CASE STUDY Drawing and Forming: Scrap Rate Reduction from 19% to 2% QUAKERDRAW® 73 XP The Challenge
CONCENTRATION
A French manufacturer of gas bottles for the global consumer market was using a 2-stage drawing process to manufacture standard gas bottles, and a 3-stage drawing process for production of Acetylene bottles. The manufacturer wanted to:
Lower is better
25 20
(%)
• Reduce its scrap rate • Improve drawing quality alkaline additive additions to maintain • Eliminate biostability of the drawing emulsion
30
15 10 5
To help improve their operations, Quaker Houghton suggested the manufacturer switch to QUAKERDRAW® 73 XP.
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Competitor
QUAKERDRAW® 73 XP
COST PER 100 PARTS 4.2
The Solution
4.1
3.9 3.8
• Improved surface finish • Fewer scratches
3.7 3.6 3.5
Quaker Houghton was able to show, on an annualized basis, a reduction in:
3.4
• 89% Scrap rate reduction from 19% to 2% • Concentration of the drawing fluid from 25% to 15% for
3.3
Acetylene gas bottles
Material
Steel, B53 P315 NB coated with HFE film
Sheet Thickness
3,35 mm
Disc Diameter
875 mm
Pressure
Stage 1: 200-400 tons Stage 2: 200-400 tons Stage 3: 100-200 tons
Water
Osmosed
Specific Operation
Deep drawing
Lower is better
Part
15
(%)
PRODUCT INFORMATION
QUAKERDRAW® 73 XP
20
Process and Equipment PRODUCT TITLE
Competitor
SCRAP RATE
Acetylene bottles
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Lower is better
4.0
Quaker Houghton introduced QUAKERDRAW® 73 XP in one drawing line. After seven months the manufacturer experienced improved lubrication, resulting in:
10
5
0
Competitor
quakerhoughton.com | info@quakerhoughton.com
QUAKERDRAW® 73 XP