed a special component with various machining processes – from roughing with iMachining, full slots, through drilling and threading to finishing. "We were able to achieve the same cutting values with ATS as with emulsion and also achieved the same surface qualities and tolerances," Raffael Eberle expresses his enthusiasm.
In 2023, HAM then held a workshop on titanium machining. The initial skepticism of the attending practitioners gave way to amazement, which continued in individual inquiries and further positive tests with other difficult-to-machine materials.
Open to changes
"Especially in the current time, where cost pressure prevails and CO2 reduction is required, every machinist should consider this cooling lubricant alternative," says Raffael Eberle. "Because if you do without emulsion, which accounts for seven to ten percent of the costs in the machining process, there is more potential for savings than with the tool, which accounts for four to six percent of the machining costs."
HAM Precision has now generally designed its standard catalog tools to be MMS-compatible. In addition to the geometric design, they are equipped with the specially developed HSF (HybridSurfaceFinish), a cutting edge preparation, and surface polishing. This reduces the force impact, minimizes heat generation, ensures optimal chip removal, and prevents built-up edges. "These properties are important in any machining, but especially in minimum quantity lubrication," says Raffael Eberle. Furthermore, HAM drill tools for MMS machining have a special shank chamfer that completely seals the tool against the holder. Raffael Eberle explains: "The low pressure of only 10 bar, with which the AerosolMaster operates, does not allow for any bypassing or pooling of the medium. Thanks to our modified shank chamfer, the aerosol reaches the cutting edge 100 percent and achieves the desired success."
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