Durasol AS GRS
Case Study
A supplier of Aero & Turbine blades to the all the major companies within the aerospace and power generation sector has revolutionised their production process by manufacturing their blades utilising Durasol AS - GRS With high speed twin wheel grinding of Inconel and Titanium product performance is key to this highly sensitive market place:
Background
Due to ongoing growth with its manufacturing partners such as Rolls Royce this blade manufacturer had utilised an “approved” fully synthetic grinding fluid on its twin-wheel creep feed grinding application and the Rolls Royce developed viper grinding. Originally developed by Rolls Royce for safety-critical components in aero -engines, VIPER is a 5-axis high-speed grinding machine capable of machining some of the toughest materials, including nickel-based Super alloys. Due to this growth, this state-of-the-art manufacturer believed they needed more from their fluid to support their continued growth.
Teklube TS was approached for its expertise and in-house chemists to help formulate a state of the art high performance grinding fluid to meet Rolls Royce specifications RPS917 and RRP 59000. The Durasol AS – GRS was then validated for the manufacture of safety-critical components:
Reduced consumption by over 50%, through improved product stability and performance. (Please see table)
Increased feeds and speeds to improve production yields
Reduced tool and consumable spend by over £100,000 per annum. (Reduced metalworking fluid and Grinding Wheel usage)
Improved the operators’ environment by removal of odours and mists from grinding operation.
Reduced their environmental impact through a reduction in machine cleanout and product disposal.
Durasol AS–GRS Details
A next-generation fully synthetic grinding and cutting fluid designed for high-speed grinding of aero blades, vanes and seal segments to Rolls Royce standard RPS 917, RRP 59000.
Durasol AS-GRS is a fully synthetic water-mix cutting and grinding fluid that forms a true solution when diluted with water. Durasol AS-GRS provides superior cooling and flushing characteristics. Durasol ASGRS provides excellent corrosion protection whilst minimising the build-up of ‘sticky’ residues.
Typical Physical Properties
Appearance: Yellow / Liquid
Odour: Bland
Emulsion Appearance: True Solution
pH: (5% dilution) 9.3 (typ)
IP 287 Corrosion Break Point, % Volume: 2.5 (typ)
Reichert Lubricity Characteristics (10% Dilution)
Noise Reduction: 10 metres
Load Bearing Capacity (Kg/mm2): 1.950
Refractometer Correction Factor: 2.1