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Case Study - Aluminium Reaming and Tapping
A major automotive engine manufacturer with a UK plant was struggling to produce consistent quality engine components with Mapal reamers. They were also suffering from frequent coolant changes due to tramp oil emulsification resulting in a frequent loss of surface finish:
- Unsatisfactory surface finish.
- Regular breakage of reamers and taps.
- Poor tool life.
- Poor sump life
Following an initial consultation, MLS recommended the introduction of a long life bio-stable cutting fluid and effected an alternative coolant management scheme. The impact of MLS’ package of proposals aligned with our fixed cost agreements produced the results seen below;
Impact:
- Savings Equal to 3 times Annual Coolant Costs.
- Increase in tool life from 1 blade per week to 1 blade per 6 months for every machine performing this operation. This represented an annual saving o approximately £ 20,000 per year.
- No tool breakage thus eliminating the necessity for any rework. The tap breakage rate was reduced from 18 to 1 a month saving another £ 8,000 per year.
- Sump life extended to 18 months thus saving 5 machine coolant changes, saving 60 hours machine time equal to £4,200 per annum
- Excellent surface finish – Consistent finish of 1.0 μm maximum maintained throughout the fluid life
PROCESS AND EQUIPMENT INFORMATION:
Operation : Reaming and tapping
Material : Aluminium.
Part produced : Cylinder head.
Machine & Tool : Enshu - Mapal reamer and straight flute tap
Coolant : 10% conc.
Pressure : 70 bars on reaming, 5 bars on tapping.