Coolant solutions from Master Chemical solve brass machining problems at lock component factory

Citation

(1998), "Coolant solutions from Master Chemical solve brass machining problems at lock component factory", Industrial Lubrication and Tribology, Vol. 50 No. 6. https://doi.org/10.1108/ilt.1998.01850fab.008

Coolant solutions from Master Chemical solve brass machining problems at lock component factory

Coolant solutions from Master Chemical solve brass machining problems at lock component factory

Keywords: Europe, Master Chemical

Master Chemical Europe has overcome a series of longstanding coolant problems in the Eskilstuna manufacturing plant of Sweden's leading manufacturer of locks and security equipment.

With machining operations predominantly in brass, the factory had experimented over a period of ten years with a range of coolants and light oils to overcome a combination of smell, airborne oil mist, fungus and poor coolant performance.

However, problems persisted and Master Chemical Europe, represented by their sole Swedish distributor, were invited to apply their expertise in an effort to find a permanent solution.

Now, 15 months on, the majority of machines in the plant are operating with Master Chemical coolants producing improvements in the environment and working conditions, cost savings due to good coolant management, the elimination of drain periods and costs of disposal, and improved metal cutting performance.

As Ray Weaver from Master Chemical's European HQ at Stowmarket explained "it was a question of reverting to first principles to overcome a range of problems and to date, our recommendations and products have been highly successful.

"Machining pure brass does not traditionally cause problems of this magnitude. Copper in the swarf has the effect of killing bacteria in the coolant and produces a good degree of biostability. In this application, however, a range of solutions had been tried and we suggested a clean start ­ a thorough clean-out of all sumps, flushing them through to remove traces of old coolants, oils and bacteria and refreshing them with new coolant in the correct concentration.

"The previous use of light oil had caused a range of human problems ­ airborne mist was being absorbed by clothing and hair and the atmosphere was unpleasant. And of course, it was far from the best coolant for the application.

"We suggested a trial with Master Chemical TRIM^® E190 which is chlorine and sulphur-free and produces an extremely tight, stable emulsion for superior performance. E190 has the added benefit of running stain-free on brass," he explained.

First the trial machine was thoroughly cleaned. The coolant tanks were emptied and flushed through, re-filled with water, a bacterial systems cleaner and a fungicidal solution before being flushed through again and filled with E190 at 6 per cent dilution in standard tap water.

After the success on the experimental machine, the majority of machine tools have been similarly cleaned and converted to TRIM^® E190. Minor problems with foaming ­ particularly on the rotary transfer machines ­ were overcome with a 1 per cent dilution of water miscible Master Chemical VHPE200A* coolant which eliminates foaming while being resistant to filtration.

Subsequently, the production management in the factory has achieved 15 months' life without the need to drain the Master Chemical coolant. This contrasted with an average of three draining operations per machine per annum using previous coolants. Concentration of the E190 is kept at between 6 and 7 per cent with a 1 per cent addition of VHPE200A* every six months to control the foaming.