Grinding technology | Technology | YUTAKA

One of our customers encountered two significant issues: hardened sludge and frequent rust formation on the machine used in surface grinding applications for brake disc parts. These issues necessitated an increase in coolant concentration, leading to higher coolant consumption (inefficiency).

Sludge, or slurry waste, is a byproduct of the grinding process and can become a serious problem if not properly managed.

The problems that may arise include:

1. Causing rust
2. Emitting foul odors
3. Clogging circulation pathways
4. Rejecting parts
5. Tank leakage

Field observations with the customer revealed the following facts:

1. Hardened sludge occurs in all machines
2. Rust is present in all machines
3. The coolant used is of the synthetic type
4. High concentration is used to prevent rust

It can be concluded that the hardened sludge and rust on the machines are due to the clinkering/hot chip process, which causes rapid hardening. This hardening and the subsequent difficulty in cleaning result in accumulation in the tank, thereby reducing the rust protection capability of the coolant.

Solution

We recommend trialing EONTRIM SC310, a semi-synthetic microemulsion coolant, for surface grinding applications.

Features and Benefits of EONTRIM SC310:

1. Specifically formulated to prevent hot chips and clinkering commonly encountered in machining cast iron
2. Contains anti-rust agents that form an easily cleanable film on the machine
3. Includes EP additives for a good surface finish and extended tool life

Results

After a one-month trial, the following results were obtained:

Parameter	Existing	EONTRIM SC310
Coolant type	Synthetic	Microemulsion
Range concentration	5-7%	3-5%
Consumption/machine/month	90 L	60 L
Toishi tool life (pcs/tool)	900,000	1,400,000
Cost coolant/piece (IDR)	235	164
Cost-saving:
a. Consumption	33%
b. Tool life	56%
c. Cost coolant/piece	30%

Conclusion

The initial goal of the trial was to eliminate hardened sludge, which was successfully achieved. Additionally, the customer experienced further improvements, such as:

1. No occurrence of hardened sludge
2. Coolant consumption reduced by 33%
3. Tool life of Toishi increased by 56%
4. Coolant cost per piece saved by 30%

By selecting the appropriate coolant, the customer can save time, materials, and costs.

For free consultation regarding machining problems, please contact us.