Productivity, economic efficiency and machining quality are the key to success in the metalworking industry. The company Sphinx Werkzeuge AG strived to optimize these factors at its production site in Porrentruy. For this purpose, the tool manufacturer consulted the metalworking fluid experts of Blaser Swisslube.

Sphinx Werkzeuge AG is a leading company for the manufacture and distribution of precision tools for the machining industry. Among its customers are well-known companies active in industry and medical technology, which rely on the quality and long-standing experience of the company. The product range includes micro drills and micro endmills that extend down to a few hundredths of a millimeter in diameter as well as drilling and special tools that are manufactured to customers’ specifications. The company operates two production sites in Switzerland – in Derendingen (Solothurn) for the micro tools and another in Porrentruy (Jura), where tools with larger diameters are manufactured.

The four factors machine, grinding wheel, material and metalworking fluid have a great influence on the grinding process. The company management was aware of this and addressed the issue at the beginning of 2013, ultimately deciding to review the current situation at the site in Porrentruy. One objective was to determine the efficiency of the production; another one dealt with the question of whether the processes and operations still complied with the latest technology. The company management reasoned that there could be opportunities for potential optimization. Blaser Swisslube was contracted to examine this question, but also to study any influencing factors. The metalworking fluid manufacturer from the Emmental has comprehensive know-how in this area and, by working closely together with its partners, offers a holistic review of the machining operations and processes. The goal always lies in the optimization of productivity, economic efficiency and machining quality so that partners are able to obtain the fullest possible use from their machinery. Rico Pollak, the Head of Grinding

Technology at Blaser Swisslube, remembers the initial discussions at the plant in Porrentruy: “First, we had to gain the trust of the plant employees. We questioned the manufacturing processes that were used up to that time and searched for optimization opportunities at every level. We knew that the workshop employees would be rather skeptical about our questions and inquiries.” But once the grinding specialists at Sphinx recognized the possibilities as well as the benefits of the co-operation with Blaser, the ice was broken. “Thanks to the cooperation with the Blaser employees, we achieved a lot more than we expected and the interaction was very pleasant,” explains Martin Arnold, Head of Technology / R&D at Sphinx Werkzeuge AG.

During the test phase, one of the tool grinding machines was filled with the grinding oil Blasogrind HC 5-56. The grinding oil, based on a synthetic oil (hydrocrack), was perfectly suited to the grinding operations and materials used at Sphinx. Besides high removal rates, the benefits of the product are, among others, its machine and operator compatibility, its low misting properties as well as the long-term stability of the oil. Furthermore, Blasogrind was designed in such a way that only a negligible amount of cobalt is leached.

The goals set by the company management consisted of an increase of productivity as well as maintaining the same level of process safety – meaning accuracy, surface quality as well as the prevention of microcracks. During the test phase, the refilled machine was used to produce carbide drills with a 5 mm diameter. Individual operations included the grinding of flutes, thinning, free grinding as well as four facet grinding. Thanks to the optimal grinding oil, it was possible to increase the feeds up to 40% for some operations. This had an immediate effect on productivity by yielding a higher output.

After the conclusion of the test phase, the defined goals were not just met, but exceeded. Productivity was increased, leading to 12% savings on the overall production time. Likewise, the surface quality did not just remain the same, but saw a noticeable improvement. A more even surface structure of the manufactured parts was the result. The switch of the metalworking fluid resulted in a further measurable added value because the consumption of metalworking fluid was reduced due to low mist. “Overall, the savings achieved by the increase in productivity and the reduction of metalworking fluid exceeded the costs of the fluid many times over,” according to Rico Pollak.

“For us, the jointly and successfully executed project yielded an increase of productivity for our production in Porrentruy. Furthermore, the switch to Blasogrind led to an improved air quality in the production hall,” said JeanMarc

Salomon, Ing. HES, Director of Porrentruy, Sphinx Werkzeuge AG. “Only the application of the optimal metalworking fluid, harmonized with the machining operations of the partner, will turn the metalworking fluid into a liquid tool and significantly influence productivity, economic efficiency as well as the machining quality,” explains Rico Pollak.

The tool-grinding machines in Porrentruy were successively switched to Blasogrind. At the present time, tests are being planned to optimize the metalworking fluid at the production site in Derendingen. Therefore, a continued cooperation of the two companies is obvious.

ExxonMobil Lubricants Private Limited participated at the 18^th National Lubricating Grease Institute (NLGI) – India Chapter’s Annual Conference and showcased its expertly formulated comprehensive range of greases available in India. The conference, organized by NLGI – India chapter from Feb. 05^th to 7^th, 2016 in Lonavala, is a premier platform for grease-related industry stakeholders in India. ExxonMobil elaborated on how leveraging comprehensive lubricant technologies and service solutions can help companies enhance safety, achieve environmental care-related goals, and maximize productivity, attracting wide attention from participating companies and representatives at the annual grease conference.

Advancement in machine and equipment designs have affected operating parameters and thus the requirement for lubricating greases. As operating parameters like speed, load, temperature, etc., vary significantly based upon the equipment, it is practically impossible for a single grease to handle all the diversified applications. Mobil has a balanced portfolio of state-of-the-art, well proved, high-performance lubricants and greases that can cater to the needs of many industrial sectors – including metals, cement, construction, mining, power generation, general manufacturing, plastics, food and beverage, pulp and paper – all backed by ExxonMobil’s technology leadership and unmatched industry expertise.

“In modern machinery design and construction, machines function under severe operating conditions with the expectation of increased productivity and less downtime. This has made it difficult for conventional lithium greases to satisfactorily fulfill these requirements. In light of this fact, high performance greases like lithium-complex and calcium-sulfonate are the best candidates for the said applications. While lithium-complex greases have excellent compatibility with the most widely used lithium greases, calcium-sulfonate greases are also moderately compatible. Lithium-complex greases generally possess good stability, high-temperature characteristics and water-resistance properties which meet the needs of a wide variety of heavy-duty applications and operating conditions. They provide balanced load-carrying capability across a spectrum of loads, speeds and temperatures,” said Mr.Imtiaz Ahmed, Asia Pacific Mobil SHC Brand Manager, ExxonMobil Lubricants Private Limited.         

To fulfill the unique needs of a wide range of industries, Mobil offers a comprehensive line of greases with advanced technology that are designed to offer customers extended re-greasing intervals, longer equipment life, and greater productivity. This includes synthetics for extreme conditions, polyurea thickener based greases for long life and use in high temperatures, food-grade solutions, and grease for environmentally sensitive applications. The level of grease’s performance depends on the formulation approach. Greases that are developed through a balanced formulation approach often offer significant performance benefits and advantages. Mobil’s advanced formulation greases are designed to provide all-round balanced performance for severe conditions experienced by today’s industrial and mobile equipment.

The mining industry is one of the most fundamental components of the industrial landscape, and also one of the most challenging from a lubrication standpoint. By combining the use of high quality lubricants and an effective technical services program, mining operators can achieve a competitive advantage in their operations, by enhancing productivity and reducing their lubrication consumption which will potentially increase the productivity and reduce downtime of their mining machinery and equipment. In addition, health and safety benefits may also be realized.

“Operators in the mining sector have to balance multiple concerns, as they try to enhance operational safety and keep their machinery running at peak performance, even when it is subjected to extreme temperatures and heavy loads. To help address these issues, it is essential to work closely with mining customers to develop a solutions-focused approach to help protect and maintain equipment across their entire operation. This can be done by leveraging comprehensive lubricant technologies and service solutions, helping companies enhance safety, achieve environmental care-related goals, and maximize productivity. Lubricant programs and services – when delivered from a solutions-oriented approach – can play an important role in advancing productivity in mining operations,” said Mr Shankar Karnik, General Manager Industrial, ExxonMobil Lubricants Private Limited.

While the primary function of a lubricant is to protect equipment, reduce unscheduled downtime and extend oil drain intervals, advancements in lubricant technology now mean mining companies can select oils and greases which provide outstanding levels of protection as well as other potential benefits such as improved fuel economy. Heavy-duty diesel engine oils, hydraulic oils and greases work hand-in-hand to enable mobile machinery on mining sites to operate effectively.

“ExxonMobil’s comprehensive portfolio of oils and greases along with robust services, combine to offer holistic solutions for mining operators. The benefits offered have been widely acknowledged by successful mining operators located all across the world. The technology leadership embodied in our greases, along with the application expertise of our engineers, can help mines: address safety exposure, mitigate environmental touch and support their desire to be more productive,” said Umut Urkun, Global Grease Marketing Advisor, ExxonMobil Fuels & Lubricants.

Backed by more than 100 years of industry expertise, Mobil’s range of  greases are expertly formulated to meet a wide variety of operating conditions in both industrial and mobile equipment, including extreme applications such as high and low temperatures; water contamination; heavy or shock loads; or variable speeds. Mobil greases are available in a range of viscosity grades to offer customers added choice and flexibility. Mobil’s grease portfolio in India includes Mobil SHC Polyrex, Mobilith SHC, Mobilgrease XHP series and Mobil Centaur XHP. The Mobilgrease XHP series includes Mobilgrease XHP 461/462, Mobilgrease XHP 222 and Mobilgrease XHP 222 Special.