Increased Productivity Through Chemistry

Transcription

1 FABTECH Atlanta 2014 Increased Productivity Through Chemistry Steve Lowery Tower Oil & Technology Co.

2 Outline Green/Bio-Based Lubricants Pros/Cons Trends Vanishing Oil Replacements V.O.C. Free Cost Effectiveness Real World Uses Case Studies Cost Savings Process Review

3 Green Lubricants Vegetable Seed Oils Steady Increase in Use Range of Applications Synthetic Technically Speaking Renewable Resource Bio-Based Free of Petroleum Oil

4 Bio-Based Defined U.S. Department of Agriculture Composition In Whole or Significant Percentage Consisting of: Plant Animal Marine

5 Bio-Based Defined Metalworking Lubricants - USDA Classifications Soluble, Semi-Synthetic, or Synthetic Contain Minimum 40% General Purpose 57% High Performance Straight Oil Products 66% Minimum Content

6 Bio-Based vs. Biodegradable Synonymous Bio-Based, Renewable Resource, Green Biodegradable Readily - Rapid & Complete Ultimately Additives/Ingredients Petroleum, Esters, Amines, Glycols, EP Additives

7 Bio-Based vs. Biodegradable Promote Environmental Benefits They Do Not Guarantee Safety Biodegradability Bio-Based Content Gain a Full Understanding

8 Benefits of Bio-Based Lubes Enhanced Lubricity Reduces Friction & Wear Lower Levels of Lubricity Additives Extreme Pressure Additives

9 Benefits of Bio-Based Lubes Higher Viscosity Index Stability over Temperature Range Petroleum Oil VI Vegetable Based VI Lower VI More Change in Viscosity at High & Low Temperatures Higher VI Less Change in Viscosity at High & Low Temperatures

10 Limiting Factors Thermal Instability Unstable at Higher Temperatures if Untreated Bio-Engineered Seeds Bio-Processing Technologies Oxidation Additives Antioxidants

11 Trends of Green Lubricants Straight Oils - Available for Many Years Recent Trend Water Extendible Fluids Reduced Friction Greater Wear Resistance Reducing Extreme Pressure Additives

12 Comparisons Chlorinated Soluble Oil Replace Significant Portion of Chlorinated Paraffin with Bio-Based Oil Twist Compression Test to Evaluate 0.25 Coefficient of Friction Chlorinated Solube Oil Bio-Based Soluble Oil Time (seconds)

13 Twist Compression Test Scientific Bench Test Very High Interface Pressures Low Speed Variable Tool & Sheet Material Lubrication Starvation

14 Tool and Work Holder

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16 Chlorinated Paraffin vs. Bio-Based Oil 0.25 Coefficient of Friction Chlorinated Solube Oil Bio-Based Soluble Oil Time (seconds)

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18 Chlorinated Paraffin vs. Bio-Based Oil 0.20 Coefficient of Friction Chlorinated Soluble Oil Bio-Based Solube Oil 0.00 Avg Avg Avg Avg Initial 1 Rev. 3 Rev. 7 Rev. Revolutions COEFFICIENT OF FRICTION Initial 1 Rev. 3 Rev. 7 Rev. Avg St. Dev. Avg St. Dev. Avg St. Dev. Ave. St. Dev. Chlorinated Soluble Oil Bio-Based Soluble Oil

19 What does it all mean? Lower Overall Coefficient of Friction Easier to Clean Parts Lower Washer Temperatures Lower Cleaner Concentrations Better Rust Protection Better Weld Through Lower Costs

20 Pure Renewable Exclusive Use of Renewable Resources Remove the Extreme Pressure Additives Chlorine, Phosphorous, Sulfur Rely Wholly on Boundary Film Lubrication Soybean Based Lubricants

21 Green Lubricants Demand on Foreign Oil Lessens US Farmers Contribute to Industrial Engine Performance Characteristics Less Toxic to Environment Easier to Dispose Lessened Health Risks

22 Vanishing Oil Replacements

23 Many Varieties - Many Names Disappearing Compounds Vanishing Oils Evaporatives Solvents Numerous Operations Drawing, Forming, Punching, Perforating Leave a Clean Dry Part

24 What is a Vanishing Oil? Carrier Petroleum Distillate Evaporates Controls Drying Time Lubricity Additives Wetting Boundary Film Lubrication Extreme Pressure Additives Corrosion Inhibitors Metal Passivators

25 Residues Dependant on Additives Dry to the Touch Oily Sticky Non-Existent

26 Application Methods Drip, Spray, Roller Caution to use only Airless Sprayers Heat Generated in Operation Facilitate Drying Too Little Applied Evaporate before Operation Completed Galling or Tool Wear Too Much Applied Wet Parts Packing Wet Drying Time Effected

27 Categorizing Flash Point Lowest Temperature at which enough vapors to ignite if ignition source. 105ºF, 125ºF, and 140ºF Lower Flash = Faster Drying Flammability Rating: 2 Drying Time <20 minutes to hours

28 Speeding Up the Drying Influence Evaporation Rate Heat from Process Fans Heat Tunnels Air Knives Enough Lube to do the Job More is Not Better

29 V.O.C. Issues Vanishing Oils High Level of V.O.C. s Volatile Organic Compounds React with Nitrogen Oxides (NOx) Ground Level Ozone Smog EPA & Clean Air Act Non-Attainment Areas Reduce Emissions Eliminate

30 Source:

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32 Complying with Regulations Pursue Necessary Permits Use Oil & Wash Parts Scrubbing Systems Incineration Carbon-Adsorption Technology Switch to Better Chemistry????

33 V.O.C. Free Alternative Water Extendible Synthetic Fluids Mimic Benefits of Solvent-Based Fluids Wetting Lubricity Drying Time Need to Evaluate Water Source All water is not the same

34 Water - Knowledge Type of Water Soft or Hard (Calcium and Magnesium) Treated Water Reverse Osmosis, Deionized, Softened Microbial Growth Staining, Spotting, Rusting

35 Mixing Variability in the Process Dry to the Touch Sticky Residue Repeatability is Key Maintain Your Ratio/Concentration Install Automatic Mixing Device

36 Mixing Devices Venturi Device Vary with Water Pressure Fixed Orifice Low Cost Positive Displacement Device Consistent Ratio Driven by Water Pressure Easy Adjustment Graduated Scale Higher Cost Photos Courtesy of Lafferty Equipment & Hydro Blend Intl.

37 Speed Up Drying Air Knives Quiet only 69dBA Hard Hitting Curtain of Air Reduced Air Consumption Uniform Airflow Photos Courtesy of Exair Corp.

38 Energy Conservation Limit Compressed Air Use Dramatically Reduce Turn Off/On Photo-Eye Photo Courtesy of Exair Corp.

39 Latest Technology V.O.C. Free Vanishing Fluids Green Fluid Technology Direct Replacement for Solvent Based Lubricants No V.O.C. permits or fees required

40 Green Fluid Technology HMIS Rating Comparison Typical Vanishing Oil Health - 1 Flammability - 2 Reactivity - 0 ACGIH TLV ppm OSHA PEL ppm VOC Free Vanishing Fluid Health - 0 Flammability - 0 Reactivity - 0 ACGIH TLV n/a OSHA PEL n/a ACGIH TLV Threshold Limit Values - Guidelines in making decisions regarding safe levels of exposure to various chemical substances. Health based values OSHA PEL Enforceable Permissible Exposure Limits protect against exposure to hazardous substances. Based on 8 hour time weighted average

41 Green Fluid Technology No Special Ventilation Required Normally Dries Twice as Fast Does not Contain Chlorine, Sulfur or Phosphorus Excellent Corrosion Protection High Lubricity Factor All Metal Safe Odorless

42 Case Studies

43 Vanishing Oil Support Brackets G30 G90 Galvanized Progressive Die Airless Spray System Parts go direct to Assembly Current Lube Petroleum Based Vanishing Oil Used as Supplied Goals Eliminate White Rust on Parts Eliminate Smell of Current Vanishing Oil

44 Water Extendible Synthetic Run at 9:1 Ratio / 10% Solution No White Rust in Over 6 months of use Some parts stacked flat Reduced Smell Issue Eliminated V.O.C. s from Plant Non-Flammable Overwhelming Acceptance

45 Switch to a Greener Fluid HSLA thick Multiple Draws Tough Part Tool Life Concerns Parts Deburred Prior to Assembly Using Chlorinated Soluble 7:1 Tough to Clean Short Term Rust Protection - Suspect

46 Switch to a Greener Fluid Switched to a Vegetable Based Soluble 7:1 Reduced Chlorinated Paraffins by half Easier to Clean Obtained desired Rust Protection No change in Tool Life Cost Savings 0.25 Lubricants Cleaning Coefficient of Friction Chlorinated Solube Oil Bio-Based Soluble Oil Time (seconds)

47 Vanishing Oil Replacement Galvanized & Aluminum Material Progressive Dies Airless Spray Applied Parts stacked, some shipped to Mexico Goals Eliminate V.O.C. s Exceeded permitted levels several times per year. Costly Permits Health Concerns from EHS

48 V.O.C. Free Vanishing Fluid Eliminated Costly Permits Required Cost Savings No White Rust or Staining Needed to add air knives for Aluminum No change in Tool Life Overwhelming Operator Acceptance

49 Vanishing Oil Replacement HRS up to.090 Galvanized Aluminum.035 Airless Sprayer System Stacked, Nested, Sent to Assembly Concerns about V.O.C. s Looking for Healthier Alternative

50 V.O.C. Free Vanishing Fluid Replaced with V.O.C. Free Vanishing Fluid No Change in Process Comparative Tool Life Less Expensive Alternative than Previous Lubricant Healthier Shop Atmosphere Faster Drying Time

51 Cost Evaluation Techniques

52 Cost Evaluation Case History Drawn Cup Resembled Bottle Cap with Hole in Bottom 304 Stainless Steel ½ hard.030 thick - approx. 1.5 dia. Prog 100 SPM - One Part / Stroke Drip Method Tied to Press Controls

53 Issues Average Run 100,000 parts Galling / Scoring of Draw Ring / Punch Polish Draw Ring/Punch every 20,000 parts Slivers in Trim Station Clean out 1 st at 30,000 Every 10,000 until pulled. Lean Shop Press Capacity Suffered

54 Goals Uninterrupted Production Runs Eliminate Production Stoppages Polishings Slivers No Water Solubles Cost Effective

55 Results Stayed with Straight Oil (Light Viscosity) Blanking Oil Highly Compounded Oil with Vegetable Derivatives Reduced Production Stoppages Once per approx 90,000 parts Polish Draw Ring No Slivers Produced in Trim Station Increased Tool Life 50% Average Runs of 150,000 vs. 100,000

56 Problem Cost of Lubricants Blanking Oil - $5.50 per gallon Compounded Oil - $9.50 per gallon Purchasing/Management Price Sensitive

57 Solution Compare Overall Costs Lubricant Costs Die Repair Costs Press Room Costs

58 Lubricant Usage & Costs Drip Method 2 quarts per 100,000 parts 1,000,000 parts 5 gallons of Lubricant Blanking $5.50 / gal. X 5 gal. = $27.50 Compounded $9.50 / gal. X 5 gal.= $47.50 Overall Lubricant Costs $20.00 Savings - Using Blanking Oil Per 1,000,000 parts Expected Life 5,000,000+

59 Tooling Usage & Costs Cost per Toolroom Hour $50.00 Cost per Press Hour $75.00 Time to Sharpen Die 4 hours Amount Removed.005 Total Die Life.100 Time to Die Set 1 hour Remove/Return

60 Tooling Usage & Costs Blanking Compounded Oil Oil 100,00 parts 150,00 parts Number of Parts Before Requiring Sharpening Number of Total Sharpenings 2,000,000 3,000,000 Total Number of Parts Produced by Tool $4,000 $4,000 Die Repair Costs over Life of Tool $.0020 $.0013 Die Repair Costs per Piece

61 Cost Effectiveness Per Piece Savings of $ % Additional 1,000,000 more parts out of die Real Savings Equating Loses Blanking Oil Needs 1,000,000 more parts What does this cost?

62 Cost Effectiveness 1,000,000 Additional Parts Required 10 Additional Runs Based on 100,000 parts per run $2,000 Die Repair Costs 10 $50 X 4 hours $750 Set-Ups Costs 10 $75 X 1 hour $2,750 Additional Cost (per 1,000,000)

63 Cost Savings Over 3,000,000 parts Blanking Oil Compounded Oil $60 in Lube Cost $2,000 in Die Repair Cost $750 in Press Cost Additionally Tooling Overhaul Cost Estimated at $8k-10k

64 Implications of Entire Process Review Evaluate All Potential Issues and Lubricants Research & Experiment in Selecting Conduct Return On Investment Costs Costs - Costs

65 Thank you Are there any questions? Steve Lowery