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 Apollo America Corp.
Test comparisons
Daphne Magplus HS32-U Hobbing Oil
Daphne Cut BR60-U Broaching Oil
Comparisons of Apollo Daphne metalworking lubricants versus existing hobbing and broaching oils at an automotive transmission plant.
Introduction: These cutting oils were specifically designed to reduce the health hazards and environmental impact of oil products, while simultaneously increasing the performance and reducing the purchase, use, and disposal costs. This required the elimination of hazardous chlorine and active sulfur additives. The solution was found by using a less costly and better performing organic molybdenum EP alternative, non-active sulfur compounds, and better quality and lighter virgin oils.
Specific Items Compared
- Viscosity
- Color
- Corrosiveness
- Chlorine content
- Odor
Viscosity
- Viscosity is a measurement of the oils thickness or resistance to flow
- Evaluated using ASTM D-445
- Higher viscosity fluids have greater "carry-off", or rate of consumption
- Lower viscosity fluids flush away chips more efficiently, and remove heat more quickly
- Lower viscosity fluids can be applied at lower pressure, reducing mist amounts.
Viscosity comparison
Viscosity @ 40C
Daphne Magplus HS32-U = 32cSt
Current Hobbing Oil = 60.72cSt
Daphne Cut BR60-U = 11.13cSt
Current Broaching Oil = 59.18cSt
Color
- Lubricants can range from clear to dark black in color.
- Evaluated using ASTM D-1500 to evaluate color
- Results can range from L0.5 to D8.0
Color Comparison
Hobbing
- Daphne Magplus HS32-U = Light Green (L3.0)
- Current Hobbing Oil = D8.0
Broaching
- Daphne Cut BR60-U = L1.5
- Current Broaching Oil = D8.0
Corrosiveness
- Copper Corrosion Test evaluates a lubricants tendency to corrode tools, machines, and parts
- Active-type sulfur and Chlorine EP agents will corrode copper, bronze and other yellow metals (such as bushings and guide ways)
- Evaluated using ASTM D-130
- Results = 1A (mild) to 4C (very corrosive)
Copper strip comparison
Hobbing
- Daphne Magplus HS32-U = 1A
- Current Hobbing Oil = 4C
Broaching
- Daphne Cut BR60-U = 1B
- Current Broaching Oil = 4C
Chlorine content
- Chlorine and chlorinated paraffins are Extreme Pressure (EP) agents used in metal working lubricants
- Evaluated using ASTM D 808
- Results are given in wt %
- Although helpful for tool life they are a health hazard and disposal problem
Chlorine Comparison
Hobbing
- Daphne Magplus HS32-U = 0.00 % Cl
- Current Hobbing Oil = 3.304 % Cl
Broaching
- Daphne Cut BR60-U = 6% Cl (Non-active type)
- Current Broaching Oil = 5.716% Cl (Active type)
Odor
Hobbing
- Daphne Magplus HS32-U - Mild, light odor
- Current Hobbing Oil - Distinct petroleum odor
Broaching
- Daphne Cut BR60-U - Mild, light odor
- Current Broaching Oil - Distinct petroleum odor
Causes of Odor
Odor is caused by two main factors:
- Low quality Base Oils
- Active type Sulfur additives
Daphne metalworking fluids have a mild, light odor due to the high quality, narrow-cut base oils. Also, due to their Non-active chemistry, the strong sulfur smell, common to many cutting oils, is greatly reduced.
Conclusions
Using Daphne Hobbing and Broaching oils will provide:
- Reduced oil consumption due to lower viscosity which means less carry off
- Easier viewing of oil contamination, effectiveness of filtration, parts and tools due to the lighter color
- Much less machine wear & part corrosiveness due to the Non-Active type chemistry
- The elimination or reduction in hazardous Chlorine and in the workplace
- Lower odor, mist levels, and substantially reduced tendency of skin irritations
- Lower flash point due to use of higher quality virgin oils
Recommendations
Great Lakes and Apollo America Corp. will assist your engineers with the selection and acquisition of suitable cutting fluids for evaluation.
In plant performance testing and comparisons:
- Testing for cutting fluid performance: 20-30% improvements in tool life have been achieved in similar gear hobbing and broaching studies.
- Reduced consumption due to less carry-off - also the use of spin stations or part air blow downs are more effective.
- Increased operator acceptance and comfort due to lower odors, mist levels, and substantially reduced tendency of skin irritations.
- Reduced purchase costs, oil maintenance and disposal problems.
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