In today's manufacturing industry, CNC machines are indispensable for achieving high levels of production with precision. However, despite their advanced design and safety features, CNC machines remain vulnerable to fires, which can lead to significant operational and financial losses. Such fires can result in extended downtime, substantial repair costs, and, in some cases, damage beyond repair. Moreover, replacing a damaged machine can take several months, leading to prolonged business disruptions and loss of market share. Therefore, understanding the underlying causes of these fires and taking proactive measures to mitigate the risks is crucial.
Causes of Fires in CNC Machines
Oil-Based Metalworking Coolants:
Oil-based coolants offer several advantages, such as increasing tool life, reducing friction and heat, and improving surface finish due to their excellent lubricity between the workpiece and cutting tools. However, their major disadvantage is poor heat dissipation, limiting their use to low-speed, low-temperature operations. When used in situations where they are necessary, there is a high risk of fire. In CNC/EDM machines, fires can occur instantly without warning. A hot metal chip can ignite oil-based coolants, producing intense heat and dense black smoke, making it difficult to control with handheld fire extinguishers.
Unmanned Machining Risks:
Unmanned machining significantly enhances productivity by allowing machines to operate continuously without human supervision, but it also introduces several fire risks. The absence of constant human oversight means fires may not be detected immediately, allowing them to grow and cause more damage. Tool breakage can increase friction and generate heat, potentially igniting flammable materials. Continuous operation can lead to overheating, while machining flammable materials like magnesium and titanium increases fire risk due to sparks or hot chips. Inadequate maintenance and inspections can result in the accumulation of flammable residues, while electrical failures, such as short circuits, can also pose fire hazards. Addressing these risks requires robust safety measures, advanced fire detection and suppression systems, and regular maintenance to mitigate the dangers associated with unmanned machining.
How to Contain the Threat of Machine Fire: The WEFIRE Solution
WEFIRE offers a versatile, tailor-made automatic fire suppression system for CNC and EDM machines. Unlike traditional systems, WEFIRE provides advanced detection technology specifically designed for CNC environments. The system uses a unique gas that suppresses fires while avoiding collateral damage from gas discharge inside the machine.
WEFIRE systems utilise UL-approved heat detection, routed inside the CNC machine near all possible fire hazards, ensuring the highest safety margins. The system quickly senses and discharges Novec 1230 / FK 5112 gas inside the machine, which does not contaminate the oil and requires no cleanup post-activation. This ensures fire detection and suppression within seconds, offering a 99 per cent fire save rate across various machines in India and providing peace of mind among fire suppression systems.
Case Study: Sliding Head CNC Machine
An orthopedic implants manufacturer experienced a fire incident in their CNC sliding head machine during an unmanned night shift. Hot metal chips fell into the oil sump at the bottom and ignited the oil. By the time the operator noticed the fire a few minutes later, it was still small and controllable, thanks to the enclosed nature of the machine, which limited the oxygen supply. However, as soon as the door was opened, exposing the inside of the machine to oxygen, a huge ball of fire erupted from below, nearly burning the operator. This incident highlights the critical need for an automatic fire suppression system inside CNC machines to prevent such dangerous flare-ups.
Consequences:
1. Lost market reputation
2. Machine damage
3. Revenue loss due to downtime
4. Fear and loss of trust among employees
5. Loss of market share
The Solution:
The WEFIRE Advantage
WEFIRE provides proven, tailor-made fire suppression systems for CNC machines, endorsed by OEMs and MNCs. These systems prevent costly downtime and production disruptions at less than three per cent of the cost of your CNC machine, ensuring continuous production and peace of mind.