Product Highlight: IC 920-R
Customer: Manufacturer of Deep Drawn, Cold-Rolled Steel Automotive Components
Objective: Replace a Costly Lubricant with Inconsistent Draw Performance and Biological Growth Issues
Description: The customer, utilizing cold-rolled steel in most operations (manual-feed, progressive and transfer presses), was using a water-soluble metal-forming lubricant that was providing extremely inconsistent performance results: unstable emulsions, varying operational temperatures, unpredictable die life and several formability issues, including wrinkling, galling and scoring. Within the underfloor pits of certain presses, biological growth was also a problem, leading to cases of dermatitis and causing harsh odors. In addition, the extremely high chlorinated paraffin content of the existing metal-forming lubricant was causing flash rust on manufactured parts during post-processing in their conveyor-type, in-line spray washers, which utilized highly alkaline and expensive cleaner chemistry.
ICC representatives surveyed their operations and determined that IC 920-R was superior in every way. IC 920-R provides extremely stable emulsions, effective bio-resistance, extended die life, consistent draw performance within a wide concentration range, and inhibited chlorinated paraffin content.
Following a thorough cleaning of affected presses utilizing IC 550-LF (a very low-foaming machine cleaner containing an extremely effective biocide), IC 920-R was extensively tested at varying concentrations in all press types in order to verify its performance and economic value.
Conclusion: The customer switched to the less expensive IC 920-R, a chlorinated water-soluble oil lubricant engineered for moderate to severe metal-forming operations. A myriad of benefits were realized following its implementation: dramatically reduced operating temperatures leading to extended die life and the total elimination of galling and scoring on components, the total elimination of biological growth (lengthening the lubricant sump life), the total elimination of flash rust in the washers, a reduction in the concentration range of the applied lubricant, and a significant reduction in scrap. All of these benefits resulted in considerably lower operational costs for the customer while improving the overall quality of their products.