Case Studies

After looking into chlorine-free metalworking fluid options for all machining operations, the customer tested ten chlorine-free products to replace their previous solution. Tool life, cost-per-unit and part finish, were the main key performance indicators (KPIs) they used to measure performance among the various cutting fluids. They also examined each fluid's characteristics, including cost per gallon, foam profile, coolant usage, biostability, emulsion stability, operator acceptance, residue and mist.

After testing ten cutting fluids from numerous companies over some months, the customer decided to convert their operations to Master Fluid Solutions™ TRIM™ MicroSol™ 690XT. The coolant is a chlorine-free, premium semisynthetic microemulsion prized for its foam control and extended sump life. MicroSol 690XT also performs exceptionally well in mixed metal environments and is compatible with aluminium and ferrous engine materials.

The majority of testing was conducted on a 2081-imperial gallon central coolant system, that supplies fluid for the chamfering operation. MicroSol 690XT outperformed all other competing cutting fluids throughout testing, in almost every measurable area. MicroSol 690XT even had greater aluminium protection and lower conductivity, providing better corrosion resistance than the company's previous solution.

After seven months of use in the sump, MicroSol 690XT reduced coolant consumption by 13 percent. During that same period, there were no issues with foam, residue or mist.

Since then, Master Fluid Solutions' representatives have implemented a continuous fluid improvement programme, setting up protocols for coolant management and offering additional support to aid the overall quality of MicroSol 690XT and its use in the plant. These improvements are expected to further reduce cost-per-unit and improve productivity.