Focus: Flashing operation iMproving Machine cycle tiMe

eXcellent Metal reMoval rates and cleanliness oF Machined coMponents. 25% increase in production rate contriButing towards a $us 5M pa increase in turnover.

case study

your advantage in an industrial world

the challenge
A leading ball bearing manufacturing customer wanted to improve the machine cycle time for the flashing operation. So, Castrol was requested to provide a solution. The operation requires high metal removal within a few hours of grinding. Operators have to work over machines without suffering objectionable odour problems. A total manufacturing cycle should be completed in 4 - 5 hours removing 200 microns of material. The grinding fluid operates at 3 - 4% concentration.

analysis and solution

The operation was studied in detail to identify key aspects. The fluid used should have high detergency properties. Water samples were also analysed to select the best product which will meet the requirements of short term rust protection. A product was selected based on a clear understanding of the operation, water quality, detergency property and rust protection requirement.

outcoMe
Excellent metal removal rates were achieved along with required surface finish levels. No rust on components. No objectionable odour and no skin irritation issues. Product operates at 3% concentration. Very good detergency properties leaving machined components in clean condition.

Cycle machining time completed in 4 hours instead of 5 hours. This means a 25% increase in production rate equating Castrol Sintolin HD37 was recommended to 60 tons per day of ball bearings manufactured versus 48 tons previously. for use at 3% concentration. This has contributed towards increasing the turnover for the customer by approximately $US 5 million per annum.

eXcellent Metal reMoval rates and cleanliness oF Machined coMponents. 25 % increase in production rate contriButing towards a $us 5M pa increase in turnover.

case study

your advantage in an industrial world

www.castrol.com/industrial Castrol, the Castrol logo and Castrol Sintolin are trademarks of Castrol Limited, used under licence.

Focus: iMproving dewatering properties and reducing process tiMe

reduced dewatering process tiMes allowing Faster water separation. dipping tiMe cut By halF, allowing dewatering oF an eXtra 10 tons oF Ball Bearings per day.

case study

your advantage in an industrial world

the challenge
A leading European ball bearing manufacturer had previously used Castrol Rustilo DWX10/DS in their dewatering process after a lapping operation with soluble oil. In each washing operation, 400 kg ball bearings are washed at a time. The customer wanted to increase production efficiency to maintain cost competitiveness by reducing the dewatering process cycle time. The challenge was to reduce the overall dewatering process time.

analysis and solution

Castrol worked closely with the customer to evalulate the dewatering process. After gaining a clear understanding of process needs, Castrol developed a new product Castrol Rustilo DWX10 DS/HP. In laboratory tests, this new product enables the dewatering time to be reduced to 1 - 2 seconds. After this operation the ball bearings are ready to pass to the final corrosion preventive operation.

outcoMe
By switching from Castrol Rustilo DWX10 DS to the new formula DWX10 DS/HP in their dewatering process operations, the customer was able to reduce its overall process times. Castrol has contributed to reducing manufacturing costs through developing and using a new product formulation which was tested and approved in co-operation with the customers Technical Group.

The customer recognises that the new dewatering product allows the water After a successful trial, the new product to be quickly separated as the ball bearings A crucial aspect is to give effective was extended to all dewatering stations are immersed into the tank. This aspect dewatering in a very short time to avoid is crucial due to the fact that the water must in the factory reducing overall process any corrosion problems before the final be separated in a very short time during the times of the dewatering operation. corrosion preventive application is made. first phase of immersion because after the initial immersion the ball bearings are static reduced dewatering process tiMes allowing and cannot be touched by any operators.

Faster water separation. dipping tiMe cut By halF, allowing dewatering oF an eXtra 10 tons oF Ball Bearings per day.

The dipping time has reduced from 1 hour to 30 minutes for each batch. So, the customer is able to dewater around an additional 10 tons of ball bearings per day.

case study

your advantage in an industrial world

www.castrol.com/industrial Castrol, the Castrol logo and Castrol Rustilo are trademarks of Castrol Limited, used under licence.

Focus: soFt and hard stage grinding processreducing cycle tiMe in slovakia
single uniQue product identiFied For entire Flashing and grinding , optiMising cycle tiMe without coMproMising coMponent Quality.

case study

your advantage in an industrial world

the challenge
This ball bearing manufacturer in Slovakia needed to reduce grinding cycle time to improve productivity. Castrol was given the challenge to reduce process time without sacrificing component quality and possibly using a unique product solution for the entire flashing and grinding process.

analysis and solution

Castrol engineers worked with the customers engineers and machine operators to optimise the different process stages and the final defined process was as follows: Cold stamping Flashing Soft grinding Heat treatment Hard grinding Lapping An initial review of the baseline revealed that the whole flashing and grinding process needed to be done with one product in all stages. Castrol Sintolin RS8SN was identified as the technical product solution for the entire process. This product choice allowed optimum cycle time to be achieved without compromising on component quality.

outcoMe
The whole grinding process is carried out with one product. This allows the customer to reduce its inventory of machining fluids, gain improved control over the complete manufacturing process and the quality standards which can be achieved and simplicity in terms of fluid monitoring. This fluid engineering solution was applied in a new production plant optimising the whole process flow on the basis of the installed production capacity and to the quality standard required by the customer.

single uniQue product identiFied For entire Flashing and grinding process, optiMising cycle tiMe without coMproMising coMponent Quality.

OperatiOn

GrindinG Wheels

Granule size bOnd

prOduct used

Flashing Soft grinding Hard grinding Lapping operation

Cast Iron Stone Ceramic Stone Ceramic Stone Bachelitic Stone

not applicable 800 800 6000

Castrol Sintolin RS8SN Castrol Sintolin RS8SN Castrol Sintolin RS8SN Castrol Product E 366

case study

your advantage in an industrial world

www.castrol.com/industrial Castrol, the Castrol logo and Castrol Sintolin are trademarks of Castrol Limited, used under licence.

Focus: Ball soFt grinding and Flashing with castrol sintolin hd 37

eliMination oF Biological and corrosion pitting issues. cleaner conveyors leading to iMproved Ball Bearing Quality. reduced Maintenance costs eQual to 150 Man hours per year.

case study

your advantage in an industrial world

the challenge
In 2000, a customers bearing factory located in Alexandria, Romania introduced the machining of ball bearings into their production process. For the flashing and soft grinding step they used a synthetic product due to its attractive price and logistic advantages (short lead time). After a few months, a number of problems started to occur: poor biological performance: huge quantities of fungi had grown in the system and the operators had to stop production every few days to clean pipes and the central systems. corrosion pit phenomena: the ball bearings remaining on the machine conveyor after roughly 1 hour became corroded and small pits appeared on their surface. Consequently the scrap rate increased and quality standards deteriorated. Final surface roughness: whilst this was within the accepted range of values it was always too near the upper limit for comfort. the conveyors became covered with a black dirt which in turn soiled the machined ball bearings.

analysis and solution

Different samples of the product being used were analysed in order to identify the possible causes of the problems. It was realised that the corrosion could be due to the fact that the synthetic solution being used showed a very high saline content and gave a very bad laboratory corrosion test. The poor biostability performance arose because the pH level was very high (above 11) and the biocide that was used quickly became ineffective in such conditions. The poor detergency of the synthetic machining fluid negatively affected the final roughness of the ball bearings and the cleanliness of machines. Castrol Sintolin HD 37 at 3-3.3% was recommended for use.

outcoMe
Since 2003, Castrol Sintolin HD 37 has been feeding centralised systems of a 25 cubic metre capacity and a number of single machines for flashing operations in the customers plant. Fungi disappeared and only occasional additions of tank biocide are needed (once every two months). Corrosion pitting stopped, resulting in increased productivity and improved quality standards. The machine conveyors remained in a clean condition and consequently the final surface roughness (R/a) of the ball bearings improved. The economical impact of the substitution is detailed as follows:

800 kg of biocide saved per year giving savings > 16k. Due to production down time for maintenance, around 13% of production loss was experienced and now the customer has recovered this gap. Savings in manpower maintenance costs equal to 150 man hours per year were achieved for the central system.

eliMination oF Biological and corrosion pitting issues. cleaner conveyors leading to iMproved Ball Bearing Quality. reduced Maintenance costs eQual to 150 Man hours per year.

case study

your advantage in an industrial world

www.castrol.com/industrial Castrol, the Castrol logo and Castrol Sintolin are trademarks of Castrol Limited, used under licence.