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Another Success Story Bio-Based Metal Cutting Fluid
Product Bio-Cool XXL Plus Water Soluble Coolant
Process Finish Turning
Application Machining the face of a carbon steel automotive part with a .7 (metric) micro-finish requirement.
Background A first tier automotive supplier was having trouble maintaining a .7 micro-finish on a finish turning operation. Tools were being changed when surface finish deteriorated after about 60 parts. Feed rates were held to .0055 per revolution to maintain finish.
Situation Customer needed to improve tool life while keeping finish within tolerances. They had tested various cutting tools and settled on a Tungaloy wiper style insert to obtain the best surface finish.
Solution Customer added five gallons of Performance Biolubes’ Bio-Cool XXL Plus coolant concentrate to the current semi-synthetic coolant in their 100 gallon sump.
Benefits Finish improved to a 3.5 micro-finish. Tool life increased to 130 parts per edge. After these results were solidified, the Performance Biolubes Representative suggested that the customer increase their feed rate. With XXL Plus, the customer was able to increase feed rate from .0055 per rev. to .014 per rev.
Cost Savings Insert cost is $7.42 each with 6 cutting edges. At $1.24 per edge, tool cost per part was $.021 for 60 parts and is now $.009 per part for 130 parts. The customer manufactured these parts on two machines with an $80 burden rate per machine. Together, the two machines produced 3000 parts per day in sixteen hours. The total burden cost was .853 per part. There were 50 five minute tool changes. After adding Bio-Cool XXL, tool changes were reduced to 23 per day, a reduction of 2.25 hours in tool change time. The increase in feed rate reduced machining time by 10 seconds per part times 3000 parts per day totals a reduction of 8.3 hours in machining time.
Total cost reduction using Bio-Cool XXL Plus is .293 per part. The annual cost savings is $219,750. This does not include the reduction in scrap parts, reworks orreduction in costs of reduced quality control and administration efforts.
 Product Bio-Cool XXL Plus Water Soluble Coolant
Application Heavy wall carbon steel tube cutoff on a Modern Cutoff Machine.
Background Second tier supplier to a large bearing manufacturer has a contract to cutoff 85,000 pieces per week of a carbon steel tube running 24 hours per day, 7 days a week. They selected a Modern Cutoff machine and tooled it with Ingersoll blade style indexable carbide cutoff tools.
Situation Customer tested various tools and determined that they could achieve 700 parts per edge consistently with an eleven second cycle time. Customer asked his distributor representative if there was anything else they could do to improve tool life or cycle time.
Solution Customer added 2-1/2 gallons of Performance Biolubes’ Bio-Cool XXL Plus coolant concentrate to the current semi-synthetic coolant in their 50 gallon sump to see if the biobased product would help with tool life.
Benefits The customer stated that he knew immediately that his tool life would improve because the surface finish in the cut area was much better and that usually translates to better tool life. As it turned out, their tool life improved dramatically. The customer now gets more than 1400 parts per tool, a 100 percent improvement.
Cost Savings Insert cost is $16.20 each with 2 cutting edges. At $8.10 per edge, tool cost per part was $.023 for 700 parts and is now $.0115 per part for 1400 parts. Tool cost savings is $24,589 per year.
With an eleven second cycle time, tool changes were every two hours and took five minutes each. Performance Biolubes coolant reduced tool changes by one half. With an $80 per hour burden rate, the savings from reduced tool change time was $14,000 annually.
Total annual savings from using Performance Biolubes coolant is $38,589.
Other Benefits Performance Biolubes’ Bio-Cool XXL Plus coolant is a truly “Green” product, made from USA grown seed crops. There are no known cases of dermatitis from this product, and most users say that they have eliminated dry skin cracking that occurred when working with petroleum-based coolants. The vapors from Bio-Cool are not hazardous. Disposal is not hazmat unless the used product contains other hazmat classified materials such as heavy metals from machining
 Product NuCut Plus Cutting/Grinding Oil Application Form Grinding heated treated high carbon steel with CBN plated wheels
Background Manufacturer of proprietary power transmission parts struggled with heat checking in hardened parts after grinding forms with CBN plated grinding wheels.
Situation Customer has ground forms in heat treated high carbon steel parts for many years. A typical plated grinding wheel ground 2000 parts before it required stripping and re-plating. The quality control department has identified small cracks in parts after the grinding process, causing increased scrap, lost production time, increased inspection, and additional administrative efforts. The grinding fluid used was a Blaser petroleum-based oil.
Solution Customer replaced their petroleum-based grinding oil with Performance Biolubes’ NuCut Plus Bio-based Cutting/Grinding Oil.
Benefits When grinding with NuCut Plus, the grinding process no longer causes the customers parts to crack. This is due of reduced heat from improved lubrication of the grinding wheel. Also, this improved lubrication allows the CBN plated grinding wheels to last over 6000 parts before requiring re-plating. The customer is able to increase feed rates while reducing smoke produced by the grinding process.
Cost Savings Grinding wheel expense is reduced $60,000 annually. Reduced quality control efforts save approximately $30,000. Reduced production time saves $200,000 per year. These savings total $290,000 per year. Additional savings comes from reduced scrap and administrative time.
Other Benefits Performance Biolubes’ NuCut Plus Cutting/Grinding Oil is a truly “Green” product, made from USA grown seed crops. There are no known cases of dermatitis from this product, and most users say that they have eliminated dry skin cracking that occurred when working with petroleum-based coolants. The vapors from NuCut Plus are not hazardous. Disposal is not hazmat unless the used product contains other hazmat classified materials such as heavy metals from machining
BioBased Lubricants – Dixon Case Study
Summary: In an effort to assist in the reduction of fossil fuel dependencies, the Dixon facility has initiated transitioning to a biobased cutting fluid and water soluble coolant used in the machining process of the screw machine department.
Strength: In addition to the reduction of foreign oil needs, the transition has improved the operating process through; improved tool/part fluid coverage, higher flash point (reduced “smoking”), reduction of airborne throw off mist, machine/tool wear and malfunction, and the potential for faster production run times.
Weakness: Purchase cost of biobased oil is currently 20% higher than petroleum based products.
Opportunities: Produces a safer healthier working environment for our employees.
Biobased oils produce a larger droplet size that reduces the amount of throw off misting.
We have had a significant decrease in misting and smoke compared to that from the petroleum based product. This has greatly reduced the accumulation of oil residue forming on floors and surrounding facility/machine surfaces.
Threats: Using petroleum based products in the quantities required in the department
increases the risk of accidental releases into the surrounding environment. Increases the health safety and environmental risk required by federal legislation and reporting requirements. Biobased oils have a much higher flashpoint compared to the petroleum based counterparts, reducing the risk of fires.
Benefits:
Increased lubricity increases tool life by up to 55% estimated annual savings $16K.
Increased lubricity increases fluid life by up to 25% reducing coolant purchases by $2K
Safer working environment through reduced slip hazard
Reduced friction reduces throw off smoke from cutting process
Production rate improvement up to 50% per item reviewed on a case by case
Automatic Precision Sawing
With NT2000 Water Soluble Coolant
Situation: CNC Machine Shop performs a critical production sawing operation with tight length and squareness tolerances. Blade life is critical to control part size, reduce scrap, increase productivity and reduce saw blade costs.
Material: A36 hot roll-formed “L” shaped bars, un-annealed with case hardness.
Tools: Amada automatic cutoff band saw machine with Lenox band saw blades and high quality, major brand name, water soluble coolant.
Blade life: Previous blade life averaged 5000 pieces per blade. Failure mode was based on cutting time, motor load and quality of cut. John, the operator, has over 30 years experience cutting similar jobs as a cutting service.
Solution: The coolant was replaced with NT2000 coolant from Performance Biolubes.
Results: With high lubricity NT2000, blade life immediately increased from 5000 pieces to 9000 pieces. Blade costs were reduced, part quality improved and productivity increased. Product mixed easily, produced no foam and left very friendly residues.
Other Applications: NT2000 is very effective on most machining operations including milling, turning, drilling, tapping and grinding. It is used successfully on both ferrous and nonferrous metals. NT2000 is also a great lubricant for metal stamping and forming operations. NT2000 has polarity which allows it to adhere to metal surfaces, thereby protecting the cutting tool and reducing friction.
Health and Safety: With NT2000, John explained, he no longer experienced alkaline burns on his skin from high Ph bactericides in other coolants. NT2000 is very skin friendly and will not cause dermatitis. Any vapors from NT2000 are much safer than vapors from petroleum based coolants. NT2000 is made from vegetable oils. It does not contain petroleum, chlorinated paraffin’s, heavy metals or dangerous bactericides.
Environmental: NT2000 is made 100% from green renewable resources. It is biodegradable and earth friendly. NT2000 can help manufacturers meet their green initiatives and qualify for the ISO 14000 requirements. NT2000 has great bio-stability and can be recycled to reduce usage and disposal.
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