Durasol HDCF
Case Study
This global supplier of innovative and problem-solving-oriented products for track and switch technology, entered into a continuous improvement scheme to support their rapidly growing production facility. As part of this initiative a modern state of the art metal working fluid was required to support their multi million pound expansion.
BACKGROUND
An aggressive modernisation project involved the replacement of its traditional milling machines with state of the art 5 axis machining centres, higher speeds and feeds supported by increased coolant pressure would dramatically change the way its components were manufactured. This would allow production to meet the rapidly growing demands of the companies growth.
Its European owners also dictated that any developments / changes were in line with its companies environmental, Health & safety and production policies. A move away from a traditional 40%, chlorine free Semisynthetic grade, supplied by one of the worlds largest lubricant manufacturer was agreed upon.
Teklube TS were approached to utilise their expertise and in-house chemists to help supply a state of the art high performance formaldehyde free fluid. The criteria was to supply a grade capable of working in high pressure, long cycle time modern manufacturing conditions on all materials but in particular Cast Iron. Cleanliness, low drag out & product stability were key requirements of the fluid.
Free from Formaldehyde and DHCA
Free From Chlorine and NP Ethoxylates
Secondary Amines
Low Oil / low misting characteristics
Low top-up rate (Please see below Table)
Significant cost reduction
Operator friendly
Environmentally respectable
High Bio-stability
Usage Per Month Per Machine (litres)
Durasol HDCF Details
Does not contain formaldehyde, chlorine, DCHA with no free boric acid offering significant safety advantages for operators in the working environment.
Suitable for use in both soft and hard water and for the use on a wide range of materials but in particular Cast Iron. The product is truly a ‘multi-metal’ fluid and is the perfect choice for all modern manufacturing, including automotive, aerospace and high end manufactured components. Its low oil content allows the product to exhibit low drag out, top up or residue, making this grade "ultra clean" and suitable for the machining of hard, brittle nonmalleable materials.
The unique low foam emulsifier system does not rely on traditional anti-foams for foam control. The emulsion when in use produces 50% less foam compared to similar emulsion types with a 50% repeatable rapid increase in foam collapse. To be used in both soft and hard water conditions from 0ppm – 750ppm.
Typical Physical Properties
| Appearance | Amber Liquid |
| Emulsion Type | Opaque White |
| Foaming Tendency @ 5% emulsion in 50ppm | Nil foam after 5 seconds |
| Specific Gravity | 0.936 typical |
| pH @ 5% | 9.4 typical |
| Refractometer Factor | 1.6 |
| IP 287 Corrosion Brak Point, % Volume | 3.0 |
| Reichert Lubricity Characteristic at 10% dilution | |
| Noise Reduction (Metres) | 37 |
| Oil Content | 20% |