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Ashburn 7090 Improves Part Finish and Tool Life in Multi-Operation Machining of Aluminum

February 2020

Ashburn Chemical was brought in to analyze the operation and provide a product recommendation in a mid west electronics manufacturer, looking to lower costs and improve finish on machined aluminum electronic parts.

THE CHALLENGE

A Midwest electronics manufacturer was looking to lower costs and improve finish on machined aluminum electronic parts. A coolant was needed that would perform in multiple machining operations, including a critical tapping application that was requiring a high mix concentration. Ashburn Chemical was brought in to analyze the operation and provide a product recommendation.

  • Part Machined: Electronic Component Housing
  • Material: 6061 Aluminum
  • Operations: Milling, Drilling, Boring and Tapping

RECOMMENDED SOLUTION

Ashburn 7090 was recommended due to its excellent performance on non-ferrous materials including aluminum. 7090 is an economical semi-synthetic coolant that runs very clean and provides excellent lubricity in tapping applications. 7090 was tested against two competitor coolants: a low-cost local product and a national brand semi-synthetic coolant (incumbent product).

THE RESULTS

The low cost soluble oil was effectively the highest cost product due to high carry-off, low tool life, part staining and poor machine condition. Ashburn 7090 outperformed the incumbent product in tool life and part finish while leaving the machine in cleaner condition. 7090 was able to be run at a lower concentrate while achieving the required tapping results. This lower concentrate usage along with lowered initial cost has resulted in a significant cost savings.

 

RESULT DATA

 

7090 Semi-Synthetic Competitor A
Low-Cost Local Soluble Oil

Competitor B (Incumbent)

Low Oil Semi-Snyth

Concentrate Cost 17% Lower Cost 40% Lower Cost
Machine Condition Excellent Surface and Table Rust Good
Foam Control Excellent Poor Excellent
Part Finish Excellent Fair Good
Staining None Minor None
Tool Life Excellent Good Good
Required Concentrate for Tapping 11% 10% 14%
Residue Slight- Excellent for Post Process Heavy-Poor for Post Process Slight- Excellent for Post Process

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