EXTEND EMULSION SERVICE LIFE WITH MABANOL CUT 264 BF

Initial situation

In a mechanical engineering company for the food industry, various machining centres are used for machining (turning, milling, drilling, thread cutting) and deep hole drilling (140 x D) of unalloyed to high-alloy steels and sintered materials. To date, two different coolants have been used for machining operations and deep hole drilling.

The machining of sintered materials and the instability of the coolants at high water hardness lead to contamination by lime soaps in the machines and premature tipping of the emulsion after 3-6 months.

Ways are being sought to prevent the precipitation of lime soaps, to avoid skin-sensitising adjusting agents and to increase machine cleanliness. Furthermore, the aim is to minimise the use to one type of universal, long-term stable coolant for all machining processes, which guarantees a longer service life.

Recommendation

Our lubricant expert has recommended the use of Mabanol Cut 264 BF based on the latest DCHA emulsifier technology. The resistance of this technology to bacterial growth promises longer emulsion service life without additional adjusting agents. Furthermore, Mabanol Cut 264 BF is hard water stable in use up to 100° dH, so that a permanently good rinsing behaviour is offered and lime soap formation is demonstrably prevented. Due to the high lubrication performance of Mabanol Cut 264 BF totalling 55%, the product can also be used for deep-hole drilling.

Field trial

During a field trial, the parameters using Mabanol Cut 264 BF are recorded under comparable conditions and compared with the data of the competitor's product. By switching to Mabanol Cut 264 BF, the emulsion service life could be increased to over 2 years without the use of any adjusting agents. Even after 2 years, the emulsion still shows very good rinsing behaviour. The improved rinsing behaviour leads to significantly cleaner machines. When using Mabanol Cut 264 BF, neither precipitation of lime soaps nor deposits in the machine rooms can be observed. This not only conserves resources and reduces material costs, but also increases employee health protection by eliminating the use of harmful adjusting agents.

Furthermore, Mabanol Cut 264 BF is highly resistant to foaming. With a water hardness of 5°dH and high-pressure cooling of 80 bar, no foam is produced.

All machining processes can be realised with a single coolant. The concentration for deep hole drilling with 140 x D can be reduced from 16-18% to 12%. Thus, minimising the product range to the universal high-performance coolant Mabanol Cut 264 BF helps to optimise the entire production process.