英国石油公司(BP石油)为宝马汽车公司提供的干式润滑方案.ppt

TheBMWPartnership,DryFilmLubricants08.03.2005PresentationoftheCastrol“DryFilm”projectatBMW,Oxford(UK),HistoryofSteelMillAppliedLubricants,CORROSIONPREVENTIVES,DRYFILMLUBRICANTSBASEDONPOLYMER,2.GENERATIONPRELUBES,SEMIDRYFILMLUBRICANTS,THIXOTROPICCORROSIONPREVENTIVES,PRELUBES,2.GENERATIONTHIXOTROPICCORR.PREVENTIVES,DRYFILMLUBRICANTSBASEDONPARAFFIN,DRYFILMLUBRICANTSBASEDONWAXDISPERSION,DRYFILMLUBRICANTSBASEDONESTER,1990,1996,2000,2001,AdvantagesoftheDryFilmTechnology,SuperiorlubricationMultisubstratecompatibilityincludingaluminumDry-to-the-touchfilmReducedquantitiesappliedMechanicalsurfaceprotectionCleanworkingenvironment,TypesofDryFilmLubricants,Ester,Mineraloilbased,Hotmelt,Polymer,Organicsolvendbased,Waterbased,VOC,Energy,TypesofDryFilmLubricants,SemiDryFilmLubricants-Greasy-KonusPenetrationappr.20mmDryFilmLubricants-Lacqueurorwaxy-NeedlePenetration300CComputerisedcalculationofthefrictioncoefficientQuickchangeofmaterial,lubricantandcoatingweightpossible,FlatDieRigDrawingI,FlatDieRigDrawingII,TestFacilityattheUniversityofWaterloo(CAN)“FlatDieRigg”modified80tpress,DryFilmLubricantondifferentmaterialsFlatDieTestStation-UniversityofWaterlooResultsofIloformPN950DFacc.VDA230-201,Forcelimitsetto400kN,Themaximumforcewaslimitesduringthetestsduetosafetyreasons(40N/mm).Ingeneralanmaximumfordeof75N/mmispossiblebyrespectingtheVDAparameters.Duringthetest,nostick-slipwereseenforCastrolIloformPN950DF.V=const.,MineraloilbasedDryFilmLubricants,Prelubes*,*ConventionalPrelubes(mineraloilbased),DryFilmLubricantonBareSteelTestResultsIloformPN950DFanalogVDA230-201,Maximumnormalforcewasonlylimitedbythesettingofthetestequipment,afteradjustingthissettingwewillbecapabletoperformtestsupto75N/mm.Duringourpreliminarytestingnostick-slipwasobserved.,DryFilmLubricantonElectrogalvanizedMaterialTestResultsIloformPN950DFanalogVDA230-201,Maximumnormalforcewasonlylimitedbythesettingofthetestequipment,afteradjustingthissettingwewillbecapabletoperformtestsupto75N/mm.Duringourpreliminarytestingnostick-slipwasobserved.,DryFilmLubricantonHot-dipGalvanizedMaterialTestResultsIloformPN950DFanalogVDA230-20,Maximumnormalforcewasonlylimitedbythesettingofthetestequipment,afteradjustingthissettingwewillbecapabletoperformtestsupto75N/mm.Duringourpreliminarytestingnostick-slipwasobserved.,DryFilmLubricantonGalvanealedMaterialTestResultsIloformPN950DFanalogVDA230-20,Maximumnormalforcewasonlylimitedbythesettingofthetestequipment,afteradjustingthissettingwewillbecapabletoperformtestsupto75N/mm.Duringourpreliminarytestingnostick-slipwasobserved.,DryFilmLubricantonAluminumTestResultsIloformPN950DFanalogVDA230-20,Maximumnormalforcewasonlylimitedbythesettingofthetestequipment,afteradjustingthissettingwewillbecapabletoperformtestsupto75N/mm.Duringourpreliminarytestingnostick-slipwasobserved.,InfluenceofDieTemperatureonFrictionCoefficientIloformPN950DFonElectrogalvanizedMaterial,Frictioncoefficientdeterminedat400mm/sdrawingspeed,RemovabilityTestIloformPN950DFacc.toVDA230-201andRenaultSpecification,AdhesiveCompatibilityTestingaccordingtoVDA230-201,CataphoreticDipPaintCompatibilityaccordingtoVDA230-202-IloformPN950DF,Source:PPG,IloformPN950DFDryFilmLubricant,Appearancewhite,solidViscosityat20CsolidViscosityat50C34mm/sFlashpoint20CyclesSaltspraytestASTMB-11724hOpenshedstoragemin.12monthIndoorstoragemin.18month,ViscosityTemperatureChartCastrolDryFilmLubricant:IloformPN950DF,Trials,DryFilmLubricantIloformPN950DFCaseStudies1/1,ElectroluxHomeProducts-Swainsboro,GAMay2002Lawnmowerdecks,part#4055IFand404blanksize807x1000 x1.9and825x750 x1.9mm,baresteelsheetmetalcoatingweightvariable1.66.0g/m,preparedbyelectrostaticspraying(Gencoat)200partssuccessfullyproducedandassembled,ca.750mm,ca.160mm,Profileofthepressingpart,ElectroluxHomeProducts,Swainsboro,GA,DryFilmLubricantIloformPN950DFCaseStudies1/2,ElectroluxHomeProducts-Swainsboro,GAOctober2003LawnmowerdecksHi-Vac“blanksize825x750 x1.9mm,baresteelsheetmetalcoatingweightvariableappr.2.0g/m,preparedmanualExtremedifficultpart,duetothehighfailurerateitiscalledinternally50:50deckResult:FailratewithCastrolDryFilmtechnologyreducedto0“,DryFilmLubricantIloformPN950DFCaseStudies2/1,Profileofthepressingpart,ElectroluxHomeProducts,Swainsboro,GA,DryFilmLubricantIloformPN950DFCaseStudies2/2,DryFilmLubricantIloformPN950DFCaseStudies2/3Picture,FordStampingPlant-Saarlouis,GermanyJune2003Inner-bodysidepanel,Focus3-doorhatchbackblanksize1525x3475x0.75mm,hot-dipgalvanizedsheetmetalcoatingweight1.21.4g/m,preparedbyelectrostaticspraying(ThyssenKruppStahlNeuwied,sprayequipmentFaraTechnology)500partssuccessfullyproducedandassembled,DryFilmLubricantIloformPN950DFCaseStudies3/1,DryFilmLubricantIloformPN950DFCaseStudies3/2-Picture,Metalsheetsdry-to-the-touchNoparticlecontaminationNoproblemsinthede-stackingprocessOnlyslightmodificationoftheclampforcewasnecessaryinthebeginningMaintrial550o.K.partsUsageofthepartswithoutproblems,DryFilmLubricantIloformPN950DFCaseStudies3/3,AUDIStampingPlant-Ingolstadt,GermanyJune2003Inner-doorpanel,A4Blanksizeappr.1525x1735x0.75mm,hot-dipgalvanizedsheetmetalCoatingweight1.21.4g/m,preparedbyelectrostaticSpraying(ThyssenKruppStahlNeuwied,sprayequipmentFaraTechnology)30partssuccessfullyproducedandpassedthrougttheadditionalprocesses(cleaning,phosphatingandpaintingo.K.),DryFilmLubricantIloformPN950DFCaseStudies4/1,MetallwerkHofmaninger,Austria“Pretrial:Pressingofaconcetemixerpart,DryFilmLubricantIloformPN950DFCaseStudies5/1,DryFilmLubricantIloformPN950DFCaseStudies5/2-Picture,190mm,390mm,578mm,part:concretemixerMetallsheet:960 x1mm,DryFilmLubricantIloformPN950DFCaseStudies5/3-Drawing,AspayablealternativeforthecurrentproductCastrolIloformPS158“.Duetotheamountofsolidadditivestheapplicationofthistheproductcouldonlybemademanuallyviarollerorbrush.Material:1,0mmDC03ofvoestalpineTheapplicationinthispretrialwasmademanualbybrushwithoutmeasuringthefilmthickness,therforewedonothaveanyinformationaboutthisfact.1punchFurtheractions:Trialswithadefinedproductamounttoevaluatetheminimumdryfilmquantityforasafeprocess.,DryFilmLubricantIloformPN950DFCaseStudies5/4,FordStampingPlant-Saarlouis,GermanyDecember2004Innerwheelhouseforthebackwheel,C-MAXgalvanealedsheetmetal,coatingweight0.61.4g/m(nothomogenous),preparedbyairspray(ARCELORFlemalle),difficultoperationneedfortheconventionalproductionwithoilaamountof5g/m1000partssuccessfullyproduced(nofailpart,verycleantoolswithoutanydeposits),DryFilmLubricantIloformPN950D