Royal Master Grinders eliminates solidified accumulations of cast iron chips on its K&T CNC mill by using a mineral-oil-based coolant emulsion from Blaser Swisslube.
Switching to a mineral-oilbased coolant emulsion gave Royal Master Grinders a 20% to 30% increase in tool life.
ONCE OR TWICE A MONTH, FOR A FEW HOURS OR A day, maintenance personnel at Royal Master Grinders used chisels to dislodge solidified clumps of cast iron chips clogging conveyors and workpiece pallets on a large horizontal K&T CNC milling center. The necessary chore was disruptive, time-consuming, and often interfered with the shop's 8 to 10 hr of lights-out machining. To remedy the situation, the Oakland, N.J., manufacturer of centerless grinders and associated automation systems switched to a nonsynthetic, emulsion-type coolant.
This type of fluid coats chips with a thin, oily film, which prevents clumping as well as rust and corrosion. Antioxidant agents keep the oil film from solidifying over time, and soapy emulsifying agents stabilize the fluid and facilitate rinsing.
Royal Grinders uses Blasocut 2000 Universal from Blaser Swisslube Inc. The fluid, which is formulated with more than 50% mineral oil for use in 5% to 25% concentrations, is resilient to biological degradation and depletion of ingredients. It self-regulates pH and quickly separates out tramp oil.
"It was like removing rusty old bolts from a car exhaust," says John Memmelaar Jr., an executive at Royal Master, referring to the situation prior to incorporating Blasocut 2000. The buildup was a continually snowballing problem. Bolt slots and other crevices on pallets plugged up first, complicating the machinists' work. Then the chip conveyor jammed, and the slag interfered with the pallet conveyor and adversely affected sensors, limit switches, and ways.
"Now, we have no clumping or rusting, and you can see how nicely the coolant drains off the parts," says Memmelaar. Operators no longer have to remove petrified chip accumulations, and there are no disruptions in the shop's lights-out operations. Overall productivity is up an estimated 24%.
One unanticipated gain since Royal Master switched to Blasocut 2000 in the cast iron operation and its other cutting operations involves tooling. "Our tool life has increased on all machines running the fluid," remarks Memmelaar. "The improvements on individual tools range from 20% to 30%."
Blaser Swisslube Inc.