The automotive industry, which manufactures motor vehicle components, generally faces the issue of low tool life (tool wastage) in the machining process. One of our customers is currently using synthetic coolant or metalworking fluid for the following processes:

• Rough milling
• Fine milling
• Rough boring
• Fine boring
• Drilling Ø 10.8
• Tapping M12

Below is the customer’s tool life data that has led to high operational costs:

Proses	Tool Life (pcs/tool)
Rough milling	240
Fine milling	200
Rough boring	200
Fine Boring	105
Drilling ꝋ 10.8	170
Tap M12	150

From surveys and field observations, in addition to the issue of low tool life, other problems identified include:

• Excessive waste generation
• Synthetic coolant mixed with tramp oil, resulting in a milky white appearance
• Rapid contamination of the leak test tank, requiring weekly cleaning

Solution

Eonchemicals offers a solution with the use of EonTrim C385 coolant. This product has proven successful in addressing the customer’s issues due to its features and benefits as follows:

• Rejects tramp oil, preventing it from dissolving in the coolant and causing cloudiness
• Low carry-off, resulting in minimal coolant being carried away with parts
• Clear and contains premium surfactants, providing excellent wetting ability to coat parts during the cutting process
• Contains EP additives that aid in lubrication at the cutting point, preventing rapid tool wear

Results

After a 3-month trial, the results were as follows :

Parameter	Existing	EONTRIM C385
Coolant type	Synthetic	Synthetic
Coolant life	3 months	12 months
Coolant appearance	Hazy liquid	Transparent liquid
Tool Life (pcs/tool)
Rough milling	240	463
Fine milling	200	463
Rough boring	200	201
Fine boring	105	209
Drilling ꝋ 10.8	170	276
Tapping M12	150	212
Leaked test dump out	Once a week	Every 4 weeks

Conclusion

The right coolant can provide numerous benefits such as extending tool life, reducing waste, maintaining machine cleanliness, and enhancing rust resistance. This not only saves operational costs but also conserves time and labor.

For free consultation on coolant or metalworking fluid, please contact us.