Bulletproof savings for security manufacturer
Overview
Impact Security, LLC, manufactures some of the toughest products in the property protection industry. DefenseLite®, their premier security glazing overlay product is comprised of a polycarbonate shield within an extruded aluminum frame.
Problem
Each DefenseLite® frame requires twelve to eighteen holes. Impact hoped to improve their manufacturing process with a coolant misting system. Instead they experienced issues with unacceptable tool life and poor cut quality requiring a time-consuming secondary cleaning process.
Solution
Unhappy with their current process, Impact Security reached out to Unist for help. Unlike their previous misting system, Unist’s recommended Minimum Quantity Lubrication system allows fluid to sufficiently lubricate the cutting edge. With a better grasp of MQL, Impact trialed Unist’s® Coolubricator JRTM.
Configured for drilling 1/4” - 1/2” diameter holes through 6061 T6 aluminum, Impact determined their optimal settings to be drilling at 3500 rpm, using Unist’s Coolube® 2210 AL lubricant dispensed at the Coolubricator JR’sTM factory settings.
Results
18 months after installation, Impact Security has been thoroughly impressed with the Coolubricator JR’sTM and Coolube® 2210 AL’s performance. The improved cut quality
virtually eliminates all material remnant, drastically reducing reaming and post cleaning processes. New found time savings amount to increased production of 20% per day!
Beyond extending tool life, Impact notes considerable fluid cost savings. Drilling 10,800 holes per shift, they use less than 1 pint of fluid per machine each month.