When sawing large-diameter solids, the traditional method is to "flood" the cut. The common industry assumption is that Minimum Quantity Lubrication (MQL) lacks the volume to lubricate a blade sufficiently for heavy solids or large structural material.

We understand the hesitation: blade failure and scrapped material are expensive, and if your current flood system works, the risk of change feels unnecessary. But while flood coolant works, it carries significant hidden costs:

  • Coolant Maintenance: Monitoring and topping off concentration and pH levels.
  • The Mess: Wet floors and intensive part cleaning.
  • Recycling Costs: Expensive fluid disposal and reduced chip value.
  • Machine Longevity: Water-soluble fluids require rust prevention maintenance.
To prove MQL is a viable alternative for heavy industry, our customer conducted a side-by-side test comparing MQL performance against traditional flood coolant on large-scale solids. 

Sawing Test Parameters:

Test Details
Saw Kasto Twin A4
Blade Mfg Bahco Bi-Metal
Blade Size 2" x .063" (54 x 1.6 mm), 2/3 TPI, Bahco Bi-Metal
Speed Fixed
Feed .47" [12 mm] per minute
Material Micro MH2. HB200-220 & D2. HB180-200
Material Profile Round
Material Diameter 18.7" [475 mm]

Lubrication System & Configuration:

The trial utilized the Unist Uni-Max® ST Minimum Quantity Lubrication system, engineered for precision performance and continuous reliability in high-production environments. 
 
  • Nozzle configuration: As recommended for ≥2" blades, the system utilized two nozzles, a BAT and a splitter nozzle.
  • Lubricant: The system applied Coolube® 2210XP. Specifically formulated for MQL, Coolube® offers superior friction reduction.
  • Delivery (less is more): Dialed in to test performance at minimum fluid settings, the system applied .65 oz. [19.2 mL] per hour.

Up to 90% increase in blade life

Results:
Cuts with coolant 10-15
Cuts with Unist 19
Blade life % increase 26-90%
Temperature rise of stock No change
Time in cut material Same as flood, 39 minutes
Volume of lubricant consumed Exactly .65 oz. [19.2 mL] per hour
Air consumption Approximately 1 CFM (30 litres)
Chip color No color
Sawing noise Reduced
Cut squareness Within customer's tolerance

Want to learn more about sawing with MQL?

  • Easily installed on any saw
  • Eliminates coolant mess
  • Improves blade life
  • Uses as little as 2-4 oz. per shift
Learn more

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