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CASE STUDIES

METAL-FORMING, DRAWING & STAMPING

PRODUCT HIGHLIGHT: International Compound 2801-DL

PRODUCT TYPE: Non-Chlorinated Straight Oil Metal-Forming Lubricant
for Moderate to Severe Operations

CUSTOMER: Manufacturer of Custom, Precision and Prototype Metal Stampings

OBJECTIVE: Replace a Costly Chlorinated Lubricant with a High Performance
Non-Chlorinated Oil

DESCRIPTION: The customer, utilizing an extremely wide range of standard and exotic metals with varying widths and thicknesses, was spending an inordinate sum of money on vapor degreasing operations which used perchloroethylene, a liquid solvent that is suspected of causing cancer in humans following extended periods of exposure. Standard wash operations were deemed ineffective at removing the highly chlorinated straight oil being utilized in their presses. It was determined that vapor degreasing was the only effective way to remove the lubricant following the stamping operations.

Due to the high cost of perchloroethylene, attempts to recycle this material were implemented. Following the custom-manufacturing of an on-site still, the perchloroethylene and various waste oils (including the highly chlorinated metal-forming lubricant and tramp oils) were boiled in a large tank, with an expectation that the waste oils would drop to the bottom and the perchloroethylene would vaporize and rise into a collector, from where it would be pumped into another tank, cooled and reused once it had returned to its liquid state. However, at 250°F, the chlorinated paraffin content of the metal-forming lubricant turns acidic, and as the acid value increases, it contaminates the perchloroethylene, rendering it useless.

Following a survey of their operations, it was determined that the implementation of a non-chlorinated straight oil engineered for this type of operation may alleviate many of their production issues, most specifically eliminating the vapor degreasing operation that was not only very expensive, but dangerous to both humans and the environment. Laboratory testing was performed by ICC to ascertain which non-chlorinated straight oil lubricants would fulfill the performance objectives of the customer. ICC 2801-DL was custom-developed; a formula based on ICC 2801, which is a semi-synthetic, sulfur-free, ash-free, rust-inhibited straight oil lubricant engineered for a multitude of metal-forming operations.

Both ICC 2801-DL and the existing chlorinated metal-forming lubricant were sent to an independent lab for lubricant ranking testing to evaluate their individual performance characteristics. Most importantly, this testing was intended to verify if ICC 2801-DL was capable of outperforming the customer’s chlorinated straight oil. The results of this testing are located below for your review:

Key:

1 inch = 25.4mm
1 pound = 4.45 N

 

Lubricant Name:

ICC 2801-DL

Sample #

 Umax

Pmax

do

df

ε

 

mm

N

mm

mm

mm/mm

31

49.96942

4142.95

25.944

27.624

0.064754857

32

49.96942

4205.25

25.675

27.357

0.065511198

33

49.9745

4254.2

25.554

27.09

0.060108007

34

49.9745

4223.05

25.343

27.25

0.075247603

35

49.96688

4191.9

25.494

27.143

0.064681886

36

49.94656

4303.15

25.262

27.078

0.071886628

37

49.99736

4191.9

25.536

27.045

0.059093045

38

49.98974

4231.95

25.538

27.248

0.066959041

39

49.96688

4294.25

25.239

27.016

0.07040691

40

49.95164

4263.1

25.737

27.382

0.063915763

Average:

49.96688

4235.84375

 

 

0.066028036

Std. Dev.

0.013302563

54.15944343

 

 

0.003733499

 

Lubricant Name:

Competitor's Chlorinated Straight Oil

Sample #

 Umax

Pmax

do

df

ε

 

mm

N

mm

mm

mm/mm

41

49.96688

4272

25.389

27.257

0.07357517

42

49.96688

4280.9

25.77

27.329

0.060496702

43

49.98466

4245.3

25.419

27.272

0.072898226

44

49.96942

4214.15

25.425

27.148

0.067767945

45

49.97958

4240.85

25.604

27.389

0.069715669

46

49.99482

4245.3

25.221

27.048

0.072439634

47

49.9618

4369.9

25.745

27.444

0.065993397

48

49.96688

4240.85

25.46

27.264

0.070856245

49

49.96688

4272

25.442

27.118

0.065875324

50

49.97958

4205.25

25.564

27.337

0.069355343

Average:

49.9754525

4254.2

 

 

0.069362723

Std. Dev.

0.011107963

51.01582388

 

 

0.00268275

 

CONCLUSION: Following a review of the above test data and a short-run on-site operational test to verify the independent laboratory’s findings, the customer switched to International Compound 2801-DL, a much less expensive and moderately higher performing, non-chlorinated straight oil lubricant engineered for moderate to severe metal-forming operations. Besides the attendant benefits of eliminating the chlorinated paraffin content found in their former metal-forming lubricant, the customer was elated to discover that ICC 2801-DL may be removed with standard chemistry in conventional machines, thereby eliminating their expensive vapor degreasing operation, including the custom-manufactured and ineffectual perchloroethylene recycling apparatus. An added benefit is the medium-term corrosion protection provided by ICC 2801-DL for manufactured components stored indoors for several months prior to any subsequent operations.

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