Delcam Professional Services

Delcam know the benefits  of the Wogaard Coolant Saver

Although Delcam is renowned for its advanced CAD/CAM software, the company has always operated an extremely well equipped machine shop. Here, the latest CNC machine tools are pushed to their limits, providing an opportunity to test software developments and machine actual components for customers around the world. All of the machining centres are fitted with  Wogaard Coolant Savers, a simple but effective way of reducing machining costs and improving efficiency.

Delcam’s recently refurbished and updated machine shop forms part of Delcam Professional Services (DPS), a division of the company that employs around 25 staff providing intellectual services such as consulting and customer software engineering services, as well as physical support from its machining services. DPS was established in early 2011 as an individual business centre, run as a separate company within the Delcam group. It supports a global network, with a small technical team in North America as well as a sales and technical presence. There is also a team in Singapore, covering Asia, as well as technical service groups in Europe, with China being added soon.
 
With a reputation for delivering class-leading support to companies across the globe it is no surprise that DPS, and particularly the machine shop, is extremely busy. A mix of low-volume prototype work has to be managed alongside ongoing medium-volume contract machining projects. Nick Hill, Operations Manager, says: “Our only real problem is finding skilled people, specifically machine operators. So, any opportunity to increase the effective working efficiency of the resources we have has to be considered fully, which is exactly what we did with the Wogaard Coolant Saver.”

The Wogaard Coolant Saver collects cutting fluid from the chip/swarf container and returns it to the CNC-machine’s main reservoir for reuse. On CNC machines equipped with automatic chip conveyors significant savings can be achieved by installing this simple but effect solution. Powered by the machine’s coolant pump, no external energy-source is required.
 
Production Supervisor, Scott Greenway, organised the fitting of the first Coolant Saver. He recalls: “On paper it was an absolute no-brainer, the fact that we would not need to drain off the swarf bins every time we emptied them would just save so much time.”
 
In terms of connecting, the Coolant Saver is very straightforward. Scott Greenway says: “It was done on the spot with only a small amount of assistance to connect the unit; it literally took just half an hour to fit.” The first Coolant Saver was fitted to the company’s Mazak Variaxis 630 5-axis machining centre, the filter head was located in the bottom of the swarf bin and, every time the machine’s coolant pump turned on, the unit siphoned any coolant that has been dragged out into the swarf bin and returns it to the coolant tank.

Although Delcam did not consider or calculate the actual coolant savings achievable in its decision to purchase the Coolant Saver, these have turned out to be significant. “If I was to hazard a guess as to how much coolant we would drain off if we had not fitted the Coolant Saver, I would say it is probably in the region of 25 litres for every full swarf bin, and they are full after a few days. Obviously it is diluted, at the recommended concentration of 8 per cent, so we were saving around £60/100 of coolant per month on just one machine,” Nick Hill explains.
 
And, it is not just the cost of replacing the coolant. There is also a significant cost attached to the correct removal and disposal of any discarded oils and coolant. By retrieving the coolant from the swarf bin, Delcam has also noted a marked improvement in its housekeeping, as the chances of spilling coolant or of it seeping out are reduced. 

Following the success of the trial DPS has purchased further Wogaard Coolant Savers, to fit to its other machines, which included a Huron KX 200, a Hermle C50U MT and a new Huron VX12. However, the second machine on the Coolant Saver list was a DMG DMU160 P, a large 5-axis machining centre that runs around-the-clock, seven days a week.

Nick Hall says: “The second Coolant Saver was fitted after we had spoken to Wogaard’s . We needed some guidance before fitting it to the machine, I know it is only a half hour job, it’s just finding that half hour in a busy day, which is every day. The potential for environmental pollution problems was too great for us not to install it across all machines, and the Wogaard Coolant Saver, while not being the only system/solution in place to prevent environmental problems, does form part of the complete ‘system’. With most machines you should get the cost of the purchase back in savings within no time at all. And, it also stops bad odours coming from the swarf bins.”
 
Director of Sales of Wogaard, Jason Hutt, says: “The Wogaard Coolant Saver is a much more cost-effective solution than the existing methods of reclaiming coolant/oil from chips such as swarf spinning centrifuges. Customers that buy the Wogaard Coolant Saver automatically get a 30 day money-back guarantee. If they are not happy with the results, they can simply return the product within 30 days of the delivery date, and a full refund will be issued, no questions asked.”

​Phil Avis concludes: “Installation is simple, especially after you have done one. Since we have had them fitted, not only are the operators happy with the results, but it will also have a major impact on our environment, especially as we pursue ISO 14001 accreditation. We want to get everything in place before we call the auditors in, and with this project allowing dragged out coolant to be effectively pumped straight back into the machines, it is a win-win situation.”  ​​​