Dual purpose lubricants by Condat to improve your cold heading processes

To optimize machine lubrication and cold heading processes, many cold heading manufacturers have grown accustomed to using two different lubricants. Unfortunately, this brings an entirely different set of issues: increased viscosity, particles of phosphate and steel in suspension, increased coefficient of friction that decrease tool life. Therefore cross contamination of these oils minimizes the targeted benefits of using separate products.
DUAL-PURPOSE EFFICIENCY
CONDAT EXTRUGLISS® Dual-Purpose oils enable the use of one and unique lubricant to settle this kind of issues. They have been specially formulated to provide both superior lubrication characteristics to machinery, as well as outstanding lubrication for your cold heading process.

EASY RECYCLING TO REDUCE LUBRICATING WASTE
In typical cold heading applications, approximately 90% of oil consumption occurs when oil is dragged out of the machine on the surfaces of formed parts. EXTRUGLISS® oils thanks to their lower viscosity limit oil drag out and decrease consumption dramatically. Reductions of more than 30% have been measured under identical manufacturing parameters (see enclosed graphic).

Stacked area chart demonstrating EXTRUGLISS oil's benefit in waste oil reduction. The chart shows a transition from competitor oil usage to EXTRUGLISS oil, with total waste decreasing from 50,550 Liters in 2013 (competitor oil) to 28,250 Liters during replacement in 2014, and further to 26,932 Liters with EXTRUGLISS oil in 2015, achieving an almost 50% waste oil reduction.

EXTRUGLISS® oils have been specially formulated to allow drawing soaps and other contaminants to settle out of the oil, carrying with them abrasive metallic particles. As a result, the lubricant remains clean and provides optimum performance.
Using EXTRUGLISS® oils makes it possible to extend the life of the tank 2 times more. So the emptying frequency could be increased up to 1500 hours without any troubles.

LUBRICITY PERFORMANCE & TOOL WEAR REDUCTION
Given the importance of tool life and its effect on operating costs, it is critical to use die lubricant which is optimized for the cold heading process.
With a main objective on improving productivity and tool life, CONDAT EXTRUGLISS range is designed to improve tool life. The benefits can be seen in the workplace environment:
- Low smokes
- Cleaner machines
- Optimum surface finish
Depicted below, illustrations of the high lubricity power of EXTRUGLISS oils: Comparison of two cold-headed metal parts: one on the left shows a rougher surface with visible striations (Ra 0.184) from standard technology, while the one on the right, produced with EXTRUGLISS technology, exhibits a much smoother finish (Ra 0.132), demonstrating improved surface quality in metal forming processes.
Thermal images comparing cold heading processes: standard technology shows a maximum temperature of 144°C, while EXTRUGLISS technology limits it to 125°C, illustrating improved temperature control.
As evidence, the cost reduction is important, mostly on difficult parts. 40% tools cost reduction and 15% less power requested on the machine could be reached.

IN A FEW WORDS
EXTRUGLISS dual-purpose oils enable the manufacture of very difficult cold headed parts while improving the tool life. Due to its high performance, these oils increase the OEE (efficiency of your machine) and can reduce your tooling expense.
These oils:
• Reduce wear of machine components
• Reduce oil consumption
• Increase tool life
• Reduce oil disposal costs
• Provide cleaner machinery and formed parts. The EXTRUGLISS oils are also available under vegetable based formulation: EXTRUGLISS GREEN. This new development enables CONDAT to provide safer solutions that correspond to health, safety and environmental concerns in cold heading companies.

Discover CONDAT's innovations at the wire Düsseldorf 2016 exhibition (April 4-8), hall 15 stand B43.
In the hall dedicated to the fastening industry, CONDAT will present the EXTRUGLISS technology and its new solutions to provide high duty lubrication with optimum safety and budget.
Besides its wide range of lubricants dedicated to the requirements of cold heading machinery, Condat will also showcase its solutions for the wire drawing industry at hall 10 stand A52.