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About Rohde & Schwarz
At the Rohde & Schwarz plant in Teisnach, around 800 tonnes of aluminium are processed annually into high-performance products via machining, using over 80 machine tools. “Aluminium accounts for around 80 per cent of the material mix, which also includes copper, bronze, brass and, of course, steel,” reports Martin Ebner, a technologist in the machining department.
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 centres 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 odour was very unpleasant and, in some cases, there was 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 took place from summer 2014 onwards, before the suitable MWF was approved for series production in autumn 2015. The versatile, boron- and formaldehyde-free MWF NOVAMET 910 is used.
NOVAMET 910 is characterised 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 halve the MWF maintenance intervals on some of the systems and are returning the purified MWF to the overall process,” emphasises Ebner. “We are very satisfied with this.”
NOVAMET 910
NOVAMET 910 is ideal for machining operations such as turning, drilling and milling. The product offers impressive performance across a wide range of applications and materials, as well as low consumption. Furthermore, NOVAMET 910 is free from boric acid and formaldehyde.
Good material compatibility with aluminium, stainless steel and yellow metals
NOVAMET 910 is a water-miscible, versatile metalworking fluid for machining that is free from boron and formaldehyde. It is characterised in particular by its high performance across a wide range of applications and materials, as well as its low consumption.
It is equally compatible with aluminium, stainless steel and yellow metals. “Exactly what we need,” says Ebner.
Improvements in various machining operations
The concentration used at the Teisnach plant is between 7 and 9 per cent. 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 behaviour and significantly extended tool life, coupled with longer cleaning intervals, the odour disappeared almost entirely.
Occupational safety has also improved – thanks to the excellent skin compatibility of NOVAMET 910, which has a pH value of 9.4 at a concentration of five per cent. And there is one more thing that Martin Ebner, a process engineer in the machining department at Rohde & Schwarz, does not want to leave unmentioned: “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 these improvements have led to a strong relationship of trust between Rohde & Schwarz Teisnach and Oemeta and are a successful example of a strong partnership – exactly as envisaged by the philosophies of both companies. And so, at the Rohde & Schwarz plant in Teisnach, precision-engineered products for transmission systems, digital radio, DAB radio and critical infrastructure such as air traffic control can continue to contribute to secure communication. For example, to ensure holidaymakers’ flights land safely – “roger and over”.
The following improvements have been made:
- Improved surface finish and subsequent coating results
- Improved occupational safety thanks to the excellent skin compatibility of NOVAMET 910
- Cleaner machines and workpieces
- Better residue behaviour
- Significantly extended service life with correspondingly longer cleaning intervals
- No more odour
United Kingdom
