High performance lubricants speed hydroforming
A
Castrol UK product story
Edited by the Engineeringtalk editorial team
Apr 18, 2003
For many years Castrol has played an active role in the hydroforming process by developing, supplying and supporting a range of specialised lubricants.
For many years Castrol has played an active role in the hydroforming process by developing, supplying and supporting a range of specialised lubricants.
So when recent advances in technology produced machines with significantly higher production rates, it was no surprise that Castrol was asked by Schuler Hydroforming, the world's leading manufacturer of this type of press, to develop new high performance lubricants that would match the latest developments in the deformation process.
The most serious problems encountered with existing lubricants were excessive application times and deposits in the aqueous hydraulic medium that led to reductions in the filter life and significant downtime filters changes.
Castrol's solution was a range of innovative lubricants that overcame the problems experienced with traditional products and significantly outperformed them in comparative trials.
The Iloform HFO range provides extreme pressure performance and excellent adhesion for tube outer lubrication, allowing smooth metal movement and preventing wall thinning.
The benefits for inner hydraulics include: excellent corrosion inhibition and high-pressure stability, as well as fast demulsification that allows oil contamination to be easily skimmed to extend filter life.
As a result, Schuler reports that OEMs are now able to consider hydroforming for more difficult applications that would previously have seemed impossible using an oil as outer lubricant.
The Iloform HFO fluids have certainly helped a leading automotive component manufacturer achieve fast, trouble-free commissioning of its new state-of-the-art Schuler hydroforming press, which is dedicated to manufacturing chassis components for one of Europe's major carmakers.
The company asked Castrol to recommend process fluids that would give it minimum disruption, from commissioning through to full production, and would provide manufactured components with effective corrosion protection during transit to their customer.
Castrol proposed its Iloform BWN 180 (for tube bending and outer lubrication) and Iloform RS5116 (a hydroforming/water-hydraulic fluid).
Both fluids are recommended by Schuler and are used successfully in other automotive hydroforming applications.
Following successful trials with both products, the customer began full production and has since asked Castrol to provide condition monitoring of the Iloform RS5116 coolant system to ensure that the fluid is always in optimum condition to maximise production.
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