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Removal of risers further to the metal casting and solidification for further machining process is achieved through riser cutting machines.
The riser cutting machines play a vital role in industries like automotive manufacturing, where precise cuts are necessary for high-quality casting components. However conventional cutting oils typically used often results in emission of machining smoke and fire hazards, while reducing cutting efficiency and compromising worker safety. The work place environment has a direct impact on shop floor productivity and employee morale.
Below case study illustrates how minimal quantity lubricants (MQL) can positively impact machining efficiency while enhancing work place safety quotient
Customer: A leading Japanese manufacturer of aluminum wheels, supplying to global OEMs in the automotive industry
Machining Parameters:
- Machine : Riser Cutting Machine
- Application : Riser cutting
- Material : Aluminum
- Cutter : Circular saw with carbide tip
Challenges encountered by the machine operators :
- Metal Swarf sticking onto the saw blade’s teeth: Cut metal chips getting stuck on the carbide-tipped circular saw blades. This led to frequent maintenance downtime and reduced cutting efficiency.
- Fire Hazards: Melted chips during the cutting process, often produced sparks, posing a significant fire risk in the workplace.
- Mist and Smoke Formation: Generation of mist and smoke, created an unhealthy and uncomfortable work environment for the operators.
- Oils residue on the machined components required subsequent cleaning process.
Considering the operational hurdles, the Bechem team recommended a synthetic-based metal cutting fluid MQL M 40, developed for minimum quantity lubrication application.
Trial observations:
- No Chip Clogging on Cutter’s Teeth: The non-sticky formulation of MQL M40 prevented metal chips from clogging the circular saw blades, improving cutting efficiency and reducing downtime for cleaning.
- Reduced Fire Risk: Sparks during the chip melting process was significantly reduced, minimizing fire risks in the workplace. MQL M4 has a high flash point of > 265°C
- Maximized Cutter Life: Extended cutter life and lower wear rate was noted
- Reduced maintenance: MQL M 40 did not leave any residue, hence interim cleaning of the component was be avoided.
- Reduction in smoke and mist formation : The operators were pleasantly surprised as MQL M40 reduced smoke and mist generation drastically when compared to the previous cutting oil.
Why MQL M 40 ?
- Enhanced tool life: Due to its advanced formulation and synthetic base oil, MQL 40 provides excellent cooling and superior lubricity, reducing wear
- Reduced maintenance: Prevents metal chips from clinging to the cutter's teeth, minimizing maintenance needs and improving cutting efficiency
- Minimizes fire hazard: With a flash point over 265°C, MQL 40 greatly reduces risk of fire hazards, especially during the chip melting process
- Safer workplace: Generates minimal mist and smoke, promoting a safer and healthier work environment.
- Superior surface finish: Neutral towards aluminum, prevents staining of workpieces and maintains high quality finish.
- Hassle free disposal: Free from harmful chemicals like chlorine, sulfur and heavy metals and hence comparatively easier to dispose.
Result :
The customer, impressed by the benefits of minimal quantity lubricant MQL M 40, including cost savings and improved production efficiency, switched over to MQL M 40.
For further details of the product, comparison chart and trial samples, write to us at [email protected]
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