Minimal Quantity Lubrication (MQL) Systems

in Metal Cutting

Excellence in
Minimal Quantity Lubrication
 Traditional metal machining –
still in line with the times?

Requirements and problems when using cool- Company responsibility: Occupational Health
ant emulsion (CE) and Safety

To use CE effectively, a coolant system with recirculat- Through constant contact by employees with CE in
ing pumps is required and coolant reservoirs along the relevant production areas health hazards and
with the piping. Furthermore, special systems are extended downtimes become a real problem.
required for cleaning or drying the workpieces, as
According to the BIA-Report (publication of the Ger-
well the swarf before recycling.
man Federal Institute for Occupational Health and
• The transport required for removal requires approved Safety), the figure corresponding to skin disorders is
licensed disposal companies, with considerable 26 % of all occupational illnesses in the metal sector
associated logistical costs, generates high costs of which 33 % can be attributed to lubricants:
and, when not done properly, leads to environ-
• CE, or rather the microorganisms they contain,
mental pollution.
trigger skin disorders, infections and allergic
• In-house preparation requires the use of tank
reactions.
systems and preparation systems which remove
• They cause irritations to the eyes, mucous mem-
the metal particles from the cooling lubricant
branes and respiratory tracts.
using expensive (in the best case waste-free and
• For some workers it is no longer possible to work
self-cleaning) filter systems and collect these, for
Example of Flood Coolant for using such machine tools due to these illnesses.
example, as bricket.
cooling and lubricating when
mechanically machining • Even in the case of good recycling the risk exists Legal requirements require compliance with increas-
components.
that the smallest swarf particles are fed to the tool ingly strict regulations by any production company.
and are included in the cutting process. The German Hazardous Substances Ordinance
• To prevent the failure of the CE through microbial (GefStoffV) ensures the protection of man and the
degradation processes, biocides harmful for the environment from substance-related damage.
environment are used. Amongst other requirements, it stipulates the adoption
• There is a corrosion hazard in the case of a drop of measures for the protection of workers whose tasks
in the pH value through the increase of acidic involve handling hazardous substances and restricts
metabolic products in the CE. the use of specific hazardous substances, prepara-
• In particular, water-mixed CE emulsions only, even tions and products. The Federal Ministry for Work
when well maintained, have limited service lives and Social Affairs (BMAS) in this respect publishes,
and must then be replaced in conjunction with a in the Technical Rules for Hazardous Substances
machine cleaning process. (TRGS 900), the relevant workstation limit values which
the employer must undertake to check regularly.

Skin allergies and illnesses

caused by coolant emulsions.

Conventional metal machining processes using

coolant emulsions are still used, in spite of inno-
vative developments (MQL), that reduces costs
as well as health and environmental risks.

2
MQL – the efficient alternative

Minimal quantity lubrication technology (MQL) in the • The MQL vaporises virtually completely
metal cutting processes is in the position to combine and immediately at the tool cutting edge.
the highest productivity with ecological and health • The machining system and the work-
benefits. The undisputable reduction alone in the pieces remain virtually oil-free.
consumption of coolant emulsions makes, in many • The swarf is dry and can be recycled
respects, improvements in the entire metal processing directly.
sector and, of course, for man and the environment.
In order to assess the benefits it is worth taking a
look at the details.

The MQL principle

The main feature of MQL is the feeding of the exact

metered quantity of oil directly to the tool operating
area. Heat is dissipated primarily via the swarf. Other
features of the machining process are:

• “Virgin” MQL oil is always used at the machining

point. This has a positive effect on the quality of
the workpieces being machined.
• This process only requires a very low power output
for transporting the MQL oil.

Coolant Emulsion costs in the

series production of traditional
metal machining.
(Source: Statist. Federal Office)
Calculation example: Medium-sized company, two-shift operation/one machine tool

Lubrication with coolant emulsion Euro Minimal quantity lubrication Euro

Power: for cooling units / pumps. 25,000 2,500 Power: approx. 200 kWh / year 20
kWh / year (pumps, high pressure coolant
skids, etc)
> 25 % energy consumption by the machine
Time required: 30 hours per year Filling / 2,250 Time required: 4 hours per year 300
topping off / inspection / maintenance / Inspection / set-up time / topping off
set-up time for coolant emulsion
CE emulsion: 10,000 litres per year 2,500 Fluid medium oil: 60 litres per year 480
CE disposal: 2x year 300 Compressed air: 20,000 m3 320
Machine downtimes: Downtime caused 1,000
by coolant emulsion
Total 8,550 Total 1,120

Two large oil tankers would be required to hold the hazardous waste resulting from the
use of CE of approx. 1 million tons generated in Germany alone every year.
(Volume incl. waste generated indirectly such as polishing sludge, oil binding agent or oily cleaning cloths)

3
Try dry …

Dry using minimal quantity lubrication

technology instead of drying !

The virtually dry machining process that comes from applying minimal
quantity lubrication technology means that laborious cleaning and
drying of the machine and workpieces is virtually eliminated.

Innovative and proven technology for • New top-of-the-range MQL lubricants offer a cost
health and the environment advantage through the small volume required com-
pared to CE in traditional machining.
Issues such as ecology, energy saving and protec-
• Higher machining speeds lead to shorter cycle times
tion of the environment, as well as occupational health
and an increase in productivity by up to 15 %.
and safety, are of increasing importance. Given that
• An even tool temperature leads to a clearly higher
the ecological benefits of the MQL is astonishing,
durability and service life.
bielomatik has set itself high goals and standards in
• The total calculation for the achievable savings
order to achieve sustainable working processes.
made from MQL in production costs is calculated
as up to 15 %.
Through MQL there is an overall consider-
able reduction in primary energy consump-
tion and in CO2 emissions as compared to
classic CE.

• According to the BGI 718, machine operators are

exposed to much higher emissions than in the
case of MQL when wet machining. In particular in
the outflow from the machine tool the emissions
during MQL are cut in halve compared to flood
lubrication.
• Through the use of MQL the tremendous drop in
health risks leads to a clear reduction in skin and
respiratory tract disorders and the resulting inability
to work. 2013, bielomatik’s efforts to put sustain-
Quality, cost savings and environmental able engineering, ecological, social and
protection in harmony economic aims into the focus of its entre-
preneurial activities were awarded by
The use of MQL ensures sustainable production the VDMA federation with the title Blue
from many perspectives: Competence Alliance Member.
• In new plants, acquisition costs and subsequent
service costs are clearly reduced without recircu-
Design study for an
MQL 1-channel system. lating pumps and cooling reservoirs.

4
Minimal quantity lubrication technology has MQL is an Innovative technology that has
become a proven manufacturing solution evolved and come into its own

During the mid 1990s solutions to dry machining and In the last ten years, MQL systems have proven
minimal quantity lubrication were systematically devel- themselves at bielomatik and in the market place
oped. bielomatik was an early participant in the relevant due to their, in many respects, outstanding process
research projects and forms part of the avant-garde in the cutting or mechanical machining of parts.
in minimal quantity lubrication technology. Nowadays, tools are available for all applications.

The health advantages have, in the meantime, led to In the automotive sector minimal quantity lubrication
the Institute also requesting in its rules that in the technology can no longer be overlooked. In the case
case of activities requiring coolant emulsions (BGR / of large car manufacturers it has long since been
GUVR 143) the companies are directly required to standard practice, now medium-sized companies
use dry machining or minimal quantity lubrication. have followed the trend and opted for MQL.

With DIN 69090 there is a new standard for minimal In order to machine 20 motor
blocks with MQL it is sufficient to
quantity lubrication technology. It stipulates the terms lubricate with an average quantity
of 50 ml per hour.
and definitions for the system elements in the entire
MQL system for cutting with tools with a geometri-
cally specified cutting edge, predominantly for using
rotating tools. Furthermore, it specifies the technical
perquisites and requirements for MQL machine tools
and standards for cutting surfaces between machine
tool and the MQL system.

All other information with regard

to the MQL subject can be con-
sult ed in the publication BGI 718
Thread Forming with the of the BGHM Institute for Wood
MQL 2-channel system. and Metal.

5
The complete minimal quantity lubrication technology

bielomatik offers both MQL 1-channel and

MQL 2-channel systems. We know the
benefits and application perameters of both
systems and can therefore offer the best
solution to meet customer requirements.

bielomatik MQL 1-channel system

In the MQL 1-channel system an aerosol is pro- In known processes the system can also be used
duced thanks to the patented bielomatik multiple for machining centers. Furthermore, this system is
nozzle technology. This is fed to the tool via the also suitable for retrofits.
aerosol line, rotary union and the spindle or the
• Easy installation in your machine.
turret.
• User-friendly operation.
The use of the bielomatik MQL 1-channel system is • Integrated control system
in cutting processes with low to medium spindle • Easy control of tool parameters via I/O coupling or
speeds It can even to be used where the spindle PROFIBUS.
has a complex inner geometry. • Suitable for up to approx. 16,000 rpm spindle
speed.
Depending on the design, oils with low viscosity can
• Use of standard rotary unions.
be used. Typical areas of application are transfer lines
• Existing machines can be easily retro-fitted.
with machines with turret tool.
• CE/MQL switchover possible.

bielomatik MQL 2-channel system

The bielomatik MQL 2-channel system is also suit- The oil feed can be calibrated and independently of
able for highly dynamic processes with high spindle the speed.
speeds because oil and air are combined very close
• Extremely fast response times.
to the process being performed.
• Accurate dosing capability between 5 and
Typical application cases are machining centers with
500 ml/ hour.
frequent tool change.
• Integrated control system
In the case of the bielomatik MQL 2-channel system
• Simple control of tool parameters via M-code
an oil film is transported by air in the direction of the
functions.
tool. Exact dosing is also possible for small tools such
• It can even used for small tools with cooling channels
as the supply of tools with a higher lubricant require-
< 1 mm.
ment. There is no contamination of the machine during
• Suitable for up to approx. 40,000 rpm spindle speed.
the tool change.
• It is also suitable for tools with a high lubricant
The “chip to chip” time can by very short due to the
consumption.
quick response time of MQL 2-channel system.

bielomatik MQL external system

The external MQL system by bielomatik injects the • It can be used in combination with the
lubricant drops in the tool via a quick valve. During MQL 2-channel system.
this, a distance of up to 800 mm can be bridged • No spray.
between the valve and tool. The drop hits the exact • Exact lubricant dosing.
point where it is needed. The alignment of the swivel- • Pure oil is used.
ling quick valve on the respective tool is automatic. • Compensation of different tool lengths through
The external system can also be combined with the pivoting valve.
internal MQL 2-channel system in order to be able to
supply tools without a feeding channel.

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bielomatik MQL 1-channel system:
For a variety of uses
Ball Valve Rotary Union Spindle Tool

Aerosol

Tool Holder

Aerosol Compact Module

Tool Holder

Tool

Adjustment Screw

Characteristics

• Generation of oil mist (Aerosol) in front of the

spindle using compressed air.
• Feeding of the aerosol using a rotating spindle.

Features

• Oil feed according to the speed.

• Maximum oil quantity according to the airflow or
the feeding channel of the tool.
• Transfer possible via angled channels.
• Applications 5–10 bar compressed air possible.
• Through the tool and external applications.

Milling a workpiece with the MQL 1-channel system.

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bielomatik MQL1-channel system:
Compact and professional

MQL 1-channel system B1-210 The compact MQL 1-channel systems

B1-210 und B1-610

• Reduced space required in and at the machine

through less installation space, compact dimen-
sions and modular structure.
• User-friendly in particular through the easy adjust-
ment of the oil quantity.
• Easy commissioning.
• Easy to retrofit.
• 3 aerosol nozzles which can be switched manually.
• Easy assembly: base / wall-mounted.
• Design B1-610 with 6 remote controllable versions
(control of the parameters via solenoid valves).
• Optional: pressure and filling level detection,
thereby providing functional safety.
• Optional: refill unit 10 liters can refill even during
production.

MQL 1-channel system B1-610

The dry swarf after the machining

process: The blue color clearly
shows that the heat dissipation is
performed efficiently via the swarf.

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 MQL 1-channel system B1-3010

Optional refill unit with 10 liter capacity.

The Professional MQL 1-channel system B1-3010

• Integrated control system with PLC (field bus or

I/O coupling).
• Easy application of the system.
• Standard use of standard valves.
• 4 point filling level monitoring, pressure monitor-
ing (System/container pressure) are standard
equipment.
• Optional: refill unit 10 liters.

Technical data B1-210 B1-610 B1-3010 B1-3060

Filling quantity 1.8 liters 1.8 liters 1.8 liters 1.8 liters

Input pressure compressed air 5–10 bar 5–10 bar 5–10 bar 5–10 bar
Merkmale und Einsatzgebiete bielomatik MMS 1-Kanal Systeme
Setting lubricant quantity Manual Manual Automatic Automatic
Setting options 1x 6x 30 x 30 x
Setting pressure stages Mechanical Mechanical Automatic Automatic
1x 2x 9x 9x
Selectable pressure stages
per pressure regulator per pressure regulator per proportional valve per proportional valve
On/off per On/off per ball valve, PLC Remote control PLC
Operation ball valve control of the parameters (Field bus or (Field bus or
with 24 V via solenoid valves IO coupling) IO coupling)
Pressure gauge /
Pressure monitoring Pressure gauge Pressure gauge Pressure transducer
Pressure transducer
Filling level monitoring 4-point X X O O
Manual refill O O – –
Automatic refill X X O O
Dimensions 460 x 290 x 170 mm 460 x 290 x 170 mm 720 x 380 x 220 mm 595 x 265 x 170 mm

Application fields (recommended)

Transfer machines ●
Transfer centers ● ●
Balancing machines ● ●
Portal milling machines ● ●
Boring mills ● ●
Compact milling centers ● ● ●
Machining centers ● ●
Double and multi-spindle
●
machining centers
X = Option O = Series ● = Recommendation = Use possible | Version: 02/11 | Subject to technical changes

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 Grinding with the MQL 2-channel system.

bielomatik MQL 2-channel system:

Also used at higher speeds
Ventilation Valve Rotary Union Spindle Tool

Quick Valve

Air
Oil

Lance Tool Holder

Hydraulic Supply

When using the MQL 2-channel system

Pneumatic
Supply Tool Holder the oil quantities (ml/h) can be selected
according to the process requirements.

Lance

Tool

Adjustment Screw
Transfer Unit

Characteristics Application areas

• Separate feeding of oil and air through spindle • Nmax ca. 40,000 rpm.
via rotating lance (inside and outside channel). • Machining centers (frequent tool change).
• Oil and air are transported together close to the • Machine tools at high production rates.
process at the tool cutting surface. • Tools with “high” oil consumption.
• Also demanding cutting processes such as e. g.
Features deep hole drilling or thread cutting are possible
without any problem.
• The oil feed can be calibrated and independently
• Set oil quantity can be checked.
of the speed.
• Due to tool independence high function reserve.
• Maximum oil quantity independent from the
airflow or the feeding channel of the tool.
• Very quick reaction (0.1 sec.); oil quantity change
at the tool center point immediately active.
Advantages of MQL 2-channel system:
In the machining process the • MQL oils with higher viscosity up to max.
removal of swarf from the hole 100 mm2/s. The oil dosing is carried out in the airflow inside
is supported by the use of
compressed air. • Applications from 4 bar up to 10 bar of com- the transfer pipe:
pressed air. • No contamination of clamping surfaces.

Because of the transfer pipe forced guidance:

• High speeds can be obtained.

Change in condition directly at the effective

point:
• Highly dynamic process adaption.

Only pure air in the spindle:

• No contamination during the tool
change (capillary effect).

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Deep hole drilling is, in particular, an application area of the MQL 2-channel technology. Milling with the MQL 2-channel
system.

MQL 2-channel system

Other examples for the use of minimal quantity lubrication technology

Aluminium Steel Casting

(e. g. AlSi, die cast aluminium) (e. g. ST-37,-52, C60, X..steels) (e. g. GGG40)

MQL machining of a 6 gear

transmission housing.

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 Milling with the MQL 1-channel system.

The advantages of the bielomatik MQL …

Quality, cost savings and environmental protection in harmony: All advantages at a glance, this is what MQL
offers you compared to wet machining:

• Due to the higher cutting speed,

processing time is reduced.
less CO2 • Work piece are remain dry.
approx. 50% emissions • Cleaning of parts is not necessary.
• No displacing of oil around the machine.
• Technical resources are not required for
up less water
90 %
the maintenance of the emulsion system.
• The chips remain dry.
to consumption
• Improved surface by using clean virgin
lubrication.
less
up
98
• By eliminating thermo-shock stresses caused
to % oil-containing by coolant, tool life can be increased.
waste • Reduced investment on new machining
lines.

… try it for yourself with our test kit !

Would you like to apply the proven advantages
of the minimal quantity lubrication and see the
benefit of your metal machining?

We are happy to provide you, under no obliga-

tion, with a bielomatik MQL 1-channel system
for a thorough practical test.

Our MQL test kit has a handheld operating terminal

which enables testing without the time-consuming
connection to the machine tool control system. The
device can be moved and contains all the components
for the easy, quick connection to machine tools.

If you are convinced by the advantages for carrying

out the test, we are happy to provide you with a
quotation for a bielomatik MQL 1 or 2-channel system
tailor-made to your requirements.

We promise you: the four test weeks will

convince you!

Feel free to call or write to us.

Your 4 steps to the start of the MQL Phone: +49 (0) 70 25 / 12-0
test: E-Mail: info-lubrication@bielomatik.de
1. Check basic prerequisites
• Internal supply
• Rotary union

2. Request test kit

3. Connect test kit

• Power supply 110 V (USA) 230 V (Europe)
• Supply with compressed air
• Aerosol line; ball valve; terminal

4. Let the test begin! Internet video: bielomatik MQL

www.bielomatik.com/mqlvideo

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The prices of raw materials are increasing, there are • Production premises with intelligent solutions in
fewer resources, energy costs are climbing fast – energy, climate and ventilation technology, e. g.
industrial firms are faced with tough challenges. through the use of dissipated heat in buildings.
Given the consequences of climate change sustain- • CO2 neutral trade fair stands.
ability is the very top priority. The sustainability of
products and processes, as well as green technolo- Sustainable Products – sustainability in
gies, are the centre of attention. product features

bielomatik is already participating in positive develop- • All new products are designed according to eco-
ments in some areas: nomic and ecological perspectives.
• The customer perceives visible benefit through in-
• Minimal Quantity Lubrication (MQL) in metal cut- creased performance, as well as a reduction in pri-
ting reduces the hazardous waste significantly, it mary energy consumption and maintenance costs.
combines high productivity with environmental
and health benefits. Sustainable Relations – sustainability in
• In the automotive sector plastic parts help to save people’s relationships with each other
on weight and, therefore, on fuel.
• The company management provides employees with
• “Gas innovation price” for our energy-efficient gas
continuous professional training and a working envi-
convection welding process.
ronment that stimulates teamwork and solidarity. The Best of
• Efficient stationery manufacturing systems sup-
• Protection of employees both on the customer’s German
port the illustration developments initiatives in Engineering
premises as well as in-house.
emerging and developing countries. Das Lexikon
• Corporate objectives are conveyed both internally des deutschen Maschinenbaus

• Die cut aluminium antennas on the basis of paper

and externally to ensure that the entire company
contribute to the sustainability of RFID converting.
(worldwide) can identify with the objectives set
The bielomatik corporate sustainability initiative and can participate in sustainability measures.
boosts the development of system designs with • Direct option for dialogue with employees regard-
efficient process chains as well as production planning ing the company and its products.
based on sustainability: • Support for fair trade.
aufgenommen:

Sustainable Processes – sustainability in Since the 1950s, bielomatik has been making con-
production and company processes tinuous progress in innovations in the key technolo-
gies paper processing, plastic welding, RFID transpon-
• Optimisation of materials and processes to be
der and minimal quantity lubrication technology. Since
as environmentally friendly as possible, easy on
2013 the company is listed in the VDMA encyclopedia
resources and suitable for recycling.
“Best of German Engineering“.
• Reduction of the waste generated, consistent
transfer for recycling. We are in favor of protecting intellectual property and
support the VDMA campaign against product piracy:
“Be sure it’s original technology!” ”.

With a wide product range from the introductory model • Process support and consultation.
to the profile solution, bielomatik offers mature solu- • Service hotline.
tions for many metal cutting processes from a single • Seminars and training in-house and on-site.
source. Through the intensive use of MQL in internal • Extensive spare parts storage with original parts.
production we have a direct relationship to practice • Individual spare parts packages / recommendations.
and to day-to-day production requirements. Our
Opt for a forward-looking partnership which at all
ProActive Service offers:
times guarantees you competent advice as well as
• Personal care through our competent service team. efficient and safe production.

13
 Paper processing lines and machines

Paper Finishing Web Finishing Systems

• Paper, board and plastic film folio sheeters for • Standard and customized collators for multi-part
stack production. forms, mailings and specialized retail products.
• Folio-size wrappers and cartonizers.
Print-Finishing-on-Demand
• High performance cut-size lines from
• Book-on-Demand binding machines.
2 to 16 pockets, wrapping lines.
• Complete Book-on-Demand automation lines.
• Register-cut sheeters for security and
• Finishing systems for digital printers.
banknote papers.
• Rebuilds of sheeters, wrapping machines RFID: Transponder Processing Systems
and cut-size lines. • Multi-layer paper and foil processing equipment
• Project and layout engineering. (pre-printed/blank).
• Reel-to-reel converting machines for dry and
Stationery Manufacturing
wet Inlays and chip modules.
• Automatic production lines for exercise books,
• Inspection and encoding machines for Smart
spiral notebooks, pads and loose-leaf fillers.
Labels, Tickets and Tags (HF/UHF).
Binding with spiral or wire comb, plastic spiral,
• Modular machine concept from entry level to
stitching, thread sewing, glue.
high end with more than 90,000 Smart Labels
• Wire comb formers.
per hour.
• Customized paper converting solutions.
• Ruling and flexoprint machines.
• Film wrapping machines.

Machines for welding and machining of plastics

• Hotplate welding machines. • Thermal contact / Thermal impulse welding machines.

• Infrared welding machines. • High frequency welding machines.
• Hot gas welding machines. • Complete automated welding lines including
• Friction welding machines with linear vibration or parts management by feeding systems, handling
rotation. For both infrared pre-heating can be solutions. Machine concepts in all variations, e.g.
integrated. rotary table or linear transfer design. Robots can
• Laser welding machines working with the quasi- be integrated depending on application.
simultanous and contour welding techniques. • Equipment for machining, milling, cutting,
• Ultrasonic welding machines for special assembling and testing of plastic components
applications. integrated in complete automated lines.

Lubrication technology for machines and for metal cutting

Minimal Quantity Lubrication Systems

Subject to technical changes · WO/WO/DW/EN/20/0614 · Printed on: PhoeniXmotion Xenon. 250/115 g/m2
• MQL 1-channel and 2-channel systems for metal cutting.
Central Lubrication Systems
• Single line lubrication systems for oil and fluid grease.
• Progressive lubrication systems for oil, fluid grease
and grease.
• Circulation lubrication systems.
• Oil/air lubrication systems.
• Block lubrication systems.

bielomatik Leuze GmbH + Co. KG

Daimlerstraße 6-10 · 72639 Neuffen · Germany · www.bielomatik.com
Phone: +49 (0) 70 25 / 12-0 · Fax: +49 (0) 70 25 / 12-200 · E-Mail: info@bielomatik.de
Certified by DQS GmbH
bielomatik jagenberg GmbH + Co. KG, Neuss, Germany Germany:
Quality Management System
bielomatik jagenberg Inc., Windsor, Connecticut, USA DIN EN ISO 9001
bielomatik Inc., New Hudson, Michigan, USA Safety, Health and Environment
Management System SCC
bielomatik do Brasil – Comércio de Máquinas e Serviços Ltda., São Paulo, Brazil Subcontractor Checklist
bielomatik s.r.l., Bologna, Italy
bielomatik Romania SRL, Cluj-Napoca, Romania
Service and
bielomatik Machinery Intern. Trading (Shanghai) Co. Ltd., Shanghai, P.R. China agents worldwide.
bielomatik Machinery Co. Ltd., Dongguan, P.R. China For further information
see our website or
bielomatik Far East Pte Ltd., Singapore call our headquarters.
14
 bielomatik Leuze GmbH + Co. KG
Daimlerstraße 6-10
72639 Neuffen · Germany
Phone: +49 (0) 70 25 / 12-0
Fax: +49 (0) 70 25 / 12-556
E-Mail: info-lubrication@bielomatik.de
www.bielomatik.com