Since 1957, General Die Casters has worked closely with their customers, to design, manufacture, and deliver the custom die castings they demand. In March 2010 they opened their new 90,000 square foot expansion casting foundry in Twinsburg, OH. service the Appliance, Automotive, Commercial, Computers & Peripherals, Electrical, Industrial, Lawn & Garden, Recreational and Transportation Industries.
Advanced Chemical Solutions was invited to discuss coolants that would not only perform well but also not have an odor, foam or cause dermatitis.
Mark Pierson from ACS with closely with Keith Kish, the Director of Manufacturing Engineering at General Die Casters. According to Keith, "I was looking for an economical coolant that would not stink, foam or have skin issues for our employees. Advanced Chemical Solutions evaluated our facility and provided Nano Tech 6800 for testing."
General Die Casters has a good number of CNC machines from Brother, Mori Seiki, Chiron, Takisowa, DMC, Kitako, and a good number Haas machines. Taking good care of their employees is important to the the company. Recently, several employees celebrated 20 years of service at the company. One of them was Anderson Grant, the first shift operator “In most companies, it’s very rare to see employees who reach 20 years of employment. At General Die Casters, it is common to see people reach 35 years at the company. We have a work culture where there is mutual respect and support of one another. When one of us succeeds, we all succeed”, says Anderson.
Having odor free coolant that didn't cause dermatitis is part of keeping employee morale high. According to Keith, "Nano Tech 6800 is absolutely the best coolant we have ever used in our machines. No Monday morning odor, coolant stays fresh and clean."
But what about tool life?
Keith tells us "This coolant has dramatically improved our work environment helping to keep our machines cleaner and improving our tool life."
Metalworking fluids have different performance properties depending on their chemical composition. This can be oil level, extreme pressure additives, cleanliness properties, biocide levels and a variety of other factors.
Below are 10 factors we consider when recommending a metalworking fluid.
If you are thinking about making a change then take a few moments and fill out out Coolant Questionnaire.
It's not always just the cost of the coolant it the concentration of the product!
This past September we visited Extreme Machine & Fabricating, Inc. Located in Hermitage, Pennsylvania, it was founded in 1995 by Richard Wanchisn. In 1998 he partnered with Jerry Taafe, and through the following years, EMF has become one of the north coast's premier full service machine shops, servicing customers worldwide in the steel, aluminum, railroad, mining, transportation, power generation and nuclear industries, as well as other capital equipment industries. EMF offers its customers state of the art CNC machining, engineering, fabrication, assembly and inspection services.
In September of 2019 we where asked do an evaluation of a competitors product. Some times it does come down to the price but it's not always the price per gallon of the coolant. It's the concentricity of the mix. Take a look the comparison below:
During our visit we checked concentration on a couple machines.
The cost savings from converting to comes from Delta Cool 120 being more concentrated: 1.5 compared to Trim at 3.3 with our recommended Brix reading of 5.8 which converts ate a Concentration of 8.7 % .
One of the often ignored but very important factors is the difference between "working" concentration and "make-up" concentration. The fluid in your tank is the working solution and should be at the recommended concentration. But when adding make-up fluid to the tank, you must allow for evaporation of the water over time from the working solution.
Typically, the makeup should be added at 1/2 the recommended "working" concentration. But there are many variables which affect this relationship, and every machine in the shop will be different. So, the best course of action is to monitor the fluid in the tank with a refractometer and adjust the makeup fluid leaner or richer to maintain proper working concentration in the tank.
Maintaining the proper concentration of your cutting fluids can save you money!
With Delta Cool 120, Extreme Machine & Fabricating, Inc. was able to eliminate "rich" solutions that waste coolant, leave sticky residues, and possibly cause operator health problems.
A refractometer is used to determine a concentration of a metalworking coolant within an aqueous solution. It operates based on the principle of refraction. When rays of light pass from one medium into another, they are bent either toward or away from a normal line between the two media. The angle between the normal ray and the incident ray is called the angle of incidence. The angle between the normal ray and the refracted ray is called the angle of refraction.
Refractometers are available with a variety of scales including Salinity, Alcohol, Automotive coolants, Urine, Serum and specific gravity. For metalworking applications at Brix Scale is used to measures metalworking fluid concentration.
Concentration is the position of the horizontal line on the brix scale and is shown in the diagram below.
Oil emulsion is signified by the blurriness of that line. As tramp oils are beaten into the coolant, the line will become blurrier. When the line is so blurry that an actual line is not visible, it is time to change the coolant.
Calibration and Use of a Refractometer
INSTALLATION & OPERATION
Chlorine in Metalworking fluids are additives in the form of a chloroparaffin or chlorinated olefin.
This is present as an extreme pressure (EP) lubricant in some metalworking fluids which are designed for use on ferrous metals.
It is believed that chlorinated olefins break down chemically under the influence of (extreme) heat and pressure near the cutting or grinding zone, to form a solid lubricant film between the ferrous work piece and the tool.
Although the same break down mechanism and film forming is unlikely in the case of aluminum, it has been observed that chlorinated olefins can help in the cutting or grinding of aluminum alloys, especially automotive alloys.
Since its founding in 1987, Maval Industries’ unsurpassed design and production of both new and remanufactured steering system components has made it a world leader in the automotive, off-road, performance and specialty vehicle markets.
Mark Pierson met with Craig Lutsch, the Machining Supervisor for Maval Industries LLC, because he was "looking for a cleaner coolant that would not foam or have skin issues for our employees."
Advanced Chemical Solutions provided NanoTech 6800 on a trial basis.
According to Craig "NanoTech 6800 is absolutely the best coolant we have used in our machines. We can see into the machine window again with no more sticky residue, no more chips clinging to the inside of the machine, tramp oil is easily skimmed off. This coolant has dramatically improved our work environment helping to keep our machines cleaner and I have noticed improved tool life. NanoTech 6800 is now running in all our machines."
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