Applications by Sector
Cooling for Metalworking Industry
Chillers for CNC machining and metallurgical processes
Cooling systems for metalworking industry. Cutting fluid cooling (15-25°C), CNC machining center climate control and thermal control for heat treatment. Pressure up to 70 bar and flow up to 500 L/min. Increase tool lifespan and dimensional accuracy.
Talk to SpecialistTechnical Specifications
Process Requirements
Thermal control of environment and cutting fluid to maintain dimensional accuracy in tight-tolerance parts. 1°C variations can cause errors up to 12 μm in 1-meter steel parts.
Extend cutting tool lifespan and improve surface finish. Fluid too hot accelerates wear; too cold can cause thermal shock.
Maintaining ideal hydraulic oil viscosity for CNC machines, presses and injection machines. High temperature reduces seal and component lifespan.
Controlled cooling in oil, polymer or water baths for heat treatment. Cooling rate determines microstructure and final hardness.
Fluid cooling to prevent thermal burn and part deformation. Grinding generates high heat density in the contact zone.
Dielectric temperature control for process stability and dimensional accuracy in wire and sinker EDM.
Controlled environment per ISO 1 for high-precision dimensional measurements. The international reference temperature is 20°C.
Cooling of MIG/MAG and TIG welding torches, plus part cooling systems for distortion control.
Technical Analysis
Thermal Control in the Metalworking Industry
The metalworking industry is highly sensitive to temperature variations. From precision machining to heat treatment, proper temperature control is fundamental for dimensional quality, tool life, and productivity.
Impact of Temperature on Machining
Temperature directly affects dimensional precision through the thermal expansion of materials:
| Material | Expansion Coeff. (μm/m/°C) | Error in 1m for ΔT=1°C |
|---|---|---|
| Carbon Steel | 11-12 | 11-12 μm |
| Aluminum | 23-24 | 23-24 μm |
| Cast Iron | 10-11 | 10-11 μm |
| Brass | 18-19 | 18-19 μm |
| Invar | 1-2 | 1-2 μm |
For parts with tolerances of ±10 μm, temperature variations of just 1°C can already cause non-conformities.
Cutting Fluids and Refrigeration
The temperature control of cutting fluid directly impacts:
- Tool life: Fluid at 20°C can increase tool life by up to 50% compared to 30°C
- Surface finish: Stable temperature prevents viscosity variations that affect lubrication
- Dimensional precision: Part and machine maintain stable dimensions
- Fluid stability: Elevated temperature accelerates degradation and bacterial proliferation
- Fluid consumption: Lower evaporation and drag with controlled temperature
Refrigeration Systems for Cutting Fluids
Helioterm offers different configurations to meet each need:
- Dedicated Chillers: One chiller per machine for independent control and maximum precision
- Centralized System: Chilled water plant for multiple machines with economies of scale
- Hybrid System: Central plant for base load + dedicated chillers for critical machines
Heat Treatment
Controlled cooling in heat treatment processes determines the final properties of the material:
- Quenching: Rapid cooling in oil (50-80°C) or polymer to obtain martensite
- Tempering: Controlled heating to relieve stresses and adjust hardness
- Normalizing: Air cooling for grain refinement
- Annealing: Slow cooling for maximum ductility
Cooling systems for quenching baths must maintain stable temperature and capacity to rapidly remove heat from the parts.
Metrology Room - ISO 1
The ISO 1 standard defines 68°F (20°C) as the reference temperature for dimensional measurements. Metrology rooms must maintain:
- Temperature: 68°F ±0.9°F (or better for high precision)
- Spatial gradient: < 0.9°F/m
- Rate of change: < 0.9°F/h
- Humidity: 45% to 55% RH (for comfort and corrosion prevention)
Sector Challenges
Cooling of soluble oil and machining fluids to extend tool lifespan. Ideal temperature (18-22°C) must be maintained even with load and ambient temperature variations.
Thermal control of machining centers to maintain dimensional accuracy. 5-axis and high-speed machines are especially sensitive to thermal variations.
Controlled cooling in quenching and tempering processes. Cooling rate must be precise to achieve desired metallurgical properties.
Intensive cooling to prevent thermal burn and metallurgical damage to the part. High-speed grinders generate intense heat in the contact zone.
Climate control of warehouses with high machine thermal load. Maintaining stable temperature is challenging with open doors and seasonal variation.
Maintaining ambient temperature at 20°C for metrology and quality control per ISO 1.
Cooling of hydraulic systems for CNC machines, presses and injection machines to maintain viscosity and component lifespan.
Dielectric temperature control for process stability and dimensional accuracy in wire and sinker EDM.
Our Solutions
Cutting fluid and hydraulic system cooling with capacities from 10 to 500 kW. Centralized systems for multiple machines.
View ProductDedicated cooling for individual CNC machines with independent temperature control. Machine-side installation.
View ProductTemperature control for molds, dies and quenching baths with heating and cooling. Range from -10°C to +150°C.
View ProductPrecision HVAC for metrology rooms per ISO 1, with ±0.5°C control.
View ProductWater temperature control for washing and surface treatment processes.
View ProductRegulations and Standards
Benefits for Your Business
Success Case
Automotive Components Manufacturer - ABC Paulista
Cooling system project for plant with 25 high-precision CNC machining centers. The solution included centralized chilled water system with 2 chillers of 100 TR, distribution to all machines, metrology room climate control and integrated monitoring.
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