Durasol X ULF Plus
Case Study
Honda Foundry is a wholly-owned company of the Honda Motor Group. The factory produces aluminium pistons for South-East Asia, which are supplied to motor cars, motorbikes and marine engines. Each production line produces 40,000 – 80,000 pistons per calendar month. As part of their "cost down" initiative, Honda Foundry approached Teklube TS Ltd to develop a lubricant grade to meet all their needs:
Machine cleanliness
Reduced consumption
Superior surface finish
Extended sump life
An overall reduction in cost per part
Teklube TS Ltd used their wealth of experience to develop Durasol X ULF Plus. It incorporates ultra-low foam technology, an in-house emulsion package with specifically selected performance additives and esters to achieve Honda’s "cost down" brief.
The key benefits of the grade are:
Cost reduction in Coolant by 62%
Reduction in fluid top up by 52%
Machine Downtime Savings of 88%
Waste Disposal Savings of 69%
Dramatically reduced consumption with minimal component residue retention with a 78% reduction seen over a multiyear period
An overall cost per component reduced by 47%
SUMMARY
The results following 30 days of testing reported a significant reduction in drag out and superior surface finish of the piston. Their daily consumption was reduced from 13.98L per day to 8.4L per day using Durasol X ULF Plus, which is a 39.91% reduction.
This equates to a 46,000L per annum reduction in fluid across the 23 production lines saving €110,000 per annum in coolant spend.
COST PER COMPONENT (£)
Durasol X ULF PLUS Details
Durasol X ULF is a highly biostable and water-miscible coolant designed to give outstanding performance when machining a wide variety of materials. It is particularly suited to the machining of aluminium including aerospace aluminium alloys. It is also suitable for use on a wide range of difficult-to-machine materials and a perfect choice for automotive parts-production.
Features and Benefits
Excellent lubricity
Ultimate chlorine-free EP performance
Long sump life
Chlorine, Secondary Amine and NP Ethoxylates free formulation
Superb surface finish
Enhanced tool-life
Low foaming
Suitable for sensitive alloys
Typical Physical Properties
Appearance: amber liquid
Emulsion type: milky white
Foaming tendency at 5% emulsion in 50 ppm water. Nil foam after 5 Seconds (0.98 typical)
Specific gravity at 20 degrees (9.2 typical - pH at 5%)
Refractometer factor: 1.1
IP 287 Corrosion break point - Volume: 2.5%
Reichart lubricity characteristics at 10% dilution: 13 m
Load bearing capacity: 1.50 kg/mm2