Here in part 2 of our Aerospace series of case studies we take a look at a renowned aerospace and bearing manufacturer in the USA. This case study focuses on moving their milling and turning operations over to Castrol Hysol SL 45 XBB cutting fluid following high additive usage, skin concerns, increasing odour issues, poor tool life and high fluid consumption. Over the agreed trial period, Castrol Hysol SL 45 XBB gave a cost reduction of 73%, whilst eliminating dermatitis concerns, extending tool life by 35%, and improving consumption by 53%.

Read the case study summary to see how moving to Castrol Hysol SL 45 XBB achieved these figures.

Sector          | Industrial

Sub-sector     | Aerospace

Application  | Milling (general machining), Turning (general machining)

Product       | Castrol Hysol SL 45 XBB

Background

A major aerospace and bearing manufacturer in the USA approached Castrol seeking a replacement cutting fluid to improve total operational costs within their milling and turning operations. They were also experiencing operator skin concerns, biological odour, and high additive usage – alongside poor tool life and high fluid consumption. We recommended a switch to Castrol Hysol SL 45 XBB. The customer was very impressed with the results over the agreed trial period, observing a total cost reduction of 73%, whilst eliminating all dermatitis concerns, extending tool life by 35%, and improving consumption by 53%.

Challenge

The customer is a renowned aerospace and bearing manufacturer based in the USA. They approached Castrol seeking a replacement cutting fluid for their milling and turning operations. The customer was using a competitor product, and was experiencing several issues. They were struggling with high operational costs, poor tool life and part quality, high concentration and consumption levels, and operator skin issue concerns.

To make an informed decision, the customer decided to conduct a year-long trial of various selected cutting fluids to identify one that would best improve their total operating costs. The minimum fluid requirements were aerospace approval, global availability, and semi-synthetic chemistry. Castrol were compared against several other competitor products, and they were tested by machining materials including inconel, stainless steel, stellite, titanium, tungsten, and aerospace aluminium.

Solution

After consideration of the trial requirements and a survey of the customer’s plant, it was determined that Castrol Hysol SL 45 XBB would be the best choice for their process – a one-stop solution. It is a high- performance, soluble metalworking fluid which is formulated without boron, formaldehyde-releasing agent and chlorine. It contains an additive package that helps to enhance machining performance and surface finish. It also provides good product stability which helps to lower the overall operational costs. After being provided with  a comprehensive fluid control plan, to effectively monitor and maintain the coolant systems. In addition, machining operations were closely monitored on titanium, inconel, tungsten, and stellite – keeping a close observation on noted improvements in both part quality and tool life.

Concentrate usage was also reviewed and then subsequently optimised throughout the trial period.

Outcome

The customer was extremely impressed with the results of the trial. Castrol Hysol SL 45 XBB delivered a preliminary 73% total cost reduction. In comparison to the competitor fluids in the trial, it maintained the lowest concentration – with 4% for machined aluminium and 8-10% on all other materials. Castrol Hysol SL 45 XBB eliminated all dermatitis concerns, biological odours, and additive usage within the trial – whilst still observing a 53% reduction in fluid usage and a 35% improvement in tool life.

Advice

To discuss your industrial lubricant needs or to see what we can do for you. Contact Kernow Oils us on 01736 757 002, email at info@kernow-oils.co.uk or visit our website at https://www.kernow-oils.co.uk/products-category/industrial-lubricants/.