Vegetable water-based coolants and cutting oils

For more than 20 years, Condat works on vegetal oils for replacing mineral oils. Since 2009, Condat proposes a range of soluble oils and cutting oil for metal working formulated from vegetable based esters. These fluids show high performances lubricating power, good stability and consumption economy. These product-ranges called Neat Green and Mecagreen are on display in Halle 4 at Hannover Messe.

The new range of Mecagreen and Neat Greens are innovative products that have needed two years to develop by Condat laboratories. The formulation of these products mark an important evolution in terms of chemistry, and ‘green’ chemistry! Unlike mineral oil based products, the new products are made of a mixture of esterified basic oils that are of 100 % vegetable origin.

Polar molecules
The problem with coolant is that we always have to find the best combination between cooling and lubricating properties. Petroleum based oils are non polar and do not coordinate with the workpiece surface, hence some compromise to do. The new vegetable oil and water-based coolant proposed by Condat benefit from a new technology that enhances the polarity of the esters used. Even for heavy duty operations, ester-based molecules still stick to the workpiece’s surface to ensure better slide and minimal wear on tools. The length of the product range allow the company to always find the best coolant adapted to the part to be machined.

20% less wear on tools announced
Mr. Xavier Pitance, in charge of the industrial lubrication business unit says: “We’ve done extensive tests and are working with customers worldwide. They are emphasizing that tool life is largely extended”. He adds: “Nevertheless we don’t want to compare solutions by ourselves; the best is that potential interested people ask for information and put us under test, and then they can see by themselves and chose based on facts”.

To be discovered in Halle 4, Booth a42 till the end of the week.

www.condat-lubricants.com
Xavier.pitance@condat.fr

By the way, the company is looking for sales representatives in Europe and Switzerland to strengthen their network… if you’re active in lubrication and would like to seize a new opportunity, feel free to contact Mr. Pitance at your early convenience.

Pigging technology in operation

As is the case with a talented chef who intends to create a delicious menu, he will need, depending on the number of courses and size of the group, quite a lot of pots, pans, bain marie pans, serving plates, etc. Similarly, when it comes to the production of over 2500 different Motorex products more or less the same principle applies. With the increased number of storage tanks and the introduction of the most recent generation of pigging technology, Motorex is again expanding its innovative infrastructure.

The storage tanks are of central importance in this process. It supplies the mixer with the required raw materials. Depending on the recipe, semi-finished goods are produced which in turn are stored temporarily in a tank and then finished goods are produced afterwards. Even finished products that after production cannot be immediately filled into containers in the large and small bottling department must be temporarily stored in tanks for short periods.

Increasing flexibility
With 8000 m3, Motorex has the largest basic oil stock in Switzerland. Moreover, additives, semi-finished products and finished products are stored separately in tanks according to type families. Ten additional 1, 2 and 4-chamber tanks that offer an additional storage volume of 500 m3 for 28 different products have now been added. These structural measures have steadily increased the flexibility in production and increase the benefit to the customer of an already high delivery capacity.

Pigging system also helps to save
Upstream and downstream of production, there are soon a few hundred litres of medium in the lines and fittings between the tanks, bottling plant and mixer. So that these lines can be completely cleaned for the next production batch without residues remaining, many of the plants must carry out rinsing processes. These processes are time-intensive and cause waste and quickly incur high costs. During the “pigging process”, the contents of the pipelines is forced out using a fitting body made of flexible special plastic (pig) and a propellant, primarily compressed air or in rare cases even nitrogen in order to reduce the risk of explosion. This procedure increases production capacities by quickly cleaning the piping systems without leaving residue and means laborious rinsing processes are not necessary.

With the extension of the storage tanks, Motorex has shown again through the expanded, highly innovative production location at Langenthal that the idea of quality has been consistently implemented since its first production step and has therefore created the ideal conditions for unimpeded further growth.

Motorex AG Langenthal
Case postale
CH-4901 Langenthal
Tél. +41 (0)62 919 74 74
Fax +41 (0)62 919 76 96
www.motorex.com

We will enter into deeper details of this new motorex capability in our next issue.

LNS Group joins with Japanese Yoshida Tekko KK to maximize their global presence

Reinforcing the one-stop-shop strategy: Yoshida Tekko KK, a leader in the Japanese market for chip conveyors, coolant systems and high level filtration systems, joins the Swiss LNS Group. This strategic union allows the LNS Group to further expand in Asia, to serve its customers globally and to offer coolant system and conveyor innovations in the Asian markets.  

The headquarters of LNS Yoshida KK in Nomi, Japan.

The Swiss LNS Group acquires the assets of Yoshida Tekko KK. Founded in 1969 Yoshida Tekko KK is one of the leading companies in the Japanese machine tool industry with more than 100 employees. “Leveraging on both companies’ product portfolios, this strategic union allows us to share technologies and offer our customers a complete solution to automate and optimize their machine tools”, states Thomas Boehmer, CEO of the LNS Group. “We want to optimize the material flow and enhance productivity and efficiency for our customers from the start to the finish of the production cycle”, says Mr. Boehmer.

New company in Japan: LNS Yoshida
The acquisition gives the LNS Group a base to introduce new products into the Japanese market and serve the Japanese clients directly. As LNS is already the market leader for bar feeders in South East Asia and has production facilities in Taiwan and China, the union with Yoshida will further facilitate the Asia expansion and the implementation of the One-Stop-Shop strategy.

Step by step: LNS’ expansion to the One-Stop-Shop
With highly successful bar feeder series such as the “Express” and “Sprint”, LNS has been a world market leader for nearly 40 years.  “The acquisition of the chip conveyor company Turbo Systems Inc. in 2002 gave LNS a market leadership position for conveyors in the USA and a base for expansion in Europe. Since then, we developed the One-Stop-Shop strategy, to automate the CNC machine tools with a concentrated array of peripheral products”, explains Thomas Boehmer. The acquisition of the Italian air filtration specialist Fox IFS in 2010 and the introduction of the air filtration products to Asia was another step on this expansion track. Mr. Boehmer: “While the One-Stop-Shop is already implemented in the United States and Europe, the acquisition of Yoshida into the LNS Group allows us to realize this strategy in Asia, too.”

LNS SA
2534 Orvin
Switzerland
Phone: +41 (0)32 358 02 00
Fax: +41 (0)32 358 02 01
LNS@LNS-world.com
www.lns-europe.com

Cryogenic machining: it works!

MAG highlighted cryogenic machining at EMO last week! The revolutionary cryogenic, through-the-tool machining system was actually presented on four high performance machine tools and a robotic system using the new, eco-friendly liquid nitrogen coolant.

MAG’s newly developed liquid nitrogen cooling system was introduced to the public last fall, finally succeeding in implementing this radically new way to work. Within a short time span, the MAG experts were able to develop a practical, through-the-tool system effectively, applying it to different materials and machining technologies.

Wide spectrum of application
Four cryo equipped machines were displayed at EMO, demonstrating breakthrough applications in difficult to machine materials:

• an aerospace titanium blisk on a vertical machining center NBV 700 5X
• an Inconel part on a vertical turning center VDM 1000
• a hardened shaft on a turn/mill center VDF 450 TM
• a CGI crankcase on the hydraulic-free SPECHT 600 E

Also, a robotic root end drilling system equipped with cryogenic technology was able to demonstrate how easy composites material machining can be, if it’s done at the right temperature. Wind turbine manufacturers will benefit greatly from this new development.

Main benefits of cryogenic machining
According to MAG’s numerous tests, the following results can be highlighted (compared to classical machining):
Aerospace titanium bliskfor aircraft turbine

• Increase tool contact angle during trochoid five axis milling (Up to 30% higher feed rate)
• Tool life doubled

Inconel ring

• Tool life doubled for ceramic rough and carbide finish turning
• 30% productivity gains

Drive shaft (see picture)

• Up to double tool life
• Up to 50 % increased cutting speed

GCF root end of wind Turbine blade

• 30% higher cutting rate
• Significantly higher productivity, machine 150 more blades per year capital investment

GCI Cylinder block

• Approximately 25 % higher output reduces capital investment (4 instead of 5 machines)

These results are quite impressive and this also stunned the jury of the EMO innovation award as MAG won this trophy for its cryogenics technology.

“This is one of the greatest breakthroughs in the history of metalworking and it promises to rewrite the book on machining speeds and costs for difficult to machine materials, which are critical in aerospace, and coming into common use in automotive and general industry applications as well,” said Michael Judge, Vice President of Cryogenic Business Development.

Want to know more?

MAG Europe GmbH
Stuttgarter Straße 50
73033 Göppingen
Tel.:  + 49 7161 201 4083
Fax: + 49 7161 201 4120
www.mag-ias.com

In Switzerland
MAG Switzerland AG
Amsler-Laffon-Strasse 1
8201 Schaffhausen, Switzerland
Tel: +41 52 63 11 119
Fax: +41 52 62 50 154

Maximising Machine Shop Productivity Through Effective Metal Working Lubrication Solutions

Whether a manufacturing company specialises in producing nuts and bolts, complex gear sets or high precision valves, keeping its equipment running efficiently is the key to profitability.  Lubrication plays an integral role in reducing friction between critical rotating or moving machine tool components, which can translate into equipment durability and availability.

To help ensure that the machine tool runs smoothly, it is important to choose a combination of high-quality lubricants – slideway oils, water soluble cutting fluids and neat cutting oils.

Slideway Oils
Poorly formulated slideway oils may not separate readily from aqueous coolants.  This can result in the formation of ‘tramp oil’ which can compromise the effectiveness of the coolant by shortening its effective life and adversely altering cutting performance.  Tramp oil can also lead to bacterial growth resulting in foul odour, short service life and potential health and safety concerns.

Water Soluble Cutting Fluids
To optimise productivity it is very important to choose technology-leading aqueous coolants.  The highest performing coolants can provide reduced maintenance requirements by resisting biological attack which helps to extend batch life.  Ease of maintenance needs to be balanced with good machining performance as well as protecting the machine tools and work pieces from corrosion and sticky deposits.  In addition, the fluids should meet the latest Health and Safety regulations and be easy to monitor and maintain in service.  Collectively, these properties will help deliver long service life, excellent cutting performance and reduced maintenance downtime.

Neat Cutting Oils
Neat or straight cutting oils are used in applications which are beyond the typical performance profile of aqueous coolants, such as tapping and threading of high alloy steels.  Properly formulated products can improve machining in high speed automated machining centres through outstanding cutting performance, reduced tool wear and enhanced surface finish.  Maintenance professionals should seek products that:
Are light coloured to allow clear visibility of the workpiece
Have low misting characteristics to help workplace safety and product usage
Are chlorine free to support environmental concerns, while balancing with a high degree of lubricity and machining performance

Maximising Productivity
As well as utilising high quality metal working fluids, manufacturing companies should also incorporate an oil and equipment monitoring programme in order to maximise productivity.  Oil analysis is a series of tests that help determine the condition of internal parts and in-service lubricants.  With this information the useful lives of both equipment and oil can be extended by identifying early warning signs such as contamination and wear, which can help minimise unscheduled maintenance.

You can meet ExxonMobil till the end of the week at EMO, Hall 6, stand H38.

For more information about ExxonMobil’s range of metal working fluids or other Mobil-branded lubricants and services, please contact the ExxonMobil Lubricants Technical Help Desk on TechDeskEurope@exxonmobil.com
+420 221 456 426
www.mobilindustrial.com

 

CECIMO Seminar: New High Precision Micro-Machining Technologies

The European Association of the European Machine Tool Industries (CECIMO) is organising a seminar about micro-manufacturing technologies at EMO in Hannover.

The seminar will reveal the results obtained from the EU-funded Integ-Micro Project* which focuses on developing new high precision micro-manufacturing technologies. The project aims to enable the eco-efficient and eco-friendly production of complex shape micro parts made of various materials.
Integ-Micro is geared at producing solutions to current challenges in micro-machining operations such as multitasking, productivity and fast reconfigurability. The project strategy is based on the integration of different machining processes on compact setups. Hybrid, reconfigurable, multitasking machines will be developed by combining at least two processes in one workholding configuration:

• Micro-milling/turning + laser process
• Electro-discharge machining + micro drilling/milling/grinding
• Ultrasonic vibration assisted micro milling/drilling/grinding
• Ultra precision diamond and CBN cutting including turning/milling + micro abrasive machining

A comprehensive presentation
Furthermore, other micro-machining problems such as micro-deburring, thermal and dynamic stability, process and control reliability and eco-sustainability will be addressed by fully exploiting some key enabling technologies such as: ultra-high speed dry manufacturing; sensing, measurements, inspection and quality assessment; control techniques; adaptronics and mechatronics; new motion units and guidance systems. The new hybrid machines will enable the machining of various materials such as engineering plastics or ultra high strength metallic alloys with better surface and geometrical quality.

The Integ-Micro technology will lead to greater accuracy, reduced handling and plant area, faster throughput and increased productivity. The target application addresses a variety of key EU markets which currently demand the development of the micro/meso scale production techniques, such as medical and bio-medical, automotive, environmental monitoring, aeronautic and aerospace industries.

Distinguished speakers from renown European institutes will join the seminar, including the BioRobotics Institute – Scuola Superiore Sant’Anna, Ce.S.I (Centro Studi Industriali), Fraunhofer IPT (Institute for Production Technology), WZL (Laboratory for Machine Tools and Production Engineering) – RWTH Aachen University, Fundacion Tekniker and Cranfield University. The seminar will be followed by a roundtable discussion on future research priorities on micro-machining and a networking lunch.

Not to miss the event…
22 September 2011, 10.00 a.m. to 12:30 p.m. (registration and welcome coffee at 9.30 a.m.)
Seminar: New High Precision Micro-Machining Technologies. The Integ-Micro Project.

Hannover Fairgrounds, Convention Center, Room Frankfurt
Language: English
The seminar program and registration form is available on the CECIMO website www.cecimo.eu (the event is free of charge, but registration is required)
For further information please contact Elisabeth Vilain, CECIMO, Tel.+32 2 502-7090, information@cecimo.eu

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100 % Al Dente: Market Leader Sweden & Martina SPA prefers Motorex Ortho NF-X

Mention dental technology in Italy, and it is likely that the company Sweden & Martina SPA will also follow in the same breath. The company, founded over 30 years ago and with around 135 highly-trained employees, develops, manufactures, and distributes a wide range of innovative dental technology components with impressive efficiency from its headquarters near Padua. The company is increasingly relying on “Hightech made in Switzerland” and, as a result, the production decision-makers are using Tornos machining centres and Motorex machining fluids.

For several decades, Sweden & Martina has been highly specialised in the area of dental prosthesis solutions and restorative implants. The company has embraced a concept of integrated prototype creation through to series production, all in its own factory. This production model not only offers many advantages in terms of the high quality standards demanded, but also significantly reduces the time-to-market for new products. From the start, production managers therefore need to rely on suppliers in all areas who can guarantee the highest quality and prompt service delivery.

Advantages of using Ortho NF-X
If the production process runs smoothly, this is due to selection of the correct machining fluid. At Sweden & Martina, Swisscut Ortho NF-X demonstrated the following proven benefits:

• Universal oil for all materials
• Increased tool life
• Perfected finishes
• Greatly reduced evaporation loss
• Longer usage times for the cutting oil
• Best skin and environmental tolerance
• Highest efficiency

Innovation secures competitive advantage
By using Motorex Ortho NF-X on all its CNC machining centres, Sweden & Martina has maximised the available innovation potential in the area of machining fluids, and thus secured a further competitive advantage. As a market leader in Italy with over 30 years’ experience, Sweden & Martina is now stepping up its export activities to Europe and the Middle East. The company also fosters close collaborations with major universities and international specialists.

We would be delighted to provide you with information about the current generation of Motorex Ortho cutting oils and the scope for optimisation within your area of application:

MOTOREX AG LANGENTHAL
After-sales service
Postfach
CH-4901 Langenthal
Tel. +41 (0)62 919 74 74
Fax +41 (0)62 919 76 96
www.motorex.com

SWEDEN & MARTINA SPA
Via Veneto 10
I-35020 Due Carrare (PD)
Tel. +39 049 91 24 300
Fax +39 049 91 24 290
www.sweden-martina.com

MOTOREX Partner:
VEMAS SRL
Macchine utensili
Via Magellano, 5/C
I-20090 Cesano Boscone (MI)
Tel. +39 02 45 86 4059
Fax +39 02 45 83 133
www.vemas.it

Improving efficiency through innovative lubrication practices

With the introduction of the SMED method (single-minute exchange of die), Boillat Technologies appreciated instantly the importance of the role that processing fluids would play in optimising set-up times during production changeovers. In close cooperation with MOTOREX, the company’s needs were analysed and the solutions were presented. The result was a reduction in product variety from 12 processing fluids to just two cutting oils.

 

Jacques Boillat, the CEO and owner of Boillat Technologies in Loveresse, Switzerland, on the benefits of the SMED method and associated reduction in processing fluids.

From proven solutions to new ones
The managers of Boillat Technologies turned, therefore, to lubrication specialists MOTOREX and enquired about the potential for optimisation in the area of processing fluids. In dialogue with Technical Aftersales and the field service employees involved, all production steps were identified, production capacities recorded and tool lives determined. Based on the evaluated data and after an appraisal of the customer’s needs, production got off to a successful start from the very first batches following the introduction of the MOTOREX SWISSCUT ORTHO TX high-performance cutting/deep-hole drilling and broaching oil.

Benefits of a multi-purpose cutting oil
The cutting oil itself may be a universal grade, but any sacrifice in terms of performance would not have been entertained. Following MOTOREX’s recommendation to change over to the revolutionary SWISSCUT ORTHO TX high-performance cutting oil, the machine operator has been able to reap several benefits: It is now possible for each and every processing step to proceed with one and the same cutting oil. SWISSCUT ORTHO TX meets the most demanding requirements in the form of extremely complex machining methods combined with the most difficult-to-cut materials. The significant reduction in the quantity of processing fluids has helped to simplify logistics and substantially increase process reliability. Thanks to the absence of unwelcome substances, such as chlorine and heavy metals, the quality of the working environment has similarly been improved.

Disposal costs cut 50 %
With the changeover to MOTOREX ORTHO TX, the managers in Loveresse have selected a low-volatility and extremely skin-friendly cutting oil with minimal tendency to mist that guarantees maximum functionality with all popular ventilation systems and is integral to sustaining a healthy environment in the production room. Another pleasing aspect is the fact that the selected product is free of chlorine and heavy metals. As a result, not only is the product less harmful to mankind and the environment, it reduces disposal costs by 50 %. Indeed, recycling costs can vary considerably, depending on chlorine content and other sometimes problematic constituents. In addition, the absence of chlorine and heavy metals makes the cutting oil easy to clean up and so reduces effort in the parts cleaning process.

Objectives comprehensively achieved
“Continuous optimisation is necessary in any production business. Together with motivated colleagues, competent suppliers and new workflow methods, the introduction of SMED into our company has resulted in great success,” explains Jacques Boillat, not without a hint of pride.

MOTOREX AG LANGENTHAL
Technical Aftersales
Postfach
CH-4901 Langenthal, Switzerland
Tel. +41 (0)62 919 74 74
Fax +41 (0)62 919 76 96
http://www.motorex.com/

BOILLAT DÉCOLLETAGE SA
Benevis 2
CH-2732 Loveresse, Switzerland
Tel. +41 (0)32 482 60 60
Fax +41 (0)32 482 60 65
vente@boillat.ch
http://www.boillat.ch/

Machining Tantalum – with chlorine-free cutting oil

In the medical devices industry, platinum is frequently used as the working material, particularly for producing cardiac implants. As platinum is very expensive material – 1kg costs a little over €35,000 Euros – alternatives that are more cost-effective are being sought. Tantalum has been identified as a suitable replacement for platinum in terms of functionality, its also convincing from a cost perspective (approximately €500 Euros per kilo).

Tantalum is used in the medical device industry, but primarily in the electronics or chemical industries for measuring devices and fittings because of its excellent resistance to acids. Occasional applications have also been found for Tantalum in the jewellery and watchmaking industries.

Machining Tantalum is a real challenge. Platinum is already ten times more difficult to machine than Titanium and machining Tantalum is ten times more difficult again! Using chlorinated solvents as “cooling lubricant” has always been one way of ensuring this material can always be machined effectively. But for modern machines accounting for the increasingly stringent legislation, there is a need, in terms of machining to only have recourse to these types of solvents in exceptional cases.

What is recommended for large production runs? The first cutting oils specially formulated for machining Tantalum are still chlorinated oils, which aren’t the preferred option for use in the medical devices industry due to the sanitary reasons we can easily guess.

In conjunction with specialists in machining Tantalum, Blaser Swisslube AG has developed chlorine-free cutting oil that is not harmful to health or the environment and it offers the required performance. This cutting oil performs as well, if not better than the special chlorinated oils for Tantalum in a number of applications. The first customers are already being supplied with the chlorine-free cutting oil developed by Blaser, and are impressed with the results.

With this new development, Blaser Swisslube AG makes it easier for those involved in machining Tantalum to carry out controlled, process-secure series production. This ends the dependence on “cooling lubricants” containing substances that no-one wants to use anymore.

Are you looking for innovative cutting oils for machining Tantalum or for other processes in the medical device industry? If so, contact us – we are here to increase your productivity.

Blaser Swisslube AG
CH-3415 Hasle-Rüegsau
Tel. +41 34 460 01 01
tantal@blaser.com
www.blaser.com

From idea to finished part

A few companies have reunited their skills in the “Technical Synergies” association. The aim of this group of companies (that are not linked by any means but member of the association) is to bring more know-how to their customers. An event was organized today in La Neuveville, Switzerland. Obviously we were there. Report!

Before the start of the show this morning. Everything was prepared to welcome visitors (also with excellent local specialties for meals and beverages). It was a first event and then a good opportunity to discover the association. You were not able to go there? No trouble, the association is reachable on the net (see below). (Although that will be more difficult to feel, taste and touch through the net)

In a very nice place, close to the lake, under the sun… the four main actors of the association accompanied by 3 sponsors and an invited of honor presented their skills in machine-tool, tooling, CAD/CAM, accessories and lubrication.

Members

• Bimu – cutting tools & accessories
• Icam – innovative computer aided manufacturing
• Urma – reaming heads and Hass factory outlet Switzerland
• Gloor – special tools

Sponsors

• Blaser – the liquid tool
• Blum – measuring technic
• Niederhauser – clamping technology and systems

Invited of honor

• CIP/CTDT – training in high precision machining

As a customer what can I expect from the association?
The whole spectrum of activities represented at the event gives us a clue on the services customers can receive. First, the companies know the market better, then they can all provide better solutions. According to the projects, the fact that every skill can be found at the same place brings more efficiency and simplicity to the customers.

You’re facing a programming, tooling or machining question? It may be that the technical synergies association actually already has the answer. Do not hesitate to contact them
info@syntech.ch
www.syntech.ch

The association is only at its start and the potential for customers is huge. Eurotec will come back on this  later.