It is the stated goal of International Chemical Company to recommend manufacturer's chemicals that perfectly suit your specific operations. In order to do that, a comprehensive understanding of your processes is absolutely paramount. Our experienced and knowledgeable representatives will perform a complete survey and analysis of your means of production. The Find My Product submitted by our representatives to the ICC technical staff provides a complete picture of your procedures, from stock to finished product, allowing us to find you the best custom metalworking fluids and compounds that match your precise needs.
To the uninitiated, these types of operations may seem simple, but they are deceptively more complex than they appear. Variables such as the thickness of the stock, the feed rates, the utilization of blanks or coils, the lubricant application methods, pressures, press speeds, part types and geometries, in addition to various subsequent operations (e.g. the methods and durations of storage, aqueous cleaning, packaging, etc.) are all critical to determining the perfect straight or soluble drawing and stamping oil, synthetic metal-forming lubricant or high speed stamping lubricant required to produce high-quality components. Synthetic metal-forming technology is gaining acceptance in an industry that has historically relied on straight and soluble oils for drawing, stamping, piercing, punching, perforating and roll-forming. The advantages of utilizing a synthetic or semi-synthetic metal-forming lubricant are many and varied. First and foremost, for central systems and very large sumps, the bio-stability of synthetic lubricants ensures cleaner operations and the virtual elimination of dermatitis. The environmentally friendly nature of the formulations also facilitates easier and less costly disposal methods. Synthetic metal-forming lubricants are coming on strong. Don't miss the boat.
Metal-forming is our bread and butter. Nobody does it better.
Precision metalworking is a continuously evolving field of manufacturing. The ongoing incorporation of advanced machinery and highly skilled operators as well as the expanded use of lightweight and exotic materials is causing an industry-wide rethink of coolant technology. Yesterday's coolants may be tried-and-true, but we must all evolve.
The first step in evaluating a metalworking operation is to examine closely the type of metals being utilized. This will provide the initial direction in which we plan to go. For the most sensitive and difficult-to-work-with alloys, some mineral oil content will be required for enhanced lubricity. However, with advances in chemical technology, it is now possible to implement a synthetic or semi-synthetic metalworking fluid into your operations. The benefits are evident: cleaner sumps and operational spaces, the elimination of dermatitis, more easily cleaned components and spent solutions that are more easily discarded.
Second, the type of operation is critical. Grinding coolants require the efficient removal of smut and fines while remaining transparent so the work piece may be easily viewed during the operation. Tapping fluids and cutting oils must flush chips, provide increased lubricity, exhibit low-foaming properties and remain clean and bio-stable. An aspect that is sometimes overlooked is the prevention of corrosion. Is short-term or in-process rust protection required? Will components be cleaned or immediately packaged,thereby requiring extended rust and corrosion protection? Answering these questions is a vital step toward recommending the perfect metalworking coolant.
We pride ourselves in the wide-ranging efforts our technical staff has undertaken to continue researching and developing advanced-technology metalworking, machining and grinding coolants for 21st century manufacturing.
Like any other industrial manufacturing process, vibratory and burnishing operations require metalworking fluids that perform at a very high level. Using just any old vibratory and burnishing fluid simply won't cut it. A complete analysis of each operation is vital. In order to recommend the perfect compound, various factors must be thoroughly investigated and analyzed. They include the intricacy and detail of the manufactured components, the metallurgical composition, types of media, in addition to cycle times, temperatures, and desired finishes.
Perhaps most important is the required duration of rust and corrosion protection. Oftentimes, "vibed" parts are stored for subsequent operations like assembly and finishing (e.g. plating or painting). Some sensitive alloys are extremely susceptible to changes in both temperature and humidity and therefore require effective protection from these possibly destructive environmental conditions.
Finally, foam can be the bane of vibratory operations. Too much foam is a cleanliness disaster. However, not enough foam may cause other problems. Controlled foam levels not only provide detergency for both the processed parts and media, but it also offers a chemical barrier between parts and media which softens the operation, thereby reducing and/or eliminating harsh contact which may lead to surface imperfections.
One question permeates these types of operations: Is it clean or not? Sometimes, the answer is not a simple "yes" or "no." A pre-determined level of cleanliness is often stipulated prior to the implementation of a cleaner. The first step is answering the real question at hand: "How clean is clean enough?" The answer will determine how aggressive your cleaner needs to be. For operations in mid-stream, simply removing surface soils is sufficient. At the opposite end of the spectrum, for operations that manufacture aeronautical and aerospace components, the answer is very often: "It's never clean enough!" For most operations, the ideal cleaner usually falls somewhere in between. But a detailed evaluation must be performed before a recommendation may be made.
The type of desired cleaner (alkaline, acidic, solvent) and the type of operation (spray, immersion, ultrasonic) in addition to the physical form of the cleaner (liquid or powder) must all be thoroughly discussed before the evaluation may commence. Important operational factors include the nature of the soil(s) to be removed, the types of metals being utilized and the manner in which processed parts will be handled once clean.
But the three-legged stool of cleaning operations consists of time, temperature and concentration—reduce one and the others must be increased to compensate. A close examination of mechanical capability and the desired level of cleanliness will go a long way to determining the ideal spray, immersion, ultrasonic or solvent cleaner.
Of all the aforementioned operations, rust, corrosion and oxidation protection is actually the most straightforward. The most oft-asked question is: "How long do the parts need to be protected?" Is it that simple? In a word...no.
What is most important is the determination of environmental conditions expected to be confronted by the protective film. Is short-term or in-process corrosion protection required? That's an easy one. Are you shipping overseas? That one gets a little trickier. Other factors include the method of application, the desired type of rust inhibitor (synthetic, straight oil, soluble oil or solvent), the methods of handling following processing and what type of coating is required (ultra-thin to heavy, oily or greasy, waxy or dry-to-the-touch films).
A painstaking evaluation will be performed by an ICC representative, with the results analyzed by our technical staff, to ensure that your parts are protected from the most offensive four-letter word in manufacturing...RUST.