Effective coolant management

Citation

(1999), "Effective coolant management", Aircraft Engineering and Aerospace Technology, Vol. 71 No. 6. https://doi.org/10.1108/aeat.1999.12771fab.009

Effective coolant management

Keywords British Aerospace, Coolants, Machining,'Machine tools

A Master Chemical turnkey coolant management system servicing the machining cells in the British Aerospace Airbus manufacturing operations in Filton is reported to be producing significant benefits in terms of reduced costs and greatly improved coolant performance.

Prior to opting for the Master Chemical solution, different machining cells at Filton had individual responsibility for not only who supplied cutting and grinding fluids but also for replenishment and monitoring. This individual cell responsibility resulted in three different suppliers, unacceptable cost controls and infrequent product management.

Having undertaken a full assessment, Master Chemical successfully tendered to supply and install a full coolant management contract providing a complete distribution, filtration and recycling system supported by a total replenishment and management system.

"As far as British Aerospace is concerned, Master Chemical now has responsibility for all aspects of coolant supply and maintenance", explains Cell Manager, John Myers. "Our previous arrangements were ad hoc and very labour intensive. In addition, coolant performance was often poor and we suffered from component corrosion and contamination in the fluid - those problems are now overcome and there is a cost benefit as well".

The installation at Filton covers over 100 machine tools, many being four- and five-axis machining centres including a new high speed machining cell. Materials used in the manufacture of predominantly aircraft wing components are aluminium and titanium.

Master Chemical recommended coolants that satisfy all of the machining requirements in the operation while overcoming the corrosion problems experienced when billets reacted with the steel beds on the machine tools.

The Master Chemical's installation necessitated the installation of a deionising water treatment plant, two Xybex coolant recycling plants with clean and dirty tanks, oil skimmers and a twin tank 1,500 litre capacity yellow bellied sump sucker in addition to all hard-plumbed distribution pipe work and pumping stations with pre-filters.

The Xybex system offers a complete, full capability single product coolant recycling system for medium and large machine tools with their own coolant sumps. The two units provide makeup coolant and recycle a sufficient quantity of fluid daily to support up to 9,600 litres of coolant in the machines.

In total the installation contains 77,000 litres of coolant and as John Myers explains, since going on-line in November 1998, coolant problems are now a thing of the past. "Coolant supply and management had been the subject of ongoing debate in our machine shops for some time." However, the cell managers agreed that a single source of supply was the way forward and having worked with Master Chemical from the outset, the installation has more than met our expectations. Apart from the vast improvement in the machine shop environment and coolant performance, we anticipate year-on-year savings of at least 5 per cent. Operator acceptance has been excellent and the combination of reduced cost, improved quality, ongoing management and the elimination of the corrosion problems have produced a very satisfactory result.

Labour for day-to-day top up and maintenance is included in the contract. In addition a Master Chemical engineer is always on standby and frequent visits are made to monitor the performance.

Details available from Master Chemicals Ltd. Tel: +44 (0) 1449 721985; Fax: +44 (0) 1449 721719.