Metal shaving is a finishing operation in which burrs from the cut edges are sheared off in order to make the edges smooth and also impart dimensional accuracy. Shaving operation is typically preceded by punching, piercing or other stamping operations that further require close dimensional tolerances.
An effective lubricant will help in component finish and can also impact die life. Below case study demonstrates benefits of using a high performance lubricant over a conventional oil in an actual use case scenario.
Customer: A leading manufacturer of precision stamping parts for commercial vehicles, agricultural machinery and construction equipment. With more than 100 stamping machines of varying capacities, the company specializes in manufacturing brake part assemblies, chassis structures and blocks.
Component : Brake-pad body
Material : Steel and mild steel
Thickness : 2-7 mm
Operation : Shaving
Customer was using a regular blanking oil with viscosity of 50 Cst at 40˚C.
The Operations team listed the below aspects as ‘improvement parameters’ against which performance of any trial lubricant would be measured,
After analyzing the operation parameters and considering the expectations put forward, the BECHEM team recommended the high-performance cold forming oil, Beruform MF 155C.
The team identified, two 150 ton punching presses to conduct trials, one with single shaving and the other with double shaving operation.
Based on the success of a pilot lot, a rigorous 24-hour trial was carried out to evaluate the performance parameters.
Post witnessing the exceptional performance with Beruform MF 155 C, the customer extended the trial for the next couple of months. It was observed that die life improved by 20% in comparison to the earlier blanking oil. Additionally, reduction in rejection rates and overall positive impact on production process was witnessed during this period. Consequently, the customer established Beruform MF 155 C as their ‘go-to’ forming oil for their processes.
For further details of the product, comparison chart and trial samples, write to us at [email protected]
Support response: Median email response time of less than 3 hours.
Performance Case study of special forming oil, Beruform MF 155 C in metal shaving operation and positive impact on rejection rates. Metal shaving is a finishing operation in which burrs…
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]]>Metal forging is the process by which metals are formed and shaped using compressive forces. Depending on temperature of the metal being worked upon, the process is classified into cold, warm and hot forging. Many automotive parts are forged due to unique advantages which include increased strength, different size/shape and mass production.
A typical forging press involves the moving vertical ram, die casts, bolster plate, ejector and frame. The vertical rams apply gradual and controlled pressure to the die holding a heated metal workpiece, causing it to take the shape of the die cavity. Due to the extreme pressure and shock loads involved in the process, the type and quality of lubricant used affects performance of these ram-based vertical presses.
Incorrect lubricant selection and inconsistent lubrication can reduce bearing life and lead to performance issues, including:
The application requires special lubrication requirements. BECHEM provides best in class, special greases for forging presses with the following advantages:
Customer: A leading automotive components manufacturer in the world supplying a wide range of automotive components (such as distributor, gibs, connecting rod, brake and clutch journal etc), catering to both domestic and international markets.
The customer was using an extreme pressure grease of a popular brand “X” which was applied through pneumatic lubrication pump. The ‘On’ time for the pump was set 50 seconds.
The hot forging machine with a capacity of 2500, Tons has in-built temperature sensors, a modern grease pump and distribution system in place.
By considering the operational parameters and challenges, the BECHEM Application Engineering team recommended the high-performance grease “BECHEM Premium” for a trial.
Trial period : 60 days
Observing the efficiency of ‘BECHEM Premium’ in optimizing production processes and minimizing maintenance costs during the trial, the customer switched over to BECHEM Premium for the rest of the presses.
*** pitting: Damage that is caused by the entry of foreign materials like dirt or other metal particles.
** EMCOR test evaluates the effectiveness of grease in preventing corrosion in roller bearings operating in water, saline water, and sodium chloride solution.
For more details on BECHEM Premium sample of the product, write to us at [email protected]
Support response: Median email response time of less than 3 hours.
Performance Case study of special forming oil, Beruform MF 155 C in metal shaving operation and positive impact on rejection rates. Metal shaving is a finishing operation in which burrs…
Metal forging is the process by which metals are formed and shaped using compressive forces. Depending on temperature of the metal being worked upon, the process is classified into cold,…
Anti-friction coatings also known as solid-film or dry-film lubricants are recommended for applications where extreme operating conditions of very high or low temperatures and significantly high pressures are prevalent. Within…
Auto manufacturers have effectively been able to address the issues of design, energy efficiency, user comfort, aesthetic appeal, engineering flexibility and durability in interior cabins of the car by use…
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]]>Anti-friction coatings also known as solid-film or dry-film lubricants are recommended for applications where extreme operating conditions of very high or low temperatures and significantly high pressures are prevalent.
Within the automotive industry, anti-friction coatings are widely used in various safety critical components and applications that require life time lubrication such as piston skirt coatings, cylinder head gaskets, exhaust gaskets, latch, pole claw, sliding components in steering column, door handles etc.
The ‘metal exhaust gasket’ is a key engine component that is used to seal the gap between engine exhaust port and exhaust manifold. The gasket is coated with dry film lubricant to withstand high operating temperatures and provide resistance against fretting corrosion due to high vibration encountered while the engine is in operation. Additionally, the coating also protects the typical stainless-steel material used against corrosion.
Ineffective dry film lubrication on the gasket may cause,
These factors may ultimately affect efficiency of engine and performance of the vehicles.
Customer: Reputed Indian manufacturer of automotive and industrial gaskets with processes conforming to the latest quality standards of ISO and IATF 16949. The auto-component manufacturer with presence across automotive segments supplies to both domestic and global OEM’s.
Products manufactured: Cylinder head gaskets, exhaust manifold gaskets, coated steel gaskets, heat shields etc.
Customer was currently using anti- friction coating of a well-known brand. The Engineering team was on the lookout for an alternative dry film lubricant that can provide better performance in terms of fretting resistance, adhesion, long term performance and anti-corrosion properties.
Operational requirements for dry film lubrication
Considering the operational parameters, BECHEM’s Application Engineering team recommended Berucoat AF 291.
BECHEM’S Berucoat AF 291 is an advanced heat-cured, bonded coating that protects frictional surfaces from wear even when exposed to the environments of oil, grease, solvents and dust.
To compare performance of the two dry film lubricants in contention, the BECHEM team recommended the SRV test of Berucoat AF 291 with the existing product, M.
The SRV test measures the physical interactions between a lubricant and two specimens in a loaded contact in either linear or oscillatory motion. The objective is to understand the lubricating effect of the anti-friction coating under actual operating conditions of repetitive high frequency oscillation of the frictional surfaces.
SRV Test procedure:
Translatory oscillation test rig (SRV) at BECHEM HQ, Hagen
Test Result:
In case of Brand “M”, increase in friction, welding of ring and disc as contacting specimen occurred in 34 seconds. In case of Berucoat AF 291, the increase in friction and welding of contact specimen occurred after 2 minutes 35 seconds. An improvement of almost 5 times with Berucoat AF 291.
*Graph replicated for actual test data points autogenerated by the SRV Machine
To further confirm the performance of Berucoat AF 291, two additional tests were conducted in-house by the Customer.
The scratch test is an established method in material testing used to check adhesive and cohesive strengths of paints coatings. The cross-cut test method determines the resistance of paints and coatings to separation from substrates by utilizing a tool to cut a right-angle lattice pattern into the coating, penetrating all the way to the substrate.
Surface preparation and coating procedure strength of coating::
| Cleaning | Before coating it is very important that surface should be fully cleaned of oil and dust traces as it may affect the adhesion of coating |
| The gaskets are cleaned by vapour de-greasing method | |
| Preparation of the coating | 1 parts of coating mixed with 1.5 part of thinner. (Coating is mixed with thinner in the ratio 1:1.5) |
| The coating is applied with spray gun to achieve the DFT (dry film thickness) between 8 to 15 microns | |
| Curing | Gaskets are left for ‘dry to touch’ for 5 minutes |
| Subsequently coated gaskets are placed in the oven for 15 minutes at 200 ˚ C for further curing. | |
| After curing, gaskets are drawn out at room temperature and coated on the other side following the same procedure |
Scratch test to compare adhesiveness
Scratch test result: No peeling of film was observed
Endurance testing also known as engine testing, is conducted usually to determine if the system can sustain the continuous expected load in actual operating conditions. The inhouse endurance test involved the coated gasket to be mounted on ‘an actual engine for 5, 60 and 500 hours consecutively’ testing out different load conditions.
Test Result: The Customer was satisfied with the ‘endurance test performance’ of Berucoat AF 291
Spread Area: Berucoat AF 219 Vs. Brand M
Further analysis of both the dry films established that Berucoat provides better film spread as compared to Brand M’s coating.
| Product | % of Solid Volume (VS) | DFT (micron) | TSR
(Sq. m) |
% Wastage | Actual Spread Area (m) | Difference in ASR (m) | % Difference in ASR |
| Berucoat AF 291 | 35 | 10 | 35.00 | 40 | 21 | 3 | 17 |
| Brand “M” | 30 | 10 | 30.00 | 40 | 18 |
TSR (Theoretical spread rate) = %VS*10/DFT
DFT = Dry film thickness
ASR = Actual Spread Area
Wastage constant as the same specimen was considered
Factoring the better spread rate and price economics, the cost benefit analysis established a savings of approximately 25% as well as better performance (5 Times) with Berucoat AF 291 against coating M.
Having observed performance of the product and test results, the customer was convinced and switched over to Berucoat AF 291.
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]]>Auto manufacturers have effectively been able to address the issues of design, energy efficiency, user comfort, aesthetic appeal, engineering flexibility and durability in interior cabins of the car by use of composite plastics. However, these composite plastics developed and manufactured by advanced technologies are no exception to the laws of friction. Frictional dynamics are unique and complex and need to be resolved by speciality lubricants. In automotive interiors, composite plastic materials are a combination of definite polymer matrix with special additives and reinforcements like glass fibers or plastic material in combination with PC + ABS etc. These composites are used in various cabin components such as HVAC unit, seat recliner and adjustment mechanism, gear shift mechanism, cup, ashtray holder, door handle mechanism etc
The demand on the lubricant is extraordinary in automobile interiors. Most of the components need to function in all extreme environmental conditions and until the lifetime of the car. Temperature build up due to friction is an undesired phenomenon. At high temperatures, plastic composites tend to diffuse and lose their inherent characteristics by borrowing or combining with ingredients of contacting surface or lubricating medium. Migration of the lubricant molecules inside the plastic composite result in swelling and softening of the plastic material. Alternatively, the polymer ingredients can diffuse into the lubricant structure, resulting in shrinkage and hardening of the polymer. Hence material compatibility of plastic parts lubrication is of paramount importance.
Stick slip is a special lubrication challenge in plastic parts where the force required to slide or roll plastic parts is not uniform. In the absence of a right lubricant this would result in an unpleasant feel of operation for the car user.
Undesirable squeaks and rattles caused by vibration in operational conditions is a common problem faced by auto and component manufacturers. The degree of noise dampening is influenced by selecting a lubricant that combines the appropriate base oil viscosity and thickener system to create the desired shear resistance, reduce stick slip and the resulting noise.
Lubricants used in the interior cabin need to work under considerable loads within a temperature range of 90 C. The grease has to be very soft and buttery in composition to ensure smooth operation. It should also be stable and not have excessive oil separation with no unpleasant odour. Oil bleeding is particularly tricky since it may cause spillage onto the driver’s hands or dress or even the expensive seat fabric.
BECHEM’s synthetic PAO and Lithium thickened greases with PTFE additives for plastic parts are soft, buttery and odourless and also provide excellent ant-wear and anti-stick slip properties. With low oil separation even at high temperatures and noise dampening properties, BECHEM lubricants are compatible with all kinds of composite plastics and provide outstanding performance for period often exceeding the life time of the component.
To avoid migration of molecules between the contacting surface and the lubricant BECHEM’s speciality grease with synthetic base oils possess narrow molecular weight distribution. This ensures low interaction with polymers. High base oil viscosity would ensure lower diffusion rates and hence better compatibility.
BECHEM’s state of the art R&D lab equipped with the latest testing installations employs both sophisticated in-house and internationally established test procedures to find the best compatible lubricant. Behavior of the lubricant and plastic composite is observed for swelling, tensi le strength, elongation and compression strain at stimulated test conditions that imitate the harshest of driving conditions.
Working closely with top auto and manufacturers worldwide, BECHEM has developed intelligent tailor made lubricants that suit their applications seamlessly.
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]]>Driving during a heavy downpour without being able to regulate the wiper can be a hazard. The wiper is one of the many applications where the electrical switch plays a crucial role as a control device. From the window regulator to the critical ignition start mechanism, modern day cars possess numerous mechatronic components that are controlled and regulated by switches. Switches internally contain fixed and movable surfaces made up of copper, silver, gold and tin plated metals for regulating the flow of current. Contacting surfaces means friction, resulting in heat generation and surface wear. Over a period of time, this would finally lead to failure of then switch itself.
Contacting surfaces in switches are either finger sliding or button type. Automotive switches carry current from the order of a few milliamps to 60 Amps and beyond depending on the intended use of the switch. Housing of these contacts is made of special engineering plastics which are sensitive to lubricants. The electrical contact in the switch has to be protected against corrosion, silver sulphurisation and sliding wear. Most importantly, it should be noiseless and provide a smooth operating experience to the user. The need is for a special lubricant that can withstand the flow of current and harsh operating conditions inside a switch with minimum presence for a very long time.
Automotive switches need to operate in diverse environmental conditions. Be it burning hot terrain or cold freezing atmosphere, the switch needs to function seamlessly. Correspondingly, the lubricant too needs to have a wide operating temperature range . Since intermittent re-lubrication of automotive switches is impossible, the lubricant needs to maintain its composition until the lifetime of the auto component. With an ability to form a thin and an everlasting strong lubrication film which helps in increasing the area of contact, BECHEM contact lubricants improve efficiency of the system.
Electric arc formation in switches is a common phenomenon that generates heat and thermally decomposes contacting surfaces. Ionization of surrounding air and rise in temperature between contacting surfaces causes metal transfer resulting in the formation of new ‘peaks and troughs’. Lubricated surfaces generally restrict arc formation. However, lubricants unable to withstand high temperatures oxidize gradually leaving dry powdery residues. This results in increased contact resistance and further increase in temperature.
An outcome of the sustained wear and degradation of the plated contacting surfaces is drop in voltage. Performance of the lubricant has a direct impact on the voltage drop and consequently on performance of the automotive component.
BECHEM’s lubricants for electrical and mechatronic components are silicon free and have the ability to perform within wide operating temperature range (-40 C to +140 C). These intelligent lubricants, formulated with special low viscosity synthetic oil and organic polymer thickeners, protect contacting surfaces by providing excellent compatibility with engineering plastics and also possess excellent noise dampening properties.
BECHEM’s lubricants for switches are tested exhaustively for over 50,000 cycles (On/off cycle) equivalent to 7 to 10 years of life of the switch under various simulated driving conditions. Working closely with top auto and component manufactures, BECHEM has developed intelligent lubricants that suit their applications and systems. When you need your electrical switches to work unfailingly, trust the international leader.
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]]>From ignition starter motors to wiper and window regulator motors, from seats and mirror adjusting mechanisms to door lock actuators, electric motors are critical for the smooth functioning of a car. A host of child parts work in tandem with motors in these applications to deliver the desired movement consistently and effortlessly to the user. From rotary, sliding to oscillatory, these sub components are involved in various motion mechanisms. Wherever there is movement by contacting surfaces, friction is bound to be generated. The result, drop in efficiencies, wear of surfaces and finally failure of component.
However, these auto electrical components demand special lubrication that can withstand the test of time whilst absorbing loads, temperature build up and unwarranted vibrations. Material compatibility, ability to perform under varying temperatures (-40 to +140ºC), resistance to water and dust are some of the other defining characteristics that the lubricant needs to possess.
Lubrication requirements of various motor mechanisms are diverse. Take for example the ‘Worm and Worm Wheel gear arrangement’ that works in tandem in applications such as Wiper, Power Window, Seat Adjustment and Door Lock Actuator mechanisms. To begin with, the lubricant should have good material compatibility with plastics and electrical contacts else cracking of plastic parts or colour alteration of consoles are sure possibilities. Noise dampening property, resistance to wear and corrosion are some of the other critical requirements of the lubricant that ensure rattle and vibration free operation. The lubricant should also possess low internal friction characteristics that would enable low starting torque. Sintered Iron and Bronze Bushes, Thrust Ball Bearing, One Way Clutch/Bendix Drive (Starter Motor) etc. are some of the other motor sub assemblies that possess unique lubrication requirements.
BECHEM’s high performance lubricants with low oxidation properties can endure excruciating conditions and provide life time lubrication whilst meeting the demanding operating requirements of various automotive electrical motor applications.
With expertise of over 175 years, BECHEM’s state of the art R&D lab equipped with the latest mechanical and physio chemical testing installations employs both sophisticated in-house and internationally established test procedures to find the best compatible lubricant. Motors are subjected to endurance test for over 2.5 million cycles in various extreme test conditions to reflect the actual usage of the component during its lifetime. Working closely with top automotive and component manufacturers, BECHEM has developed the next generation of intelligent lubricants that provide unmatched performance and reliability for all automotive motor components. Lubrication recommendations by BECHEM’s specialists have proven and exceeded the expectations of auto and component manufacturers time and again.
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