Case Studies

The drilling process was operating at 2100 RPM, 390 SFM, and 0.0107 feed per tooth, with a feed rate of 45.0. Under these conditions, inserts lasted approximately five parts, equating to around 500 in³ of material removal per insert.

At $120 per insert and approximately 250 production days per year, annual tooling costs reached ~$30,000. Although performance was acceptable, frequent insert changes and associated costs made the application a strong candidate for improvement.

Master Fluid Solutions introduced TRIM^® MicroSol^® 685XT through a controlled trial. Existing machining parameters were maintained to ensure a direct comparison with the incumbent coolant. The evaluation was conducted over three months under normal production conditions to confirm consistent performance.

TRIM MicroSol 685XT delivered measurable improvements without changes to speeds or feeds. Insert life doubled from five to ten parts per insert, increasing material removal from ~500 in³ to ~1,000 in³ per insert and reducing insert consumption by half.

This resulted in a reduction in annual tooling costs from ~$30,000 to ~$15,000, generating estimated annual savings of $15,000. The operation also reported cleaner machines and finished parts with less residue buildup, with no negative impact on machining performance or stability.