Nerc turns to Rocol to realise significant cutting fluid savings

Bristol-based Nerc Precision Engineering (NPE) Ltd which has been on a rapid growth trajectory since its establishment four years ago, recently marked the milestone with the installation of a new DMG Mori CMX600V machining centre.

Investing in ‘state of the art’ technology is a philosophy of the small business, and this has been bolstered by a newly formed partnership with Leeds-based Rocol a cutting fluid specialist, which is part of ITW, one of the world’s leading manufacturers of specialised industrial equipment, consumables and related services.

Managing director Konrad Nerc said: “When my wife and I started the business, we aimed to invest in the best technology to ensure that we can deliver the highest quality components and service with lead times and pricing that would be the industry benchmark. As a small and agile manufacturer with innovative technology investments that include five-axis machining, our philosophy and customer service is enabling us to evolve rapidly.”

In the last two years, the sub-contractor has also invested a DMG Mori machining centres, a five-axis DMU50 as well as the three-axis CMX600V which is supported by zero-point clamping from Lang, cutting tools from Ceratizit, Hoffmann and Tungaloy and cutting fluid from Rocol.

Producing everything from one-offs and prototypes to batch production, the ISO: 9001:2015 sub-contract manufacturer serves customers in the defence, offshore, automotive and general sub-contract sectors with the aerospace industry rapidly emerging as its most prominent market sector.

Like any fledgling business, finding the best quality products and services is a learning curve; and this has certainly been the case for the company located near Bristol airport when considering its cutting fluids. A trial and error process led Nerc to seek out the advice of Ian Fenney, the metalworking segment specialist at Rocol.

Impressive quality
Mr Nerc said: “Ian came to visit us and investigate our cutting fluid requirements. Following an initial consultation, we tested three different Rocol fluids. Trialling more than one product was due to the diversity of the materials we were cutting, the varying operations and machining parameters and some of the products were new to market. Rocol emptied and cleaned the sump of a machine, and we tried our first fluid, and the quality was impressive.”

Since the trial commenced last year, Nerc has won a series of new customers and sizeable orders in the aerospace industry — with work in this sector now accounting for 95% of turnover. This has seen the materials machined narrow from stainless, steel, copper, brass and a multitude of ferrous and non-ferrous materials to primarily aluminium and aerospace-grade alloys.

With this evolution, Rocol identified its TRI-Logic cutting fluid as the most suitable solution. TRI-Logic is a range of maximum life extreme pressure cutting fluids that demonstrate excellent inherent stability and cutting performance that improves surface finish and tool life while reducing foaming and odours. Furthermore, as a fluid formulated from a unique blend of specially selected additives that maximise sump life, TRI-Logic also offers excellent corrosion protection.

To undertake the trial, the cutting fluid specialist supplied a 55-litre barrel of its industry-leading TRI-Logic to Nerc. This barrel was used in the initial trial that required the emptying and cleaning of one machine sump to demonstrate the difference between Rocol and its fellow ‘premium brand’ rivals.

With the results rapidly becoming evident, the remainder of the barrel was used to continually ‘top-up’ the fluid of the remaining three machines to limit the disruption to production while delivering maximum results for Nerc.

Significant savings
As a result, the fluid life has improved dramatically, and oil consumption has reduced by over 50% and as the Rocol TRI-Logic EP is around 50% cheaper than its rival premium brands, the overall saving is significant.

Mr Nerc added: “The 50% cost reduction is something that every small business wants to take advantage of, but when the consumption also reduces by 50%, the cost of coolant stops being a concern. The initial 55-litre barrel lasted from July to February and we have recently taken delivery of a new 200-litre drum of TRI-Logic. Our initial projections were that the fluid would provide a cutting fluid consumption reduction of 25%.

“However, with the new aerospace work, we are running four machining centres up to 16hr a day and we are busier than ever before. Running at optimal production rates, we are seeing that our cutting fluid consumption is at least 50% less.”

The 200-litre barrel of Rocol’s TRI-Logic high-performance cutting fluid has been supplied with an automatic fluid mixer that accurately mixes and dispenses the correct dilution of cutting fluid and water. With a built-in double check valve and vacuum breaker that is WRAS (Water Regulations Advisory Scheme) approved, the system meets the most stringent of safety requirements for category 3 fluids and ISO EN: 1717 regulations. Fast, efficient and easy to use, the mixing station always ensures that Nerc Precision has the optimal fluid concentration in its machine tools.

Mr Nerc continued: “For our business, specifying cutting fluid has been the hardest thing to get right and find an improvement. Unlike capital and ancillary equipment, the challenges with cutting fluid can be the most difficult aspect of the business to get right. The challenge of trialling new coolants has several implications.

“For example, emptying and cleaning machines to trial fluids can be time-consuming with machine downtime – and then there is the concern that the new fluid may not improve productivity, fluid life and tool life; or it may not be compatible with the materials machined. There is also concern over tramp oil, foaming, residue on components, skin irritation, disposal and much more. Thankfully, Rocol resolved all of this, and the results have been fantastic.

Mr Nerc concluded: “The service and support from Rocol is second to none. The company reviewed our business, listened to our concerns and then provided a solution that has exceeded everything else that went before. Most importantly, a Rocol engineer is always on call to support us in checking the fluid levels in the machines, the ph levels and fluid concentration. We couldn’t ask for a better service.”