One of our customers encountered two issues: hardened sludge and frequent rusting of the machines used in surface grinding applications for brake disc parts. These problems forced them to increase the coolant concentration, leading to higher coolant consumption (excessive usage).

From our joint observations with the customer in the field, we found the following facts:

• Hardened sludge occurred in all machines
• Rust was present in all machines
• The coolant used was of the synthetic type
• High concentration was used to prevent rust

It can be concluded that the causes of the hardened sludge and rust on the machines are due to the clinkering process or hot chips, which harden quickly. The hardened sludge, being difficult to clean, accumulates in the tank, reducing the rust protection capability of the coolant.

Solution

Eonchemicals provided a solution with the use of the EonTrim SC310 coolant, a semi-synthetic micro emulsion designed for surface grinding applications. Its features and benefits include:

• Specially formulated to prevent hot chips and clinkering, common in machining cast iron
• Contains rust inhibitors that form an easily cleaned film on the machine
• Includes EP additives for a better 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:
Consumption	33%
Tool life	56%
Cost coolant/piece	30%

Conclusion

The initial goal of the trial was to address the hardened sludge issue, but numerous successes were achieved, including:

• No hardened sludge occurred
• Coolant consumption reduced by 33%
• Tool life of Toishi increased by 56%
• Coolant cost per piece reduced by 30%

By choosing the right coolant, the customer was able to save time, materials, and costs. For free consultation regarding machining problems, please contact us.