Improving Tool Cutting Life, Finishes Starts with a 'Code Blue' Lubricant

Universal Precision Instruments, Inc. (UPI), Elkhart, IN, is a contract manufacturer that specializes in high-precision medical machined devices that require highly-accurate dimensions and superior finishes.

UPI accomplished its registration for ISO 13485:2003 and 9001:2000, and has provided its customers a one-stop-shop with prototyping services, advice for instrument design, and full production run capabilities under one roof. UPI utilizes CAD/CAM software that provides a direct link via a wireless network from the engineering office to all CNC machining stations.

Their machining processes start from raw metal and material stocks to highly finished parts utilizing CNC lathes, chuckers, mills, EDM, laser etching, grinding, bead blasting, buffing, and polishing. Many state-of-the-art machining centers have been added within the last five years, allowing UPI to offer manufacturing capabilities for intricate, accurate devices. Materials that are commonly processed are titanium, stainless steels (including the toughest of alloys), Cobalt-Chrome, Delrin, PEEK, UHMW, and aluminum. Highly accurate tolerances of 0.0005" can be achieved with live tooling, even on the most complex parts by UPI's operators.

Best Practices, Solutions

Because UPI seeks continuous improvement and tighter repeatability for its parts production, it is always searching for the best practices, tooling, and lubrication solutions. At the same time, it wants to be as environmentally responsible as possible – not only for their customers, but also for their workers, neighbors, and community. Like many other shops in the medical component market, the company had used black sulfurized-chlorinated oils, spike additives, and heavy-duty solubles to maximize tool life and achieve the best finishes. The choice of lubricant-coolant mix often depends on the exact machining process, tooling, and materials being cut. Where possible, John Zeitler, manufacturing manager, favored highpowered compounded oils to provide the maximum lubricity and extreme pressure (EP) effectiveness in order to extend tool life and reach the tightest tolerances with the smoothest finishes.

There are some severe limitations with older technology neat oils. These include dirtiness created on the machinery, nasty sulfur odors, misting, heat build up, foam with high fluid delivery rates, cleaning difficulties, and environmental issues raised by the disposal of chlorinated paraffins. Water solubles cannot deliver the EP punch and lubrication value, especially on titanium and certain grades of stainless, that oil can. This lubrication deficiency can result in lower tool life and more finishing steps in order to achieve bright surfaces. Because of these limitations, Zeitler sought a new technology lubricant that would eliminate the drawbacks of oil, upgrade the overall quality of his production, and save money by reducing tool changes.

'Code Blue' Solution

PICO Chemical, Chicago Heights, IL, recently developed PICOCUT CODE BLUE in response to customers' requests for a chlorine-free oil that could replace older technology products, but at the same time surpass their desire for longer tool life, higher production speeds, and improved finishes. PICO believed that a clear oil with an appealing distinctive color and low misting characteristics would offer machining companies in the medical industry a solution for productivity, satisfy machine operators, and produce positive financial results. Instead of using the older additives, PICO approached the issues by examining both the base oils and incorporating new technology synergistic additive systems without chlorinated paraffins.

CODE BLUE gives the oil great performance from the initial cut to the final operation.

According to PICO's chemists, CODE BLUE can operate over a wide range of temperatures because its EP and lubrication system kick-in during the entire gamut of metal-removal applications, giving the oil outstanding performance from the initial cut to the final CNC operation.

As long as the oil is filtered to remove the chips and fines, CODE BLUE's bath life is virtually unlimited because it is formulated to be protected from oxidation and to avoid selective additive depletion. CODE BLUE does not develop "Monday morning" odors, and needs no concentration checks, mixing, or fluid management services.

Precision's Advancements

According to UPI operational personnel, the results have been rather remarkable. After a year's use, CODE BLUE has replaced all older cutting oils and has exceeded their expectations by significantly increasing tool life cutting. According to Chris Kusnierek, UPI's quality manager, PICOCUT CODE BLUE has allowed UPI to achieve higher tolerances in a repeatable fashion, and in some cases reduce the need for further finishing steps such as polishing and buffing.

Machine operators report that they truly appreciate CODE BLUE's clarity for machine and part cleanliness. Its mild odor and pleasant blue color improve the work environment from the old black smelly sulfurized oils. Because it is chlorine free, PICOCUT CODE BLUE does not have undesirable cleaning, staining, and environmental issues often found in the older formulated "red" oils that were popular in the stainless machining industry.

As Zeitler states: "Using PICOCUT CODE BLUE wherever I can has saved us time and money by reducing tool usage and lowering maintenance expenses of downtime for tooling changes, concentration control, biological concerns, disposal costs, rusting issues, and excessive foam generation." UPI customers will often remark how bright the machined surfaces are that come directly from the CNCs.

Zeitler believes that job shops in the medical or high-precision machining business will call for CODE BLUE when they need to upgrade their lubrication requirements without introducing any negative environmental issues caused by chlorinated paraffins.

Older technology formulated cutting fluids for stainless steel, titanium, and highly-alloyed steels often required large quantities of chlorinated paraffins for their EP properties, or high soluble oil concentrations to achieve adequate lubrication. Chlorinated paraffins have serious drawbacks for environmental, cleaning, and corrosion issues. CODE BLUE has proven its value through improved tool life, better finishes, and overall lower operating costs. Its effectiveness is maximized in difficult and demanding applications such as those found in the medical device industry. For those cutting oil applications that require an oil used as a dual purpose machine oil without staining copper or brass alloys, PICO offers a modified version called PICOCUT CODE BLUE 2.