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Metalworking fluid ideal for Cosworth machine shop

Edited by the Engineeringtalk editorial team Dec 14, 2000

For Cosworth Racing's machine shop, Shell recommended Sitala E5202, a high oil content water extendible metalworking fluid formulated for the machining of high magnesium content aluminium alloys

Shell's on-going rationalisation of coolant usage for Cosworth Racing paid dividends for the company's busy machine shop.

Cosworth Racing, part of the Ford-owned Cosworth group, is a world leader in race engine manufacturing with experience spanning over four decades.

The company has established an enviable reputation for the design and precision engineering of high-performance race, rally and road car engines and builds a greater variety of racing engines than any other manufacturer.

In the current season the company will supply engines to the Jaguar Racing Formula One team, ten cars competing in the North American Champ CART Championship, the World Rally Championship and the all-American NASCAR series.

Cosworth Racing engines are manufactured at the company's Northampton factory, where the machine shop has a staff of 350 highly skilled operators and accommodates around a hundred machine tools.

These include twenty-five CNC machining centres, twelve CNC lathes, three CNC grinders and a range of lathes, drilling machines, grinders and borers.

Work is concentrated on the production of a variety of engine components in a wide range of materials.

Heads, blocks and pistons are machined from aluminium, covers and other components in magnesium, cranks, cams and valves in steel, con rods in titanium and steel, and some parts in cast iron.

The development and production of motor racing engines is a continuous process so the machine shop needs to be able to respond quickly to new designs and design changes at any time throughout the season; so every aspect of the operation has to give maximum performance.

This, says maintenance engineer Brian Watts, is why Cosworth Racing rely on Shell's coolant monitoring service and why Shell also provide all the company's cutting oils, fluids and lube oils.

Part of the monitoring service has also involved the two companies working together to rationalise oil and fluid usage to minimise the number of different products used and stocked.

The magnesium machining operation, which typically uses alloys up to 93%, had experienced some problems with staining of components and poor coolant life, and was one of the first areas to be investigated.

Says Brian Watts: "Magnesium causes the coolant to separate; and the remaining water was leaving stains on the components.

Also, because we weren 't machining with magnesium all the time, we needed a coolant that would work effectively with other materials." After conducting machine trials, Shell recommended their Sitala E5202, a high oil content water extendible metalworking fluid specifically formulated for the machining of high magnesium content aluminium alloys.

Sitala is suitable for all metal removal operations on aluminium and magnesium aluminium alloys.

Its properties include very low staining and foaming and it contains an effective biocide to increase fluid life.

Brian says they are very pleased with the change to Sitala and quotes impressive improvements in coolant life.

"In 1,500 litre sumps coolant life has been increased six-fold." He says: "And in 120 litre sumps we have seen a ten-fold increase!" Brian concludes by saying that coolant management is a difficult area to deal with, but with Shell fluids and their Total Fluid Management programme, it's one he no longer has to worry about.