KEVOS® MAKEOS · Manufacturing
Machine Coolant System Sizing
How much coolant flow, tank volume and pump power does this machine need?
Sizing of a machine-tool coolant system: the flow to carry the cutting heat away at an allowed temperature rise (as the coolant heat-flow tool), the flow the nozzles need for the jet velocity, the governing flow, tank volume for the chosen turnover time, and pump shaft power for the head and efficiency (as the pump power tool).
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How this tool works
Inputs, units and where to find them
| Input | Unit | Typical source |
|---|---|---|
| Cutting power | kW | Cutting power at the spindle during heavy cuts. |
| Share of cutting heat into the coolant | % | Share of the heat carried by the coolant (most goes into chips and coolant). |
| Allowed coolant temperature rise | K | Temperature rise of the coolant you accept per pass. |
| Coolant specific heat | kJ/kg·K | Specific heat of the coolant (about 4.0 for water-based emulsions). |
| Coolant density | kg/m³ | Coolant density. |
| Number of nozzles | Number of nozzles delivering coolant. | |
| Nozzle bore | mm | Bore of each nozzle. |
| Jet velocity | m/s | Jet velocity wanted at the nozzle (higher for chip flushing). |
| Tank turnover time | min | Minutes of flow the tank holds (5–10 settles chips and releases air). |
| Pump head | m | Total head the pump must deliver (nozzle pressure plus losses). |
| Pump efficiency | % | Pump efficiency. |
Method and formulas
- Flow for heat Q = heat ÷ (ρ c_p ΔT).
- Nozzle flow = number × area × jet velocity; design flow = the larger.
- Tank volume = design flow × turnover time.
- Pump shaft power = ρ g Q H ÷ η.
- Example: 10 kW of cutting needs 21 L/min, a 105 L tank and a 0.11441 kW pump.
Limitations
- Average heat; through-spindle and high-pressure systems need their own pump curves.
- Tank size also depends on chip settling and filtration.
- Example values are illustrations. Replace them with values for your actual task.
Typical uses
- Specify a coolant pump and tank for a machine
- Check whether a coolant system keeps temperature stable
- Size a central coolant supply for several machines
Who it is for
- Machinists
- Manufacturing engineers
- Tooling engineers
What you get
- Flow for heat and for nozzles
- Tank volume
- Pump power
Interpreting the result
- If nozzle flow governs, fewer, better-aimed nozzles save pump power.
References
- Machinery’s Handbook, 29th edition (Industrial Press, 2012), printed pp. 1112–1121, 1183–1190. Topic reference; no source tables or recommended settings are reproduced.
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