Impressive macro high-speed footage: visible in slow motion, the carbide milling cutter cuts through the brass with a perfect trajectory. Blaser Synergy 735 metalworking fluid becomes cloudy around the rolled up chips – where the heat is greatest. It separates out the oily phase, resulting in a more effective lubricating emulsion. Metalworking fluid specialists from Blaser Swisslube carried out an in-depth analysis of the machining process through a series of tests in the Technical Center. Our motto: Get better metalworking fluids faster with expertise and data!
As part of a joint project with the renowned ETH Zurich, the machining process, chip formation and properties of metalworking fluids are captured more precisely and displayed in images and video. The R&D team at Swiss metalworking fluid specialist Blaser Swisslube has planned and implemented the idea. Clear and precise recordings can be achieved by using a high-speed camera with a macro lens, placed behind the sight glass and at a distance from the metalworking fluid. Use a ring light to provide the necessary light intensity and a hard metal milling cutter with a 0° helix angle specially ground for this test.
Stunning results: High-speed photography reveals for the first time how oil-free, water-soluble metalworking fluid Synergy 735 works – i.e. fluid improves lubrication at higher temperatures Fast enough to optimize the milling process. That is to say, Synergy 735 will change its characteristics and adapt to the processing process like a “chameleon”.
When machining titanium, temperatures are highest near the cutting edge and in the center of the chip.The bright cloud formation around the swarf is evidence of both
“Our Technology Center allows us to observe and explore with greater accuracy than our competitors. This attention to all details, and the collaboration between our chemists and processing experts, has allowed us to develop sustainable improvement processes, lowering Production costs and metalworking fluids that extend tool life,” explains Marc Blaser, Managing Director of Blaser Swisslube.
The Synergy 735 metalworking fluid used in the aforementioned tests, after cooling, becomes clear again, keeping the machine clean and ensuring good process visibility. Its benefits also include a neutral odor and excellent skin compatibility. Synergy 735 is suitable for surface finishing of various materials including aluminium alloys, titanium alloys and stainless steels, to name a few. It is also ideal for high pressure systems because it forms very little foam.
For more than ten years, the technical center of Blaser Swisslube has been continuously expanded. Currently, the center covers an area of more than 1,500 square meters and uses four CNC milling machines and a state-of-the-art grinding machine for research. Such as testing newly developed products, simulating customer production under real conditions, etc. High-precision measuring equipment and sensors are able to correctly interpret the data obtained.
Lead-free brass slides on the cutting edge and forms thin chips
Wear measurement reveals savings potential
For example, wear measurements are performed with a microscope camera, which automatically takes a microscopic image of the blade every two minutes. “The wear of the tool often limits the efficiency of the machining process. Thanks to the new measurement method, we can receive meaningful information directly from the machine in the shortest possible time,” explains Dr. Linus Meier, tribology expert at Blaser Swisslube. Thanks to an optimized data flow, we can make adjustments to metalworking fluids easier and faster in the lab. “Our customers benefit from this. Because high-performance metalworking fluids can realize savings in every aspect of the production process, whether it is increased productivity or reduced tool wear,” stresses Linus Meier.
The experimental setup is part of a joint project with ETH Zurich
Liquid Tool™ Overview
An optimal metalworking fluid typically has more than a dozen components, including oils, emulsifiers, and additives. Making metalworking fluids a liquid cutting tool that optimizes the efficiency of the entire production process requires both the expertise of the machining technician and the study of precise formulations. Blaser Swisslube has long relied on the collaboration between these two disciplines. Marc Blaser: “We can only make great strides in the development of metalworking fluids when our chemists verify the actual performance of metalworking fluids in performance tests and can interpret the data obtained from production technicians.”
Blaser Swisslube was founded in 1936 to provide advanced lubrication solutions with significant added value that are friendly to people and the environment. As a Swiss family-owned company, we develop, produce and sell a comprehensive range of metalworking fluids that are not only of high quality, reliability and performance, but also suitable for use in many different industries. With a strong team of application experts, customized customer service, and excellent products, Blaser Swisslube can help you realize the full potential of your machine tools and tools, making metalworking fluids a key factor in your success.
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