Grinding Machine Protection

Company Name: Q8Oils

Location: Leeds, UK

Eclipse Product Installed: MicroMag MM20

Industry: Oils, Lubricants and Single Supply Solutions

Process Type: Steel and Cast Iron Grinding

Application Background

Offering a range of products, services, and solutions that increase the profitability and sustainability of businesses around the globe, Q8Oils are not only one of the leading brands names for oils and lubricants, but also a provider of single supply solutions for a variety of applications in the Automotive, Energy, Metalworking and General Industry market segments.

The Challenge

Working with their client, Twiflex, Q8Oils were looking for effective improvements to their metalworking filtration needs. Twiflex designs and manufactures advanced braking technologies for industrial applications. As a global leader in their field, it is imperative to the business that the finished products, such as their industrial brake discs, are manufactured to the highest possible standard.

Whilst their current process was working sufficiently, Twiflex was exploring new methods to improve the productivity of their grinding machine that grind both cast iron and steel. Whilst other filtration methods, such as paper filters, can offer an effective barrier against larger particles, they can allow for smaller ferrous particles to pass through with the fluids which can lead to a significant reduction in tool life expectancy.

The Solution

Q8Oils regularly install Eclipse Magnetics products to a number of their customers' metalworking tools as part of their equipment solution services and, through partnering with expert filtration suppliers, can offer advice and support to address metalworking cleanliness issues, particularly to those with high-precision needs.

In addition to the use of their Berlioz XRS synthetic grinding fluid, Q8 installed an Eclipse Magnetics MicroMag MM20 in-line, prior to fluid delivery, to bolster the filtration system of Twiflix’s grinding machine. With its high-intensity magnetic core and patented fluid flow path, the MicroMag captures almost 100% of ferrous contamination from metalworking fluids, providing one of the most effective filtration methods on the market. The range also boasts a compact and easy-clean design with a high-capacity collection that doesn’t block the throughflow, nor does it impact the pressure or flow of the fluids.

Having had the MM20 installed for one month, with intermittent usage, the filter had caught over 2kg of ferrous materials when removed for cleaning. Q8Oils has also reported that Twiflex has seen a substantial improvement to the grinding stone life, with the grinding wheel dressing time reduced. An improvement in fluid cleanliness was also noted that in-turn had prevented the ‘flecking’ effect caused by fine debris caught between the wheel and the workpiece during the grinding process.

The MM20 will maintain its effectiveness throughout the duration of the tool’s lifespan without losing intensity. Plus, with no need to replace filters or other consumables, as well as a reduction in scrap and reject rate, the MicroMag offers an impressively quick return on investment.

Comment

A Maintenance and Service Engineer for Twiflex said, “We tried the Eclipse magnetic filter on a demo for a month on our surface grinding machine and found it to be so effective that we decided to purchase it. We can see a difference with tool life and coolant life is much longer. This machine doesn’t have any other filters on it so we can really see the benefits.”

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