East China comprehensive machinery manufacturer uses Wenou products to achieve a comprehensive cost reduction of 18% in processing and protection links

A comprehensive machinery manufacturing enterprise located in East China, providing core components for engineering machinery and automation equipment. Its production covers turning, milling, and grinding of various materials such as cast iron, carbon steel, and alloy steel, as well as complex parts storage and assembly processes. The manufacturer uses different brands of products for the use of original metalworking fluids and rust prevention between processes, facing the challenges of short lifespan of black metalworking fluids and high tool wear; Insufficient rust prevention between processes has led to multiple challenges such as high corrosion rates of workpieces. After introducing the WOUCOOL 755 semi synthetic black metal machining fluid and WRP 556 film type long-lasting metal protective agent provided by Shanghai Wenou, the integrated lubrication and rust prevention solution of "machining fluid+protective agent" has been developed. The manufacturer has eliminated the problem of bulk rusting, stabilized product quality, extended the replacement cycle of the centralized liquid supply system, and achieved comprehensive cost reduction.

Challenge

The manufacturer has insufficient lubricity of the original metalworking fluid under moderate loads during the turning, milling, and grinding of various materials such as cast iron, carbon steel, and alloy steel, resulting in tool wear rates higher than the industry average. Its resistance to impurities and antibacterial capabilities is weak. In the centralized liquid supply system, the frequency of full line shutdown and replacement is high, and the daily replenishment rate is high, directly pushing up fluid consumption and shutdown costs. During the storage period before entering the assembly workshop, the original rust prevention measures for precision steel parts after processing cannot effectively resist the humidity of the workshop environment. The corrosion rate of the workpiece fluctuates between 3% and 5% for a long time, resulting in additional polishing, repair, and even scrapping, seriously disrupting the production rhythm and pushing up quality costs.

Solution

To address these challenges, the Wenou technical team was invited to conduct a comprehensive evaluation and diagnosis of the manufacturer's equipment, water quality, processing technology, and working fluid management.

On the black metal processing line of cast iron and carbon steel, it is recommended to use WOUCOOL 755 semi synthetic black metal processing fluid. This product is formulated with composite anti rust additives and refined mineral oil and other additives, and is an excellent black metal processing fluid suitable for medium to heavy load processing. It has good anti microbial stability, lubrication, cleanliness, cooling and anti rust properties, which can reduce tool wear from the root and extend the service life of the working fluid.

In the process of rust prevention, all unstable old methods are eliminated, and the Wenou WRP 556 film type long-lasting metal protective agent is used. This product provides medium to long-term rust prevention protection for iron-based and non-ferrous workpieces. Through immersion, spraying, coating, flushing and other operations, a very thin but dense protective film is formed on the surface of the workpiece, achieving indoor rust prevention for several months without sticking to the hands and affecting subsequent assembly. WRP 556 film type long-lasting metal protective agent can quickly replace moisture and provide direct protection for damp parts; Compatible with most bearing lubricants and greases, eliminating cleaning processes and reducing cost expenditures; Proper use can provide up to 5 years of indoor protection, achieving effective protection; And the oil film is very thin, which facilitates the inspection, handling, packaging, and stacking of parts.

achievement

The manufacturer has fundamentally improved the challenges and difficulties they previously faced after using products from Wenou. The manufacturer uses WOUCOOL 755 semi synthetic black metal machining fluid, which reduces the frequency of fluid replacement and extends the service life. The stable service life in the centralized liquid supply system is extended to more than 14 months, and the daily replenishment rate is reduced by 25%. The comprehensive wear rate of cutting tools is reduced, and the cost is lowered. After treatment with WRP 556 film type long-lasting metal protective agent, the workpiece did not experience batch corrosion during the storage period, solving the repair process caused by corrosion and reducing the overall cost.

Value provided to customers

·Extended coolant usage cycle, reduced replacement frequency, and reduced machine downtime

·The problem of workpiece corrosion has been solved, reducing overall costs