April 2007 Edition

Coolants

Coolant Change Increases Tool Life 20 Percent

Skepticism has its place – it pays to be from Missouri, where the state motto is “Show Me” – but a willingness to try something new can have a big pay-off

With 22 years of experience in the machining business, Anthony Zalonis has seen just about everything. That’s why he’s skeptical when it comes to promises of superior product performance by vendors, especially in consumables such as coolants.

“In all these years, it has been hard to convince me that one coolant is better than the rest,” he said. “Every coolant I have tried had its good points and bad points.”

Zalonis has tried a number of them during his seven years at Piper Precision, Inc., Pearland, TX, where he is the general manager of the shop specializing in machining parts for the oil, gas, medical, chemical, inspection, and aerospace industries

Commodity Trading

Coolants were a commodity for Piper, one seemed as good – and as bad – as the next. They all had drawbacks, such as bacteria build-up, peeling paint off the machines, foul odors, irritating cuts on hands, and deteriorating machine rubber seals.

When John Hinders, area manager for Blaser Swisslube, suggested Piper try Blasocut 4000 Strong, Zalonis was doubtful. When Hinders promised Blaser coolant could eliminate the problems presented by other coolants, as well as increasing Piper’s tool life, Zalonis decided to do a trial run.

Piper equipment includes CNC lathes, a CNC mill, and a wire EDM. To produce some of its precision parts, which include equalizing darts for safety valves used in oil fields, Piper needed a coolant that outclassed the rest to meet their customer’s production goals, many of which had tolerances of ±0.0002".

With an international customer base, Piper maintains tolerances and finishes to within ±0.001", usually higher than what is specified in customers’ prints.

“I require my machinist to hold these tolerances even if the prints call for ±0.005",” said Zalonis.

“Because of the high demands, which manufacturing involves in all industries the company services, Piper required a coolant with a performance to yield the finishes and tolerances they need for the highest quality parts,” Hinders said. “Their customers demand perfection and Piper provides that with attention to detail. The Blaser coolant helps them achieve the results needed.”

“Cool” Coolants

“Hinders explained Blaser coolant’s advantages,” Zalonis said. “So I decided to try it.” Hinders guaranteed the performance of 4000 Strong to meet the company’s needs and was prepared to refund the cost of the drum should it not.

“It was more expensive than the other coolants we were using but the lesson I have learned over the years is you get what you pay for,” Zalonis said.

The improvements with the new coolant were immediate. Pablo Pico, Piper lead machinist, reported the previous problems went away. An additional benefit was the screws holding down the inserts and toolholders no longer stuck and easily unscrewed during change-out.

While the new coolant solved the chronic problems presented by other coolants, a major benefit of the Blasocut 4000 Strong was increased tool life.

Mark Gallegos, lead lathe machinist at Piper,
reported a 20 percent increase in tool life,
exceeding an estimated and anticipated five percent.

Piper quantified Blaser coolant benefits in increased tool life by examining tool usage on the large number of jobs machining Inconel. Beth Rocha, Piper assistant manager, documented insert usage on various materials. The company machines Stellite, Inconel, MP35N, titanium, brass, and plastics such as Peek, Teflon, and Torlon.

“I was surprised,” Zalonis said. Since the trial run, Piper switched all of its machines to Blaser coolant. “We have been able to raise the speeds and feeds since using the Blaser coolant,” said Zalonis.

Piper, owned and operated by Antonio Gambini, employs nine operators who manufacture isoguard systems, centering instruments, oil field valves, hydraulic pistons, and other products.

Zalonis said switching to coolants from Blaser Swisslube Inc., Goshen, NY, has maintained Piper’s goal of using the best materials and processes to produce the best quality for its customers.

“What separates us from other companies who machine similar parts is our quality and customer satisfaction,” he said. “Keeping up with the latest technology is important. Blaser Swisslube

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