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Extreme surface pressures and specific frictional forces are critical aspects that affect tool and work piece in a wire drawing process. Knowledge of distribution of contact stresses and friction coefficients over the die surface is critical in formulating the right lubricant that has to perform under demanding conditions.
BECHEM’s Unopol and Berudraw range are globally sought after lubricants for wire drawing processes of Copper, Aluminium, Steel and alloys. These advanced lubricants provide superior lubricity ensuring excellent surface finish for drawn wires. The dynamic additive package extends the service life of the lubricant and drawing die as well.
WIRE DRAWING FLUIDS
High performance drawing lubricant recommended for rod breakdown and medium wire drawing process of Copper and alloys. Also suitable for drawing copper in multiple wire machines up to final diameters of 0.20 mm. Provides excellent lubrication combined with effective cleaning of wire and machine. BECHEM Unopol G 560 provides long service life of emulsion.
| Product | Application | Send Your Queries |
|---|---|---|
BECHEM Unopol G 560
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Rod Breakdown |  |
Semi synthetic drawing lubricant recommended for use in drawing medium and fine wires of bare, tinned, nickel and silver plated copper wires. The product is apt for drawing in single and multi wire systems with diameters down to 0.10 mm till even up to 0.07 mm. Combination of selected lubricating additives and inhibitors in Unopol F 811 ensures stable viscosity and longer sump life. Can be applied in dipping and spraying machines.
| Product | Application | Send Your Queries |
|---|---|---|
BECHEM Unopol F 811
|
Fine wire drawing | |
Next generation water miscible, mineral oil containing semi synthetic drawing lubricant that is specially designed as an annealing fluid for continuous annealing in fine and superfine wire drawing processes. Unopol SPG 623 contains high level of Copper inhibitors, which protect the wire against discolouration after intense annealing.Product offers excellent cleaning effect as well as protection against corrosion and staining
| Product | Application | Send Your Queries |
|---|---|---|
BECHEM Unopol SPG 623
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Annealer lubricant | |
Non water miscible drawing lubricant for wet drawing of Aluminium and alloys. Can also be used in medium wire breakdown systems of diameters upto 0.60 mm. Combination of selected lubricating additives and inhibitors ensures stable viscosity and longer sump life. Can be applied in dipping and spraying machines.
| Product | Application | Viscosity [mm2/S] at 40 °C | Send Your Queries |
|---|---|---|---|
Berudraw AL 20
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Rod Breakdown | 180 – 200 | |
Low viscous non emulsifying medium to fine wire drawing lubricant for continuous wet drawing of Aluminium and alloys. Berudraw AL 3 contains proven combination of lubricity improvers and oxidation inhibitors that provide superior lubricating properties with high resistance to ageing and corrosion protection. Additionally Berudraw AL 3 extends die life.
| Product | Application | Viscosity [mm2/S] at 40 °C | Send Your Queries |
|---|---|---|---|
Berudraw AL 3
|
Fine wire drawing | 27-33 | |
Non water miscible drawing oil for wet cold drawing of low and high alloy steel. Forming degrees about 20% to 30% can be achieved. Suitable for round bars, profiles (squares & hexagonal) with difficult geometries. Ensures long tool life and excellent surface finish
| Product | Viscosity [mm2/S] at 40 °C | Application | Send Your Queries |
|---|---|---|---|
Berudraw 4046
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277 – 337 | Rod Breakdown / Bright bar drawing | |
Non water miscible chlorine free oil for medium and fine wire drawing of Steel and SS wires. EP and AW additive package in the lubricant ensures extended tool life
| Product | Application | Viscosity [mm2/S] at 40 °C | Send Your Queries |
|---|---|---|---|
Berudraw 244
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Medium and fine wire drawing | 20-24 | |
Beruclean Eco is a high performance cleaner based on synthetic hydrocarbons with no ozone depleting agents. Compatible with plastics and rubber. Universal cold cleaning agent, free of aromatic hydrocarbons, almost no smell, readily biodegradable according to OECD 301 F. Also NSF-H1 appoved. Gives temporary rust protection.
| Product | Viscosity [mm2/S] | Materials | Send Your Queries |
|---|---|---|---|
Beruclean Eco
|
1.8 | Copper, Aluminium, Steel and Stainless Steel | |
FREQUENTLY ASKED QUESTIONS
Emulsifiers help in increasing solubility of the cutting oil in water by breaking down the oil into smaller globules and thereby maintaining a stable and uniform emulsion. A stable emulsion provides longer tank life and also ensures lower carry over loss resulting in minimum top ups.
The basic function of a cutting fluid is to provide adequate lubrication to the tool and work piece friction zone as well as remove heat generated by cooling the deformation area. Some additional properties that are desired in the cutting fluid are,
- Ability to rinse away the metal debris from the friction zone
- Provide adequate protection against corrosion to the machine and work piece
- Compatible to machine paint and ensure stain free machines
- Easy to handle and comply to safety and environmental regulations
Intense amount of heat is generated between the grinding wheel and work piece due to friction and cutting process. Uncontrolled heat can lead to structural damage of the work piece and increase in wear rate of the wheel. Fine dust and metal debris are continuously generated and needs to be cleared out from the wheel, work piece interface. The cutting fluid for Grinding process should possess the right amount of lubricity and cooling property to reduce friction and manage temperature rise. Additionally the cutting fluid should also possess the right amount of detergency and flushing property to clear the fine machined debris.
With a higher dosage of lubricity to reduce friction and temperature rise, the coolant should also contain EP additives that can protect the tool by forming a thin layer between the tool and work piece. Additionally, the cutting fluid should possess the right amount of flushing property to clear the machined swarf from the machined area
Ideally, de mineralized (DM) water with neutral pH of 7 and hardness less than 50 ppm is recommended. The chloride level should be less than 25 ppm with no bacterial and fungal presence. Usage of hard water leads to increased conductivity, hence poor rust protection and lower sump life.
‘Oil into water’ or ‘oil in last (OIL)’ is a recommended practice for better solubility of the coolant in water. Water in oil would result in large size oil globules with the oil loving ‘oleopphilic’ ions of the emulsifier being ineffective. This would lead to a unstable oil water emulsion.
- Keep a regular check on the concentration of the emulsion, maintain recommended concentration
- Remove any tramp oil from the coolant tank thoroughly
- Measure pH regularly
- Avoid all sorts of dust near the tank, remove the machined debris from the tank regularly.
- Follow the prescribed procedure while changing the coolant.
Including the effectiveness of ‘cutting fluid’, tool life is impacted by a host of other parameters including cutting speed, feed rate, depth of cut, tool and work material, nature of cut and machine rigidity. Cutting fluids with high amount of EP additives would insulate the tool from frictional wear and ensure longer life. Studies have shown that with all other parameters remaining the same, cutting fluids with good EP properties can increase tool life by 20 to 40%.
Aluminum alloys which contain Copper and Zinc as alloying elements are susceptible to chemical reaction (black stains) with cutting fluids that contain Amines as ingredient. For machining such Aluminum alloys, amine free cutting fluids are recommended
Colour change of the emulsion is notable during machining of Cast Iron with the Fe ions dissolving with the emulsion. However with all other parameters such as pH, conductivity, concentration and microbial behavior remaining within the specified limits, colour change does not impact performance of the emulsion.
Operators handling components with bare hands and in constant touch with the emulsion could feel irritation and itchiness or develop rashes as well. As sensitivity of the skin is subjective, operators need to handle machined components with proper gloves and other protective gear with the objective of avoiding direct contact with the emulsion. Barrier creams could also be considered where direct contact is unavoidable.
Ensuring a stable emulsion with regular check on pH levels and microbial growth by removing chips, swarf and tramp oil from the tank will also help in reducing possibilities of such concerns. Encourage operators to maintain good personal hygiene, recommend regular laundry of their work dress, avoiding wet rags into pockets, usage of mild soaps etc.