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July 22, 2023Advanced neat oils for productivity and cleaner work environment
The research and advancement of neat oils in high speed metal cutting application is aimed at achieving higher productivity and improved surface quality. Unlike water miscible cutting fluids which are typically designed to dissipate heat, neat oils are formulated to reduce frictional heat making it convenient for applications from light machining to heavy-duty operations.
While the use of conventional neat oils often poses challenges of retaining lubricity and certain safety hazards, synthetic based neat oils deliver twin advantage of better lubricity and higher flash points. Keeping these parameters in focus, Bechem’s advanced range of neat oils have been developed to cover complete spectrum of materials and metal cutting applications.
Below case studies demonstrate how advanced synthetic neat oils can positively affect tool life and process reliability.
Customer:
A multipurpose component manufacturer from southern part of India supplying wide range of components to leading automotive and medical industries and general engineering segments.
Customer was using mineral based neat oil of a reputed brand “X” with viscosity of 30cst (at 206˚ C) in their Sliding Head/Bar Feeder CNC machines of a reputed Japanese brand.
As the customer was facing several issues with the existing oil, BECHEM’s engineering team got the opportunity to conduct trials with two different components.
Trial of component 1
Component: Connectors
Material: Mild steel
Machining process: Parting, grooving, drilling and turning
Issues faced:
- High foam generation during normal operating conditions
- High consumption: High carry over of the existing oil with the machined chips and swarfs resulted in higher oil consumption
- Unhealthy work environment: Oil misting resulting in high smoke generation
BECHEM’s application team reviewed the operations and recommended a trial with Bechem’s synthetic based neat oil, “Berucut XC 1010”.
Trial observations with Berucut XC 1010:
- Reduction in foam generation during the trial period
- No fume formation: Oil mist was not observed during the entire span of operations
- Low consumption: Oil carry over reduced notably with less consumption of oil thereby extending relubrication intervals
- Improvement noted in surface finish of the component as well as in cleanliness of the machines.
10X increase in tool life with advanced neat oil, Berucut XC 1010
Trial of Component 2:
Component: Nuts for medical industry machineries.
Material: Stainless steel (SS 303)
Machining process: Parting, grooving, drilling, milling, tapping, boring.
Issues faced:
- Low tool life leading to higher production cost
- Extended operation cycle with low spindle speed.
Based on machining parameters, BECHEM’s engineering team proposed to conduct a trial with “Berucut XC 1010” a non-water miscible coolant developed for high speed machining processes.
Trial Observations with Berucut XC 1010:
- Operation time for each cycle reduced from 90 seconds to 43 seconds
- Spindle speed increased from 2000 to 4000 rpm
- Tool life extended remarkably across the production range. (data as per below)
|
Operations |
No. of components per insert with Brand ‘X’ |
No. of components per insert with Berucut XC 1010 |
% of increase |
|
Drilling |
15000 | 23945 |
60% |
|
Milling |
16000 | 16226 |
1% |
|
Tapping |
10000 | 10000 |
- |
|
Boring |
2000 | 9000 |
350% |
|
Grooving |
2000 | 14200 |
610% |
|
Parting |
2000 | 5382 |
169% |
Why Berucut XC 1010?
Berucut XC 1010, a non-water miscible oil fully based on synthetic fluids for superior performance and high-speed machining processes.
- Single product to meet entire machining needs with zero foaming issues
- Longer tool life: Fortified with excellent extreme pressure and anti-wear additives, ensures longer tool life
- Safer work place: Developed with synthetic base oil and free from unsaturated hydrocarbons and other aromatic agents, ensures an oil mist-free environment
- Low consumption: Low carry over characteristics and low evaporation tendency ensures minimal consumption and hence cost effective
- Better surface finish and cleaner machines : Berucut XC 1010 with optimal viscosity (13 cst at 185 ˚C) and low stickiness ensures cleaner machines. Also, high surface-finish and dimensional accuracy of the finished product can be achieved.
Result
Having evidenced the results of Berucut XC 1010 to optimize production process and with the clear possibility of achieving substantial reduction in production cost the satisfied customer shifted over to “Berucut XC 1010”.
For more details on Bechem’s neat oil range, write to us at [email protected]
Support response: Median email response time of less than 3 hours.
