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METALWORKING

07.14-V002© 2014 Quaker Chemical Corporation. All Rights Reserved.

THE PRODUCT

QUAKERCOOL® 7200 HBFF is a high performance micro-emulsion ideally suited to all operations where high surface finish quality and high lubrication is needed. It is ideal for general purpose machining of most engineering materials. QUAKERCOOL® 7200 HBFF is well suited for difficult metalworking operations on cast iron, steel and aluminum. The concentration range is recommended to be between 4 - 10% depending on type of operation.

THE EXPERTISE

Metalworking lubricants represent a very minor part of the costs in a metalworking process, typically less than 1%. This case illustrates the importance of correct fluid selection. The impact of the fluid can be a multiple of its costs, making the price of a metalworking fluid insignificant. That is why Quaker focuses on developing fluids with the highest performance without compromise, fluids that sharpen your competitive edge.

PROCESS AND EQUIPMENT

Material Diecast Aluminum, Magnesium and Zinc

Concentration 6 to 8 %

Water Hardness 10 °dH / 18 °F / TH 180 ppm

Specific Operation Milling/Drilling

Machines > than 20 Haas and Chiron machines

System Size 200-300 litres tank capacity

MACHINING AND GRINDINGQUAKERCOOL® 7200 HBFF

THE SOLUTION Quaker visited the most critical plant located in Czech Republic which was never visited by the competitor. As a result of the visit, Quaker introduced QUAKERCOOL® 7200 HBFF after performing compatibility tests with different polish pastes, cleaners, electroplating, etc. The product was recommended based on the following advantages:

CHALLENGES

A leading German die casting company experienced problems related to their metalworking coolant and service from the supplier. The die caster produces automotive modules, home appliances and consumer goods from aluminum, magnesium and zinc with decorative surfaces, and was looking to alleviate the following problems:

» Skin irritation » Bacterial problems » Low coolant lifetime » Coolant containing Boron

and Formaldehyde

» Formaldehyde releaser free » Boron free » Excellent bio-resistance

» Cleanliness of tools/machinery even on cast iron in hard water

» Excellent corrosion protection

Beginning in November 2012 thru June 2013, QUAKERCOOL® 7200 HBFF was gradually introduced into machines located in Germany and Czech Republic. At the end of the trial, the customer realized the following results: » 10% lowered total cost from the competitor » 50% reduction of the coolant consumption due to better coolant lifetime in Czech Republic plant » Improved biostability of the coolant over the competitor » Elimination of skin irritation » Elimination of bacteria related problems

quakerchem.com | 1.800.523.7010

METALWORKING

In an effort to address regulatory changes, Quaker Chemical has developed a safer and more performing alternative to boric acid-based formulations. The new pH buffer system is anchored on a boron-free and formaldehyde-free micro-emulsion product, QUAKERCOOL® 7200 HBFF.

Quaker has demonstrated that the new pH buffer system can effectively replace boron-based formulations and provide enhanced machining performance. It addresses the lubrication and finish quality issues for companies working with aluminum.

» The new pH buffer was tested with a series of measures on forces, cutting power and surface roughness to simulate field operations. Lower forces and torques in our aluminum machining protocols were measured - drilling with internal and external cooling, tapping and reaming with external cooling

» The biggest improvement is in the aluminum surface finish: in reaming operation, a much lower Ra (Roughness Average) and Rz (Mean Roughness Depth) was reached compared to the reference product

1. Roughness measurements in straight flute reaming on aluminum alloy (AlSi7Mg)

Single step through hole on a CNC vertical milling center Diameter: 10.2mm – Depth: 44mm – Cutting speed: 20m/mn – Spindle speed: 625 rpm – Feed: 0.25 mm/rot

0.20

0.16

0.12

0.08

0.04

0.00

0.18

0.10

-44%

REFERENCE PRODUCT QUAKERCOOL® 7200 H BFF

STRAIGHT FLUTE RAMING ROUGHNESS AVERAGE (Ra)

Lower is better

2. Forces measurement in drilling operation on aluminum alloy (AlSi7Mg)

Single step through hole on a CNC vertical milling center Diameter: 10.2mm – Depth: 44mm – Cutting speed: 20m/mn – Spindle speed: 625 rpm – Feed: 0.25 mm/rotDRILLING-INTERNAL COOLING TORQUE

109876543210 0.10 0.30 0.50 0.70 0.90 1.10 1.30 1.50 1.70 1.90 2.10 2.30

REFERENCE PRODUCT

QUAKERCOOL® 7200 HBFF

3. Cutting power measurement in drilling operation on aluminum alloy (AlSi7Mg)

Single step through hole on a CNC vertical milling center Diameter: 9.8mm – Depth: 38mm – Cutting speed: 200m/mn – Spindle speed: 6500 rpm – Feed: 0.15 mm/rot – internal cooling

8.00

6.00

4.00

2.00

0.00

6.96

4.01

-42%

REFERENCE PRODUCT QUAKERCOOL® 7200 H BFF

DRILLING - INTERNAL COOLINGTOTAL CUTTING POWER (kJ)

Lower is better

MACHINING AND GRINDINGQUAKERCOOL® 7200 HBFF

Additionally, the pH buffer system provides significant improvements over both traditional boric acid-based products and other boron-free formulations in terms of inhibiting bacterial and fungal growth

» Over a ten-week period, Quaker injected samples of both bacteria (Gram negative and Gram positive) and fungi (molds and yeast) into the new pH buffer system and competing products

» QUAKERCOOL® 7200 HBFF, equipped with the new pH buffer system, remained biologically stable during the test and outperformed the boron-containing and other boron-free formulations

© 2014 Quaker Chemical Corporation. All Rights Reserved.