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…
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,…
Drilling as a machining process is often considered a challenging process due to multiple factors such as strain hardening, toughness, high plasticity, tendency to form built-up edges and difficulty in…
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…
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]]>Drilling as a machining process is often considered a challenging process due to multiple factors such as strain hardening, toughness, high plasticity, tendency to form built-up edges and difficulty in chip evacuation. The role of cutting fluid is indispensable to reduce both temperature as well as friction between chips and the drill flutes and additionally to clear off the hot chip debris. However, the conventional ‘flood lubrication’ process typically used for lubrication, cooling and chip evacuation, often trigger issues like frequent re-lubrication, abrupt tool wear, disposal of used coolant etc.
Among other lubricant application techniques, the process of spraying out limited quantity of cutting fluid as cold mist to the cutting zone has proved to be effective. With MQL, there is minimal or no need to clean the tool and workpiece regularly after every machining process. Additionally, the task of disposal of used medium gets eliminated completely.
Customer: A leading Indian manufacturer with over four decades of experience in manufacturing forged engine and drive-line components. The technology driven company with multiple production facilities caters to the automotive, earth moving, tractor and pipe fitting industries across the globe.
Machining Parameters
Application: Pin hole drilling
Machine type: Oil hole machine
Machine OE: Reputed Indian brand
Material: Steel
Existing cutting fluid type: Mineral, OE recommended
Viscosity at 40˚C: 47 mm²/S
Pressure- 3-4 bar
Customer was using OE recommended non-water miscible oil, brand “X” for over seven years. During this phase the customer with an intention to reduce operational cost had conducted multiple trials with alternate cutting fluid brands available in the market. However, none of the trials were successful due to concerns of tool life and machining performance.
Consequently, when approached by BECHEM’s Engineering team, the Customer was skeptical. Nevertheless, the team convinced the customer for a trial opportunity for its MQL product, Beruform STO 110.
Trial observation:
Result:
Customer was pleasantly surprised with the result of Beruform STO 110 which facilitated near-dry machining. Convinced on factors of cost saving when compared to the existing product, the customer switched over to Beruform STO 110 readily.
Why Beruform STO 110?
The next generation of Bechem MQL lubricants have been specifically formulated to solve existing problems of wet machining with performance and productivity.
For more information on BECHEM’s mist oil range and to experience reliable and cost-effective MQL solutions, write to us at [email protected].
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]]>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
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: Automotive components
Material: Mild steel
Machining process: Parting, grooving, drilling and turning
Issues faced:
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:
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:
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:
|
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% |
Berucut XC 1010, a non-water miscible oil fully based on synthetic fluids for superior performance and high-speed machining processes.
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]
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]]>Case study demonstrates the impact of lubricating oil in the process efficiency of sheet metal drawing and blanking operations.
Deep drawing is one of the most convenient sheet metal forming process, widely used to produce cup, box, hollow shaped and other complex -curved metal objects of high precision in large volumes. However, during cold forming processes, the act of forcing metal into a given shape can cause a host of possible problems due to the amount of pressure and stress generated. Die wear, wrinkling, tearing of sheet metal, poor surface finish, scratches and cracks on the drawn product or on the edges of punched-out pieces are some operational challenges that manufacturers encounter regularly.
The effectiveness of a deep drawing oil generally depends on its ability to form a lubricating film of sufficient strength. This resilient film forms a ‘boundary,’ preventing direct metal-to-metal contact under the conditions of extreme surface pressure during deep drawing and blanking operations.
Regular oils with poor lubricating properties can cause heating and breakdown of the lubricating film. This further leads to abrasive wear of the tool and workpiece, resulting in higher rejection rates and production downtime. Beruform MF 155 C is a specially developed forming oil with excellent lubrication properties recommended for cold extrusion, sheet forming, piercing, punching, blanking and drawing operations.
Below example illustrates how Beruform MF 155 C replaced multiple forming oils used for drawing and blanking operations of varying sheet thicknesses.
Customer: A leading Indian manufacturer of precision bearing cages and stamped components in terms of capacity and operations. The technology driven company has an extensive production infrastructure comprising of manual, semi-automatic and fully automatic machineries. The company supplies to diverse industries including automotive and engineering across the globe and has its processes certified to ISO and IATF standards.
| Product: | Bearing roller cages |
| Material: | Bearing steel |
| Machine: | 1000 T press |
| Drawing length: | 150 mm to 260 mm |
| Application(s): | Deep Drawing and blanking |
The Production team used different drawing oils for different sheet thicknesses.
Brand “X” with a viscosity of 171mm²/s for 2 – 4 mm and brand “Y” for 4 to 12.5 mm sheet thickness.
Considering the operational parameters, Bechem’s Application Engineering team recommended straight drawing oil Beruform MF 155 C.
Bechem’s neat drawing oil ‘Beruform MF 155 C’, has been specially developed to ensure seamless drawing and blanking operations.
Having observed performance of the product in optimizing production process efficiency and minimizing rejection rates during the trial period, the satisfied customer switched over to ‘Beruform MF 155 C’.
Beruform MF 155 C helped increase process efficiency as well as better surface finish of formed components.
Advantages with Beruform MF 155 C,
Beruform MF 155 C is a non-water miscible forming oil for the processes of cold extrusion, sheet forming, piercing, punching, blanking, drawing etc.
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]]>Traditionally carbide grinding has been tricky with issues of carbide stickiness leading to wheel loading and affecting tool finish. The Production team at a leading manufacturer of carbide tools had weathered this concern by managing the machining process with repeated wheel dressing improvisations. A trial with Berugrind 7 HC, a neat cutting oil with special additives from BECHEM, unraveled possibilities for the production team to ensure seamless grinding with superior job finish.
With over two decades of experience in manufacturing high quality cutting tools, the company supplied to an impressive list of customers across industry segments. The list included top brands in automotive, aerospace, medical instrument manufacturers as well as die casting and machine tool industries. Equipped with advanced machining centers and well-trained personnel, the company always maintained highest levels of satisfaction with its customers.
The company’s portfolio included standard long end mills, uneven helix mills, taper end mills, drills, routers, reamers, turning and special tools.
Additionally, excessive mist generated from the coolant during the grinding process spoiled the work environment for operators. Based on a reference, the BECHEM team contacted the coordinates at the Company’s Production Dept. The BECHEM team after understanding the machining process and the pain points of wheel loading and mist formation during the grinding process recommended a trial with Berugrind 7 HC.
Production set-up: To meet Customer requirements and ensure a steady supply, the company had installed state of the art machines that included a sizeable number of ‘multi axis CNC tool and cutter grinding’ machines. As a regular machining practice, resin bond diamond wheel was used for grinding process.
An issue that Machine operators faced repetitively was of wheel loading affecting job finish. Grinding Tungsten-Carbide generated a lot of dust that continued to stick to the grinding wheel leading to the occurrence of wheel loading. The operators ensured extra caution during the process by limiting cutting speed.
Machining Applications
Berugrind 7 HC Recommended for
The non-water miscible metal cutting fluid had proven its performance in severe machining applications against hard metals such as carbides, tungsten carbide, cast steel, titanium etc. Berugrind 7 HC was effective in dirt carrying capability as well as good flushing property.
The specially formulated cutting fluid was developed to provide better cooling affect during the intensive machining processes. Berugrind 7 HC had also demonstrated lower evaporation tendency compared to other neat oils available in the market.
Grind Tough Metals With Ease
Low Viscosity oil for Carbide and HSS grinding
Impressed with the consistent performance of Berugrind 7 HC in grinding, the Production team did a complete changeover for complete machining process of carbide tools.
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]]>In Bright bar drawing process, extreme surface pressure and specific frictional forces are critical aspects that can affect tool life and workpiece finish. Typical challenges for manufacturers include dull finish of drawn bars, frequent die wear, cracks or even breakage in drawn products. Traditionally use of conventional oil or even mustard oil with suboptimum viscosities has often led to multiple complications resulting in production down time. The drawing oil plays a key role in increasing production efficiencies for manufacturers.
Beruform MF 155 I is recommended for the critical stage of ‘deep drawing’ in the bar drawing process. The multifunctional drawing oil has the right viscosity and advanced additive package that ensures superior surface finish of the drawn bar, longer die life and extended oil service life.
Customer: A reputed manufacturer of steel and special alloy bars with supplies to diverse industries including automotive, engineering, bearing and allied industries. The company has an advanced manufacturing set-up with extensive use of automation for the production process. The company supplies to the top brands in the automotive and heavy engineering industry and has its processes and environmental practices certified to the standards of ISO and IATF.
With an annual capacity to produce 24,000 MT of bright bars, the company managed the shift round the clock to meet the market requirement. Any downtime meant additional pressures on the production team to meet the targets.
| Product: | Bright bar steel of various shapes |
| Grade: | Plain carbon steel to high alloyed steel |
| Size: | 16 mm to 120 mm for round bar 19.5 mm to 40.5 mm hexagonal bar |
Current drawing oil: Mustard oil was in use during cold drawing process of steel bar
Issues faced:
Considering the operational parameters and Customer’s concern of frequent production downtime, Bechem’s Application Engineering team recommended Beruform MF 155 I.
‘Beruform MF 155 I’ is a non-water-miscible multifunctional oil, specially formulated to provide optimum lubrication between work piece and tool by reducing friction, heat and wear, thereby extending tool/ die life and ensuring high quality formed products.
Having observed performance of the product and increase in production efficiency during the trial period, the satisfied customer switched over to ‘Beruform MF 155 I’ completely. Further, the safety quotient of the work environment improved significantly with minimum man and machine interference.
Beruform MF 155 I is also recommended as ‘multi-function’ oil for the processes of blanking, punching and deep drawing. The product has provided superior results in forming of automotive components such as clutch cover body, keys, exhaust shell etc. Other interesting components where Beruform MF 155 I has proven its performance as well as cost benefits include blanking of bearing cages, deep drawing of cylinders etc.
Beruform MF 155 I is compatible with both ferrous and nonferrous metals like steel, stainless steel, aluminium, copper, brass etc. An iteration of the product with Chlorine additives named, Beruform MF 155 C is also available for severe bar drawing operations.
For more information on Bechem’s Cold forming oil range, technical comparison, case studies and references, drop in a query or mail us on [email protected]. We will connect you with our product specialist.
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]]>Exposure to regular bearing and part cleaners can cause uneasiness in the short term and adversely affect health in the long run.
Bearing cleaning and re-greasing is a part of the regular ‘Maintenance, Repair and Overhaul’ activity in all industries. Typically, the dismounted bearings contain used grease debris, scales and other foreign residues which need to be cleaned thoroughly for inspection prior to lubricating with fresh grease and re-use. Improper cleaning can impact performance and diminish bearing life. Based on the type of bearing, manufacturers have provided clear instructions on the process of dismounting and cleaning for small to large bearings.
While bearing manufacturers recommend an oil bath or rinse tank, It is common practice for maintenance teams in industries to set-up component cleaning machines that use water-based cleaners. This set-up is commonly observed in industries such as Railways where the quantum of bearings to be cleaned is huge and regular. Bearings cleaned through such parts washers with water-based emulsions are dried out thoroughly with hot air or through vacuum dry outs. BECHEM’s range of water-based cleaners (Beruclean 3843, Beruclean 113 EMF and Beruclean 111 EHF) for high pressure cleaning systems have provided excellent cleaning results in such set ups.
The alternate arrangement observed in heavy industries such as Steel and metal processing that operate with large, heavy duty bearings is to soak the used bearings in rinse tanks or by manually spraying and rinsing them with the cleaning agent. Subsequently the operator brushes off the residues from the bearing. Traditionally light oil, kerosene or degreaser based on Isopropyl alcohol are recommended as the cleaning agent. However, the industry practice has been to provide commonly available diesel, mineral turpentine oil (MTO) and kerosene as the cleaning agent to its Maintenance team.
While cleaning effect with diesel is good, the low flash point and continuous exposure of the personnel to the nauseating odour of diesel renders the working environment vulnerable. Apart from the known symptoms such as irritation to skin and eyes, continuous exposure to diesel without safety gear can affect central nervous system, immune and hormonal systems in adults.
Continuous exposure to kerosene is known to cause irritation to eyes and skin in humans. Studies have shown that chronic exposure to kerosene can result in drowsiness, irritability, restlessness and even convulsions. Flash point of kerosene varies between 23°C to 61°C.
Owing to their low flash points and associated safety concerns, authorities in many countries prohibit and dissuade industries from using diesel and kerosene as a cleaning.
Even more dangerous is the use of MTO as a cleaning agent, the health hazards and environmental impact associated with this traditional cleaning agent has been well established. Fortunately, with increased awareness, the use of MTO has waned within the industry. Disposal of used cleaning agent is also a factor that is controlled by Authorities and expensive to manage.
| Characteristic | Beruclean Eco | Diesel | Kerosene |
| Odour | Neutral, almost no smell | Strong nauseating | Strong odour |
| Flash point | 70°C | 32°C | 23°C to 61°C |
| Biodegradable | Yes | No. Increases disposable costs | No. Increases disposable costs |
| Evaporation rate | Low | High | High |
| Exposure hazard | None | High probability. Can cause skin and eye irritation. Can affect nervous system | Causes skin and eye irritation. Chronic exposure can lead to drowsiness, irritability and convulsions |
Beruclean Eco is a high-performance cleaner for de-greasing and cleaning of used industrial bearings and machinery components. Beruclean Eco is NSF H1 certified (food grade approved for incidental contact) and is biodegradable as well (OECD 301 F: 70% after 28 days). Compared to diesel which has a low flash point of 32°C, Beruclean Eco has a higher flash point of 70°C reducing the risk of accidental fire. The colourless cleaning liquid removes all types of oil and grease contaminations, waxes and typical residues within used bearing and parts. Beruclean Eco can be used for regular manual cleaning processes as well as in flood and immersion baths and ultrasonic cleaning machines.
As a bearing and parts cleaner with lower evaporation rate, Beruclean Eco is more stable than diesel thereby reducing the overall consumption rate. Irrespective of the size of bearing, Beruclean Eco has proven cleaning performance across industries including Steel, Automotive Components and Food & Pharma as well.
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]]>Personnel deputed at the component cleaning section of a reputed cutting tool manufacturer were not too happy with the pungent smell of ‘mineral turpentine oil (MTO)’ that polluted the work environment.
While MTO provided just adequate cleaning, the Production team was on the lookout for a product that would provide better cleaning effect. Additionally, with bulk consumption and used oil output, the management was keen for a bio degradable alternative.
An effective cleaner that was physiologically harmless and eco friendly at the same time was need of the hour.
The Customer, a well established Indian brand in manufacturing HSS cutting tools is the largest exporter in its category and also caters to the biggest names in Indian machining and automotive industry. With a comprehensive product range of over 50,000 tools, the company offers multiple options for various machining applications.
With production of close to 50 to 60k cutting tool units manufactured every day, the customer consumed tons of MTO as a part of the cleaning process during both the raw material preparation stage as well as in the final finishing stage.
During the raw material preparation stage, the cleaner was used to remove dirt, grease and other impurities from the metal bar prior to machining operations. Similarly, the finished component was cleaned off any oil residues or grinding dust after the final operations.
The customer had set up inline cleaning systems through dipping for initial raw material preparation and intermittent cleaning requirements. Ultrasonic machines were installed for the final finishing process.
The company had continued to use MTO as the inexpensive cleaning agent in all the cleaning processes. Personnel continuously exposed to the pungent odor of MTO experienced mild headaches and nausea at end of their shifts. The Management was keen to replace MTO that impacted work environment and employee morale.
While MTO has fairly low ‘acute toxicity’ that could impact through vapor inhalation or through continuous skin contact, continuous exposure could lead to drowsiness, nausea as well as severe irritant dermatitis or even chemical burns. Long term studies have shown continuous exposure could lead to chronic central nervous system effects impacting memory, concentration and irritability.
The Quality and Production team on the other hand were not too impressed with the finish of the cleaning with MTO. Traces of impurities and oil could still be seen on the components.
At this juncture, BECHEM’s Product team pitched in with an advanced cleaning formulation that had proven better cleaning finish, was odorless as well as bio degradable. The Customer’s Production team promptly opened up for a trial of Beruclean S 4050 and measured the performance on following parameters,
To compare the performance of both the products, two 300 ml beakers were filled in with MTO and Beruclean S 4050 and left in ambient conditions (30 °C) for a period of 3 days. While there was marked loss of about 100 ml in the MTO beaker, the beaker with Beruclean S 4050 showed minimal loss of about 25 ml. During trials on one of the cleaning lines with Beruclean S 4050, it was recorded that there was a reduction of consumption by 67% compared to MTO.
At the same time, the Operators informed that Beruclean S 4050 dried off from the cutting tools within 3 minutes approximately. This evidence was recorded with temperatures hovering about 30 to 32°C at the shop floor.
There was remarkable improvement in the cleaning effect with Beruclean S 4050. Hardened grease residues, high viscous oils and stubborn dirt that used to be stuck on carbide and HSS rods with MTO had been cleaned with Beruclean S 4050.
The company personnel were pleased to work with the odorless cleaning agent that did not give them a nauseating experience unlike MTO. The operators voted completely in favor of Beruclean S 4050.
QUICK COMPARISION
SL no |
Properties |
Mineral Turpentine Oil (MTO) |
Beruclean S 4050 |
|---|---|---|---|
| 1 | Appearance | Colourless | Colourless |
| 2 | Type | Halogenated hydrocarbon | Non halogenated hydrocarbon |
| 3 | Biodegradable | No | Yes |
| 4 | Smell | Typical pungent hydrocarbon | Odorless |
| 5 | Operator friendliness | Long term exposure is not recommended | No impact |
| 6 | Flash point | 38°C | >50°C |
| 7 | Evaporation | Very High | Moderate |
| 8 | Cleaning effect with stubborn residues | Ineffective | Cleans, leaves no residues |
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]]>With an intent to reduce cost per component, the Production team at an Automotive component manufacturer compares tool life achieved with Berucut SCO 322 HC and other alternative cutting fluids.
Focusing on machining productivity, manufacturers of cutting fluids have been working out special coolant formulations with the right mix of lubricity and anti-wear additives to extend tool life.
The Customer having conducted trials with multiple products, was pleasantly surprised with the results. The study proved a tool life increase of over 40% with Berucut SCO 322 HC when compared to the existing product as well as an alternative product, popular in the market.
The owner led firm had built a reputation as a reliable supplier of high quality components with ability to deliver within deadlines. The company manufactured precision components and catered to the requirements of automotive, marine and bearing industries. With stringent quality processes, the employees imbibed the company philosophy of delivering high quality components consistently at competitive prices. The production team were always on the lookout for initiatives to reduce manufacturing cost by improving process efficiency.
Out of the 60 machines installed, the split was equal between conventional and CNC machines. The standalone machining centres run with neat oils had capability to perform all regular machining processes such as turning, milling, tapping, drilling, grinding, thread cutting etc. Daily operations involved machining of regular steel, special alloy steel, leaded and non leaded materials.
With regular production schedules, the Production team was concerned about ways to improve tool life as it had significant impact on CPC. Right coolant management practices with suitable filtration systems had ensured that the existing coolant, ‘Product I’ performed adequately for the past 6 years.
However the Customer was keen to check if cutting fluids could impact tool life in any way. Given the circumstances, Bechem was provided an opportunity along with another prominent coolant brand to prove performances of their respective products against customer’s existing cutting fluid.
BECHEM’s ‘go to’ product for the trial was Berucut SCO 322 HC, the non water miscible coolant formulated with lubricity improvers and anti wear additives for superior machining performance and increased tool life. Developed for high speed machining, the Chlorine and heavy metal free coolant has a flash point of over 210 C and resists smoke formation even during intensive machining operations on tough metals. The ‘yellow clear fluid’ is resistant to ageing and provides good corrosion protection to machine and components.
Take 1 : Comparison for Tool Life
The first trial was conducted for a period of 1 month on two similar machining centers and operations with only the coolant being the varying parameter.
With Berucut SCO 322 HC, the customer observed that the tool life almost increased by 50% compared to the existing coolant. There was marked improvement in surface finish of the component as well as cleanliness of the machines. The Customer was surprised with the results and wanted a confirmation on repeatability.
Take 2 : Reduction in cycle time
While a trial for repeatability was being scheduled, the BECHEM team proposed to increase machining speed with an intention to reduce cycle time and subsequently compare the results. At this point in time, the other prominent player in the market also pitched in with their offering, ‘Product B’. A second trial was conducted with change in machining speeds.
Tool Life Comparison Chart
Measured in no. of machined components
SL no |
Tools |
Berucut SCO- 322HC |
Product I |
Product B |
|---|---|---|---|---|
| 1 | Insert V (Parting) | 5000 | 3600 | 3700 |
| 2 | Insert D5 (OD Turning) | 5200 | 3600 | 3800 |
| 3 | Insert D00 (OD Finish) | 3000 | 1600 | 1600 |
| 4 | Insert V725 (Grooving) | 8000 | 6000 | 6000 |
| 5 | Insert VB725 (Back Turn) | 1500 | 1000 | 1200 |
| 6 | 8 mm Endmill | 4000 | 2800 | 2800 |
The result was no different from trial 1, Berucut SCO 322 HC beat both the products in tool life, machine cleanliness and component finish.
The Customer was able to experience increased tool life with Berucut SCO 322 HC by over 50% with existing coolant and over 40% with the other popular brand in the market.
With increase in tool life and reduction in CPC established, the Customer changed over from his earlier product to Berucut SCO 322 HC.
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]]>The production team at an auto component manufacturing company had trouble cleaning its component bins, impacting both component and shop floor cleanliness. Having embraced ‘total quality management’, the ISO/IATF certified company was keen to arrive at an effective solution to this niggling issue.
The Auto component manufacturer supplies to top Auto brands with exposure to both segments of passenger and commercial vehicles. Credited as one of the largest manufacturer of steering yokes in India, the company’s product portfolio also includes, connecting rods, automobile housing, gears as well as other precision turned components.
With close to 30 years of experience, and having imbibed the principles of ‘total quality management system’ the company had mastered complexities in manufacturing critical automotive parts. Supported by a highly aware and ‘quality conscious’ work force, the company had adopted stringent quality checks and was known for its commitment to fulfil clients’ requirements with precision.
During one of its regular exercises to identify areas for improvement, the Production team at the works noticed unclean bins in use for moving auto parts from one department to another. These bins would often contain grease and oil residues that in turn would attract dust contaminants resulting in dry sludge over time. Dirty bins meant contamination threat for finished components and possible rejection scenario from the Customer.The team realized that the existing cleaning system for bins in place was not effective despite the best efforts. As contaminants remained visible, the team had to establish a secondary manual cleaning process that was unproductive and affected the workflow.
However, unclean bins did not reflect the quality standards employed and posed a potential embarrassing situation for the Production team during Customer visits. Also, unclean bins are a major reason for corrosion of finished components
Finished auto parts are subjected to tests to ensure cleanliness at supplier’s end and also at customer’s end. Millipore test is one of the popular tests to check for impurities. Failure in this test at supplier’s end results in additional cleaning of parts. In case of failure at the customer’s end would result in rejection of the entire batch.
The existing cleaning agent wasn’t sufficient enough to obtain cleaner bins. During a regular prospecting visit, the BECHEM team learnt about the concern of unclean bins from the Production personnel. The BECHEM team understood the criticality of the issue and suggested an inspection of the existing bin cleaning process.
Cleaning machine installed at the works used jet spray to rinse off impurities from plastic bins. The cleaning process utilized DM (de-mineralized) water along with regular washing powder with cycle time of 5 minutes. The setup with tank capacity of 400-liter had in built heater that could maintain the sump temperature up to 60 °C. However, the team observed the lack of filtration system in the existing set up resulting in accumulation of excess sludge at the bottom.
Upon examining the process followed, BECHEM suggested few modifications to the existing setup including installation of pre-filtration system, repositioning of heat sensors and increasing the size of exit valves for better drainage of sludge.
Product recommendation was very critical as the bin cleaning system utilized jet spray and hot water for cleaning. A typical solvent based cleaner with low flash point could cause a potential fire incident during the process. A water based cleaner with good wetting and soaking properties was vital.
BECHEM recommended Beruclean 113 EMF, a universal water-soluble alkaline cleaning agent with low foaming properties. Equipped with special wetting additives, the high performance industrial cleaner is suitable for Aluminium, Cast Iron, Steel and non-ferrous metals as well. Although alkaline in nature, Beruclean 113 EMF is compatible with the piping or flanges from copper alloys used in cleaning systems. Also, Beruclean 113 EMF is highly recommended for spray jet cleaning.
Beruclean 113 EMF provided a much better result with bin cleanliness compared to the washing powder. Additionally, with Beruclean 113 EMF, the cycle time reduced from 5 minutes to 3 minutes as well as reduction in dilution ratio from 4% to 1.5%.
Product Name |
Washing Powder |
Beruclean 113 EMF |
|---|---|---|
| Washing Cycle | 5 mins | 3 mins |
| Concentration (in percent) | 4% | 1.5% |
| Cleaning Effects | Required additional rubbing | No additional cleaning |
The Production Dept. was delighted with the results as Beruclean 113 EMF enhanced output, reduced opex and helped them in achieving their 5S objective. Additionally, with lesser contamination on finished parts, the company had attained higher success ratio in Millipore test.
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