Jemtech cutting fluids increase tool life

Precision manufacturing specialist NSP Engineering has made a facility-wide decision to change metal cutting fluids provider.

The decision, made in late 2007, has seen the company move its entire cutting fluids business to Jemtech UK, the exclusive supplier of Blaser Swisslube metal cutting fluids in the UK and Ireland.

Since making the move over to Blaser the company has experienced a number of benefits.

Alan George, NSP's general manager said: 'Improvements have included a significant increase in cutting tool life and substantial reductions in machine tool downtime.

'The Blaser product has a longer sump life, which means we now devote less time and cost to draining, cleaning, re-filling and disposal.

However, this was not the main driving force behind NSP's decision to change suppliers.

George added: 'The air rifles we design and manufacture not only have to perform (consistently) to exacting standards, they have to look the part too.

'Part accuracies and surface finish are critical issues.

'We regularly machine parts to high surface finishes (0.4 micron Ra - 0.2 micron Ra), while certain components are machined to tight tolerances (+/-0.02mm).

'To achieve these results and to meet the growing demand for our air rifles, we make regular and significant investments in the latest manufacturing technologies.

'In recent years this has seen us invest in multi-axis machine tools (horizontal machining centres and mill-turn centres) with built-in automation, plus revamp and overhaul our tooling.

Despite these investments NSP found that it was experiencing a number of problems manufacturing high-precision complex aluminium components for its air rifles.

George said: 'The main problem was in roll-form tapping (producing internal thread forms on components), and ensuring that sufficient coolant was lubricating the large contact between tool and component.

'Although we recognise that tapping is a delicate operation and involves controlling a number of variables - we were having problems achieving the required thread quality.

'As a result parts were being scrapped or having to be re-worked where possible.

'We needed external help and advice and that's when we turned to Jemtech.

Following initial consultation and problem identification with Jemtech technical staff, the decision to trial Blaser (BC 25MD) cutting fluid on one of NSP's Matsuura horizontal machining centres was made.

George added: 'The improved lubricity of the Blaser BC 25MD product solved the tapping problems immediately.

'But there were other advantages too.

'The Blaser solution eliminated problems we were experiencing with part corrosion - a problem that we noticed during secondary finishing operations.

'It also reduced excessive foaming problems and, because the Blaser product contains no biocide or fungicide additives, we were able to improve the health and safety of our operators.

These positive results meant that it didn't take long for NSP to decide to use Blaser cutting fluids for all of its machine tools.

The trial also helped elevate the importance of correct cutting fluid selection and raised the issue of strategic fluid management as a route to improving productivity and performance.

George said that with Jemtech's assistance they were able to put in place a fluid management system where it was possible to systematically check cutting fluid pH values, bacteria levels, concentration, temperature, appearance, odour, contamination levels and so on.

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