Can smoke formation be eliminated while machining with neat oils?

BECHEM’s range of high-performance neat cutting oils, based on synthetic technology have been developed for a wide range of demanding metal cutting applications. The Berucut XC series of neat oils by BECHEM possess high flashpoints, low evaporation rates, better lubricity and good air release characteristics.

An interesting short case study in this regard based on actual user trial demonstrates the advantages on the parameters of work environment, tool life and oil consumption with Berucut XC 1115.

Customer: A reputed global supplier of automotive components in the field of steering and suspension systems.

Component: Torsion bar

Material: ‘Spring steel’

Machine: High speed sliding head bar feeder machine
Tools: Coated carbide tool

Machining process: Turning, grooving and parting

Customer was using neat metal cutting fluid from a popular brand ‘I’ with viscosity of 32 cSt (at 40 ˚C).

Issues faced:

• High smoke generation during normal operating conditions leading to unhealthy work environment
• Low tool life and frequent tool changes leading to high production downtime
• Oil consumption observed to be on the higher side
• At high speeds, heavy smoke generation was observed, consequently, the machine was run at lower rpm’s leading to underutilization of the machine and sub optimal productivity

BECHEM’s application engineering team studied the issue in detail and identified the definite causes:

• The neat cutting oil from brand ‘I’ that was in use, was typical conventional neat oil developed on mineral base. Accordingly, as per their characteristic, these oils tend to contain higher number of unsaturated hydrocarbons in the form of aromatic compounds, leading to high smoke emission
• Also, the conventional neat oil from brand ‘I’ used was of a higher viscosity (32 Cst). The high viscosity of oil caused low dissipation of heat, leading to significant rise in temperature, tool heat up and higher emission
• The neat oil was observed to have lower lubricity leading to high friction and frequent tool wear

High carry over losses (due to high viscosity and stickiness of oil along with evaporation losses

Based on the machining parameters and above observations, BECHEM’s application engineering team recommended Berucut XC 1115, a fully synthetic based neat oil for superior performance.

• Based on fully synthetic base oil technology, Berucut XC 1115 is free from unsaturated hydrocarbons and other impurities for almost emission free machining experience
• Berucut XC 1115 has optimal viscosity (14 cst at 40 ˚C) required for machining process. Excellent air release characteristics of Berucut XC 1115 ensures better cooling performance at the operating zone thereby extending tool life
• Low evaporation tendency and low carry over property ensures minimal consumption and therefore cost effective
• Berucut XC 1115 provides excellent lubricity and further reduces tool wear due to advanced EP and anti-wear additives
• Very low PAH (polycyclic aromatic hydrocarbons) levels makes Berucut XC 1115 a safer option for operators

1. Smoke generation reduced by more than 80%
2. Tool life increased up to 64%
3. As an outcome of low carry over rate and lower emission, neat oil consumption reduced by 50%

*For details of the insert and other trial details, drop in a mail at [email protected]

Extrapolating the data recorded during the trial period of 30 days, it was further analysed that the machine uptime period could be increased by 89 hours/machine per annum.

Having observed performance of the product to combat the plaguing issues effectively and further optimize production process, the customer switched over to “Berucut XC 1115” completely.

Berucut XC 1010 is a non-water miscible coolant based on synthetic fluids developed for difficult machining processes. The high-performance cutting fluid based on advanced formulation is recommended for demanding and high-speed machining processes while ensuring longer tool life.

The special cutting fluid has low evaporation tendency and high flash point enabling higher safety quotient and better work environment.  Berucut XC 1010 ensures low consumption for machining processes and also provides good corrosion protection. Recommended for machining steel and cast iron.

Recommended for turning, drilling, milling, thread cutting, tooth grinding, thread forming operations etc.