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Benchmarking the Consumption of Metal Cutting Fluids

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Benchmarking the Consumption of Metal Cutting Fluids BENCHMARKING THE CONSUMPTION OF METAL CUTTING FLUIDS EG179 GUIDE Water-based metal cutting fluids are essential for machining a wide range of materials and components throughout the engineering industry. Many operators are, however, unaware of the potential savings that can be made by implementing and improving fluid management and control practices. This Guide provides data and advice to help you reduce fluid consumption so that you can: save money on fluid purchase and disposal costs reduce machine downtime due to fluid related problems optimise intervals between fluid changes minimise problems associated with product quality improve your working environment and environmental performance perform better than your competitors ENVIRONMENTAL PERFORMANCE GUIDE: The benchmark for profitable environmental improvement THE SURVEY Fig 2 Number of machines employed A confidential questionnaire was sent to a cross-section of engineering companies throughout the UK, to determine 101 - 500 >500 industry profiles and statistical information on the 7% 5% management and use of cutting fluids (metalworking 51 - 100 fluids). While the UK engineering industry is extremely 7% <10 diverse, resulting in a wide variation in the data collected, 26 - 50 39% useful comparisons and conclusions can be drawn from the 22% information.1 The survey of the UK engineering industry highlighted a broad range of companies using cutting fluids in their machining operations. It identified a considerable variation 11 - 25 in fluid consumption and management procedures, 20% suggesting that many operators could improve and reduce their use of cutting fluids. Fig 3 Number of operators employed This Environmental Performance Guide: >500 I summarises the survey findings, allowing you to compare 101 - 500 5% 10% your current fluid use with that of your competitors; <10 27% I provides a Fluid Management Index that helps 51 - 100 demonstrate the connection between production levels, 24% 11 - 25 fluid use, costs, and degree of fluid management; 17% I will help you estimate the cost savings achievable through improved fluid management; I presents an Action Plan and suggestions for reviewing 26 - 50 and reducing your current level of fluid use, thereby 17% reducing your costs. as the major activity. This is shown in Table 1, which gives Profile of Respondents the response breakdown of the three main machining Market sectors processes. The response profile by sector is shown in Fig 1. While Table 1 Machining processes used many companies serve more than one sector, the dominant markets are general and precision engineering, Machining process Total number of representing over 65% of respondents. machines used by Fig 1 Response breakdown by sector respondents (%) Rotating workpiece (eg turning) 43 Rotating tool (eg milling) 37 General Aerospace 36% 12% Abrasive (eg grinding) 20 Automotive 20% FLUID CONSUMPTION Trends in Cutting Fluid Use The respondents’ use of the three fluid types is shown in Table 2. Precision Table 2 Fluid type breakdown 32% Fluid type Typical appearance Total volume of fresh used by Respondent size mixed fluid respondents (%) Figs 2 and 3 show the response breakdown by size of Synthetic Clear (coloured) 10 machining operation. Around 40% of companies surveyed solution use fewer than ten machines or employ fewer than 25 machine operators. Just under 5% of respondents have Semi-synthetic Cloudy, 83 more than 500 machines and 500 operators. translucent The aerospace and automotive sectors have the highest Macro emulsion Traditional 7 proportion of large companies with 69% employing more milky suds than 50 operators. This compares with 25% in general and precision engineering. The survey data indicated high use of semi-synthetic fluid. This fluid offers benefits in terms of increased machining Machine types quality and reduced operator health problems such as skin While many different machining operations are used irritation. On the other hand, synthetic and semi-synthetic throughout the engineering industry, turning is recognised waste fluids are more difficult to treat and separate on disposal. 1 The survey conclusions are based on 41 full and verified responses. Calculation and Comparison of Fluid Consumption compare your company’s Specific Fluid Consumption with that of others throughout the engineering industry. For Fluid consumption varies greatly from company to company example, Metalcutters Ltd uses 1 880 litres of fluid/m3 of because of the diversity in production levels, component swarf generated. Approximately 82% of respondents types, materials and fluid management practices. To therefore use fluid more efficiently than this company. compare levels of use across the range of companies, a measure of fluid consumption was devised which links the consumption to component production levels and is based WHY IMPROVE CUTTING FLUID MANAGEMENT AND on easily measured and monitored information. This is the REDUCE CONSUMPTION? Specific Fluid Consumption expressed as litres of fluid used Companies often consider cutting fluid to be a low cost, per m3 of metal swarf generated. Use Table 3 to calculate disposable necessity and pay little regard to its purchase, your company’s Specific Fluid Consumption. Data for a management and disposal. However, the survey showed fictitious company, Metalcutters Ltd, are given as an that the cost of cutting fluid concentrate (all types) ranged example calculation. between £0.70 - £4.54/litre with an average of £2.32/litre. During initial collation of the survey data, only two-thirds This equates to an average cost of around £460/m3 of of companies could provide readily available data on fluid swarf generated for the lowest users, to over £2 300/m3 for consumption and/or swarf production. A follow-up the highest users (see Fig 4). There is therefore exercise increased the response to over 90%. This illustrates considerable potential for most companies to reduce their that one person at a company is unlikely to know all of the fluid costs. Savings of 40 - 60% may be possible for data required for a review of fluid use and a team approach companies with poor management procedures. is necessary. Used cutting fluids are a mix of chemicals that require Do you know how much fluid you use? careful disposal. As environmental legislation tightens, disposal methods are becoming more stringent and The Specific Fluid Consumption data for the survey were costly. Consequently, reduction of disposal volumes can collated and are shown graphically in Fig 4 to show the yield additional savings and environmental benefits. ranking of all respondents. You can use the chart to Table 3 Calculating your metalworking specific fluid consumption Example for Metalcutters Ltd* Cutting fluid concentrate used in one year (all water mix types) litres A ....4 625... litres Weight of swarf produced using water mix fluid in same period: eg for steel tonnes B ....14.....tonnes eg for aluminium tonnes C ......2.....tonnes eg for titanium tonnes D .............tonnes Equivalent volume of swarf produced: (÷ by density)** Steel-based (= B ÷ 8) m3 E .....1.75........m3 Aluminium-based (= C ÷ 2.8) m3 F .....0.71 .......m3 Titanium-based (= D ÷ 4.5) m3 G ....................m3 Specific fluid use (litres/m3 swarf generated) litres/m3 A ....1880...litres/m3 E+F+G * Metalcutters Ltd uses 2 500 litres of one semi-synthetic fluid, 1 800 litres of another semi-synthetic fluid and 325 litres of macro emulsion per year, a total of 4 625 litres of cutting fluid concentrate. It manufactures precision components and produces 14 tonnes/year of steel-based swarf and 2 tonnes/year of aluminium alloy swarf. ** Use the same calculation for any other metals that you use, eg iron (density 7.5), copper (density 8.9), brass (density 8.5), bronze (density 8.0), nickel (density 8.9), zinc (density 7.0). Fig 4 Specific fluid consumption benchmark table 10 000 Metalcutters Ltd. 1 880 1 000 swarf produced) 3 100 (litres/m Annual specific fluid consumption 10 020406080 100 Lowest usersRanking of respondents’ specific fluid consumption Highest users FLUID MANAGEMENT In both cases the fluid life could potentially be extended by Fluid management plays an important role in maximising improving fluid management practices. fluid life and reducing fluid costs. The companies surveyed Over half of the companies surveyed reported one reason were asked to provide data on their normal fluid for replacement as being that of excessive suspended solids monitoring and maintenance procedures together with or tramp oil, or reasons often attributable to these their usual reasons for fluid disposal. Indices were conditions (such as increased oil mist or smoke). In many assigned to each category, as shown in Table 4. such cases the use of filtration or oil skimming equipment Determine your fluid management status by following the would be beneficial. procedures given in Table 4. In order that the effect of fluid management on fluid Figs 5, 6 and 7 show the response based on each Fluid consumption can be determined, the three separate Management Index. It is interesting to note: management indices are combined into an overall Fluid Management Index, as shown at the bottom of Table 4. I 39% of companies reported that fluid is replaced due to Again, Metalcutters Ltd is used to illustrate the calculation. reasons attributable to loss of control (see Table 4, Section C); I a further 37% replace fluid on a schedule basis. Table 4 Estimating your overall fluid management index Survey results Fluid management techniques Example for Metalcutters Ltd* Fig 5 Monitoring index response A Fluid Monitoring Tick the box that indicates the level of monitoring Index 2 Index 0 that you generally carry out. 50% 15% Monitor sump level only I Monitoring index 0 I Index 1 35% Monitor sump level I Monitoring index 1 I + fluid concentration Monitor sump level, I Monitoring index 2 I concentration + pH/other fluid parameters Fig 6 Maintenance index response B Fluid Maintenance Tick the box that indicates your usual level Index 2 Index 0 of fluid maintenance.
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