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About Rohde & Schwarz
At the Rohde & Schwarz plant in Teisnach, approximately 800 tons of aluminum are processed annually into high-performance products through machining using over 80 machine tools. “Aluminum accounts for about 80 percent of the material mix, which also includes copper, bronze, brass, and, of course, steel,” reports Martin Ebner, a machining technologist.
High-frequency technology, in particular, places the highest demands on precision. Here, tolerances of +/- 2 µm must be maintained. The 3- and 5-axis machining centers mill, turn, drill, ream, and cut threads. The volume of material removed is often substantial for workpieces that are clamped as blocks and frequently emerge from the machine as delicate lattice structures.
The Challenge
At Rohde & Schwarz, housings, half-shells, shafts, frames, and connectors for high-performance products are manufactured with a high degree of vertical integration.
The situation at the site in the Bavarian Forest is particularly unique, and the processes following machining place high demands on the metalworking fluid. The water is very soft, which results in significant foaming. “With the previous product, we had to use a lot of defoamer,” recalls Martin Ebner of Rohde & Schwarz. “Furthermore, the odor was very unpleasant, and in some cases, it caused skin irritation. Overall, the performance was unsatisfactory. And consumption was also excessively high.”
NOVAMET 910 was approved following an extensive testing phase
Oemeta was selected as the partner for lubrication and the supply of the appropriate MWF. Extensive testing began in the summer of 2014, and the suitable MWF was approved for series production in the fall of 2015. The versatile, boron- and formaldehyde-free metalworking fluid NOVAMET 910 is used.
NOVAMET 910 is characterized by exceptionally high performance across a wide range of applications and materials, low consumption, high stability, and long tool life. “We have been able to reduce the MWF maintenance intervals on the systems by up to half in some cases and are returning the purified MWF to the overall process,” emphasizes Ebner. “We are already very satisfied with this.”
NOVAMET 910
NOVAMET 910 is ideal for machining applications such as turning, drilling, and milling. The product delivers outstanding performance across a wide range of applications and materials, while offering low consumption. Additionally, NOVAMET 910 is free of boric acid and formaldehyde.
Good material compatibility with aluminum, stainless steel, and yellow metals
NOVAMET 910 is a water-miscible, versatile metalworking fluid for machining that is free of boron and formaldehyde. It is characterized in particular by high performance across a wide range of applications and materials, as well as low consumption.
It is equally compatible with aluminum, stainless steel, and yellow metals. “Exactly what we need,” says Ebner.
Improvements in various machining operations
The concentration used at the Teisnach plant ranges from 7% to 9%. The individually filled machines are replenished via a central supply system. The improvements were not only striking in the machining processes. In addition to better residue control and significantly extended tool life—coupled with longer cleaning intervals—the odor disappeared almost entirely.
Workplace safety has also improved—thanks to the excellent skin compatibility of NOVAMET 910, which has a pH of 9.4 at a five percent concentration. And there’s one more thing Martin Ebner, a manufacturing technologist in the machining department at Rohde & Schwarz, doesn’t want to leave out: “Our machines and workpieces are much cleaner than they used to be.” This is due to the high cleaning and rinsing power of NOVAMET 910.
All of these improvements have fostered a strong relationship of trust between Rohde & Schwarz Teisnach and Oemeta and serve as a successful example of a strong partnership—just as the philosophies of both companies envision. And so, at the Rohde & Schwarz plant in Teisnach, precision-engineered products for broadcast systems, digital radio, DAB radio, and critical infrastructure such as air traffic continue to contribute to secure communication. For example, to bring vacationers safely back down to earth—“roger and over.”
The following improvements have been made:
- Improved surface finish and subsequent coating results
- Improved occupational safety due to the excellent skin compatibility of NOVAMET 910
- Cleaner machines and workpieces
- Better residue behavior
- Significantly extended service life with correspondingly longer cleaning intervals
- No more odor
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