CNC Machining Waste Recycling System with Thermal Drying
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Solution Overview
Problem
Conventional recycling systems for CNC machining waste are inefficient in reducing moisture content in machining waste, making it difficult to recycle and less valuable for scrap metal dealers, and hinder effective recycling due to unknown proprietary formulations of machining coolants.
Innovation Solution
A process and system that mechanically separates machining waste into scrap metal and coolant, decants and filters to separate oils and solids, exposes the coolant to UV light to kill bacteria, and dilutes with ultrapure water to form a recycled coolant, while adding virgin coolant to maintain original specifications, ensuring nearly 100% recycling of machining waste components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional gravity-based separation is used to reduce moisture content in machining waste, then some separation of coolant from solid waste is achieved, but the moisture content remains too high (around 8%) for scrap metal dealers to accept
Solution Approach 1:
The patent extracts moisture from machining waste through a multi-stage process: first using gravity separation to remove free water, then employing centrifugal separation to extract additional moisture, and finally using thermal drying to remove remaining bound moisture. This progressive extraction approach reduces moisture content from typical levels of 8-20% down to below 4%, making the scrap metal acceptable for dealers.
Solution Approach 2:
The patent replaces the purely passive gravity-based mechanical separation with an active thermal processing system. By introducing thermal energy through drying ovens or drum dryers, the system can remove bound moisture that gravity and centrifugal force cannot extract, thereby achieving the low moisture content required for scrap metal recyclability.
2Reliability
If machining coolant is continuously filtered and recirculated, then cooling and lubrication functions are maintained, but the coolant becomes contaminated with metal particles, tramp oils, and other substances over time
Solution Approach 1:
The patent segments the coolant recycling process into distinct functional stages: filtration to remove solid particles, decantation to separate tramp oils through density differences, and centrifugal separation for further purification. This multi-stage segmentation allows each process to target specific contaminants, maintaining coolant purity while preserving its cooling and lubrication properties.
Solution Approach 2:
The patent changes physical parameters throughout the recycling process: using fine mesh screens for filtration, adjusting density gradients for decantation, applying centrifugal force for separation, and controlling temperature for thermal drying of solids. These parameter changes enable progressive purification of the coolant, removing contaminants while maintaining its functional properties.
3Loss of information
If proprietary formulations of machining coolants are not known, then manufacturers can protect their trade secrets, but effective recycling of the coolant is hindered
Solution Approach 1:
The patent employs a self-service approach where the recycling system automatically adapts to the specific coolant formulation without requiring prior knowledge of its proprietary composition. Through automated filtration, decantation, and centrifugal separation, the system purifies the coolant based on its physical and chemical properties alone, making the recycling process independent of formulation secrets while maintaining effectiveness.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach achieves nearly 100% recycling of machining waste, reducing landfill disposal, increasing scrap metal value, and ensuring the recycled coolant meets original product specifications, thereby facilitating efficient reuse and resale.
Implementation Method 1
exposes the coolant to UV light to kill bacteria
Implementation Method 2
decants the machining waste liquid component to separate oils and solids
Data Source
AI summary
A system and process for recycling machining waste into a solid/scrap material component and a recyclable machining coolant. The system and process comprise collecting the waste machining waste and mechanically separating the machining waste into a solid/scrap material component and a machining waste liquid component. The machining waste liquid component is decanted to separate oils and solids from the recyclable machining coolant. The machine recyclable machining coolant is then filtered through at least a first filter and preferably a second, finer mesh filter. The recyclable machining coolant is then exposed to UV light to kill bacteria and microorganisms. Lastly, ultrapure water is added to dilute the recyclable machining coolant and form the recycled machining coolant. If desired, a virgin machining coolant can be added to the recycled machining coolant, to replenish any additive(s) stripped during the recycling process, prior to resale of the recycled machining coolant.