With over two decades of experience in manufacturing high quality cutting tools, the company supplied to an impressive list of customers across industry segments. The list included top brands in automotive, aerospace, medical instrument manufacturers as well as die casting and machine tool industries. Equipped with advanced machining centers and well-trained personnel, the company always maintained highest levels of satisfaction with its customers.

The company’s portfolio included standard long end mills, uneven helix mills, taper end mills, drills, routers, reamers, turning and special tools.

Additionally, excessive mist generated from the coolant during the grinding process spoiled the work environment for operators. Based on a reference, the BECHEM team contacted the coordinates at the Company’s Production Dept. The BECHEM team after understanding the machining process and the pain points of wheel loading and mist formation during the grinding process recommended a trial with Berugrind 7 HC.

Production set-up: To meet Customer requirements and ensure a steady supply, the company had installed state of the art machines that included a sizeable number of ‘multi axis CNC tool and cutter grinding’ machines. As a regular machining practice, resin bond diamond wheel was used for grinding process.

An issue that Machine operators faced repetitively was of wheel loading affecting job finish. Grinding Tungsten-Carbide generated a lot of dust that continued to stick to the grinding wheel leading to the occurrence of wheel loading. The operators ensured extra caution during the process by limiting cutting speed.

Impressed with the consistent performance of Berugrind 7 HC in grinding, the Production team did a complete changeover for complete machining process of carbide tools.

The owner led firm had built a reputation as a reliable supplier of high quality components with ability to deliver within deadlines. The company manufactured precision components and catered to the requirements of automotive, marine and bearing industries. With stringent quality processes, the employees imbibed the company philosophy of delivering high quality components consistently at competitive prices. The production team were always on the lookout for initiatives to reduce manufacturing cost by improving process efficiency.

Out of the 60 machines installed, the split was equal between conventional and CNC machines. The standalone machining centres run with neat oils had capability to perform all regular machining processes such as turning, milling, tapping, drilling, grinding, thread cutting etc. Daily operations involved machining of regular steel, special alloy steel, leaded and non leaded materials.

With regular production schedules, the Production team was concerned about ways to improve tool life as it had significant impact on CPC. Right coolant management practices with suitable filtration systems had ensured that the existing coolant, ‘Product I’ performed adequately for the past 6 years.

However the Customer was keen to check if cutting fluids could impact tool life in any way. Given the circumstances, Bechem was provided an opportunity along with another prominent coolant brand to prove performances of their respective products against customer’s existing cutting fluid.

BECHEM’s ‘go to’ product for the trial was Berucut SCO 322 HC, the non water miscible coolant formulated with lubricity improvers and anti wear additives for superior machining performance and increased tool life. Developed for high speed machining, the Chlorine and heavy metal free coolant has a flash point of over 210 C and resists smoke formation even during intensive machining operations on tough metals. The ‘yellow clear fluid’ is resistant to ageing and provides good corrosion protection to machine and components.

The first trial was conducted for a period of 1 month on two similar machining centers and operations with only the coolant being the varying parameter.

With Berucut SCO 322 HC, the customer observed that the tool life almost increased by 50% compared to the existing coolant. There was marked improvement in surface finish of the component as well as cleanliness of the machines. The Customer was surprised with the results and wanted a confirmation on repeatability.

While a trial for repeatability was being scheduled, the BECHEM team proposed to increase machining speed with an intention to reduce cycle time and subsequently compare the results. At this point in time, the other prominent player in the market also pitched in with their offering, ‘Product B’. A second trial was conducted with change in machining speeds.

Tool Life Comparison Chart
Measured in no. of machined components

The result was no different from trial 1, Berucut SCO 322 HC beat both the products in tool life, machine cleanliness and component finish.

The Customer was able to experience increased tool life with Berucut SCO 322 HC by over 50% with existing coolant and over 40% with the other popular brand in the market.

With increase in tool life and reduction in CPC established, the Customer changed over from his earlier product to Berucut SCO 322 HC.

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Apart from providing the lowest consumption and increased sump life, the Avantin range also provides excellent corrosion protection to machines and components.

Get in touch with BECHEM’s well-trained Service Engineers who work systematically to ensure that you stay focused on surpassing production targets than being bothered about coolant issues.