November 2017 - Located only 50 miles apart, Kalamazoo, Michigan-based Sigma Machine Inc. and Unist Inc. in Grand Rapids, Michigan, know that convenience is invaluable. A family-owned company, Sigma is a Tier I supplier to Tesla and has delivered design, prototype and manufacturing services to the electric vehicle, aviation and food processing industries since 1955. Even after 62 years, Sigma’s executives are continually seeking ways to improve operations and facilities. Recently, Sigma leaders sought to create a cleaner and drier work environment for its employees.
After a round of research, Sigma brought in Unist to discuss its line of Coolube lubricants. Unist, which started manufacturing minimum quantity lubrication (MQL) solutions in 1957, offers lubrication application systems for the metalforming industry.
Among other benefits, Unist’s Coolube reduces fluid usage, promotes tidier and safer work areas and floors, and improves cut quality and tool life. Perhaps most significantly, because a minimal amount of lubricant is needed for such tasks, MQL saves money.
Although the exact amount of savings varies by plant, industry estimates report that between 8 percent and 16 percent of total operation costs are reduced by using Unist’s metalworking fluids. Sigma’s production leaders were persuaded and purchased Unist’s advanced metal cutting lubricants.
“Unist MQL equipment and Coolube lubricants have had a positive impact here at Sigma,” says Tia Stevenson, a lead quality technician for the automotive parts maker.
“With Unist, we’ve been able to cut our lubricant use and realize significant savings. The minimal amount of Coolube we apply with Unist MQL systems means less time and money spent cleaning, and a cleaner shop overall.”
When Sigma was using flood coolant, she says, “we would have massive floods. Machinists were constantly wet and had skin irritations. Some workers’ skin conditions were so bad, they could no longer work here. The Coolube lubricant is so much better. We love lubricant now.”
Michael Biscorner, a Unist sales and technical support technician, says the superior lubricity of Coolube translates to a longer tool life and enhanced cut quality. The protective barrier formed by Coolube effectively diminishes friction. As a result, some Coolube customers have reported 500 percent gains in tool life, he notes.
When used in conjunction with a Unist MQL system, the benefits are multiplied. The pumps and equipment required for fluid treatment are eliminated and this saves electricity. There’s no need to dispose of used fluid that falls under government regulation and can be costly.
According to Biscorner, “Coolube’s polar properties allow its molecules to cling to the metallic surfaces of the tool and the workpiece. This generates a thin protective layer which is incredibly effective at reducing friction and, therefore, heat buildup.”
With Coolube, he adds, “most of the heat goes into the chip that is ejected away from the cutting zone.”
With heat lessened, Biscorner explains, many shops are able to increase their machining rates (“speeds and feeds”) and still enjoy substantial increases in a tool’s lifespan.
“The majority of Coolube is consumed in the MQL process,” adds Biscorner. “This makes for clean machines, floors, finished parts, and chips/swarf. A lot of people refer to MQL as Near Dry Machining which makes sense as it is basically a dry process.”
Coolube differentiates itself from competing lubricants because it’s refined to stringent standards. “There are other plant-based lubricants on the market created specifically for MQL applications. Many of them aren’t as highly refined, which can lead to oxidation and gummy buildup on tools over time.”
Coolube, alongside MQL, creates a balance between lubricity and biodegradability that is unmatched when compared with other metal cutting fluids. While Unist’s lubricant is useful for multiple industries, it’s especially critical for metal cutting and machining. Proper use of the lubricant minimizes unnecessary stoppages and prolonged periods of downtime.
“Switching from traditional flood coolants to MQL with Unist Coolube eliminates many housekeeping tasks and headaches associated with coolant,” says Biscorner.
“With Coolube, the minimal amount of lubricant applied is consumed in the process. This eliminates the need to treat, filter, or recalculate fluid and tasks such as draining sumps, cleaning floors and disposing of used coolant. With Coolube, not only does equipment stay cleaner, but machinists spend more time actually machining instead of dealing with fluid mess.”
Unist’s Coolube lubricants have helped Sigma Machine establish a drier, safer and cleaner workspace.
Sigma Machine Inc.
Kalamazoo, Michigan
phone: 269/345-6316
www.sigmamachine.net
Unist Inc.
Grand Rapids, Michigan
phone: 800/253-5462
www.unist.com
