MACHINING CASE STUDY - ECOCOOL S761B Titanium Machining - April 2009 Aerospace Industry The client, an aerospace and military subcontractor more consistent fluid performance and a safer performs high speed and precision manufacturing work environment for employees. Additionally, of aerospace and military components. Complex the product has very good stain control on sensitive parts are machined from solid billets at high speed aluminum alloys, while promoting superb tool life using metal removal operations including milling, and surface finishes. parallel planing, gun drilling, boring, and reaming. By pushing their equipment to maximum capacity, Results the company has become a leader in their industry. Their high productivity methods utilise high fluid 1. Improved Tool Life pressures, flow rates, and spindle speeds which After changing to ECOCOOL S761B , the client was place severe demands on the cutting fluid. able to change tools less frequently reducing tooling costs and labour time for adjustments. The tool life The Customer Demands savings were measured at over £15,000 per month. FUCHS was tasked to improve cutting fluid service life and reduce maintenance labour and costs while maintaining the same level of high cutting performance. The competitor’s high pressure soluble oil required high maintenance to keep pH & emulsion stability within norms and required regular additions of hazardous additives to maintain the fluid, resulting in additional costs and multiple incidents of ECOCOOL S761 COMPETITOR GRADE A COMPETITOR GRADE B emergency room visits due to handling. The FUCHS Solution FUCHS proposed the Boeing approved grade, ECOCOOL S761B, which is FUCHS’ advanced technology high performance soluble oil coolant with excellent microbial control. ECOCOOL S761B has a sophisticated lubricity package allowing it to operate at lower dilutions than conventional products. It is very low foaming, even when filtered to 10 micron, and has no residues. ECOCOOL S761B is low maintenance with a very long service life, essentially eliminating the need for tank side additives such as 2007 2008 2009 biocide, pH buffers or caustic materials, resulting in 2. Improved microbial control and emulsion Conclusions stability Recent advances in machine tool and tooling technology have made the goal of high metal removal rates with Before using ECOCOOL S761B, the client was making longer tool life possible, even for hard metals such regular additions of tank side additives to maintain as titanium. pH and keep the emulsion tight. The robust chemistry eliminates the need for these labour intensive However, maximum efficiency can only be achieved if maintenance practices. While regular refractometer the coolant technology is matched to meet the operating checks are still required to maintain concentration during criteria of titanium machining and FUCHS has used daily topping up of coolant, the result is less time needed its global research team to develop ECOCOOL S761B to monitor pH and sample for lab analysis. to achieve these aims. The customer has also benefited from consistent As a result, manufacturers can now produce high quality emulsion quality. There is less manufacturing variability. titanium components with shorter cycle times, increased tool life, and higher machine shop productivity Since switching to ECOCOOL S761B, the customer has by utilising FUCHS technology. been free from the fear that pH boosters and biocides could cause staining. Sensitive grades of aerospace aluminum (6061, 7075) can be easily affected by high pH and alkalinity. By eliminating tank side additives, the risk from incorrect doses has prevented random occurrences of staining. 3. Operational Cost Savings Sump life was extended thus reducing costs of draining, cleaning and re-filling as well as reducing costs for disposal and downtime. The instability of the client’s previous product & use of tank side additives caused staining of metal. Because ECOCOOL S761B controls well, it is more tolerant to allow parts to sit longer without damage, so fewer labour hours were spent in the rinsing process. Better surface finish was also achieved. 4. Operator Acceptability ECOCOOL S761B was welcomed by operators due to reduced smells, foaming, less irritancy and ease of operation.
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