Fogless Mister Systems

**Boyan Silyavski** · 24-03-2015

Some update. i like designing and challenge.
I tried the way they tell it but the effect was not to my liking. The spray pattern was not good and the control of the flow was lame.

So in my free time i started experimenting and little by little i designed my own fog-less mister cooling. Bellow is a video of me testing the nozzles while Jeff is cutting my Z axis spindle mount, this today. Unfortunately the phone battery run low so i captured the moment with too much flow from the nozzle, you can see the mist at the back, though in fact its no mist but droplets, there was too much flow. So the video is of how it should not be, but you can see the cleaning effect of the air blowing away the chips.

Later when i lowered the flow it was perfect, blowing the chips, cooling the bit but at the same time no mist in the room after half an hour milling. I am thinking to manufacture some and sell them for a reasonable price.

What i can say is that just sticking tubes together as per some drawing does not work well, all flow connections and transitions should be well thought and shaped, plus the exit nozzle must be shaped properly. when done properly the flow seems to reach ultrasonic speed judging by the sound and at the same time does not mist but forms nice, thin, long, properly shaped flame like cloud that disappears completely after hitting the material. The best result is when at the middle of the "flame" at "ultrasonic" speed forms a nice needle like thicker stream of droplets.

what i mean without wanting to insult somebody is that after i played around and experimented for a couple of days, i saw that even a product which all worship and is worth 350$ is not so well thought of, as they want us to believe. Some day when i have more time will illustrate what i say with photos and proper video. lets say that with the bigger flow nozzle when adjusted properly i achieved a 40-50cm long stream where at this long distances is only 5cm wide and still no mist there. Its only flow being too much flow, though maybe for stone will be ok. In fact if there was a reflector at the back where the flow could hiot it there was no mist at all, cause all droplets were falling down. The problem comes with too much flow and nothing to stop them. At the end there is transition to mist, so that must be avoided, by limiting the flow for example or the nozzle size and shape.

For now a crappy video of the system . Forgot to say also- crappy Chinese valves and speed adjuster did not work. Same with custom valves made from this and that. But "made in Italy " valve worked like a charm for precise flow control. Guess why.

**johnsattuk** · 25-03-2015

I got fed up with trying to get the flows right, so made this

**Boyan Silyavski** · 25-03-2015

Originally Posted by johnsattuk

I got fed up with trying to get the flows right, so made this

You could sell that at Etsy as steam punk art

. Man, its beautiful. Looks like a mist cooler coming from the future or like something savaged from a spaceship station

**johnsattuk** · 25-03-2015

Totally independent control of Fluid and air, air can be pulsed for better pocket clearance,without affecting the amount of fluid delivered. Can squirt fluid alone (up to 90 cc's a min )for some jobs.

Fluid container can be put wherever you like ( within reason) , does not siphon or drain back, will handle different viscosity's .

**JAZZCNC** · 25-03-2015

Originally Posted by johnsattuk

Totally independent control of Fluid and air, air can be pulsed for better pocket clearance,without affecting the amount of fluid delivered. Can squirt fluid alone (up to 90 cc's a min )for some jobs.

Fluid container can be put wherever you like ( within reason) , does not siphon or drain back, will handle different viscosity's .

I Like the sound of that John and very well made. . . . Got couple of Q's if you don't mind answering. You may have just added another Job to my endless list.!

Whats on the heat sink on right.? Looks like thermister, resistors and black box which I'm not sure about.! And what are they doing.?
What and where's the power source.? ie voltage.
Where did you get the peristaltic pump.?

**johnsattuk** · 25-03-2015

Originally Posted by JAZZCNC

Whats on the heat sink on right.? Looks like thermister, resistors and black box which I'm not sure about.! And what are they doing.?
What and where's the power source.? ie voltage.
Where did you get the peristaltic pump.?

Not really a heat sink, just a packer. underneath is an SSR to control the air valve, the square with a red blob is a 12v lamp-flasher which gives me the pulses, next to it is a 12v reg. (with a couple of ceramic capacitors ) needed because I am supplying 24 volts from my main panel. The AUTO mode is an M7 relay in the panel.

www.wmcpumps.com as on the back of the pump. I chose a 3mm tube but if I replace it will use a 1.5 mill

**JAZZCNC** · 25-03-2015

Originally Posted by johnsattuk

Not really a heat sink, just a packer. underneath is an SSR to control the air valve, the square with a red blob is a 12v lamp-flasher which gives me the pulses, next to it is a 12v reg. (with a couple of ceramic capacitors ) needed because I am supplying 24 volts from my main panel. The AUTO mode is an M7 relay in the panel.

www.wmcpumps.com as on the back of the pump. I chose a 3mm tube but if I replace it will use a 1.5 mill

Thanks John I got the Jist of what would be needed to make this work from pic and the Reg I recognised but it was the Blackbox with what looked like a Thermister above it that thru me off.! . . . . . Now I look again can see it's part of the black box.!

**Boyan Silyavski** · 25-03-2015

That being said it still leaves the question of the nozzle/delivering tube/body /support/connectors assembly. How do you do that?

Another question is the complexity, some times simple things last longer in industrial enviroment , on the other hand it can be expensive for eventual time to time home use or on a small cheap machine.

I mean is one thing to design an usefull system. My Russian friend who is an experienced model maker did his system for under 5 minutes from what he had at hand.
Its another thing to design cheap, clever, reliable and nice looking product/in that order that could cover most of the real needs of fellow machinists.

You made that for yourself or with the idea of selling it?

And when you will need the squirting? from my experiments even tiny tube could give tremendous flow. In fact for comparison 1mm nozzle gives 160l/min flow if i remember correctly some plasma cutter torch specifications

**JAZZCNC** · 25-03-2015

Originally Posted by silyavski

My Russian friend who is an experienced model maker did his system for under 5 minutes from what he had at hand.

I could make a crude system in 1min by just piercing tiny hole in bottle and letting gravity do the work dripping droplets in front of my air nozzle. It would have the same characteristics has Johns system in that it would be independant control of air and fluid but I wouldn't because it won't be affective and look shite.!! . . . . I don't get your point is what I'm trying to say.!

John's system is metered indepedant control of air and fluid which in practice will be be much more usable than any Fogger sytem. I would relate Fogger equivalent to normal hammer and based on my experience estimate Jonh's sytem to be equivalent to Piano tuners hammer.!! . . . . Both hammers but different.

**johnsattuk** · 25-03-2015

Originally Posted by silyavski

That being said it still leaves the question of the nozzle/delivering tube/body /support/connectors assembly. How do you do that?

Another question is the complexity, some times simple things last longer in industrial enviroment , on the other hand it can be expensive for eventual time to time home use or on a small cheap machine.

I mean is one thing to design an usefull system. My Russian friend who is an experienced model maker did his system for under 5 minutes from what he had at hand.
Its another thing to design cheap, clever, reliable and nice looking product/in that order that could cover most of the real needs of fellow machinists.

You made that for yourself or with the idea of selling it?

And when you will need the squirting? from my experiments even tiny tube could give tremendous flow. In fact for comparison 1mm nozzle gives 160l/min flow if i remember correctly some plasma cutter torch specifications

Since there is no requirement for a venturi or pressurized container almost anything works, I just used an old NOGA that I had.

I made it for myself, I have no commercial intentions whatsoever. I am 80yrs old and in the middle of a delayed midlife crisis.

If you don't need squirting, then don't use it