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METALWORKING
CUSTOMER CHALLENGE'S
Customer Challenge:
A machine tool manufacture in Kansas rebuilt a shop
lathe for a customer. The lathe worked fine, but the noise level was very
close to the maximum allowed by OSHA standards, 80 db. They tried
everything they could, but nothing worked.
PIPGI Solution:
They added Petron Plus Transmission & Gear Box
Supplement to the main gear box. It reduced
the decibel level from 79 db to 73 db, and it only took five minutes of
operation to notice the difference. They added Petron Plus
Transmission & Gear Box Supplement to a smaller gear box, and in approx. 15 minutes they recorder a decibel reading
of 71 db, well within OSHA standards.
Customer Challenge:
A major aircraft manufacture in California had reported
high scrap problems on the aluminum skins (while being stretched) used on a
fighter plane.
PIPGI Solution:
Petron Plus Metalform 2000 (a concentrate) was added to
their existing metal form fluid. The orange
peel problem no longer existed, and they could pull and stretch more parts
without having to coat every part. They approved Petron Plus Metalform
2000-P (a finished product) to be used in this application.
Customer Challenge:
A machine shop in Kansas that does mostly government
work, was having problems on their horizontal milling machine, milling 1½
x 3 slots, and used 5 milling cutters which cost approx. $75. each.
PIPGI Solution:
They used Petron Plus Industrial Super Lube on the next
job, and only used 3 milling cutters to do
the same job. A savings of $150.00
Customer Challenge:
A European Automotive manufacture was experiencing high
cost on a Herbert Detroit Broaching Machine.
PIPGI Solution:
They added Petron Plus Metalpro Alpha to their existing
coolant, extended the regrind interval on a
trail new broach from 500 parts to 2,500 parts. This saves on broach and
regrind costs and provides longer uninterrupted production runs.
Customer Challenge:
A major Aerospace company in Europe was having problems
in milling five exotic aerospace material; QAJ Nickel, EAK St. Steel, 611C
Corrodible Steel, TAF Titanium, & INCO (901).
PIPGI Solution:
They added Petron Plus Metalpro Alpha to their existing
coolant. They reported the following: A
22.22% wear reduction, a 9.18% wear reduction, A 0.01% wear increase, A
22.20% wear reduction, A 18.98% wear reduction.
Customer Challenge:
A large Aerospace Machine Shop in Connecticut mills
aircraft structural parts for major aircraft and aerospace companies. They
work mostly with 7050, 7075, and 2219 aluminum alloy, as well as titanium.
They were experiencing difficulty in milling these parts with their current
lubricants.
PIPGI Solution:
They switched to Petronomics Heavy-Duty,
General-Purpose Soluble Machining Oil. They reported: Increase Tool Life as Much as 150% to 200%, Increased
Production, Dramatically Improved the General Working Environment,
Eliminated Smoke and Odor, Reduced Make-Up Demand, Reduced Down-Time and
Parts Costs.
Customer Challenge:
The same Aerospace Machine Shop in Connecticut listed
above submitted an up-dated report 2 years later.
PIPGI Solution:
They Reported: ...we
continue to experience the extended tool life and improved working
environment by using your ...coolant in our milling operation. We have also
determined that the finish of our aerospace parts has much improved. ...the
need to now remove only 30% to 40% of what we used to in the finishing
dept. saves time and money with a vastly better finished look.
Customer Challenge:
A manufacturer in Kansas conducted a test comparing
metalworking lubricant performance characteristics and Petrons ability to
enhance metal drilling operations on test materials. They reported: ...on
3/16 304 Stainless Steel, ...no lubricant ...drilled 42 holes before bit
wore out. On the next test they used a well known lubricant that was
applied to the material surface. They reported: ...began drilling and
continued uninterrupted for 28 holes before bit wore out. ...operator was
surprised that lubricant actually retarded the efficiency of the operation
which did better without lubrication. The next test the same lubricant was
used, but it was applied every 5th hole. They reported: ...we applied the
lubricant and continued drilling unabated for 33 holes before the bit wore
out. On the next test they tested Petron Plus Industrial Super Lube.
PIPGI Solution:
They reported: ...we
drilled 4 holes, they sprayed the bit again. ...we sprayed a moderate
amount of Petron on the drill bit after every 5th hole and continued to
drill uninterrupted for 175 holes with the same drill bit before it finally
wore out. Summary: Petron Plus Industrial Super Lube generated a
significant increase of 417% in drill bit life.
Customer Challenge:
A sub-contractor for the a major aero-space company in
Kansas conducted the following test on 3/16 Aluminum T-6 Aircraft Skins.
They reported: ...applied lubricant normally used to drill bit and to
material surface then drilled 10 holes and applied more. Using lubricant
continuously on surface, and applying to drill bit every 10 holes, operator
completed 220 holes before drill bit wore out. The next test they used
Petron Plus Industrial Super Lube.
PIPGI Solution:
They reported: ...drilled
2 holes without lubricant, then applied Petron Super Lube aerosol in small
amount to tip of drill bit, none to material. Drilled 20 holes, then
applied additional Petron to bit. Continued to drill holes throughout the
day and completed 880 holes by the end of the test using a single drill
bit. Summary: Petron Plus Industrial Super Lube showed an increase in bit
life over 400%, with no down-time for changing bits or re-tooling.
Customer Challenge:
A major aircraft manufacturer in Oklahoma conducted the
following test on a stretch press using .063 Aluminum A1 Clad Material -
pylon for a fighter. They reported: ...each time a pylon part is stretched
or pulled, the die is completely lubricated with an automatic air-spray
gun, virtually coating the die with lubricant to prevent as much marring
and scratching of the aluminum material as possible, and to aid in the
stretching process. ...in spite of the effort, the current lubricant still
does not prevent a slight marring or scratching of the inside surface of
the material being stretched, nor does it prevent the exterior from
exhibiting a cosmetic characteristic known as orange peel effect, The
next test they used Petron Plus Metalform 2000 blended at 20% with the
above lubricant.
PIPGI Solution:
They reported: ...there
was no evidence of scratching, marring, or any kind of stress-related
damage to the interior part of the material. Additionally, there was
absolutely no orange peel effect noted. ...there was also no damage or
marring to the die. ...the press foreman noted that there was still an
unusual amount of lubricant remaining on the die surface. ...he ordered
another part pulled without re-lubricating the die surface. ...a total of 5
pylon parts were examined extensively with superior quality results after
only a single coating of Petron Plus Metalform 2000.
Customer Challenge:
Reserved for your company metalworking story.
PIPGI Solution:
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