Reduce tool wear by more than 20% with metalworking fluid

AMI Industries, a precision manufacturer in Tainan, Taiwan, set ambitious targets for the use of Blaser Swisslube metalworking fluids for its new machining centre. With the holistic approach of Blaser Swisslube and a change to the metalworking fluid B-Cool 755, all these goals were achieved.

About AMI Industries Inc.

AMI Industries Inc. is a fully integrated manufacturer specialising in precision machining of complex components with value added operations, engineered electro-mechanical assemblies and services for the aerospace, automotive, medical, computer, hydraulic, optical, and pneumatic industries. The company was established in 2008 and is located in Liuying Technology Park in Tainan, Taiwan. The AMI Industries machinery park features the most modern multi-axis processing machines for turning, milling and drilling.

Ambitious targets

When AMI Industries purchased a new German machining centre, the engineers of the machine manufacturer recommended the use of Blaser Swisslube metalworking fluids. AMI Industries contacted Blaser to find an ideal coolant solution for the new machine. After first talks, it was soon clear that there was optimisation potential in the whole production processes. “Our main goal was to extend the tool life, reduce the tool and production costs as well as improve the surface quality of the machined parts,” explains Mr. Jian Yao Huang, Manager Aerospace Business Division of AMI Industries.

Dennis Wu, Blaser Customer Service Manager of Taiwan, recounts: “Besides a better cooling performance, a better surface quality and reduced cycle time, we also aimed to achieve an improved dimensional accuracy.” In order to suggest an ideal metalworking fluid, the Blaser experts needed to evaluate the production processes, the machines, materials and tools thoroughly. This Blaser-specific integrated approach ensures that the metalworking fluid becomes a “Lliquid Tool”, positively influencing parameters such as tool life, surface quality, and production costs.

Test phase with B-Cool 755

AMI Industries and Blaser Swisslube agreed to conduct a first test on a vertical lathe in the production of aerospace engine parts out of Inconel 718. After careful consideration, Dennis Wu suggested the use of B-Cool 755. B-Cool is a water miscible, mineral oil based, chlorine free cutting fluid. Its characteristics include low foaming behaviour in hard and soft water with good stability, good protection from corrosion and low consumption. “B-Cool 755 was initially developed for use on aluminium and aluminium alloys, but it also proved to be very efficient when machining more difficult to process materials. This metalworking fluid has helped customers to achieve increased tool life across the range of materials being machined. That is why we were convinced that it can significantly extend the tool life for AMI Industries, while at the same time save costs and increase the production efficiency,” says Dennis Wu.

Tool wear reduced by more than 20%

The test phase, which was conducted in the autumn of 2018, produced very satisfying results: With the new metalworking fluid, the tool wear was reduced significantly. The tool wear on the front of the cutting tool was reduced by 21%, on the side it was reduced by 26%. Dennis Wu: “Tool life and process stability have been improved. And, last but not least, the surface quality of the produced parts has been optimised as well!”

Optimising the cycle time

According to the wear condition, the process parameters were adjusted to optimise the cycle times and improve the overall production efficiency. Feed rates were increased, cycle times and the cost of machine tools were reduced. On top of that, the metalworking fluid costs could be decreased as well, saving 133.500 New Taiwan Dollar (approx. 31.350 RMB) per year.

Blaser Swisslube and AMI Industries aim to continue to cooperate to increase the production efficiency.