The super fast machines I have seen on You Tube all appear to use moderately
high volume flood coolant. There are plenty of people who claim they dry
cut at 10-24K, but cutter life suffers. Also sticking happens more often if
you try to get a little aggressive. I dry cut a lot, but if I care about
the finish of the part I stand there with a can of WD in my hand (aluminum
All oils are bad. For that matter, so are all metalworking fluids, with the
sole exception of pure water. Back when I used a mister, the mist gave me a
form of bronchitis, and I ended up wearing a real facemask. I looked like a
Preying Mantis. Nor was the mist as effective as I would hope, unless it was
very heavy. The shop looked like a fogbank. This is why I went to flood or
Quite a lot. Full enclosure is probably a good idea. Negative pressure isn't a
bad idea either, and isn't hard to arrange. I bet 10000 rpm spindles generate a
lot of aluminum dust.
Finely atomized oils, of ANY kind, are quite bad for the lungs! There
is a finite capacity
for the lungs to remove foreign materials, and liquids which don't mix
with water are
difficult for the cilia to sweep upward. I forget the exact medical
term, but the common
term is oil pneumonia. The lungs start producing large quantities of
fluid trying to
dilute the oil so it can be coughed up, which, of course, doesn't work.
This can sneak up on you, and when you realize you have a problem, it is
to do anything about it. It can take months to recover from a dose of
Mess is not the problem, the chips will be ever so slightly coated with
a hint of an oily
film, assuming you have the mister running at a low level.
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