Bechem: 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.
Smoke formation cut down by 80% with Berucut XC 1115, a safer neat oil alternative.
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.
Why Berucut XC 1115?
- 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 115 a safer option for operators
Trial observation:
- Smoke generation reduced by more than 80%
- Tool life increased up to 64%
- As an outcome of low carry over rate and lower emission, neat oil consumption reduced by 50%
| Brand I | Berucut XC 1115 | Brand I | Berucut XC 1115 | Brand I | Berucut XC 1115 | |
| Turning | Parting | Grooving | ||||
| No. of components per insert* | 650 | 950 | 700 | 926 | 1900 | 3116 |
*For details of the insert and other trial details, drop in a mail at sales@bechemindia.com
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.
Result:
Having observed performance of the product to combat the plaguing issues effectively and further optimize production process, the customer switched over to “Berucut XC115” completely.
This content was first posted on the Bechem website.
